CN109311235A - 接合体的制造方法 - Google Patents
接合体的制造方法 Download PDFInfo
- Publication number
- CN109311235A CN109311235A CN201780035359.4A CN201780035359A CN109311235A CN 109311235 A CN109311235 A CN 109311235A CN 201780035359 A CN201780035359 A CN 201780035359A CN 109311235 A CN109311235 A CN 109311235A
- Authority
- CN
- China
- Prior art keywords
- conjugant
- sheet material
- joint element
- components
- material portion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 70
- 239000000463 material Substances 0.000 claims abstract description 97
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 82
- 238000000034 method Methods 0.000 claims abstract description 43
- 239000012783 reinforcing fiber Substances 0.000 claims description 15
- 238000002844 melting Methods 0.000 claims description 5
- 230000008018 melting Effects 0.000 claims description 5
- 229920000049 Carbon (fiber) Polymers 0.000 description 71
- 239000004917 carbon fiber Substances 0.000 description 71
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 68
- 239000000835 fiber Substances 0.000 description 57
- 238000003466 welding Methods 0.000 description 51
- 229920005989 resin Polymers 0.000 description 49
- 239000011347 resin Substances 0.000 description 49
- -1 polyethylene naphthalate Polymers 0.000 description 20
- 229920002292 Nylon 6 Polymers 0.000 description 10
- SNRUBQQJIBEYMU-UHFFFAOYSA-N dodecane Chemical compound CCCCCCCCCCCC SNRUBQQJIBEYMU-UHFFFAOYSA-N 0.000 description 8
- 239000004615 ingredient Substances 0.000 description 8
- 230000008569 process Effects 0.000 description 8
- 238000000926 separation method Methods 0.000 description 8
- 238000012360 testing method Methods 0.000 description 8
- 238000000465 moulding Methods 0.000 description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 6
- 229910052799 carbon Inorganic materials 0.000 description 6
- 230000000630 rising effect Effects 0.000 description 6
- 239000004753 textile Substances 0.000 description 6
- 230000008859 change Effects 0.000 description 5
- JBKVHLHDHHXQEQ-UHFFFAOYSA-N epsilon-caprolactam Chemical compound O=C1CCCCCN1 JBKVHLHDHHXQEQ-UHFFFAOYSA-N 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 239000004417 polycarbonate Substances 0.000 description 5
- 229920000515 polycarbonate Polymers 0.000 description 5
- 238000005476 soldering Methods 0.000 description 5
- 238000005728 strengthening Methods 0.000 description 5
- 229920001169 thermoplastic Polymers 0.000 description 5
- 239000004677 Nylon Substances 0.000 description 4
- 229920002302 Nylon 6,6 Polymers 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 238000011156 evaluation Methods 0.000 description 4
- 239000011152 fibreglass Substances 0.000 description 4
- 230000010358 mechanical oscillation Effects 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- 229920001778 nylon Polymers 0.000 description 4
- 229920001707 polybutylene terephthalate Polymers 0.000 description 4
- RSJKGSCJYJTIGS-UHFFFAOYSA-N undecane Chemical compound CCCCCCCCCCC RSJKGSCJYJTIGS-UHFFFAOYSA-N 0.000 description 4
- 101100132433 Arabidopsis thaliana VIII-1 gene Proteins 0.000 description 3
- 101000623895 Bos taurus Mucin-15 Proteins 0.000 description 3
- 239000004734 Polyphenylene sulfide Substances 0.000 description 3
- 150000001412 amines Chemical class 0.000 description 3
- 239000007767 bonding agent Substances 0.000 description 3
- 150000004651 carbonic acid esters Chemical class 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 230000006866 deterioration Effects 0.000 description 3
- 239000006185 dispersion Substances 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 229920000069 polyphenylene sulfide Polymers 0.000 description 3
- MHSKRLJMQQNJNC-UHFFFAOYSA-N terephthalamide Chemical compound NC(=O)C1=CC=C(C(N)=O)C=C1 MHSKRLJMQQNJNC-UHFFFAOYSA-N 0.000 description 3
- JVKRKMWZYMKVTQ-UHFFFAOYSA-N 2-[4-[2-(2,3-dihydro-1H-inden-2-ylamino)pyrimidin-5-yl]pyrazol-1-yl]-N-(2-oxo-3H-1,3-benzoxazol-6-yl)acetamide Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)C=1C=NN(C=1)CC(=O)NC1=CC2=C(NC(O2)=O)C=C1 JVKRKMWZYMKVTQ-UHFFFAOYSA-N 0.000 description 2
- 208000032765 Device extrusion Diseases 0.000 description 2
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- 229920003189 Nylon 4,6 Polymers 0.000 description 2
- 229920000305 Nylon 6,10 Polymers 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 2
