CN1853911A - 橡胶/树脂超声波接合方法 - Google Patents

橡胶/树脂超声波接合方法 Download PDF

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CN1853911A
CN1853911A CNA2006100765297A CN200610076529A CN1853911A CN 1853911 A CN1853911 A CN 1853911A CN A2006100765297 A CNA2006100765297 A CN A2006100765297A CN 200610076529 A CN200610076529 A CN 200610076529A CN 1853911 A CN1853911 A CN 1853911A
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rubber
resin
connection method
matsurface
plastics according
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CN100515734C (zh
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内田安则
芦边正夫
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Toyoda Gosei Co Ltd
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Toyoda Gosei Co Ltd
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    • 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
    • B29C66/45—Joining of substantially the whole surface of the 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
    • 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
    • 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
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    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30321—Particular design of joint configurations the joint involving an anchoring effect making use of protusions or cavities belonging to at least one of the parts to be joined making use of protusions belonging to at least one of the parts to be joined
    • B29C66/30322—Particular design of joint configurations the joint involving an anchoring effect making use of protusions or cavities belonging to at least one of the parts to be joined making use of protusions belonging to at least one of the parts to be joined in the form of rugosity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • 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
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    • 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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
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    • 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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
    • B29C66/7316—Surface properties
    • B29C66/73161—Roughness or rugosity
    • B29C66/73162—Roughness or rugosity of different roughness or rugosity, i.e. the roughness or rugosity of the surface of one of the parts to be joined being different from the roughness or rugosity of the surface of the other part
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/924—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2995/0072—Roughness, e.g. anti-slip

Abstract

本发明提供了一种超声波接合方法，将橡胶部件具有预定粗糙度的橡胶接合粗糙面与由热塑性树脂制成的树脂部件的具有预定粗糙度的树脂接合粗糙面连接，以构成接合界面，并从橡胶部件侧对接合界面施加超声波振动。只有树脂部件由于接合界面中产生的摩擦热而熔融，从而将熔融树脂压入橡胶部件中，这样被压入橡胶部件中的熔融树脂在其中固化，从而借助由缠结在一起的两个部件所产生的固定效应，橡胶部件和树脂部件二者机械地接合。

Description

橡胶/树脂超声波接合方法
技术领域
本发明涉及橡胶/树脂超声波接合方法，更具体地，涉及将橡胶部件的接合面与熔点低于橡胶部件的树脂部件的接合面连接，以形成接合界面，并通过从橡胶部件侧对接合界面施加超声波振动产生的摩擦热，将树脂部件熔融，从而将两种部件接合的橡胶/树脂超声波接合方法。
背景技术
通常，例如当将橡胶部件附着于树脂部件时，目前使用的方法为使用压敏粘合剂双面涂层带的粘贴方法，以及树脂针束接法，树脂针束接法中，设置在树脂部件上的树脂针穿过橡胶部件中的孔，使树脂针在其远端束接。
另外，还已知硫化粘接法，其中在树脂部件成型时，对树脂部件的接合面进行压花处理，使得橡胶部件可以在硫化时接合于经过上述压花处理的树脂部件接合表面(例如参见JP-A-5-99266)。
另一方面，虽然超声波熔接法不是用于接合橡胶部件和树脂部件的接合方法，但是超声波熔接方法还已知用于使用超声波振动将硬质树脂部件和软质树脂部件熔接，软质树脂部件是由与硬质树脂部件相同树脂系的热塑性弹性体制成(例如，参考JP-A-2001-275751)。
在这种超声波熔接方法中，将由聚丙烯(PP)制成的硬质树脂部件的接合表面与由烯烃基塑料弹性体(劭氏A硬度(JIS-A硬度)最小为90，并与PP相容)制成的软质部件的接合表面连接，以形成接合界面，并通过从软质部件侧对接合界面施加超声波振动，通过在接合界面中产生的摩擦热将两个部件熔融，从而使两个部件通过由分子结合产生的化学接合力而熔接。
常规的方法各自具有如下的问题。
