CN106715108A - 接合构造体以及接合构造体的制造方法 - Google Patents

接合构造体以及接合构造体的制造方法 Download PDF

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Publication number
CN106715108A
CN106715108A CN201580044632.0A CN201580044632A CN106715108A CN 106715108 A CN106715108 A CN 106715108A CN 201580044632 A CN201580044632 A CN 201580044632A CN 106715108 A CN106715108 A CN 106715108A
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China
Prior art keywords
component
junction structure
perforated portion
laser
perforated
Prior art date
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Pending
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CN201580044632.0A
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English (en)
Inventor
西川和义
角谷彰朗
广野聪
博田知之
上松裕滋
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Omron Corp
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Omron Corp
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Publication of CN106715108A publication Critical patent/CN106715108A/zh
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    • B32B3/02Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C37/00Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0078Measures or configurations for obtaining anchoring effects in the contact areas between layers
    • B29C37/0082Mechanical anchoring
    • B29C37/0085Mechanical anchoring by means of openings in the layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0006Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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    • B23K26/352Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
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    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
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    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • B29C66/73941General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset characterised by the materials of both parts being thermosets
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74Joining plastics material to non-plastics material
    • B29C66/742Joining plastics material to non-plastics material to metals or their alloys
    • B29C66/7422Aluminium or alloys of aluminium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
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    • B29C66/74Joining plastics material to non-plastics material
    • B29C66/742Joining plastics material to non-plastics material to metals or their alloys
    • B29C66/7428Transition metals or their alloys
    • B29C66/74281Copper or alloys of copper
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B32LAYERED PRODUCTS
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Abstract

本发明的接合构造体是将第一部件与第二部件接合而得的接合构造体,在第一部件的表面形成有具有开口的穿孔部,且在第一部件的穿孔部中填充有第二部件。并且,穿孔部具有在深度方向上开口直径从表面侧朝向底部增大的扩径部、及在深度方向上开口直径从表面侧朝向底部减小的第一缩径部,扩径部形成在表面侧,第一缩径部形成在底部侧。

Description

接合构造体以及接合构造体的制造方法
技术领域
本发明涉及接合构造体以及接合构造体的制造方法。