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 230000021615 conjugation Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 150000003951 lactams Chemical class 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 229920003207 poly(ethylene-2,6-naphthalate) Polymers 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 239000011112 polyethylene naphthalate Substances 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 229920006324 polyoxymethylene Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 239000011342 resin composition Substances 0.000 description 2
- 230000006641 stabilisation Effects 0.000 description 2
- 238000011105 stabilization Methods 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- OEPOKWHJYJXUGD-UHFFFAOYSA-N 2-(3-phenylmethoxyphenyl)-1,3-thiazole-4-carbaldehyde Chemical compound O=CC1=CSC(C=2C=C(OCC=3C=CC=CC=3)C=CC=2)=N1 OEPOKWHJYJXUGD-UHFFFAOYSA-N 0.000 description 1
- ZRPAUEVGEGEPFQ-UHFFFAOYSA-N 2-[4-[2-(2,3-dihydro-1H-inden-2-ylamino)pyrimidin-5-yl]pyrazol-1-yl]-1-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)ethanone Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)C=1C=NN(C=1)CC(=O)N1CC2=C(CC1)NN=N2 ZRPAUEVGEGEPFQ-UHFFFAOYSA-N 0.000 description 1
- PGGROMGHWHXWJL-UHFFFAOYSA-N 4-(azepane-1-carbonyl)benzamide Chemical compound C1=CC(C(=O)N)=CC=C1C(=O)N1CCCCCC1 PGGROMGHWHXWJL-UHFFFAOYSA-N 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 235000017166 Bambusa arundinacea Nutrition 0.000 description 1
- 235000017491 Bambusa tulda Nutrition 0.000 description 1
- 241001330002 Bambuseae Species 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 1
- 101000836394 Homo sapiens Sestrin-1 Proteins 0.000 description 1
- 239000004727 Noryl Substances 0.000 description 1
- 229920001207 Noryl Polymers 0.000 description 1
- 229920006154 PA11T Polymers 0.000 description 1
- 235000015334 Phyllostachys viridis Nutrition 0.000 description 1
- 239000004696 Poly ether ether ketone Substances 0.000 description 1
- 239000004695 Polyether sulfone Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 229920006121 Polyxylylene adipamide Polymers 0.000 description 1
- 206010037660 Pyrexia Diseases 0.000 description 1
- 102100027288 Sestrin-1 Human genes 0.000 description 1
- 239000004902 Softening Agent Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- 229920006387 Vinylite Polymers 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
- 125000002252 acyl group Chemical group 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 239000011425 bamboo Substances 0.000 description 1
- LEDRCCVNHBPBAG-UHFFFAOYSA-N benzene;prop-2-enenitrile Chemical compound C=CC#N.C1=CC=CC=C1 LEDRCCVNHBPBAG-UHFFFAOYSA-N 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- YQLZOAVZWJBZSY-UHFFFAOYSA-N decane-1,10-diamine Chemical compound NCCCCCCCCCCN YQLZOAVZWJBZSY-UHFFFAOYSA-N 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000011549 displacement method Methods 0.000 description 1
- QFTYSVGGYOXFRQ-UHFFFAOYSA-N dodecane-1,12-diamine Chemical compound NCCCCCCCCCCCCN QFTYSVGGYOXFRQ-UHFFFAOYSA-N 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 230000005284 excitation Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- NAQMVNRVTILPCV-UHFFFAOYSA-N hexamethylene diamine Natural products NCCCCCCN NAQMVNRVTILPCV-UHFFFAOYSA-N 0.000 description 1
- 125000004836 hexamethylene group Chemical group [H]C([H])([*:2])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[*:1] 0.000 description 1
- 230000008676 import Effects 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 150000004702 methyl esters Chemical class 0.000 description 1
- 230000000116 mitigating effect Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 210000003205 muscle Anatomy 0.000 description 1
- SXJVFQLYZSNZBT-UHFFFAOYSA-N nonane-1,9-diamine Chemical compound NCCCCCCCCCN SXJVFQLYZSNZBT-UHFFFAOYSA-N 0.000 description 1
- 229920006119 nylon 10T Polymers 0.000 description 1
- 238000000879 optical micrograph Methods 0.000 description 1
- 239000007800 oxidant agent Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920006115 poly(dodecamethylene terephthalamide) Polymers 0.000 description 1
- 229920006111 poly(hexamethylene terephthalamide) Polymers 0.000 description 1
- 229920000747 poly(lactic acid) Polymers 0.000 description 1
- 229920006128 poly(nonamethylene terephthalamide) Polymers 0.000 description 1
- 229920002492 poly(sulfone) Polymers 0.000 description 1