即，在使用压敏粘合剂双面涂层带的粘贴方法中，由于使用压敏粘合剂双面涂层带而增加了生产成本。另外，由于粘合剂双面涂层带是通过在接合界面上保有不同材料而制成，因此存在不能采用该方法的情况。
另外，在树脂针束接方法中，树脂部件和橡胶部件都需要高精度成型，以使树脂部件上树脂针的厚度和位置可以精确地匹配橡胶部件中孔的直径和位置，这也导致高成本。
此外，在橡胶硫化粘接方法中，树脂部件已预先成型为预定形状，放置在橡胶硫化和成型模具中的预定位置，在这样的状态下，橡胶件需要硫化以粘着于树脂件，并在同时硫化成型为预定形状，因此需要具有特殊和复杂结构的模具作为硫化和成型模具，这导致较高的模具生产成本。
另一方面，在超声波熔接方法中，这实际上是一种将彼此相容的相同树脂系的部件熔融在一起使得通过化学接合力熔接的方法，不能通过这种方法将橡胶部件与树脂部件接合。
发明内容
考虑到这种情况提出本发明，本发明要解决的技术问题为如何提供这样一种方法，该方法可避免在接合界面处置入不同类型的材料如压敏粘合剂双面涂层带，还可避免将要接合的两种部件以高精度成型，从而能够使用通用的模具成型，而无需使用具有特殊和复杂结构的模具，由此以低成本将橡胶部件与树脂部件接合。
为了解决此问题，根据本发明的第一方面，提供了一种用于将橡胶部件与树脂部件接合的超声波接合方法，其中橡胶部件具有预定粗糙度的橡胶接合粗糙面，以及树脂部件由热塑性树脂制成并具有预定粗糙度的树脂接合粗糙面，该方法包括：
放置橡胶部件和树脂部件，从而通过使橡胶接合粗糙面与树脂接合粗糙面连接，在两部件之间形成接合界面(放置步骤)；
从橡胶部件侧对接合界面施加超声波振动，从而通过在接合界面中产生的摩擦热，只将树脂部件熔融，并从而将熔融的树脂压入橡胶部件中(树脂熔融步骤)；以及
将熔融的树脂固化，从而通过赋予由接合界面中橡胶部件与树脂部件缠结而产生的固定效应，而将橡胶部件与树脂部件机械地接合(树脂固化步骤)。
在本发明的超声波接合方法中，在树脂熔融步骤，通过从橡胶部件侧对接合界面施加超声波振动，仅将树脂部件熔融。在本发明中，此时，由于橡胶部件与树脂部件的接合表面构成要进行超声波接合的接合界面，这些接合表面被制成为具有各自预定粗糙度的橡胶接合粗糙面和树脂接合粗糙面，因而本发明提供了以下作用和优点。
即，在从橡胶部件侧对接合界面施加超声波振动的树脂熔融步骤中，在接合界面处，只有树脂接合粗糙面上的峰部与橡胶接合粗糙面局部压力接触，或树脂接合粗糙面上的峰部以比谷部更高的压力与橡胶接合粗糙面接触。由此，在树脂接合粗糙面上的峰部和与该峰部接触的橡胶接合粗糙面之间产生较大应力，相对于树脂接合粗糙面上的谷部，振动能量更优先地传送到峰部。因此，在树脂接合粗糙面上的峰部和谷部之间产生熔融时期的时间差，由此，在至少树脂部件开始熔融的熔融初始阶段，谷部没有熔融而只是峰部被摩擦热熔融。另外，在这种树脂接合粗糙面中，取决于作用于与橡胶接合粗糙面的接合界面的外加压力、压入橡胶部件的量和超声波振动的振动时间，谷部没有熔融但全部或部分的峰部熔融，或全部或部分的峰部和全部或部分的谷部熔融。因此，由于峰部比谷部更早熔融，树脂接合粗糙面中产生的熔融树脂进入橡胶部件内或进入位于橡胶接合粗糙面上的凹部内。然后，由于已经进入橡胶部件凹部内的熔融树脂在橡胶部件中没有逃逸去路，在橡胶部件本身弹性变形的同时，橡胶部件本身被推动和压迫以钻入未熔融的谷部中。因此，在接合界面中产生熔融树脂充分地进入橡胶部件的状态，并且通过使熔融树脂冷却从而在这种状态下固化，借助于在接合界面或目前已经接合的接合界面中充分缠结的橡胶部件和树脂部件之间的固定效应，两个部件可以机械地接合。
另外，由于构成接合界面的橡胶接合粗糙面和树脂接合粗糙面被粗糙处理，在接合界面处树脂部件和橡胶部件之间的接触面积减少。由此，振动能量可以在接合界面处以较高效率转化为热能，这使得能够以较低能量进行超声波接合。
这里，使用平坦性高的树脂接合粗糙面，在熔融时期峰部与谷部之间的时间差变小，从而几乎整个树脂接合粗糙面几乎同时熔融。这样，在接合界面中不能充分呈现通过橡胶部件与树脂部件缠结而产生的上述固定效应。