背景技术
以往,已知有将由不同材料构成的第一部件及第二部件接合而得的接合构造体(例如,参照专利文献1)。
在专利文献1中,公开有一种使金属材料与树脂等不同种类材料接合的技术。具体而言,通过在金属材料的表面呈十字状地实施激光扫描加工,而在该表面形成大量突起(凹凸部)。并且,在将不同种类材料接合于形成有该突起的金属材料的情况下,不同种类材料进入凹状部,由此发挥锚定效应(anchor effect),因此提高了金属材料与不同种类材料的接合强度。
现有技术文献
专利文献
专利文献1:日本特许第4020957号公报
发明内容
发明所要解决的课题
此处,如上所述,若在金属材料的表面形成突起,则不同种类材料进入凹状部,由此可提高相对于剪切方向(沿接合界面错开的方向)的接合强度,但在剥离方向(相对于接合界面的垂直方向)上难以实现接合强度的提高。
本发明是为了解决所述课题而完成的,本发明的目的在于提供一种除了剪切方向以外在剥离方向上也可实现接合强度的提高的接合构造体以及接合构造体的制造方法。
用于解决课题的手段
本发明的接合构造体是将第一部件与第二部件接合而得的接合构造体,在第一部件的表面形成有具有开口的穿孔部,并且在第一部件的穿孔部中填充有第二部件。并且,穿孔部具有在深度方向上开口直径从表面侧朝向底部增大的扩径部、及在深度方向上开口直径从表面侧朝向底部减小的第一缩径部,扩径部形成在表面侧,第一缩径部形成在底部侧。
通过以所述方式构成,扩径部在穿孔部内向内侧突出,因此在剥离方向上将扩径部与填充于穿孔部中的第二部件卡合,由此可实现剥离方向的接合强度的提高。由此,除了剪切方向以外在剥离方向上也可实现接合强度的提高。
在所述接合构造体中,可具有在深度方向上开口直径从表面侧朝向底部减小的第二缩径部,且将第二缩径部形成于比扩径部靠表面侧的位置。
在所述接合构造体中,可在第一部件的表面形成有多个穿孔部,且相邻的穿孔部的间隔(中心间距离)为200μm以下。
在所述接合构造体中,穿孔部的表面的开口直径可以是30μm~100μm。
在所述接合构造体中,穿孔部的深度可以是30μm~300μm。
在所述接合构造体中,第一部件可以是金属、热塑性树脂、或热固性树脂。
在所述接合构造体中,第二部件可以是热塑性树脂、或热固性树脂。
在所述接合构造体中,可在穿孔部的开口的周围设置有从表面朝上方隆起的隆起部。
在所述接合构造体中,穿孔部可以被形成为轴心相对于表面倾斜。
在所述接合构造体中,扩径部及第一缩径部可以被形成为相互连接,且在深度方向上形成有多组。
本发明的接合构造体的制造方法是将第一部件与第二部件接合而得的接合构造体的制造方法,其包括:在第一部件的表面形成具有开口的穿孔部的步骤;及在第一部件的穿孔部中填充第二部件并使其固化的步骤。穿孔部具有在深度方向上开口直径从表面侧朝向底部增大的扩径部、及在深度方向上开口直径从表面侧朝向底部减小的第一缩径部,在表面侧形成扩径部,在底部侧形成第一缩径部。
通过以所述方式构成,扩径部在穿孔部内向内侧突出,因此在剥离方向上将扩径部与填充于穿孔部中的第二部件卡合,由此可实现剥离方向的接合强度的提高。由此,除了剪切方向以外在剥离方向上也可实现接合强度的提高。
在所述接合构造体的制造方法中,可设为如下:第一部件为金属,通过在惰性气体环境下或减压环境下对第一部件的表面照射激光,形成穿孔部。
在所述接合构造体的制造方法中,也可设为如下:第一部件为金属,第二部件为热塑性树脂或热固性树脂,且在惰性气体环境下或减压环境下将第二部件填充于第一部件的穿孔部中并使其固化。另外,减压环境包括由大气形成减压环境的情况、及导入惰性气体后形成减压环境的情况。
发明的效果
根据本发明的接合构造体以及接合构造体的制造方法,除了剪切方向以外在剥离方向上也可实现接合强度的提高。
附图说明
图1是本发明的第一实施方式的接合构造体的剖面的示意图。
图2是表示图1的接合构造体的在第一部件形成有穿孔部的状态的示意图。
图3是表示第一实施方式的第一变形例的第一部件的示意图。
图4是表示第一实施方式的第二变形例的第一部件的示意图。
图5是表示第一实施方式的第三变形例的第一部件的示意图。
图6是表示第一实施方式的第四变形例的第一部件的示意图。
图7是表示实施例的接合构造体的第一部件的立体图。
图8是表示实施例的接合构造体的立体图。
图9是本发明的第二实施方式的接合构造体的剖面的示意图。
图10是表示图9的接合构造体的在第一部件形成有穿孔部的状态的示意图。
图11是表示第二实施方式的第一变形例的第一部件的示意图。
图12是表示第二实施方式的第二变形例的第一部件的示意图。
图13是表示第二实施方式的第三变形例的第一部件的示意图。
图14是表示第二实施方式的第四变形例的第一部件的示意图。
图15是用于说明本发明的第三实施方式的接合构造体的制造方法的图,是表示于在第一部件形成穿孔部时从喷嘴喷射惰性气体的例子的概略图。
图16是用于说明本发明的第三实施方式的接合构造体的制造方法的图,是表示于在第一部件形成穿孔部时将第一部件配置于腔室内并使该腔室成为惰性气体环境的例子的概略图。
图17是用于说明本发明的第三实施方式的接合构造体的制造方法的图,是表示于在第一部件形成穿孔部时将第一部件配置于腔室内并使该腔室成为减压环境的例子的概略图。
图18是用于说明本发明的第三实施方式的接合构造体的制造方法的图,是表示在将第一部件与第二部件接合时从喷嘴喷射惰性气体的例子的概略图。
具体实施方式
以下,参照附图对本发明的实施方式进行说明。
(第一实施方式)
首先,参照图1对本发明的第一实施方式的接合构造体100进行说明。
接合构造体100如图1所示,是将由不同材料构成的第一部件10及第二部件20接合而得的。在第一部件10的表面13形成有具有开口的穿孔部11,且在该穿孔部11的内周面形成有向内侧突出的突出部12。并且,在第一部件10的穿孔部11中填充并固化有第二部件20。另外,图1是将第一部件10及第二部件20的接合界面放大进行示意性表示的图,实际上设置有多个穿孔部11,但在图1中仅示出一个。
第一部件10的材料为金属、热塑性树脂、或热固性树脂,第二部件20的材料为热塑性树脂、或热固性树脂。
作为所述金属的一例,可列举:铁系金属、不锈钢系金属、铜系金属、铝系金属、镁系金属、及该些金属的合金。另外,可以是金属成型体,也可以是锌压铸件、铝压铸件、粉末冶金等。