- 229920006396 polyamide 1012 Polymers 0.000 description 1
- 229920001230 polyarylate Polymers 0.000 description 1
- 229920006393 polyether sulfone Polymers 0.000 description 1
- 229920002530 polyetherether ketone Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920005678 polyethylene based resin Polymers 0.000 description 1
- 239000004626 polylactic acid Substances 0.000 description 1
- 229920006380 polyphenylene oxide Polymers 0.000 description 1
- 229920005673 polypropylene based resin Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920005990 polystyrene resin Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 150000003254 radicals Chemical class 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 125000000101 thioether group Chemical group 0.000 description 1
- 230000010415 tropism Effects 0.000 description 1
- 238000002604 ultrasonography Methods 0.000 description 1
- 238000010792 warming Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
- B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
- B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
- B29C65/5064—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped
- B29C65/5071—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped and being composed by one single element
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/82—Testing the joint
- B29C65/8207—Testing the joint by mechanical methods
- B29C65/8215—Tensile tests
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
- B29C66/3022—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined
- B29C66/30221—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined said melt initiators being point-like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
- B29C66/3024—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being non-integral with the parts to be joined
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General 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
- B29C66/71—General 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 composition of the plastics material of the parts to be joined
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General 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
- B29C66/72—General 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 structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
- B29C66/72141—Fibres of continuous length
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General 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
- B29C66/72—General 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 structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
- B29C66/72143—Fibres of discontinuous lengths
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General 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
- B29C66/73—General 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
- B29C66/735—General 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 extensive physical properties of the parts to be joined
- B29C66/7352—Thickness, e.g. very thin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General 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
- B29C66/73—General 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
- B29C66/739—General 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
- B29C66/7392—General 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
- B29C66/73921—General 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
- B29C66/832—Reciprocating joining or pressing tools
- B29C66/8322—Joining or pressing tools reciprocating along one axis
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
- B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
- B29C66/949—Measuring or controlling the joining process by measuring or controlling the time characterised by specific time values or ranges
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
- B29C66/951—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools
- B29C66/9517—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools characterised by specific vibration amplitude values or ranges
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered 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
- B32B3/26—Layered 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 a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/30—Layered 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 a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General 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