然后，根据本发明的第二方面，树脂接合粗糙面被赋予Rz 5μm到300μm的表面粗糙程度作为表面粗糙度。因此，如果以预定表面粗糙度对树脂接合粗糙面进行粗糙处理，则可以增加固定效应，继而又可增加接合强度。
因此，根据本橡胶/树脂超声波接合方法，无需在接合界面处置入不同种类的材料，如压敏粘合剂双面涂层带，也无需将待接合的两个部件以高精度成型。另外，有可能使用通用的模具将橡胶部件和树脂部件成型，而不使用具有特殊和复杂结构的模具。因此，可以低成本将橡胶部件与树脂部件接合。
附图说明
图1为剖视图，示出根据本发明的实施例，通过超声波接合将橡胶部件和树脂部件接合的状态。
图2为局部放大剖视图，示例性示出根据本发明实施例所形成树脂部件的树脂接合粗糙面的横截面。
图3为示出树脂接合粗糙面的表面粗糙度与接合强度之间关系的图。
图4为示出橡胶部件的橡胶厚度与接合强度之间关系的图。
图5为示出超声波接合时外加压力与接合强度之间关系的图。
图6为示出超声波接合时压入量与接合强度之间关系的图。
图7为示出超声波接合时振动时间与接合强度之间关系的图。
具体实施方式
在本发明的橡胶/树脂超声波接合方法中，将橡胶部件和由热塑性树脂制成的树脂部件进行超声波接合。
橡胶部件不限于任何具体类型，但是可使用以下的合成橡胶和天然橡胶(NR)；合成橡胶包括乙丙橡胶(EPDM)、丁苯橡胶(SBR)、丁基橡胶(IIR)、丁腈橡胶(NBR)、氯丁橡胶(CR)、丙烯酸橡胶、聚氨酯橡胶、硅橡胶、氟橡胶、等等。
如果橡胶部件的硬度太高，引起的不利后果是，会使由橡胶部件与树脂部件缠结产生的固定效应不能充分地呈现。相反，如果橡胶部件的硬度太低，则超声波振动被橡胶部件衰减，导致妨碍树脂的熔融。为此，较好地，橡胶部件的硬度通过劭氏A硬度(JIS-A硬度)测量为Hs 50到Hs 80，优选地，通过劭氏A硬度(JIS-A硬度)测量为Hs 60到Hs 70。
树脂部件不限于任何特定类型，只要使用可以通过从橡胶部件侧施加于接合界面的超声波振动而熔融的热塑性树脂即可，并且有可能适当地选用自PP(聚丙烯)、PE(聚乙烯)、PA(聚酰胺)、PVC(聚氯乙烯)、POM(聚缩醛)、PS(聚苯乙烯)、PPS(聚苯硫醚)和ABS(丁腈橡胶)。
对于橡胶部件和树脂部件的形状和尺寸没有具体限制，因此，可任意地设定形状和尺寸。另外，对于橡胶部件和树脂部件的成型方法没有具体限制，因此，可使用通用的模具通过常规的方法如注射成型或挤出成型方法成型橡胶部件和树脂部件。
然而，为了增加接合强度，从橡胶部件侧施加于接合界面的超声波振动的振动方向上，橡胶厚度较好为0.5mm到5mm，优选为0.7mm到1.0mm。如果在振动方向上的橡胶厚度太厚，则会增加在橡胶件内超声波振动的振动能量衰减量，因此，施加于接合界面的振动能量不足，引起树脂熔融不充分。相反，如果振动方向上的橡胶厚度太薄，则熔融树脂进入橡胶部件中的渗透不充分，造成固定效果降低。
另外，在本发明的橡胶/树脂超声波接合方法中，橡胶部件和树脂部件分别具有橡胶接合粗糙面和树脂接合粗糙面，这两种接合面具有各自的预定粗糙度。
在橡胶接合粗糙面上平坦度增加的情况下，由于熔融树脂不能进入橡胶接合粗糙面上的凹部，在接合界面中不能充分地呈现借助于橡胶部件与树脂部件缠结而产生的上述固定效应。因此，为了增加固定效应从而提高接合强度，较好将橡胶接合粗糙面制成为具有最多100的网目尺寸，优选最多为60的网目尺寸。需要指出的是，具有最多100的网目尺寸的橡胶接合粗糙面是指，橡胶接合粗糙面具有由模具转移的表面粗糙程度，所述模具具有通过施加喷砂修整而实现的最多100的网目尺寸的模具粗糙度；而类似地，具有最多60的网目尺寸的橡胶接合粗糙面是指，橡胶接合粗糙面具有由模具转移的表面粗糙程度，所述模具具有通过施加喷砂修整而实现的最多60的网目尺寸的模具粗糙度。
对于橡胶接合粗糙面的形成方法没有具体限制。例如，在成型橡胶部件时，于成型橡胶接合粗糙面的模具表面施加预定的喷砂修整。因此，可以通过对相关模具表面施加这种表面修整而形成具有预定粗糙度的橡胶接合粗糙面。
为了增加固定效应从而提高接合强度，作为表面粗糙度，较好赋予树脂接合粗糙面以Rz 5μm到300μm的表面粗糙程度，更好赋予树脂接合粗糙面以Rz 10μm到100μm的表面粗糙程度，优选赋予树脂接合粗糙面以Rz 10μm到50μm的表面粗糙程度。如果树脂接合粗糙面的表面粗糙度小于Rz 5μm，如前所述，因为峰部和谷部之间的熔融时期的时间差变小，不能充分地呈现出上述的固定效应。