作为所述热塑性树脂的一例,可列举:聚氯乙烯(Polyvinyl chloride,PVC)、聚苯乙烯(Polystyrene,PS)、丙烯腈-苯乙烯(Acrylonitrile-styrene,AS)、丙烯腈-丁二烯-苯乙烯(Acrylonitrile-butadiene-styrene,ABS)、聚甲基丙烯酸甲酯(Polymethylmethacrylate,PMMA)、聚乙烯(Polyethylene,PE)、聚丙烯(Polypropylene,PP)、聚碳酸酯(Polycarbonate,PC)、改质聚苯醚(modified-Polyphenyleneether,m-PPE)、聚酰胺6(Polyamide 6,PA6)、聚酰胺66(PA66)、聚缩醛(Polyacetal,POM)、聚对苯二甲酸乙二酯(Polyethylene terephthalate,PET)、聚对苯二甲酸丁二酯(Polybutyleneterephthalate,PBT)、聚砜(Polysulfone,PSF)、聚芳酯(Polyarylate,PAR)、聚醚酰亚胺(Polyetherimide,PEI)、聚苯硫醚(Polyphenylenesulfide,PPS)、聚醚砜(Polyethersulfone,PES)、聚醚醚酮(Polyetheretherketone,PEEK)、聚酰胺酰亚胺(Polyamideimide,PAI)、液晶聚合物(Liquid crystal polymer,LCP)、聚偏二氯乙烯(Polyvinylidenechloride,PVDC)、聚四氟乙烯(Polytetrafluoroethylene,PTFE)、聚氯三氟乙烯(Polychlorotrifluoroethylene,PCTFE)、及聚偏二氟乙烯(Polyvinylidene fluoride,PVDF)。另外,也可以是热塑性弹性体(Thermoplastic elastomer,TPE),作为TPE的一例,可列举热塑性烯烃(Thermoplastic olefin,TPO)(烯烃系)、热塑性苯乙烯(Thermoplasticstyrene,TPS)(苯乙烯系)、热塑性酯(Thermoplastic polyester elastomer,TPEE)(酯系)、热塑性胺基甲酸酯(Thermoplastic urethane,TPU)(胺基甲酸酯系)、热塑性尼龙(Thermoplastic polyamide,TPA)(尼龙系)、及热塑性氯乙烯(Polyvinyl chloride basedthermoplastic,TPVC)(氯乙烯系)。
作为所述热固性树脂的一例,可列举:环氧(Epoxy,EP)树脂、聚胺基甲酸酯(Polyurethane,PUR)树脂、脲甲醛(Urea-formaldehyde,UF)树脂、三聚氰胺甲醛(Melamineformaldehyde,MF)树脂、酚甲醛(Phenol formaldehyde,PF)树脂、不饱和聚酯(Unsaturated polyester,UP)树脂、及硅(Silicone,SI)树脂。另外,也可以是纤维强化塑料(Fiber reinforced plastics,FRP)。
另外,也可在上述的热塑性树脂及热固性树脂中添加填充剂。作为填充剂的一例,可列举无机系填充剂(玻璃纤维、无机盐类等)、金属系填充剂、有机系填充剂、及碳纤维等。
穿孔部11在俯视时为大致圆形的非贯通孔,在第一部件10的表面13形成有多个。穿孔部11的表面13的开口直径R1优选为30μm~100μm。这是因为,若开口直径R1小于30μm,则存在第二部件20的填充性变差而锚定效应降低的情况。另一方面,原因在于:若开口直径R1大于100μm,则存在每单位面积的穿孔部11的个数减少而锚定效应降低的情况,另外,变得难以形成突出部12。
另外,穿孔部11的深度优选为30μm~300μm。这是因为,如果穿孔部11的深度小于30μm,则变得难以形成突出部12。另一方面,原因在于:如果穿孔部11的深度大于300μm,则由于开口直径R1容易减小,因此第二部件20的填充性变差。另外,在穿孔部11中,深度相对于开口直径R1的比率(深度/开口直径R1)优选为0.3~10,更优选为0.6~3.7。
另外,穿孔部11的间隔(规定的穿孔部11的中心与相邻于规定的穿孔部11的穿孔部11的中心的距离)优选为200μm以下。这是因为,如果穿孔部11的间隔大于200μm,则存在每单位面积的穿孔部11的个数减少而锚定效应降低的情况。另外,作为穿孔部11的间隔的下限的一例,为穿孔部11重叠而不挤破的距离。即,相邻的穿孔部11的间隔(中心间距离)优选为穿孔部11的开口直径R1以上。另外,优选为穿孔部11的间隔相同。这是因为,如果穿孔部11间隔相等,则剪切方向的接合强度是各向同性的。
此处,第一实施方式的穿孔部11被形成为在深度方向(Z方向)上开口直径从表面13侧朝向底部113增大的扩径部111、与在深度方向上开口直径从表面13侧朝向底部113减小的缩径部112相互连接。扩径部111被形成为呈曲线状扩径,缩径部112被形成为呈曲线状缩径。另外,缩径部112为本发明的“第一缩径部”的一例。
此外,扩径部111配置于表面13侧,并且缩径部112配置于底部113侧。因此,在穿孔部11中,扩径部111与缩径部112的边界部分的开口直径(内径)R2最大,且开口直径R1小于开口直径R2。即,穿孔部11的深度方向上的扩径部111的部分形成为突出部12。即,由扩径部111形成突出部12。由此,突出部12的顶点配置于第一部件10的表面13侧。该突出部12例如是在周向上的全长范围内形成的,且形成为环状。
如上所述,通过在穿孔部11的内周面形成向内侧突出的突出部12(扩径部111),而将突出部12与填充于穿孔部11中的第二部件20在剥离方向(Z方向)上卡合,由此可实现剥离方向的接合强度的提高。由此,除了剪切方向以外在剥离方向上也可实现接合强度的提高。进而,在热循环环境下,即便产生由第一部件10及第二部件20的线膨胀系数差引起的剥离应力,也可维持接合强度。即,可实现在热循环环境下的耐久性的提高。
该穿孔部11例如通过照射激光而形成。作为激光的种类,就可进行脉冲振荡的观点而言,可选择光纤激光、钇铝石榴石(yttrium aluminum garnet,YAG)激光、钒酸钇(yttrium orthovanadate,YVO4)激光、半导体激光、二氧化碳激光、准分子激光,若考虑激光的波长,则优选为光纤激光、YAG激光、YAG激光的二次谐波、YVO4激光、半导体激光。另外,激光的输出是考虑激光的照射直径、第一部件10的材料的种类、第一部件10的形状(例如厚度)等而设定的。例如,激光的输出上限优选为40W。这是因为,若激光的输出超过40W,则能量增大,难以形成具有突出部12的穿孔部11。
作为形成穿孔部11的装置的一例,可列举欧姆龙(OMRON)制造的光纤激光打标机MX-Z2000或MX-Z2050。关于该光纤激光打标机,可照射一个脉冲由多个子脉冲构成的激光。因此,容易使激光的能量集中于深度方向,故而适宜于形成穿孔部11。具体而言,若对第一部件10照射激光,则通过将第一部件10局部熔融而进行穿孔部11的形成。此时,由于激光由多个子脉冲构成,因此熔融后的第一部件10不易飞散,而容易堆积于穿孔部11的附近。并且,若进行穿孔部11的形成,则通过将熔融后的第一部件10堆积于穿孔部11的内部而形成突出部12。另外,激光的照射方向例如是垂直于表面13的方向,穿孔部11的轴心相对于表面13而垂直。