- B29C66/72—General 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 structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
- B29C66/951—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools
- B29C66/9513—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools characterised by specific vibration frequency values or ranges
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
Abstract
根据本发明,能够提供一种接合体的制造方法,该方法将接合部件配置在含有热塑性树脂的部件A与含有热塑性树脂的部件B之间,至少使所述接合部件的一部分熔化,得到接合有所述部件A和所述部件B的接合体,其中,所述接合部件具有:片材部,含有热塑性树脂;和多个突起部,在所述片材部的至少一个面与所述片材部形成为一体,并且含有热塑性树脂。
Description
技术领域
本发明涉及包含热塑性树脂的接合体的制造方法。更详细而言,涉及生产性和接合强度良好的接合体的制造方法,能够适合用作以汽车为代表的结构部件的制造方法。
背景技术
包含热塑性树脂的成形体被广泛使用在各种领域中,特别是近年来,在机械领域中,包含热塑性树脂和碳纤维等强化纤维作为基材的所谓的纤维强化热塑性树脂成形体(以下,也称为“纤维强化热塑性塑料”)受到关注。例如,提出了在制造汽车用的零部件、结构部件时需要的在纤维强化热塑性塑料彼此的接合中,通过形成封闭截面结构,从而提高刚性的方法。在对使用热塑性树脂作为基材的纤维强化热塑性塑料彼此进行接合时,提出了使用螺栓·螺母、铆钉等的机械接合、使用粘接剂的化学接合、使用热板熔接、IR熔接、振动熔接、超声波熔接等的热接合。其中,超声波熔接除了不需要第三材料之外,由于循环时间短等理由,在各种产业领域被广泛使用。
超声波熔接是指,将被称为熔接焊头的共振体按压在被接合体,并且从该共振体施加高频的机械振动,将传递到被接合体的机械振动转换成热能,对被接合体的一部分进行加热·熔化,从而将被接合体和与其接触的其他被接合体熔接的方法。
在超声波熔接中,为了稳定地得到高接合强度,已知有以下方法:即,在被接合体的表面与所述被接合体一体地形成被称为导能器的突起,并在施加超声波时使导能器集中地振动·熔化,更高效地进行熔接(专利文献1)。
在专利文献2中记载了以下方法:即,在将两个纤维强化热塑性树脂接合时,在至少一方的纤维强化热塑性树脂的被接合面预先接合热塑性树脂材料,然后,将两个纤维强化热塑性树脂接合。
另外,在非专利文献1中记载了以下方法:即,在碳纤维强化尼龙6的成形板的被接合面配置包含尼龙6或尼龙66的单丝纺织品网状物或者膜,并对成形板施加超声波而进行熔接。
现有技术文献
专利文献
专利文献1:国际公开第2015/163218号
专利文献2:日本特许第5787150号公报
非专利文献
非专利文献1:竹内和保(Kazuho Takeuchi)、大谷昭夫(Akio Ohtani),“超声波焊接的焊接条件对C-FRTP接头性能的影响”,第14届日本国际SAMPE研讨会和展览,2015年12月8日在金泽举行的会议
发明内容
发明欲解决的技术问题
但是,使用专利文献1中所记载的与被接合体一体形成的导能器的接合方法,存在以下问题。
(1)存在为了将导能器设置在被接合部件表面,需要制造实施了微细加工的模具,因此存在导致成本增大的问题。
(2)特别是在导能器被设置在大型部件的末端部的情况下,存在赋形时容易产生压力分布、形状和尺寸不稳定、容易产生偏差这样的问题。
(3)特别是大型部件有时因各种因素而产生变形、翘曲,并且有时设有导能器的被接合面无法与想要接合的其他部件接触,从而导致接合强度不够或无法接合。
(4)在经由导能器而熔接后的接合部的一部分已剥离的情况下,无法对剥离面重新赋予导能器,因此,难以通过对成形中的导能器的再形成来进行修复。
另外,在专利文献2记载的接合方法中,在两个纤维强化热塑性树脂的接合中,需要将热塑性树脂材料层与被接合面接合的工序以及之后的将两个纤维强化可塑性树脂接合的工序这样的两个工序,工序繁杂,耗费时间和成本。另外,在配置于两个被接合面之间的热塑性树脂材料的表面未设置作为导能器而发挥功能的突起,故难以稳定地得到高的接合强度。
另外,在非专利文献1的方法中,将由热塑性树脂的单丝形成的纺织品网状物插入到被粘物之间,使其作为导能器而发挥功能。但是,在纺织品的情况下,存在因其纺织结构而造成单丝交叉的卷曲部。由于卷曲部的单丝容易相互移动,因此存在所提供的振动能量发生损失、接合强度下降的这样问题。另外,对于纺织品网状物而言,较薄者能够容易地制作出来,但是厚的很难得到。
因此,本发明的目的是提供一种接合体的制造方法,其成本低且生产性优异,即使在被接合部件的所有部位的接合或者已发生了翘曲变形的被接合部件的接合中也能够以稳定且高的接合强度进行接合,并且在接合面发生局部剥离时也能够简单地修复。
用于解决问题的技术手段
本发明人进行了深入研究,结果发现,通过以下示出的方法能够解决上述课题,从而完成本发明。
<1>
一种接合体的制造方法,其中,
将接合部件配置在含有热塑性树脂的部件A与含有热塑性树脂的部件B之间,至少使所述接合部件的一部分熔化,得到接合有所述部件A和所述部件B的接合体,其中,所述接合部件具有:片材部,含有热塑性树脂;和多个突起部,在所述片材部的至少一个面与所述片材部形成为一体,并且含有热塑性树脂。
<2>
根据<1>中记载的接合体的制造方法,其中,所述片材部的厚度为5~5000μm。
<3>
根据<1>或は<2>中记载的接合体的制造方法,其中,所述突起部的最大高度为50~500μm。
<4>
根据<1>~<3>的任一项中记载的接合体的制造方法,其中,对于所述接合部件的至少一面,由下述式(S1)定义的、突起部的投影面积相对于片材部的面积的合计的比率为25~95%,
式(S1)
突起部的投影面积的合计相对于片材部的面积的比率=(片材部的一个面中的突起部的投影面积的合计/片材部的所述一个面的面积)×100(%)。
<5>
根据<1>~<4>的任一项中记载的接合体的制造方法,其中,在所述接合部件的所述片材部两面赋予有所述突起部。
<6>
根据<1>~<5>的任一项中记载的接合体的制造方法,其中,由下述式(S2)定义的、接合体中的部件A与部件B之间的接合面间距相对于接合前的接合部件的高度的比率为95%以下,
式(S2)
接合体中的部件A与部件B之间的接合面间距相对于接合前的接合部件的高度的比率=(接合体中的部件A与部件B之间的接合面间距/接合前的接合部件的高度)×100(%)。
<7>
根据<1>~<6>的任一项中记载的接合体的制造方法,其中,使所述接合部件的至少一部分熔化的方法是施加振动能量的方法。
<8>
根据<1>~<7>的任一项中记载的接合体的制造方法,其中,所述部件A、所述部件B和所述接合部件中的至少一个含有强化纤维。
发明效果
根据本发明,能够提供一种接合体的制造方法,其成本低且生产性优异,即使在被接合部件的所有部位的接合或者已发生了翘曲变形的被接合部件的接合中也能够以稳定且高的接合强度进行接合,并且,在接合面的局部发生了剥离时也能够简单地修复。
另外,根据本发明,能够提供一种接合强度和设计的自由度高、也能够适用于大量生产的接合体的制造方法。
附图说明
图1是示出接合部件的一个例子的截面示意图。
图2是示出接合部件的一个例子的截面示意图。
图3是示出接合体的制造方法的一个例子的示意图。
图4是用于说明接合部件的一个例子中的片材部的厚度和突起部的最大高度的截面示意图。
符号说明
1 接合部件
2 片材部
3 突起部
4 熔接焊头
A 部件A
B 部件B
t 片材部的厚度
h 突起部的最大高度
具体实施方式
以下,对本发明的实施方式依次进行说明。
本发明的接合体的制造方法如下:将接合部件配置在含有热塑性树脂的部件A与含有热塑性树脂的部件B之间,并且至少使所述接合部件的一部分熔化,得到接合有所述部件A和所述所述部件B的接合体,其中,所述接合部件具有:包含热塑性树脂的片材部;和在所述片材部的至少一个面与所述片材部形成为一体的含有热塑性树脂的多个突起部。
[接合部件]
在本发明的接合体的制造方法中使用的接合部件具有:含有热塑性树脂的片材部;以及在所述片材部的至少一个面与所述片材部形成为一体的含有热塑性树脂的多个突起部。
(片材部)
接合部件的片材部至少含有热塑性树脂。
片材部的厚度没有特别限制,但是从接合部件的操作性、组装被粘物时现实的互相摩擦的范围这样的观点考虑,优选为5~5000μm,更优选为40~4000μm,进一步优选100~3000μm。例如在图4所示的接合部件1中,片材部2的厚度由t表示。
即使在被接合部件(部件A或者部件B)中发生了翘曲变形的情况下,本发明中的接合部件通过调节片材部的厚度来填补因翘曲变形而导致的在部件A与部件B之间的间隙,从而即使存在这样的本来难以熔接的间隙,也能够简单地得到高接合强度的接合体。
接合部件的片材部的大小和形状没有特别限制。
本发明中的接合部件可以与被接合部的形状、大小匹配地使用任意大小和形状的接合部件,因此,接合体的接合强度和设计自由度非常高。另外,即使在接合后的接合面局部发生了剥离,通过与已剥离部分的大小匹配地切下必要的接合部件,并配置在已剥离部分进行接合,从而能够简单地进行修复。
<热塑性树脂>
作为片材部中含有的热塑性树脂的种类,没有特别限定,例如可以列举:氯乙烯系树脂、偏氯乙烯系树脂、乙酸乙烯酯系树脂、聚乙烯醇系树脂、聚苯乙烯系树脂、丙烯腈-苯乙烯系树脂(AS树脂)、丙烯腈-丁二烯-苯乙烯系树脂(ABS树脂)、丙烯酸系树脂、甲基丙烯酸系树脂、聚乙烯系树脂、聚丙烯系树脂、各种热塑性聚酰胺系树脂、聚缩醛系树脂、聚碳酸酯系树脂、聚对苯二甲酸乙二醇酯系树脂、聚萘二甲酸乙二醇酯系树脂、聚萘二甲酸丁二醇酯系树脂、聚对苯二甲酸丁二醇酯系树脂、聚芳酯系树脂、聚苯醚系树脂、聚苯硫醚系树脂、聚砜系树脂、聚醚砜系树脂、聚醚醚酮系树脂、聚乳酸系树脂等。其中,优选地列举:尼龙(热熔化性聚酰胺)、聚碳酸酯、聚甲醛、聚苯硫醚、聚苯醚、改性聚苯醚、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚萘二甲酸乙二醇酯、聚乙烯、聚丙烯、聚苯乙烯、聚甲基丙烯酸甲酯、AS树脂、ABS树脂等。