虽然对于树脂接合粗糙面的形成方法没有具体限制，但是优选地，通过对构成树脂接合粗糙面的树脂部件进行表面压花，可以形成具有预定表面粗糙度的树脂接合粗糙面。对于通过压花加工形成的压花图案没有具体限制，并且可以采用格子、皮革、木纹、石纹、绸纹或几何图样，对得到的树脂接合粗糙面进行修整。另外，压花加工是指这样的加工方法，其中通过使用在模具表面上设有压花的不规则表面的模具，使树脂部件成型，在得到的树脂部件的接合表面上形成压花的不规则表面。另外，举例来说，施加30μm的压花加工是指：施加压花加工，使得相邻的谷部(或相邻的峰部)之间的平均间距(相邻的谷部(或相邻的峰部)的中心之间的距离)为30μm，以及各个谷部距离参考面的平均深度和各个峰部距离参考面的平均高度分别为30μm。
本发明的橡胶/树脂超声波接合方法包括放置步骤、树脂熔融步骤和树脂固化步骤。
在放置步骤中，将橡胶部件的橡胶接合粗糙面与树脂部件的树脂接合粗糙面连接，从而构成接合界面。此时，例如，将橡胶接合粗糙面与树脂接合粗糙面连接，并且为了保持这种状态，可以使用夹具等将两个部件彼此固定。
在树脂熔融步骤中，从橡胶部件侧施加于接合界面的超声波振动所产生的摩擦热仅将树脂部件熔融，以将熔融的树脂压入橡胶部件内。
对于施加超声波振动的方法没有具体限制，由此，例如能使用市售的超声接合机。另外，没有具体限制用于这种情况的条件，如外加压力、压入量、超声波振动的振动时间、振动频率和振幅，因此，可以适当地设定这些条件。例如，施加于接合界面的外加压力可为0.03MPa到0.35MPa的水平，优选将其设定为0.2MPa到0.3MPa的水平。如果这种外加压力太小，因为会减少渗透橡胶部件的熔融树脂，可能引起的风险是不能得到足够的接合强度。相反，如果外加压力太大，则可能引起的风险是，超声波振动不能进行，或橡胶部件破损。另外，相对于橡胶部件的压入量(熔融树脂被压入橡胶部件的量)可为0.2mm到1.4mm的水平，并优选为0.4mm到0.9mm的水平。如果这种压入量太小，由于熔融树脂向橡胶部件中渗透减少，可能引起的风险是，不能得到足够的接合强度。相反，如果压入量太大，可能引起的风险是，其中熔融树脂被挤出接合界面产生毛刺或不能进行振动。另外，振动时间可为0.2秒到1.0秒的水平，优选为0.35秒到0.6秒的程度。如果振动时间太短，由于树脂熔融量降低，有可能引起的风险是，不能得到足够的接合强度。相反，如果振动时间太长，可能引起的风险是，熔融树脂被挤出接合界面造成毛刺或在橡胶部件的表面上产生凹痕(针孔)。
在树脂固化步骤中，将进入橡胶部件的熔融树脂固化，从而通过在接合界面或现已接合的接合界面上缠结的橡胶部件和树脂部件产生的固定效应，两部件机械地接合。可以将已经在前述树脂熔融步骤中使树脂部件熔融之后得到的状态保持0.5秒到1.0秒的程度，以进行此树脂固化步骤。
[实施例]
以下描述本发明的橡胶/树脂超声波接合方法的具体实施例。
(实施例1)
通过使用硫化模具的硫化成型，由EPDM成形板状橡胶部件1(8mm×40mm，橡胶厚度：1.0mm)。这时，通过对硫化模具表面施加预定喷砂修整，橡胶部件1的整个外表面被赋予最大100网目尺寸的表面粗糙程度。如图1中所示，橡胶部件1的下表面被制成最大100网目尺寸的橡胶接合粗糙面10。
另一方面，通过使用注塑模具的注射成型，由聚丙烯(PP)成形板状树脂部件2(120mm×340mm，板厚：0.8mm)。这时，通过在注塑模具表面上预定位置处提供压花的不规则表面，对树脂部件2的上表面施加35μm的压花修整，使其形成压花表面。因此，树脂部件2的上表面被制成具有Rz 35μm表面粗糙度的树脂接合粗糙面20。
在此树脂接合粗糙面20上，图2示出其剖视图，示例性说明以交替方式提供多个峰部21和多个谷部22，峰部21距离由虚线所示参考面A的平均高度h为35μm，谷部22距离参考面A的平均深度d为35μm。另外，相邻的峰部21之间的平均间距P(相邻的峰部21的中心之间的距离)和相邻的谷部22之间的平均间距P(相邻的谷部22的中心之间的距离)都形成为35μm。另外，在整个树脂接合粗糙面20上以格栅状方式形成谷部22。