另外,作为利用所述光纤激光打标机的加工条件,优选为子脉冲的一个周期为15ns以下。这是因为,若子脉冲的一个周期超过15ns,则因导热导致能量变得容易扩散,而变得难以形成具有突出部12的穿孔部11。另外,子脉冲的一个周期是照射一次子脉冲的时间、与该子脉冲的照射结束起至开始下一次子脉冲的照射为止的间隔的合计时间。
另外,作为利用所述光纤激光打标机的加工条件,优选为一个脉冲的子脉冲数为2个以上且为50个以下。这是因为,若子脉冲数超过50个,则子脉冲每单位的输出减小,而变得难以形成具有突出部12的穿孔部11。
此外,第二部件20接合于形成有穿孔部11的第一部件10的表面13。该第二部件20例如通过注塑成型、热板熔敷、激光熔敷、浇铸固化、超声波熔敷、或振动熔敷而接合于第一部件10。由此,第二部件20在被填充于穿孔部11中的状态下进行固化。
此种接合构造体100例如可应用于将树脂盖(省略图示)接合于光电传感器的金属外壳(省略图示)的情况。在该情况下,金属外壳相当于第一部件10,树脂盖相当于第二部件20。
-接合构造体的制造方法-
继而,参照图1及图2,对第一实施方式的接合构造体100的制造方法进行说明。
首先,在第一部件10的表面13形成穿孔部11,并且在该穿孔部11的内周面形成突出部12。如图2所示,该穿孔部11及突出部12例如通过照射一个脉冲由多个子脉冲构成的激光而形成。作为具体例,使用上述的光纤激光打标机MX-Z2000或MX-Z2050而形成。
然后,将第二部件20填充于第一部件10的穿孔部11中,并使该第二部件20固化。由此,将第一部件10及第二部件20接合,而形成接合构造体100(参照图1)。另外,第二部件20例如是通过注塑成型、热板熔敷、激光熔敷、浇铸固化、超声波熔敷、或振动熔敷而被接合的。
-第一部件的变形例-
继而,参照图3~图6,对第一部件10的变形例进行说明。
图3是表示第一实施方式的第一变形例的第一部件10a的示意图。如图3所示的第一部件10a那样,也可在穿孔部11的开口的周围形成有从表面13朝上方隆起的隆起部14。隆起部14被形成为包围穿孔部11的周围,形成为俯视时大致圆形。该隆起部14例如在照射一个脉冲由多个子脉冲构成的激光时,通过堆积熔融后的第一部件10a而形成。若以此种方式构成,则通过隆起部14也会产生锚定效应,因此可进一步提高接合强度。
图4是表示第一实施方式的第二变形例的第一部件10b的示意图。如图4所示的第一部件10b那样,也可以是,穿孔部11b的轴心被形成为相对于表面13倾斜。在穿孔部11b的内周面形成有向内侧突出的突出部12b。该穿孔部11b例如是通过使激光的照射方向相对于表面13倾斜(45°以上且小于90°)的方式而形成的。由此,即便在形成穿孔部11b的区域的上方存在照射激光时的障碍物的情况下,也可形成穿孔部11b。
图5是表示第一实施方式的第三变形例的第一部件10c的示意图。如图5所示的第一部件10c那样,也可在穿孔部11c形成有多个突出部121c及突出部122c。即,也可形成为使扩径部及缩径部相互连接,并且在深度方向上形成多组该扩径部及缩径部。该穿孔部11c例如可变更激光的输出条件,通过对相同部位照射激光而形成。若以此种方式构成,则穿孔部11c的表面积增大,并且形成多个突出部121c及突出部122c,由此可进一步提高接合强度。另外,在图5中,突出部是121c及122c的两个部位,但也可形成三个部位以上。
图6是表示第一实施方式的第四变形例的第一部件10d的示意图。如图6所示的第一部件10d那样,也可通过位置错开的多次激光照射而形成一个穿孔部11d。即,也可使通过激光照射而形成的穿孔部的一部分重叠,由此形成一个穿孔部11d。在穿孔部11d的内周面形成有向内侧突出的突出部12d。
另外,也可适当组合上述的第一变形例~第四变形例。
-实验例-
继而,参照图7及图8,对为了确认上述的第一实施方式的效果而进行的实验例1及实验例2进行说明。
[实验例1]
在该实验例1中,制作对应于第一实施方式的实施例1的接合构造体500(参照图8)与比较例1的接合构造体,并对各接合构造体进行接合评价。另外,作为接合评价,对未进行热冲击试验的接合构造体测量接合强度,并且对热冲击试验后的接合构造体测量接合强度,基于该测量结果判定合格与否。将其结果示于表1。
[表1]
首先,对实施例1的接合构造体500的制作方法进行说明。
在实施例1的接合构造体500中,使用Al(A5052)作为第一部件501的材料。该第一部件501如图7所示,形成为板状,长度为100mm,宽度为29mm,厚度为3mm。
然后,对第一部件501的表面的规定区域R照射激光。该规定区域R是接合接合构造体500的面积,设为12.5mm×20mm。另外,该激光的照射使用欧姆龙制造的光纤激光打标机MX-Z2000进行。激光的照射条件如以下所述。
<激光照射条件>
激光:光纤激光(波长1062nm)
频率:10kHz
输出:3.0W
扫描速度:650mm/sec
扫描次数:20次
照射间隔:65μm
子脉冲数:20
另外,频率是由多个(该例中为20个)子脉冲构成的脉冲的频率。即,在该照射条件中,1秒内移动650mm,并且以65μm的间隔照射1万次激光(脉冲),该脉冲由20个子脉冲构成。另外,扫描次数是对相同部位反复照射激光的次数。
如上所述,通过照射一个脉冲由多个子脉冲构成的激光,而在第一部件501的表面的规定区域R形成穿孔部,并且在该穿孔部的表面侧形成突出部。即,如表1所示,可获得扩径部与缩径部的边界部分的开口直径R2(参照图1)大于表面的开口直径R1(参照图1)的穿孔部。
然后,通过嵌件成型,将第二部件502接合于第一部件501的表面。在实施例1的接合构造体500中,使用PBT(温泰克聚合物(WinTech Polymer)制造的DURANEX(注册商标)3316)作为第二部件502的材料。另外,成型机是使用日本制钢所制造的J35EL3。成型条件如以下所述。
<成型条件>
预干燥:120℃×5小时
模具温度:120℃
气缸温度:270℃
保压:100MPa
以所述方式制作实施例1的接合构造体500。另外,第二部件502形成为板状,长度为100mm,宽度为25mm,厚度为3mm。
继而,对比较例1的接合构造体的制作方法进行说明。
在比较例1的接合构造体中,作为第一部件及第二部件的材料,使用与实施例1相同的材料,并且成型条件也设为相同的设定。此外,在比较例1的接合构造体中,使用无脉冲控制功能的光纤激光形成穿孔部。即,通过照射一个脉冲不由多个子脉冲构成的激光形成穿孔部。因此,在比较例1的第一部件中形成研钵状(圆锥状)的穿孔部。即,如表1所示,在比较例1的第一部件中未形成自内周面向内侧突出的突出部,未形成对应于实施例1的开口直径R2的形状。
然后,对实施例1的接合构造体500及比较例1的接合构造体进行接合评价。