考虑到成本和物理性质兼得,更优选从由尼龙、聚丙烯、聚碳酸酯和聚苯硫醚组成的组中选出的至少一种。另外,作为尼龙(以下有时也简称为“PA”),优选从由PA6(也称作聚己内酰胺(plycaproamide)或聚己内酰胺(polycaprolactam),或者聚-ε-己内酰胺)、PA26(聚己二酰乙二胺)、PA46(聚己二酰丁二胺)、PA66(聚己二酰己二胺)、PA69(聚壬二酰己二胺)、PA610(聚癸二酰己二胺)、PA611(聚十一烷二酰己二胺)、PA612(聚十二烷二酰己二胺)、PA11(聚十一烷桥内酰胺)、PA12(聚十二烷桥内酰胺)、PA1212(聚十二烷二酰十二烷二胺)、PA6T(聚对苯二甲酰己二胺)、PA6I(聚间苯二甲酰己二胺)、PA912(聚十二烷二酰壬二胺)、PA1012(聚十二烷二酰癸二胺)、PA9T(聚对苯二甲酰壬二胺)、PA9I(聚间苯二甲酰壬二胺)、PA10T(聚对苯二甲酸癸二胺)、PA10I(聚间苯二甲酰癸二胺)、PA11T(聚对苯二甲酰十一烷二胺)、PA11I(聚间苯二甲酰十一烷二胺)、PA12T(聚对苯二甲酰十二烷二胺)、PA12I(聚间苯二甲酰十二烷二胺)以及聚酰胺MXD6(聚己二酰间苯二甲胺)组成的组中选出的至少一种。这些热塑性树脂根据需要也可以含有稳定剂、阻燃剂、颜料、填充剂等添加剂。这些热塑性树脂可以单独使用,也可以两种以上并用。
虽然片材部中含有的热塑性树脂与在部件A和部件B的至少一方中含有的热塑性树脂可以相同也可以不同,但是从热熔接工艺的限制、确保树脂的热历史所伴随的接合强度的观点考虑,优选片材部中含有的热塑性树脂的熔点与在部件A和部件B的至少一者中含有的热塑性树脂的熔点之差为50℃以下,更优选为20℃以下。
片材部也可以含有热塑性树脂以外的成分。
作为片材部也可以含有的除热塑性树脂以外的成分,没有特别限定,例如可以列举:强化纤维、填料、阻燃剂、抗UV剂、稳定剂、脱模剂、颜料、软化剂、增塑剂、表面活性剂、抗氧化剂等。
在本发明中,在接合部件的片材部和突起部的至少一者中,也可以含有在部件A或部件B中未含有的添加剂,也可以赋予各种功能。
作为强化纤维,可以列举:碳纤维、玻璃纤维、芳纶纤维等,从力学特性以及重量轻的观点考虑,优选碳纤维。
<碳纤维>
虽然对碳纤维没有特别限定,具体地可以列举:PAN系碳纤维、沥青系碳纤维。其中,PAN系碳纤维由于重量轻,因此,也可以适当用于减轻接合体的重量等。需要说明的是,碳纤维可以单独使用,也可以并用两种以上碳纤维。碳纤维的形态没有特别限制,可以是连续纤维,也可以是不连续纤维。
连续纤维的平均纤维直径通常5~20μm是恰当的。
另外,在不连续的碳纤维的情况下,碳纤维可以取向为热塑性树脂中的特定方向,可以是在平面内二维地无序分散的状态,也可以是三维地无序分散的状态。对于不连续的碳纤维,优选使用平均纤维直径为5~20μm、平均纤维长度在0.05~20mm的范围内、更优选为0.1~10mm者。如果平均纤维长度为0.05mm以上,则增强效果特别优异,如果为20mm以下,则片材部或突起部特别容易形成。
不连续的碳纤维是:以由下述式(a)定义的临界单纤维数以上构成的碳纤维束(A)与小于临界单纤维数的碳纤维束(B1)和/或碳纤维单丝(B2)混合存在,并且,碳纤维束(A)相对于碳纤维总量的比例为20~99Vol%,优选为30~90Vol%,进一步地,上述碳纤维束(A)中的平均纤维数量(N)优选满足下述式(b)。
临界单纤维数=600/D(a)
0.6×104/D2<N<6×105/D2(b)
(其中,D是碳纤维的平均纤维直径(μm)。)
更优选的平均纤维数量(N)的范围是0.6×104/D2<N<1×105/D2。
碳纤维也可以将连续纤维与不连续纤维组合使用。
片材部例如可以通过注塑成形、挤出成形进行制造,另外,也可以与突起部一起利用加压成形来进行制造。
(突起部)
接合部件的突起部至少含有热塑性树脂,并且被与片材部一体地设置在片材部的至少一个面。
在本发明中,在超声波熔接那样的利用施加振动能量的方法使其接合的情况下,接合部件的突起部优选作为导能器而发挥作用。此处,导能器表示为了实现均匀的熔化状态和高效的熔接而赋予接合面的突起形状。如果在平滑面彼此的接合中赋予超声波等振动能量,则由于表面粗糙度等而引起树脂的熔化位置不均匀,无法得到均匀且稳定的熔接强度。另外,在接合面的发热温度上升慢并且工序时间过长的情况下,不仅效率差,而且导致树脂的劣化。另一方面,如果是形成有导能器的面的接合,则树脂的熔化位置总是成为突起形状的顶点,并且保持不变,因此,被赋予的振动能量集中地作用在该部分,得到均匀的熔化状态,从而能够得到稳定的熔接强度。另外,达到接合面的树脂熔化温度的发热是极短时间,因此,能够有效率地进行熔接,因此,能够抑制树脂的劣化。
本发明中的接合部件可以在片材部的至少一个面具有多个突起部,也可以仅在片材部的单面具有突起部(参照图1),也可以在片材部的两面具有突起部(参照图2)。特别是为了填充由于部件A或部件B产生的翘曲变形而导致在部件A与部件B的接合面之间的间隙,而使用具有厚壁片材部的接合部件进行熔接的情况下,通过对厚壁片材部的两面都赋予突起部,从而得到更稳定的高接合强度。此处,所谓厚壁片材部,尽管也取决于熔接的激振时间(excitation time)等的熔接条件,但通常是指厚度为300μm以上的片材部。
突起部的形状没有特别限制,可以列举:在片材部的表面的法线方向延伸的柱状(例如,圆柱状、棱柱状)、锥体状(例如,圆锥状、棱锥状)、沿着圆锥台、棱锥台、片材部的表面延伸的棒状(可以是直线状,也可以是曲线状。而且,片材部表面的法线方向的截面形状没有特别限制)、板状、具有曲面或球面的形状(球冠状)等。另外,所有的突起部的形状可以相同,也可以具有不同形状的突起部。
关于突起部的高度,从熔接前后的接合部的尺寸稳定性的观点考虑,突起部距离片材部表面的最大高度优选为50~500μm,更优选为100~300μm。如果突起部的最大高度为50μm以上,则在使接合部件熔化时,突起部容易成为熔化的起点,能够以稳定且高的接合强度进行熔接。另一方面,如果突起部的最大高度为500μm以下,则能够使用于突起部完全熔化的熔接时间变短,生产性优异,同时能够抑制构成突起部的热塑性树脂的劣化。例如在图4所示的接合部件1中,突起部3的最大高度由h表示。
需要说明的是,作为本发明中使接合部件熔化的方法,在使用施加振动能量的方法特别是振动熔接方法的情况下,还可以进一步提高所述突起部的最大高度,此时,例如,也可以将所述突起部的最大高度设定为50~5000μm的范围内。
本发明中的突起部的个数没有特别限制,优选的突起部的个数可以在所选择的突起部的高度和突起部的投影面积的组合中适当设计,以稳定地得到高的接合强度。
本发明中,在片材部上形成的突起部的比例根据本发明的接合部件的用途等而适当调整即可,没有特别限定,但是对于接合部件的至少一个面,由下述式(S1)定义的突起部的投影面积的合计相对于片材部的面积的比率优选为25~95%,更优选为30~85%。如果上述比率在上述范围内,则在将接合部件熔化时,突起部成为熔化的起点,能够得到充分的接合强度。
式(S1)
突起部的投影面积的合计相对于片材部的面积的比率=(片材部的一个面中的突起部的投影面积的合计/片材部的所述一个面的面积)×100(%)
需要说明的是,“片材部的面积”在仅在片材部的单面形成有突起部的接合部件中是指形成有突起部的表面的面积。如果是在片材部的两面形成有突起部的接合部件,则针对各个面评价所述突起部的投影面积的比率。
“突起部的投影面积”是指从形成有上述片材部的突起部的面的法线方向对突起部进行投影而得到的投影图的面积,“突起部的投影面积的合计”是指处于片材部的一个面的所有突起部的投影图的面积的合计。
突起部中含有的热塑性树脂的种类的具体例和优选范围与上述的片材部中含有的热塑性树脂的种类的具体例和优选范围相同。
虽然突起部中含有的热塑性树脂与片材部中含有的热塑性树脂可以相同,也可以不同,但是从热熔接工艺的限制、确保树脂的热历史所伴随的接合强度的观点考虑,优选突起部中含有的热塑性树脂的熔点与在片材部中含有的热塑性树脂的熔点之差为50℃以下,更优选为20℃以下。另外,虽然突起部中含有的热塑性树脂与在部件A和部件B的至少一者中含有的热塑性树脂可以相同也可以不同,但是从热熔接工艺的限制、确保树脂的热历史所伴随的接合强度的观点考虑,优选突起部中含有的热塑性树脂的熔点与在部件A和部件B的至少一者中含有的热塑性树脂的熔点之差为50℃以下,更优选为20℃以下。
突起部也可以含有热塑性树脂以外的成分,作为热塑性树脂以外的成分,与上述的片材部也可以含有的热塑性树脂以外的成分相同。
(接合部件的制作方法)
接合部件的制作方法没有特别限制,例如可以通过对热塑性树脂进行加压成形或者注塑成形来制作。另外,也可以通过将热塑性树脂成形为片材状,然后利用浮雕加工等形成突起部来制作。特别是利用浮雕加工进行制作的方法是容易连续生产接合部件,能够降低生产成本,因此优选。
[部件A]
部件A至少含有热塑性树脂。
部件A中含有的热塑性树脂的种类的具体例和优选范围与上述的片材部中含有的热塑性树脂的种类的具体例和优选范围相同。
部件A也可以含有热塑性树脂以外的成分,作为热塑性树脂以外的成分,与上述的片材部可以含有的热塑性树脂以外的成分相同。
部件A优选含有强化纤维,更优选含有碳纤维。
对于碳纤维,除了在上述的片材部也可以含有的碳纤维中记载的事项之外,优选以下说明的事项。
在碳纤维是连续纤维的情况下,可以是编织物、纺织物的形态,也可以是使碳纤维在一个方向排列以成为片材状的所谓UD片材。在是UD片材的情况下,也可以使用以各层的纤维排列方向互相交叉的方式层叠为多层(例如在正交方向交替地层叠)者。
部件A也可以对含有连续纤维的一个部件和含有不连续纤维的其他部件进行层叠等而组合。