另外，如图1所示，橡胶部件1重叠在树脂部件2的上表面上，并使用夹具(未示出)将它们在该状态下固定，从而使橡胶部件1的橡胶接合粗糙面10和树脂部件2的树脂接合粗糙面20连接，以构成接合界面30。
使用市售的2点喇叭式超声接合机(商品名为“S-1200”，由SEIDENSHA Co.，Ltd.生产)，在保持放置的状态下，将橡胶部件1的橡胶接合粗糙面10与树脂部件的2树脂接合粗糙面20超声波接合，以得到橡胶/树脂接合产品。下文描述前述的条件。需要指出的是，在这些条件下，橡胶部件没有熔融，而只是树脂部件2熔融。
外加压力：0.07MPa
压入量：0.4mm
振动时间：0.15秒
振动频率：19.15±0.15Hz
振幅：18μm
(实施例2)
通过对树脂部件2的上表面施加10μm的压花修整，得到表面粗糙度Rz 10μm的树脂接合粗糙面20，以使得上表面如实施例1中所述成为压花表面，除此之外，通过类似于实施例1中进行的超声波接合得到橡胶/树脂接合产品。
(比较例)
没有通过如实施例1中所述对树脂部件2的上表面施加压花来进行表面粗糙加工，以及由此得到的树脂部件2的树脂接合粗糙面20保留为平坦的树脂接合表面(Rz 1.2μm的表面粗糙度)，除此之外，通过类似于实施例1中进行的超声波接合得到橡胶/树脂接合产品。
(接合强度的评价)
对实施例1、2和比较例中通过超声波接合得到的橡胶/树脂产品的接合强度进行评价。使用由IMADA SEISAKUSHO Co.，Ltd.生产的拉伸和压缩试验机AUTOGRAPH在以下条件下进行评价：速度：10mm/分钟。其结果如表1和图3中所示。
[表1]
  实施例1   实施例2   比较例
  表面粗糙度   Rz 35m   Rz 10m   Rz 1.2m
  接合强度   8N到10.60N   6N到8.58N   5N到8.36N
从上述结果容易看出，通过对树脂部件2的接合表面施加最小10μm的压花修整以产生表面粗糙度最小为Rz 10μm的树脂接合粗糙面20，可以保证至少6N的接合强度。具体地，在实施例1中，在树脂部件2的接合表面施加35μm的压花修整(其为大于等于30μm)，以产生具有Rz 35μm表面粗糙度(其为Rz 30μm或以上)的树脂接合粗糙面20，可以保证最小为10N的接合强度。
(橡胶厚度与接合强度之间的关系)
在实施例1中，橡胶部件的厚度从0.67mm变化到0.85mm和1.05mm，并且在以下条件下进行超声波接合，以研究橡胶厚度与接合强度之间的关系。研究结果如表2和图4所示。
外加压力：0.1MPa
压入量：0.2mm
振动时间：1.0秒
振动频率：19.15±0.15Hz
振幅：18μm
[表2]
             橡胶厚度(mm)
  0.67   0.85   1.05
接合强度(N)   n   1   27.3   44.68   17.01
  2   26.04   55.47   21.78
  3   23.32   33.12   35.83
  4   25.29   44.94   25.74
  5   24.95   37.51   37.74
  平均值   25.38   43.14   27.62
从结果容易看出，橡胶厚度保持在0.67mm到1.05mm的范围，在该范围内的任何厚度都可确保最小为10N的接合强度。另外，从结果可以理解到，优选地，橡胶厚度在0.7mm到1.0mm的范围内，可以进一步提高接合强度。
(超声波接合条件与接合强度之间的关系)
在实施例1中，将外加压力、压入量和振动时间分别进行各种变化，以研究接合强度如何受到影响。研究结果如表3和图5到7中所示。
[表3]
  振动时间(s)   外加压力(MPa)   压入量(mm) 强度 外观 备注
  1   0.2   0.2   0.4   B或C   A
  2   0.35   0.2   0.4   C   A
  3   0.60   0.2   0.4   A或B   B   熔融表面