另外,接合强度使用英斯特朗(Instron)制造的机电式万能试验机5900进行测量。具体而言,关于剪切方向是以拉伸速度5mm/min进行试验,关于剥离方向(垂直方向)是以三点弯曲试验方式的挤压速度2mm/min进行试验,以第二部件的断裂或接合界面的断裂结束试验。并且采用该试验中的最大强度作为接合强度。
另外,热冲击试验是使用爱斯佩克(ESPEC)制造的冷热冲击装置TSD-100进行的。具体而言,反复进行100次-40℃下30分钟的低温曝露与85℃下30分钟的高温曝露。
此外,为了判断在热循环环境下的可靠性,而按照以下的基准进行合格与否的判断。
合格(○):“热冲击试验后的接合强度”/“热冲击试验前的接合强度”≥90%
不合格(×):“热冲击试验后的接合强度”/“热冲击试验前的接合强度”<90%
如上述的表1所示,在热冲击试验前,实施例1的接合构造体500的剪切方向及剥离方向的接合强度高于比较例1的接合构造体。由此,可知如实施例1的接合构造体500那样,通过在穿孔部的内周面形成突出部,提高了接合强度。另外,在热冲击试验后,实施例1的接合构造体500的剪切方向及剥离方向的接合强度也高于比较例1的接合构造体。
进而,可知在实施例1的接合构造体500中,在热冲击试验后也可将热冲击试验前的接合强度维持90%以上。相对于此,在比较例1的接合构造体中,在热冲击试验后接合强度大幅降低。因此,如实施例1的接合构造体500那样,通过在穿孔部的内周面形成突出部,可实现在热循环环境下的耐久性的提高。
[实验例2]
在该实验例2中,制作对应于第一实施方式的实施例2的接合构造体与比较例2的接合构造体,并对各接合构造体进行接合评价。另外,接合评价是以与实验例1相同的方式进行。将其结果示于表2。
[表2]
在该实验例2中,变更第一部件的材料与激光照射条件而区别于实验例1。具体而言,在实施例2的接合构造体中,使用PPS(宝理(Polyplastics)制造的FORTRON(注册商标)1140)作为第一部件的材料。另外,将激光照射条件设为如以下所述。
<激光照射条件>
激光:光纤激光(波长1062nm)
频率:10kHz
输出:1.1W
扫描速度:650mm/sec
扫描次数:3次
照射间隔:65μm
子脉冲数:3
如上述的表2所示,在热冲击试验前,实施例2的接合构造体的剪切方向及剥离方向的接合强度高于比较例2的接合构造体。进而,可知在实施例2的接合构造体中,在热冲击试验后也可将热冲击试验前的接合强度维持90%以上。即,可知在实验例2中,可获得与实验例1同样的结果。即,即便在使用作为树脂的PPS作为第一部件的材料的情况下,通过形成具有突出部的穿孔部,也可实现接合强度的提高,并且可实现在热循环环境下的耐久性的提高。
(第二实施方式)
继而,参照图9,对本发明的第二实施方式的接合构造体200进行说明。
接合构造体200如图9所示,是将由不同材料构成的第一部件30及第二部件20接合而得的。在第一部件30的表面33形成有具有开口的穿孔部31,且在该穿孔部31的内周面形成有向内侧突出的突出部32。并且,在第一部件30的穿孔部31中填充并固化有第二部件20。
第二实施方式的穿孔部31被形成为在深度方向(Z方向)上开口直径从表面33侧朝向底部314减小的缩径部311、在深度方向上开口直径从表面33侧朝向底部314增大的扩径部312、及在深度方向上开口直径从表面33侧朝向底部314减小的缩径部313相互连接。缩径部311被形成为呈直线状缩径,扩径部312被形成为呈曲线状扩径,缩径部313被形成为呈曲线状缩径。另外,缩径部311为本发明的“第二缩径部”的一例,缩径部313为本发明的“第一缩径部”的一例。
此外,从表面33侧朝向底部314侧依次配置有缩径部311、扩径部312及缩径部313。即,将缩径部311配置于比扩径部312靠表面33侧的位置。因此,在穿孔部31中,缩径部311与扩径部312的边界部分的开口直径(内径)R4小于表面33的开口直径R3、及扩径部312与缩径部313的边界部分的开口直径R5。即,穿孔部31的深度方向上的缩径部311及扩径部312的部分被形成为突出部32。即,由缩径部311及扩径部312形成突出部32。由此,将突出部32的顶点配置于进入底部314侧的位置。该突出部32例如是在周向上的全长范围内形成的,且形成为环状。
另外,第一部件30的其它构成与上述的第一部件10相同。
如上所述,通过在穿孔部31的内周面形成向内侧突出的突出部32(扩径部312),而将突出部32与填充于穿孔部31中的第二部件20在剥离方向(Z方向)上卡合,由此可实现剥离方向的接合强度的提高。由此,除了剪切方向以外在剥离方向上也可实现接合强度的提高。进而,在热循环环境下,即便产生由第一部件30及第二部件20的线膨胀系数差引起的剥离应力,也可维持接合强度。即,可实现在热循环环境下的耐久性的提高。
-接合构造体的制造方法-
继而,参照图9及图10,对第二实施方式的接合构造体200的制造方法进行说明。
首先,在第一部件30的表面33形成穿孔部31,并且在该穿孔部31的内周面形成突出部32。该穿孔部31及突出部32例如是如图10所示,通过照射一个脉冲由多个子脉冲构成的激光而形成的。作为具体例,使用上述的光纤激光打标机MX-Z2000或MX-Z2050而形成。另外,在第二实施方式中,与第一实施方式不同,将突出部32配置于进入底部314侧的位置,此种不同例如由第一部件30的材料或激光照射条件等的不同所引起。
然后,将第二部件20填充于第一部件30的穿孔部31中,并使该第二部件20固化。由此,将第一部件30及第二部件20接合,而形成接合构造体200(参照图9)。另外,第二部件20例如是通过注塑成型、热板熔敷、激光熔敷、浇铸固化、超声波熔敷、或振动熔敷而被接合的。
-第一部件的变形例-
继而,参照图11~图14,对第一部件30的变形例进行说明。
图11是表示第二实施方式的第一变形例的第一部件30a的示意图。如图11所示的第一部件30a那样,也可在穿孔部31的开口的周围形成有从表面33朝上方隆起的隆起部34。隆起部34被形成为包围穿孔部31的周围,形成为俯视时大致圆形。该隆起部34例如在照射一个脉冲由多个子脉冲构成的激光时,通过堆积熔融后的第一部件30a而形成。若以此种方式构成,则通过隆起部34也会产生锚定效应,因此可进一步提高接合强度。
图12是表示第二实施方式的第二变形例的第一部件30b的示意图。如图12所示的第一部件30b那样,也可以是,穿孔部31b的轴心被形成为相对于表面33倾斜。在穿孔部31b的内周面形成有向内侧突出的突出部32b。该穿孔部31b例如是通过使激光的照射方向相对于表面33倾斜(45°以上且小于90°)的方式而形成。由此,即便在形成穿孔部31b的区域的上方存在照射激光时的障碍物的情况下,也可形成穿孔部31b。
图13是表示第二实施方式的第三变形例的第一部件30c的示意图。如图13所示的第一部件30c那样,也可在穿孔部31c形成多个突出部321c及突出部322c。即,也可使扩径部及缩径部形成为相互连接,并且在深度方向上形成多组该扩径部及缩径部。该穿孔部31c例如可变更激光的输出条件,通过对相同部位照射激光而形成。若以此种方式构成,则穿孔部31c的表面积增大,并且形成多个突出部321c及突出部322c,由此可进一步提高接合强度。另外,在图13中,突出部是321c及322c的两个部位,但也可形成三个部位以上。