在碳纤维是不连续且二维地无序分散的情况下,可以是利用加压成形得到的部件,可以是碳纤维进行湿法抄制成为片材状的情况,也可以是不连续的碳纤维以分散重叠的方式进行配置以形成片材状或者垫状(以下,有时总成为“垫”)的情况。此时的平均纤维直径为5~20μm,平均纤维长度优选为1~100mm,更优选为3~100mm,进一步优选为10~100mm,其中,更进一步优选为12~50mm。在后者的垫中,垫中含有的碳纤维的平均纤维长度是重要的,在平均纤维长度大于1mm的情况下,能够容易地发挥作为碳纤维的功能,容易得到充分的强度。相反地,在平均纤维长度小于100mm的情况下,成形时的流动性良好,容易得到期望的成形体。
部件A可以是三维各向同性的碳纤维垫,其中,碳纤维通过缠绕等成为棉状,碳纤维的长轴方向无序地分散在XYZ的各方向,不过,在使用后述的加压成形的情况下,优选碳纤维是上述平均纤维长度的范围,并且实质上是二维无序取向的垫(以下,也称为“无序垫”)。
此处,实质上二维无序地取向是指以下状态:碳纤维在纤维强化热塑性塑料的面内方向上,不是一个方向这样的特定方向而是无秩序地取向,整体上不会表现出特定的方向性地配置在面内。
无序垫中,虽然碳纤维的全部或者大部分可以以原纤化为单丝状的状态存在,但是特别优选成为各向同性无序垫,其中,某个根数以上的单丝聚集而成的纤维束与单丝或者接近单丝状态的纤维束以预定比例混合存在。对于这样的各向同性无序垫及其制造方法,在国际申请第2012/105080号、特开2013-49208号公报的说明书中有详细记载。
上述适合的无序垫是以由下述式(a)定义的临界单纤维数以上构成的碳纤维束(A)与小于临界单纤维数的碳纤维束(B1)和/或碳纤维单丝(B2)混合存在的各向同性无序垫,该各向同性无序垫中的碳纤维束(A)相对于纤维总量的比例为20~99Vol%,优选为30~90Vol%,进一步地,上述碳纤维束(A)中的平均纤维数量(N)满足下述式(b)。
临界单纤维数=600/D(a)
0.6×104/D2<N<6×105/D2(b)
(此处,D是碳纤维的平均纤维直径(μm)。)
更优选的平均纤维数量(N)的范围是0.6×104/D2<N<1×105/D2。
碳纤维的平均纤维直径为5~20μm,其中,优选为5~12μm。
部件A的碳纤维的单位面积质量为25~10000g/m2的范围,在以由上述式(a)定义的临界单纤维数以上构成的碳纤维束(A)中,相对于碳纤维总量的比例为上述范围并且碳纤维束(A)中的平均纤维数量(N)满足上述式(b),从而良好地平衡了部件A的作为复合材料的成形性和机械强度。碳纤维的单位面积质量优选为25g/m2~4500g/m2以下。
作为部件A中的热塑性树脂的含量,相对于碳纤维100重量份,优选为3~1000重量份。
在部件A中,虽然由下述式(1)定义的碳纤维体积比例(以下,有时简称为“Vf”)没有特别限制,但是碳纤维体积比例(Vf)优选为10~70Vol%。
Vf=100×碳纤维体积/(碳纤维体积+热塑性树脂体积)式(1)
在碳纤维的体积比例为10Vol%以上的情况下,容易得到期望的机械物理性质。另一方面,如果是70Vol%以下,则热塑性树脂充分,干碳纤维不会增加,故优选。部件A中的碳纤维体积比例(Vf)的更优选的范围是20~60Vol%,进一步优选的范围是30~50Vol%。
部件A的大小和形状没有特别限制。
例如,在部件A是板状的情况下,部件A的厚度没有特别限制,通常优选在0.5~20mm的范围内,更优选为0.5~10mm的范围内,进一步优选0.5~5mm的范围内,更进一步优选1~5mm的范围内。
[部件B]
部件B至少含有热塑性树脂。
对于部件B,与上述的部件A同样。
虽然在部件A中含有的热塑性树脂与在部件B中含有的热塑性树脂可以相同也可以不同,但是从热熔接工艺的限制、确保树脂的热历史所伴随的接合强度的观点考虑,优选在部件A中含有的热塑性树脂的熔点与在部件B中含有的热塑性树脂的熔点之差为50℃以下,更优选为20℃以下。
在本发明中,优选部件A、部件B和接合部件中的至少一个含有强化纤维,更优选部件A、部件B和接合部件中的至少一个含有碳纤维。
[熔接方法]
在本发明中,将上述的接合部件配置在部件A与部件B之间,并使接合部件的至少一部分熔化,得到接合有部件A和部件B的接合体。
使接合部件熔化的方法没有特别限制,但从使作为接合介质的接合部件熔化的能量效率的观点考虑,优选施加振动能量的方法,更优选振动熔接法,进一步优选超声波熔接法。利用超声波熔接法,对部件A和部件B的形状、大小的限制少,能够使用任何形状的部件A和部件B,因此,利用本发明,能够制造在广泛用途中使用的接合体。
使用图3,对使用超声波熔接法实施本发明的接合体的制造方法的情况下的一个例子进行说明。
如图3所示,使部件A(图3的A)和部件B(图3的B)的表面中想要彼此接合的部分面对面,将接合部件(图3的1)配置在部件A与部件B之间,从部件A侧向该接合面施加超声波,将热塑性树脂熔化,从而部件A与部件B被固定,接合完成。在这种情况下,也可以在施加超声波将热塑性树脂熔化之后,适当地实施冷却工序,也可以在将接合部件配置在部件A与部件B之间时,使用公知的手段(例如直接熔接等)暂时固定接合部件。
需要说明的是,虽然在图3中从部件A侧施加超声波,但是也可以从部件B侧施加。
超声波熔接法是指以下方法:将被称为熔接焊头(图3的4)的共振体按压在部件A或部件B,同时从该共振体施加高频的机械振动,并将传递到部件A或部件B的机械振动转换为摩擦热,使接合部件的至少一部分熔化,从而将部件A和部件B熔接,例如,可以使用超声波熔接机(BRANSON公司制、产品名:2000Xdt)进行。
此处,作为施加超声波以使其熔接的控制因素有超声波的频率、超声波的振幅、超声波的施加时间、按压样品的压力等。虽然存在超声波的振幅、超声波的施加时间、按压样品的压力越大,接合强度越大的倾向,但是可以根据装置的使用、接合部件的片材部的厚度、突起部的形状和尺寸、需要的循环时间等而适当地进行控制,以得到稳定的熔接。
作为超声波熔接时的控制条件有频率、熔接时间、振幅、加压力等,作为优选的条件,可以是频率为15~50kHz、熔接时间为0.1~5秒、振幅为30~100μm、加压力为500~2000N的范围。从熔接的生产性考虑,更优选频率20~40kHz、熔接时间0.5~2秒、加压力500~1500N的范围。
另外,超声波熔接时,在将被接合体的位置固定以固定熔接位置的情况下,也可以使用称为砧的夹具。
[接合体]
对于利用本发明制造的接合体,由下述式(S2)定义的、接合体中的部件A与部件B之间的接合面间距相对于接合前的接合部件的高度的比率优选为95%以下,更优选为80%以下。如果上述比率为95%以下,则熔接充分,接合强度优异。
需要说明的是,上述“接合前的接合部件的高度”是指接合部件的突起部的高度和片材部的高度(厚度)的合计值。例如在图4所示的接合部件1中,接合部件的高度是指突起部3的最大高度h和片材部2的厚度t的合计值。
式(S2)
接合体中的部件A与部件B之间的接合面间距相对于接合前的接合部件的高度的比率=(接合体中的部件A与部件B之间的接合面间距/接合前的接合部件的高度)×100(%)
实施例
以下,通过示出制造例、实施例、参考例和比较例,对本发明进行更具体的说明,但是本发明不限于此。
各实施例、参考例和比较例中的各值按照以下方法进行评价。
(1)各纤维强化树脂材料中的强化纤维的平均纤维长度
各纤维强化树脂材料中的强化纤维的平均纤维长度是,将纤维强化树脂材料在500℃的炉内加热1小时,除去热塑性树脂,然后,用游标卡尺对随机抽取的强化纤维100根的长度进行测量至1mm单位,作为其平均值。在平均纤维长度小于1mm的情况下,在光学显微镜下测量至0.1mm单位。
(2)各纤维强化树脂材料中的强化纤维的体积含有率
各纤维强化树脂材料中的强化纤维的体积含有率是利用水中置换法求出纤维强化树脂材料的密度,并且根据预先测定的强化纤维单独的密度与树脂单独的密度之间的关系,算出强化纤维的体积含有率。
(3)纤维强化树脂接合体的拉伸剪切强度
按照汽车技术会在1987年3月发行的(The Society of Automotive Engineersof Japan)No.M406-87进行测量。具体而言,拉伸剪切强度(拉伸剪切粘合强度)的评价以拉伸速度5mm/秒来实施,根据利用下述(4)的方法求出的熔接部分的面积,求出每个单位面积的拉伸剪切强度(MPa)。
(4)熔接部分的投影面积
关于得到的纤维强化树脂接合体,剥离作为被接合体的部件A或者部件B,从垂直方向目视观察接合面,将施加超声波之后的熔接面积中的最长轴作为长边,将与长边正交的轴作为短边,分别用尺子测定至0.1mm单位,然后,计算为椭圆面积。
(部件A和B的制造例)
以下,对作为被接合体的部件A和B的制造例进行说明。
(制造例1)
在制造例1中,描述与作为导能器而发挥作用的突起一体地成形的被接合体的制造例。
使用已切成平均纤维长度30mm的TOHOTENAX公司制造的PAN系碳纤维“TENAX(注册商标)”STS40-24KS(平均纤维直径7μm、密度约1750kg/m3)作为强化纤维,使用UNITIKA公司制造的尼龙6树脂A1030(密度约1130kg/m3)作为热塑性树脂,并且以碳纤维的体积比例相对于碳纤维和尼龙6树脂的合计体积达到35%的方式进行混合,利用加热到280℃的加压装置以压力2.0MPa加热压缩5分钟,从而制作了碳纤维在面内方向二维无序取向的纤维强化树脂材料。
将得到的成形板切成390mm×390mm的大小,在用120℃的热风干燥机干燥4小时之后,利用红外线加热机将成形板的温度升温至280℃。将该加热后的成形板以能够形成预先准备的导能器的突起的方式导入到雕刻有凹部的模具。将模具的温度设定为140℃,然后,以加压压力5MPa加压1分钟,得到400×400×2.5mm的平板状的成形体。将该成形体切成大小为100×25mm的长方形。作为导能器的突起处于该长方形成形体的长边方向的端部即成为接合面的预定部分,其面积为25mm×25mm。导能器的突起为球冠状,最大高度0.2mm、突起的投影面积相对于接合面的面积的比率为60%。
这样,制作了作为被接合体的部件I。将结果记录在表1。
需要说明的是,对部件I,通过在100×25mm的长方形成形体的长边方向的另一个端部用粘接剂(PLEXUS MA530)粘贴38×25mm的长方形标签,进行拉伸剪切接合试验来完成。
(制造例2)