图14是表示第二实施方式的第四变形例的第一部件30d的示意图。如图14所示的第一部件30d那样,也可通过位置错开的多次激光照射而形成一个穿孔部31d。即,也可使通过激光照射而形成的穿孔部的一部分重叠,由此形成一个穿孔部31d。在穿孔部31d的内周面形成有向内侧突出的突出部32d。
另外,也可适当组合上述的第一变形例~第四变形例。
-实验例-
继而,对为了确认上述的第二实施方式的效果而进行的实验例3进行说明。
在该实验例3中,制作对应于第二实施方式的实施例3的接合构造体与比较例3的接合构造体,并对各接合构造体进行接合评价。另外,接合评价是以与实验例1相同的方式进行。将其结果示于表3。
[表3]
在该实验例3中,变更第一部件的材料与激光照射条件而区别于实验例1。具体而言,在实施例3的接合构造体中,使用SUS304作为第一部件的材料。另外,将激光照射条件设为如以下所述。
<激光照射条件>
激光:光纤激光(波长1062nm)
频率:10kHz
输出:3.8W
扫描速度:650mm/sec
扫描次数:20次
照射间隔:65μm
子脉冲数:20
在实施例3的接合构造体中,通过照射一个脉冲由多个子脉冲构成的激光,在第一部件的表面形成穿孔部,并且在从该穿孔部的表面进入的位置形成突出部。即,如表3所示,开口直径R4(参照图9)小于表面的开口直径R3(参照图9)及开口直径R5(参照图9)。另外,在比较例3的第一部件中形成研钵状(圆锥状)的穿孔部,而未形成对应于实施例3的开口直径R4及开口直径R5的形状。
如上述的表3所示,在热冲击试验前,实施例3的接合构造体的剪切方向及剥离方向的接合强度高于比较例3的接合构造体。进而,可知在实施例3的接合构造体中,在热冲击试验后也可将热冲击试验前的接合强度维持90%以上。即,可知在实验例3中,可获得与实验例1同样的结果。即,即便将突出部配置于进入底部侧的位置,也可实现接合强度的提高,并且可实现在热循环环境下的耐久性的提高。
-关于穿孔部的间隔-
继而,对为了确认相邻的穿孔部的间隔(中心间距离)的优选范围而进行的实验例3-1进行说明。
在该实验例3-1中,制作实施例3-1~实施例3-3的接合构造体与参考例3-1及参考例3-2的接合构造体,并对各接合构造体进行接合评价。另外,接合评价是以与实验例1相同的方式进行。将其结果示于表4。
[表4]
在该实验例3-1中,在将频率设为恒定(10kHz)的状态下,通过变更扫描速度,而变更各接合构造体中的激光的照射间隔。另外,在实施例3-1~实施例3-3及参考例3-2中,激光的照射间隔为穿孔部的间隔(中心间距离),但在参考例3-1中,激光的照射间隔短,穿孔部被重叠而成为槽状。如表4所示,实施例3-1的穿孔部间隔为54μm,实施例3-2的穿孔部间隔为65μm,实施例3-3的穿孔部间隔为200μm,参考例3-2的穿孔部间隔为250μm。另外,在各接合构造体中共同的激光照射条件如以下所述。
<激光照射条件>
激光:光纤激光(波长1062nm)
频率:10kHz
输出:3.8W
扫描次数:20次
子脉冲数:20
如上述的表4所示,在实施例3-1~实施例3-3的接合构造体中,在热冲击试验后也可将热冲击试验前的接合强度维持90%以上。相对于此,在参考例3-1及参考例3-2中,热冲击试验后的接合强度保持率低于90%。因此,相邻的穿孔部的间隔优选为重叠而不挤破的距离,且为200μm以下。另外,在实施例3-3的接合构造体中,由于穿孔部个数少于实施例3-1及实施例3-2,因此接合强度本身变低,但可确保在热循环环境下的耐久性。
-关于穿孔部的表面的开口直径-
继而,对为了确认穿孔部的表面的开口直径R3的优选范围而进行的实验例3-2进行说明。
在该实验例3-2中,制作实施例3-4~实施例3-6的接合构造体与参考例3-3及参考例3-4的接合构造体,并对各接合构造体进行接合评价。另外,接合评价是以与实验例1相同的方式进行。将其结果示于表5。
[表5]
在该实验例3-2中,通过变更激光的照射条件,而变更各接合构造体中的穿孔部的表面的开口直径R3。另外,在参考例3-4中形成有研钵状的穿孔部。如表5所示,实施例3-4的开口直径R3为30μm,实施例3-5的开口直径R3为58μm,实施例3-6的开口直径R3为100μm。另一方面,参考例3-3的开口直径R3为28μm,参考例3-4的开口直径R3为120μm。另外,在各接合构造体中共同的激光照射条件如以下所述。
<激光照射条件>
激光:光纤激光(波长1062nm)
频率:10kHz
输出:3.8W
扫描速度:1200mm/sec
照射间隔:120μm
如上述的表5所示,在实施例3-4~实施例3-6的接合构造体中,在热冲击试验后也可将热冲击试验前的接合强度维持90%以上。相对于此,在参考例3-3及参考例3-4中,热冲击试验后的接合强度保持率低于90%。因此,穿孔部的表面的开口直径R3优选为30μm~100μm。另外,在实施例3-4~实施例3-6的接合构造体中,由于穿孔部个数少于上述的实施例3-1及实施例3-2,因此接合强度本身变低,但可确保在热循环环境下的耐久性。
-关于穿孔部的深度-
继而,对为了确认穿孔部的深度的优选范围而进行的实验例3-3进行说明。
在该实验例3-3中,制作实施例3-7~实施例3-9的接合构造体与参考例3-5及参考例3-6的接合构造体,并对各接合构造体进行接合评价。另外,接合评价是以与实验例1相同的方式进行。将其结果示于表6。
[表6]
在该实验例3-3中,通过变更激光的照射条件,而变更各接合构造体中的穿孔部的深度。另外,在参考例3-5中形成有研钵状的穿孔部。如表6所示,实施例3-7的深度为30μm,实施例3-8的深度为60μm,实施例3-9的深度为300μm。另一方面,参考例3-5的深度为24μm,参考例3-6的深度为340μm。另外,在各接合构造体中共同的激光照射条件如以下所述。
<激光照射条件>
激光:光纤激光(波长1062nm)
频率:10kHz
输出:3.8W
扫描速度:650mm/sec
照射间隔:65μm
如上述的表6所示,在实施例3-7~实施例3-9的接合构造体中,在热冲击试验后也可将热冲击试验前的接合强度维持90%以上。相对于此,在参考例3-5及参考例3-6中,热冲击试验后的接合强度保持率低于90%。因此,穿孔部11的深度优选为30μm~300μm。
(第三实施方式)
继而,对本发明的第三实施方式的接合构造体进行说明。在该第三实施方式中,在进行形成穿孔部时、与将第一部件及第二部件接合时的至少任一者时,设为惰性气体环境或减压环境。
在第三实施方式的接合构造体中,第一部件为金属,第二部件为对激光具有透过性的热塑性树脂或热固性树脂。另外,第三实施方式的接合构造体的其它构成与上述的第一实施方式或第二实施方式相同。
-接合构造体的制造方法-
继而,参照图15~图18,对第三实施方式的接合构造体的制造方法进行说明。
在第三实施方式中,是在惰性气体环境下或减压环境下进行如下步骤:通过对由金属构成的第一部件的表面照射激光而在第一部件的表面形成穿孔部。若以此种方式构成,则由于可抑制由激光的照射引起的第一部件表面上的过度的氧化膜的形成,因此可进一步提高在热循环环境下的耐久性。
例如,如图15所示,在从激光打标机的激光头50对金属制的第一部件40的穿孔部形成区域Ra照射激光L1时,通过从喷嘴51向该穿孔部形成区域Ra喷射惰性气体G,而在惰性气体环境下在第一部件40形成穿孔部(省略图示)。作为惰性气体G的一例,可列举氮气、二氧化碳气体(CO2)、氩气、氦气等。另外,惰性气体G的喷射量例如为2L/分钟。
另外,也可以构成为可调节从喷嘴51喷射的惰性气体G的温度。这是因为,在惰性气体G的喷射量多(例如,50L/分钟)时,存在第一部件40的表面被冷却,而利用激光L1的加工特性降低的可能,但通过调整惰性气体G的温度,抑制了喷射量多的情况下的加工特性的降低。
另外,也可如图16所示,将金属制的第一部件40配置于腔室52内,将该腔室52内设为惰性气体环境,而从激光打标机的激光头50对第一部件40的穿孔部形成区域Ra照射激光L1。另外,腔室52例如是透明的丙烯酸制的密封容器,设置有惰性气体的导入口(省略图示)及排出口(省略图示)。在该情况下,由于惰性气体不会喷附在第一部件40的表面,因此不会发生由冷却引起的加工特性的降低。
另外,也可如图17所示,将金属制的第一部件40及激光打标机的激光头50配置于腔室53内,通过真空泵54将该腔室53内设为减压环境,而从激光头50对第一部件40的穿孔部形成区域Ra照射激光L1。减压条件例如为500mm/Hg(666.6hPa)以下。另外,可由大气形成减压环境,也可在腔室53内填充惰性气体后形成减压环境。在填充惰性气体后进行减压的情况下,可进一步抑制第一部件40的氧化。另外,腔室53例如是具有耐压性的密封容器。
另外,激光L1的一个脉冲由多个子脉冲构成,例如使用上述的光纤激光打标机MX-Z2000或MX-Z2050而照射。因此,与上述第一实施方式及第二实施方式同样地,在第一部件40上形成穿孔部,并且在该穿孔部的内周面形成突出部(省略图示)。
另外,在第三实施方式中,通过将第一部件与第二部件层叠,并从第二部件侧向第一部件的表面照射激光,而在惰性气体环境下或减压环境下进行将第一部件与第二部件接合的步骤。若以此种方式构成,则由于可抑制由激光的照射引起的第一部件表面上的过度的氧化膜的形成,因此可进一步提高在热循环环境下的耐久性。
例如,如图18所示,在从第二部件41侧向第一部件40的表面照射接合用的激光L2时,通过从喷嘴55向第一部件40与第二部件41的接触界面F喷射惰性气体G,而在惰性气体环境下将第一部件40与第二部件41接合。具体而言,将第二部件41填充于第一部件40的穿孔部中,然后将第二部件41固化。另外,在图18中,将形成于第一部件40与第二部件41的接触界面F的微小的间隙示意性放大而示出。
另外,接合用的激光L2例如为半导体激光。另外,也可不向第一部件40与第二部件41的接触界面F喷附惰性气体G,而是在惰性气体环境下或减压环境下的腔室内通过激光L2将第一部件40与第二部件41接合。
此处,如上所述,可在形成穿孔部时、与将第一部件及第二部件接合时的两种情况下设为惰性气体环境或减压环境,也可在形成穿孔部时、与将第一部件及第二部件接合时的任一情况下设为惰性气体环境或减压环境。另外,在形成穿孔部时,第一部件的温度高于将第一部件及第二部件接合时的温度。因此,在形成穿孔部时,由设为惰性气体环境或减压环境获得的氧化膜的抑制效果大于将第一部件及第二部件接合时的抑制效果。
-实验例-
继而,对为了确认上述的第三实施方式的效果而进行的实验例4进行说明。
在该实验例4中,制作基准例的接合构造体与实施例4~实施例11的接合构造体,并对该些接合构造体测量热冲击试验耐性。然后,将其结果示于表7。另外,实施例4~实施例11的接合构造体对应于第三实施方式者,相对于此,基准例的接合构造体并不与第三实施方式相对应。另外,实施例4~实施例11及基准例对应于第一实施方式或第二实施方式,如下文所述那样,在第一部件形成有穿孔部,并且在该穿孔部的内周面形成有突出部。
[表7]
首先,对基准例的接合构造体的制作方法进行说明。
在基准例的接合构造体中,使用精炼铜(C1100)作为第一部件的材料。该第一部件形成为板状,长度为100mm,宽度为29mm,厚度为0.5mm。
然后,向第一部件的表面的规定区域照射加工用的激光。该规定区域是接合接合构造体的面积,设为12.5mm×20mm。另外,该激光的照射是使用欧姆龙制造的光纤激光打标机MX-Z2000进行的。加工用的激光的照射条件如以下所述。此处,在基准例中,在大气环境下进行加工用的激光照射。即,在不进行惰性气体的喷附或减压的状态下进行激光的照射。
<加工用的激光照射条件>
激光:光纤激光(波长1062nm)
频率:10kHz
输出:3.8W
扫描速度:650mm/sec
扫描次数:40次
照射间隔:65μm
子脉冲数:20
如上所述,通过照射一个脉冲由多个子脉冲构成的激光,在第一部件的表面的规定区域形成穿孔部,并且在该穿孔部的内周面形成突出部。
然后,将第二部件层叠于第一部件的规定区域。使用PMMA(三菱丽阳(MitsubishiRayon)制造的ACRYLITE(注册商标))作为该第二部件的材料。第二部件形成为板状,长度为100mm,宽度为25mm,厚度为3mm。
然后,从第二部件侧向第一部件的规定区域照射接合用的激光。接合用的激光的照射条件如以下所述。此处,在基准例中,是在大气环境下进行接合用的激光照射。
<接合用的激光照射条件>
激光:半导体激光(波长808nm)
振荡模式:连续振荡
输出:30W
焦点直径:4mm
扫描速度:1mm/sec
紧贴压力:0.6MPa
通过该激光的照射,对第一部件进行加热,通过该热将第二部件熔融。然后,将熔融后的第二部件填充于穿孔部中后,将第二部件固化。由此,将第一部件与第二部件接合。
以所述方式制作基准例的接合构造体。
继而,对实施例4~实施例11的接合构造体的制作方法进行说明。
在实施例4中,如上述的表7所示,在照射加工用的激光时,向第一部件的规定区域喷射惰性气体。使用氮气作为惰性气体,并将其流量设为2L/分钟。即,在惰性气体环境下在第一部件形成穿孔部。另外,实施例4的其它方面与基准例相同。
在实施例5中,在减压环境下照射加工用的激光。即,在减压环境下在第一部件形成穿孔部。另外,实施例5的其它方面与基准例相同。
在实施例6中,在照射接合用的激光时,向第一部件及第二部件的接触界面喷射惰性气体(氮气)。即,在惰性气体环境下将第一部件及第二部件接合。另外,实施例6的其它方面与基准例相同。