除了作为导能器而发挥作用的突起不在加压成形时制作以外,与制造例1同样地制造被接合体的部件II。将结果记录在表1。
(制造例3)
除了使用切成平均纤维长度20mm的碳纤维以外,与制造例2同样地制造被接合体的部件III。将结果记录在表1。
(制造例4)
除了以碳纤维的体积比例相对于碳纤维和尼龙6树脂的合计体积达到45%的方式混合并调整以外,与制造例2同样地制造了被接合体的部件IV。将结果记录在表1。
(制造例5)
将100重量份作为碳纤维的切成平均纤维长度10mm的TOHOTENAX公司制造的碳纤维“TENAX”(注册商标)STS40-24KS和320重量份作为热塑性树脂的UNITIKA公司制造的尼龙6树脂A1030投入到双轴混炼挤出机,进行混炼,制成纤维强化树脂组合物。该树脂组合物中的碳纤维是单丝状,碳纤维体积比例为17%。使用已得到的纤维强化树脂组合物,利用日本制钢所制造110ton电动注塑成形机(日本制钢公司制造JSW180H),导入120×120mm的模具中,制造120×120×2.5mm的成形体。将该成形体切成大小为100×25mm的长方形,制作作为被接合体的部件V。将结果记录在表1。需要说明的是,对于部件V,通过在长边方向的另一端部用粘接剂(PLEXUSMA530)粘贴38×25mm的长方形标签并进行拉伸剪切接合试验来完成。部件V中的碳纤维的平均纤维长度如表1记载的那样为0.9mm。
(制造例6)
除了使用聚碳酸酯(帝人株式会社制造:L-1225Y)作为热塑性树脂并且将聚碳酸酯调整为相对于100重量份碳纤维而达到380重量份以外,与制造例5同样地制造了被接合体的部件VI。将结果记录在表1。
(制造例7)
除了使用聚碳酸酯(帝人株式会社制造:L-1225Y)作为热塑性树脂并且将聚碳酸酯调整为相对于100重量份碳纤维而达到200重量份以外,与制造例5同样地制造了被接合体的部件VII。将结果记录在表1。
[表1]
(接合部件的制造例)
以下,针对接合部件的制造例进行说明。
(制造例8-1~8-8)
将UNITIKA公司制造的尼龙6树脂A1030投入到双轴混炼挤出机,并从T模具吐出,得到宽400mm、厚度0.1mm的片材。按照希望制造的接合部件的片材部厚度重叠多张已得到的片材,以能够形成预先准备的成为导能器的突起部的方式设置在雕刻有凹部的模具,在合模后,在模具温度280℃、压力0.5MPa下保持20分钟,然后将模具温度冷却至100℃以下,得到大小为400×400mm的片材部和在所述片材部上形成有与片材部一体的突起部的接合部件。
以成为表2记载的突起部的形状和高度(最大高度)、片材部的厚度、设置突起部的面(单面或双面)、突起部的投影面积的合计相对于片材部的面积的比率(“突起的投影面积比率”)的方式,适当地调整所使用的模具的上模和下模之间的空隙、雕刻在模具的凹部的尺寸和分布。这样,制造了接合部件VIII-1~VIII-8。
(制造例9)
除了使用将100重量份作为碳纤维的切成平均纤维长度10mm的TOHOTENAX公司制造的碳纤维“TENAX”(注册商标)STS40-24KS和355重量份作为热塑性树脂的UNITIKA公司制造的尼龙6树脂A1030投入双轴混炼挤出机中并从T模具吐出而得到的宽400mm、厚度0.1mm的片材以外,与制造例8-2同样地制造了接合部件IX。将结果记录在表2。
(制造例10)
除了使用作为热塑性树脂的聚碳酸酯(帝人株式会社制造:L-1225Y)以外,与制造例8-2同样地制造了接合部件X。将结果记录在表2。
[表2]
(实施例1~9)
使用部件II作为部件A和部件B,如图3那样,使部件A和部件B的成为接合面的预定部分相对,并在其间分别设置接合部件VIII-1~VIII-8、IX,使用超声波熔接机(BRANSON制、2000Xdt),利用直径18mm的焊头从部件A侧与接合部件的导能器(突起部)所在的部分对应地施加超声波,得到接合体(纤维强化拉伸剪切熔接试验片)。熔接条件为频率20kHz、振幅60μm、熔接力1000N、触发力250N、冷却时间2秒,对于超声波施加时间,在使用接合部件VIII-1~VIII-5、VIII-8、IX的情况下,为1秒,在使用接合部件VIII-6和VIII-7的情况下为2秒。
对制作成的接合体用所述(3)中记载的拉伸剪切试验评价方法评价其拉伸剪切强度(接合强度)。将结果示于表3。
另外,在表3中也记载了“接合前后的接合面间的距离的比例”、“熔接时的接合面间的最小分离量”、“接合前的接合部件的高度”。关于“熔接时的接合面间的最小分离量”,将在后面叙述。
“接合前后的接合面间的距离的比例”是由
(接合后的接合面间的距离/接合前的接合面间的距离)×100(%)
算出的,但是在实施例1~13中,“接合后的接合面间的距离”与“接合体中的部件A与部件B之间的接合面间距”相同,“接合前的接合面间的距离”与“接合前的接合部件的高度”相同,因此,“接合前后的接合面间的距离的比例”与“式(S2)的值”相同。
需要说明的是,“式(S2)的值”是指,上述式(S2)的“接合体中的部件A与部件B的接合面间距相对于接合前的接合部件的高度的比率”。
(实施例10~13)
除了将部件A和部件B的接合面附近分别用夹具固定,使得接合体中的部件A和部件B的接合面间以“熔接时的接合面间的最小分离量”中示出的一定的空隙(最小)分离以外,分别与实施例1、实施例4、实施例6、实施例7同样地制作接合体(纤维强化拉伸剪切熔接试验片)。
另外,将制作成的接合体用与实施例1~9同样的评价方法评价其拉伸剪切强度(接合强度)。将结果示于表3。
需要说明的是,“熔接时的接合面间的最小分离量”是指在熔接中不使部件A和部件B比该值更接近的限制值,是熔接中的部件A和部件B的接合面间距的下限值。只要是“熔接时的接合面间的最小分离量”的值以上,则部件A和部件B的距离可以自由地变更。
实施例1~9的“熔接时的接合面间的最小分离量”记载为“无”,这表示熔接中的部件A与部件B之间的距离的下限值不存在(未设定下限值)。
以往,通常将要接合的部件彼此的接合面设计成相互接触,但是例如在部件产生翘曲等情况下,有时在接合面间产生间隙。在这样的情况下,如果存在通过熔接时的加压力也无法消除的间隙,则无法熔接继而无法得到接合体。在后述的比较例1~3中,模拟地示出了这样的方式,由于未使用本发明的接合部件,因此无法得到具有充分接合强度的接合体。
与此相对,在本发明中,即使部件A与部件B以一定间隔分离,也能够在其间夹着接合部件地填充间隙,因此,能够得到接合强度优异的接合体,将其模拟地示出的是实施例10~13。在实施例10~13中,即使将“熔接时的接合面间的最小分离量”设定为一定的值,通过使用适当厚度的接合部件,也能够得到接合强度优异的接合体。
(参考例1)
使用部件I作为部件A,使用部件II作为部件B,并且使部件A和部件B的成为接合面的预定部分相对,使用超声波熔接机(BRANSON制、2000Xdt),利用直径18mm的焊头从部件A侧与部件A的导能器的存在部分对应地,施加超声波,得到接合体(纤维强化拉伸剪切熔接试验片)。熔接条件为频率20kHz、振幅60μm、熔接力500N、触发力250N、激振时间1秒、冷却时间2秒。
对制作成的接合体用所述(3)中记载的拉伸剪切试验评价方法评价其拉伸剪切强度(接合强度)。将结果示于表3。
(比较例1~3)
除了部件A与部件B的接合面附近用夹具固定,使得熔接中的部件A和部件B的接合面的最少间隔(分离量)分别成为0.3mm、0.9mm和2.8mm以外,与参考例1同样地进行熔接。其结果,无法得到供拉伸剪切试验的充分的接合体,对应的接合强度为“0”。将结果示于表3。
[表3]
(实施例14~16)
除了使用部件III~V作为部件B以外,与实施例2同样地得到接合体。将结果示于表4。
(实施例17)
除了在部件A和部件B中使用部件VI并且在部件A与部件B之间使用接合部件X以外,与实施例2同样地得到接合体。将结果示于表4。
(实施例18)
除了使用部件VII作为部件B以外,与实施例17同样地得到接合体。将结果示于表4。
[表4]
产业实用性
根据本发明,能够提供一种接合体的制造方法,其成本低且生产性优异,即使在被接合部件的所有部位的接合或者已发生了翘曲变形的被接合部件的接合中也能够以稳定且高的接合强度进行接合,并且,在接合面的局部发生了剥离时也能够简单地修复。
另外,根据本发明,能够提供一种接合强度和设计的自由度高、也能够适用于大量生产的接合体的制造方法。
虽然详细且参照特定实施方式地对本发明进行了说明,但在不脱离本发明的精神和范围的情况下,能够进行各种各样的变更和修改,这一点对于本领域技术人员来说是不言而喻的。
本申请基于2016年6月7日提出的日本专利申请(特願2016-113592),并以引用的形式将其内容并入本文。
Claims (8)
1.一种接合体的制造方法,其中,
将接合部件配置在含有热塑性树脂的部件A与含有热塑性树脂的部件B之间,至少使所述接合部件的一部分熔化,得到接合有所述部件A和所述部件B的接合体,其中,所述接合部件具有:片材部,含有热塑性树脂;和多个突起部,在所述片材部的至少一个面与所述片材部形成为一体,并且含有热塑性树脂。
2.根据权利要求1所述的接合体的制造方法,其中,
所述片材部的厚度为5~5000μm。
3.根据权利要求1或2所述的接合体的制造方法,其中,
所述突起部的最大高度为50~500μm。
4.根据权利要求1~3中任一项所述的接合体的制造方法,其中,
对于所述接合部件的至少一个面,由下述式(S1)定义的、突起部的投影面积的合计相对于片材部的面积的比率为25~95%,
式(S1)
突起部的投影面积的合计相对于片材部的面积的比率=(片材部的一个面中的突起部的投影面积的合计/片材部的所述一个面的面积)×100(%)。
5.根据权利要求1~4中任一项所述的接合体的制造方法,其中,
在所述接合部件的所述片材部的两面赋予有所述突起部。
6.根据权利要求1~5中任一项所述的接合体的制造方法,其中,
由下述式(S2)定义的、接合体中的部件A与部件B之间的接合面间距相对于接合前的接合部件的高度的比率为95%以下,
式(S2)
接合体中的部件A与部件B之间的接合面间距相对于接合前的接合部件的高度的比率=(接合体中的部件A与部件B之间的接合面间距/接合前的接合部件的高度)×100(%)。
7.根据权利要求1~6中任一项所述的接合体的制造方法,其中,
使所述接合部件的至少一部分熔化的方法是施加振动能量的方法。