在实施例7中,在减压环境下照射接合用的激光。即,在减压环境下将第一部件及第二部件接合。另外,实施例7的其它方面与基准例相同。
在实施例8中,在惰性气体环境下在第一部件形成穿孔部,并且在惰性气体环境下将第一部件及第二部件接合。另外,实施例8的其它方面与基准例相同。
在实施例9中,在惰性气体环境下在第一部件形成穿孔部,并且在减压环境下将第一部件及第二部件接合。另外,实施例9的其它方面与基准例相同。
在实施例10中,在减压环境下在第一部件形成穿孔部,并且在惰性气体环境下将第一部件及第二部件接合。另外,实施例10的其它方面与基准例相同。
在实施例11中,在减压环境下在第一部件形成穿孔部,并且在减压环境下将第一部件及第二部件接合。另外,实施例11的其它方面与基准例相同。
然后,对实施例4~实施例11及基准例的接合构造体对热冲击试验的耐久性进行评价。该热冲击试验是使用爱斯佩克(ESPEC)制造的冷热冲击装置TSD-100进行的。具体而言,以-40℃下30分钟的低温曝露与85℃下30分钟的高温曝露作为一个循环,将该循环反复进行。然后,在100、250、500、750、1000及1500个循环的时间点确认在各接合构造体中接合界面是否剥离。
如上述的表7所示,在基准例的接合构造体中,在500个循环的时间点接合界面剥离,且在250个循环前未产生剥离。即,在基准例中,至少在250个循环前具有对热冲击试验的耐性。
相对于此,在实施例5~实施例7及实施例11中,至少在500个循环前具有对热冲击试验的耐性。另外,在实施例4、实施例9及实施例10中,至少在750个循环前具有对热冲击试验的耐性。另外,在实施例8中,至少在1000个循环前具有对热冲击试验的耐性。
因此,在实施例4~实施例11中,与基准例相比,可提高对热冲击试验的耐性。认为这是因为,通过在加工时及接合时的至少一种情况下设为惰性气体环境或减压环境,可抑制形成于第一部件的表面的氧化膜。
另外,根据实施例4及实施例6的结果,在将加工时或接合时的任一者设为惰性气体环境的情况下,在加工时设为惰性气体环境的情况对热冲击试验的耐性变高。另外,根据实施例4及实施例5的结果、与实施例8及实施例11的结果,相较于减压环境,设为惰性气体环境的情况对热冲击试验的耐性变高。
(其它实施方式)
另外,此次公开的实施方式在所有方面均为例示,并非成为限定性解释的根据。因此,本发明的技术范围并不仅由上述的实施方式解释,而是基于权利要求的记载而划定。另外,在本发明的技术范围中,包括与权利要求相同的含义及范围内的全部变更。
例如,在第一实施方式中,表面13可平坦,也可弯曲。另外,第二实施方式也为同样。
另外,在第一实施方式中,示出了扩径部111与缩径部112被形成为相互连接的例子,但并不限于此,也可在扩径部与缩径部之间形成沿深度方向笔直延伸的部分。另外,第二实施方式也为同样。
另外,在第三实施方式中,示出了通过照射接合用的激光L2将第一部件40与第二部件41接合的例子,但并不限于此,也可通过热压成型将第一部件与第二部件接合。在该情况下,可在热压成型时从喷嘴向第一部件与第二部件的接合界面喷附惰性气体,也可在惰性气体环境下或减压环境下的腔室内进行热压成型。另外,也可通过嵌件成型将第一部件与第二部件接合。在该情况下,也可在将第一部件配置于模具上后,在合模(mold closing)为止的期间喷附惰性气体。另外,在进行热压成型及嵌件成型的情况下,第二部件对于激光可不具有透过性。
产业上的可利用性
本发明可用于接合由不同材料构成的第一部件及第二部件而得的接合构造体及其制造方法。
标号说明
10、10a、10b、10c、10d、40:第一部件
11、11b、11c、11d:穿孔部
12、12b、121c、122c、12d:突出部
13:表面
14:隆起部
20、41:第二部件
30、30a、30b、30c、30d:第一部件
31、31b、31c、31d:穿孔部
32、32b、321c、322c、32d:突出部
33:表面
34:隆起部
100:接合构造体
111:扩径部
112:缩径部(第一缩径部)
113:底部
200:接合构造体
311:缩径部(第二缩径部)
312:扩径部
313:缩径部(第一缩径部)
314:底部

Claims (13)

1.一种接合构造体,其是将第一部件与第二部件接合而得的接合构造体,所述接合构造体的特征在于:
在所述第一部件的表面形成有具有开口的穿孔部,并且在所述第一部件的穿孔部中填充有所述第二部件,
所述穿孔部具有在深度方向上开口直径从表面侧朝向底部增大的扩径部、及在深度方向上开口直径从表面侧朝向底部减小的第一缩径部,
所述扩径部形成在表面侧,所述第一缩径部形成在底部侧。
2.根据权利要求1所述的接合构造体,其中,
所述穿孔部具有在深度方向上开口直径从表面侧朝向底部减小的第二缩径部,
所述第二缩径部形成于比所述扩径部靠表面侧的位置。
3.根据权利要求1或2所述的接合构造体,其中,
在所述第一部件的表面形成有多个所述穿孔部,
相邻的穿孔部的间隔为200μm以下。
4.根据权利要求1~3中的任意一项所述的接合构造体,其中,
所述穿孔部的表面的开口直径为30μm~100μm。
5.根据权利要求1~4中的任意一项所述的接合构造体,其中,
所述穿孔部的深度为30μm~300μm。
6.根据权利要求1~5中的任意一项所述的接合构造体,其中,
所述第一部件为金属、热塑性树脂或热固性树脂。
7.根据权利要求1~6中的任意一项所述的接合构造体,其中,
所述第二部件为热塑性树脂或热固性树脂。
8.根据权利要求1~7中的任意一项所述的接合构造体,其中,
在所述穿孔部的开口的周围设置有从表面朝上方隆起的隆起部。
9.根据权利要求1~8中的任意一项所述的接合构造体,其中,
所述穿孔部被形成为轴心相对于表面倾斜。
10.根据权利要求1~9中的任意一项所述的接合构造体,其中,
所述扩径部及所述第一缩径部被形成为相互连接,且在深度方向上形成有多组。
11.一种接合构造体的制造方法,其是将第一部件与第二部件接合而得的接合构造体的制造方法,该接合构造体的制造方法的特征在于包括:
在所述第一部件的表面形成具有开口的穿孔部的步骤;以及
在所述第一部件的穿孔部中填充所述第二部件并使其固化的步骤,
所述穿孔部具有在深度方向上开口直径从表面侧朝向底部增大的扩径部、及在深度方向上开口直径从表面侧朝向底部减小的第一缩径部,
在表面侧形成所述扩径部,在底部侧形成所述第一缩径部。
12.根据权利要求11所述的接合构造体的制造方法,其中,
所述第一部件为金属,
通过在惰性气体环境下或减压环境下向所述第一部件的表面照射激光,形成所述穿孔部。
13.根据权利要求11或12所述的接合构造体的制造方法,其中,
所述第一部件为金属,所述第二部件为热塑性树脂或热固性树脂,且
在惰性气体环境下或减压环境下将所述第二部件填充于所述第一部件的穿孔部中并使其固化。
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