8.根据权利要求1~7中任一项所述的接合体的制造方法,其中,
所述部件A、所述部件B和所述接合部件中的至少一者含有强化纤维。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2016-113592 | 2016-06-07 | ||
JP2016113592 | 2016-06-07 | ||
PCT/JP2017/021212 WO2017213201A1 (ja) | 2016-06-07 | 2017-06-07 | 接合体の製造方法 |
Publications (2)
Publication Number | Publication Date |
---|---|
CN109311235A true CN109311235A (zh) | 2019-02-05 |
CN109311235B CN109311235B (zh) | 2021-06-04 |
Family
ID=60577918
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CN201780035359.4A Active CN109311235B (zh) | 2016-06-07 | 2017-06-07 | 接合体的制造方法 |
Country Status (5)
Country | Link |
---|---|
US (1) | US20190308373A1 (zh) |
EP (1) | EP3466652B1 (zh) |
JP (1) | JP6302606B1 (zh) |
CN (1) | CN109311235B (zh) |
WO (1) | WO2017213201A1 (zh) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN110428748A (zh) * | 2019-08-09 | 2019-11-08 | 厦门强力巨彩光电科技有限公司 | 一种led显示屏面罩的制造方法 |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN110366487A (zh) * | 2017-03-24 | 2019-10-22 | 株式会社槌屋 | 超声波熔敷用构件和超声波熔敷方法 |
US11517977B2 (en) * | 2017-09-15 | 2022-12-06 | Tech-Sonic, Inc. | Dual cam servo weld splicer |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104526152A (zh) * | 2013-08-08 | 2015-04-22 | 通用汽车环球科技运作有限责任公司 | 使用多高度能量引导装置改进超声焊接的系统和方法 |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS52150447A (en) * | 1976-06-09 | 1977-12-14 | Toyoda Chuo Kenkyusho Kk | Method of adhering polyolefin synthetic resin |
JPH0953057A (ja) * | 1995-08-10 | 1997-02-25 | Ikeda Bussan Co Ltd | ホットメルトシート、積層ホットメルトシートおよび表皮材 |
JP2001334576A (ja) * | 2000-05-29 | 2001-12-04 | Takashimaya Nippatsu Kogyo Co Ltd | 小部品が溶着されている車輛部材およびその製造法 |
JP3794947B2 (ja) * | 2001-10-19 | 2006-07-12 | 三菱ふそうバス製造株式会社 | 積層パネルの剥離防止構造 |
JP2004107605A (ja) * | 2002-09-20 | 2004-04-08 | Jfe Chemical Corp | 吸音材用粉末接着剤、これを含む接着性表皮、吸音材および自動車内装材 |
JP5760424B2 (ja) * | 2010-12-17 | 2015-08-12 | 横浜ゴム株式会社 | タイヤ騒音低減装置 |
-
2017
- 2017-06-07 US US16/308,067 patent/US20190308373A1/en not_active Abandoned
- 2017-06-07 WO PCT/JP2017/021212 patent/WO2017213201A1/ja unknown
- 2017-06-07 EP EP17810375.0A patent/EP3466652B1/en active Active
- 2017-06-07 JP JP2017560834A patent/JP6302606B1/ja active Active
- 2017-06-07 CN CN201780035359.4A patent/CN109311235B/zh active Active
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104526152A (zh) * | 2013-08-08 | 2015-04-22 | 通用汽车环球科技运作有限责任公司 | 使用多高度能量引导装置改进超声焊接的系统和方法 |
Non-Patent Citations (1)
Title |
---|
VILLEGAS等: "Process and performance evaluation of ultrasonic, induction and resistance welding of advanced thermoplastic composites", 《JOURNAL OF THERMOPLASTIC COMPOSITE MATERIALS》 * |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN110428748A (zh) * | 2019-08-09 | 2019-11-08 | 厦门强力巨彩光电科技有限公司 | 一种led显示屏面罩的制造方法 |
Also Published As
Publication number | Publication date |
---|---|
EP3466652A4 (en) | 2019-06-26 |
JP6302606B1 (ja) | 2018-03-28 |
WO2017213201A1 (ja) | 2017-12-14 |
US20190308373A1 (en) | 2019-10-10 |
CN109311235B (zh) | 2021-06-04 |
EP3466652B1 (en) | 2021-03-31 |
EP3466652A1 (en) | 2019-04-10 |
JPWO2017213201A1 (ja) | 2018-06-14 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
JP5770395B2 (ja) | 繊維強化プラスチック接合体及びその製造方法 | |
JP5973690B2 (ja) | 繊維強化プラスチック接合体、繊維強化プラスチック接合体の製造方法、および繊維強化成形体 | |
JP5883545B1 (ja) | 繊維強化樹脂接合体、中間体及び締結棒 | |
US20150013898A1 (en) | Method for Joining Composite Materials | |
CN109311235A (zh) | 接合体的制造方法 | |
WO2013084963A1 (ja) | 接合部材の製造方法 | |
JP6341156B2 (ja) | 樹脂接合体、樹脂接合体の製造方法及び車両用構造体 | |
CN107498879A (zh) | 热塑性复合材料的超声焊接 | |
JP5827771B2 (ja) | 複合材料の接合装置、接合体の製造方法 | |
US10105898B2 (en) | Resin joined body, manufacturing method of resin joined body, and vehicle structure | |
US10252472B2 (en) | Method for joining fiber-reinforced plastic material | |
JP2013233729A (ja) | 接合部材の製造方法 | |
JP2015131394A (ja) | 繊維強化熱可塑性樹脂一体化構造体 | |
RU2635223C2 (ru) | Скрепленный смолой элемент конструкции транспортного средства, способ производства скрепленного смолой элемента конструкции транспортного средства и элемент конструкции транспортного средства | |
JP2013129159A (ja) | 接合体の製造方法 | |
JP2017119433A (ja) | 複合成形体およびその製造方法 | |
JP2023101237A (ja) | 繊維強化樹脂接合体 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PB01 | Publication | ||
PB01 | Publication | ||
SE01 | Entry into force of request for substantive examination | ||
SE01 | Entry into force of request for substantive examination | ||
GR01 | Patent grant | ||
GR01 | Patent grant |