  4   0.35   0.3   0.4   A或B   A
  5   0.35   0.1   0.4   B   A
  6   0.35   0.2   0.9   A或B   A
  7   0.50   0.3   0.9   A   B   毛刺
  8   0.60   0.3   0.9   A   B   熔融表面，毛刺
  9   0.35   0.2   1.4   B   A
注：
(强度)
A：测定接合强度大于等于20N。可确保获得大于等于10N的接合强度。
B：测定接合强度在10N到20N范围内。在一些情况下，仅有少量偏差，能保证超出10N的接合强度。
C：在一些情况下，接合强度低于10N。不能可靠地获得10N或更高的接合强度。
(外观)
A：没有缺陷或异常
B：毛刺或熔融表面，如备注所示
从结果可以理解，较好外加压力最小为0.2MPa，并且优选最小为0.3MPa，在这样情况下，可以确保优选得到最小为10N的接合强度。应指出的是，在0.4MPa的外加压力下，不能进行振动。
另外，应该理解，使用0.9到1.4mm范围内的压入量，可以确保优选得到最小为10N的接合强度。
另外，应该理解，较好的振动时间最短为0.35秒，并且优选最短为0.6秒，在这样情况下，优选可以确保得到最小为10N的接合强度。

Claims (18)

1.一种用于将橡胶部件与树脂部件接合的超声波接合方法，其中所述橡胶部件具有预定粗糙度的橡胶接合粗糙面，以及所述树脂部件由热塑性树脂制成并具有预定粗糙度的树脂接合粗糙面，所述方法包括：
放置所述橡胶部件和所述树脂部件，从而通过将所述橡胶接合粗糙面与所述树脂接合粗糙面连接，在两部件之间形成接合界面；
从橡胶部件侧对所述接合界面施加超声波振动，从而通过在所述接合界面中产生的摩擦热，只将所述树脂部件熔融，并从而将熔融的树脂压入所述橡胶部件；以及
将熔融的树脂固化，通过赋予由所述接合界面中所述橡胶部件与所述树脂部件缠结而产生的固定效应，将所述橡胶部件与所述树脂部件机械地接合。
2.根据权利要求1所述的橡胶/树脂超声波接合方法，其中所述树脂接合粗糙面被赋予表面粗糙程度为Rz5μm到300μm。
3.根据权利要求2所述的橡胶/树脂超声波接合方法，其中所述树脂接合粗糙面的表面粗糙程度为Rz10μm到100μm。
4.根据权利要求3所述的橡胶/树脂超声波接合方法，其中所述树脂接合粗糙面的表面粗糙程度为Rz10μm到50μm。
5.根据权利要求1所述的橡胶/树脂超声波接合方法，其中所述橡胶部件的硬度由劭氏A硬度测量为Hs50至Hs80。
6.根据权利要求5所述的橡胶/树脂超声波接合方法，其中所述橡胶部件的硬度为Hs60至Hs70。
7.根据权利要求1所述的橡胶/树脂超声波接合方法，其中在施加的超声波振动的振动方向上，所述橡胶部件的厚度为0.5mm到5mm。
8.根据权利要求7所述的橡胶/树脂超声波接合方法，其中所述橡胶部件的厚度为0.7mm到1.0mm。
9.根据权利要求1所述的橡胶/树脂超声波接合方法，其中施加于所述接合界面的压力为0.03MPa到0.35MPa。
10.根据权利要求9所述的橡胶/树脂超声波接合方法，其中施加于所述接合界面的压力为0.2MPa到0.3MPa。
11.根据权利要求1所述的橡胶/树脂超声波接合方法，其中所述树脂被压入所述橡胶部件中的压入量为0.2mm到1.4mm。
12.根据权利要求11所述的橡胶/树脂超声波接合方法，其中所述压入量为0.4mm到0.9mm。
13.根据权利要求1所述的橡胶/树脂超声波接合方法，其中振动时间为0.2秒到1.0秒。
14.根据权利要求13所述的橡胶/树脂超声波接合方法，其中振动时间为0.35秒到0.6秒。
15.根据权利要求1所述的橡胶/树脂超声波接合方法，其中在树脂部件已经于先前树脂熔融步骤中熔融之后，通过保持该状态0.5秒到1.0秒，使树脂固化。
16.根据权利要求1所述的橡胶/树脂超声波接合方法，其中所述橡胶接合粗糙面制成为具有最多100的网目尺寸。
17.根据权利要求16所述的橡胶/树脂超声波接合方法，其中所述橡胶接合粗糙面制成为具有最多60的网目尺寸。
18.根据权利要求1所述的橡胶/树脂超声波接合方法，其中通过施加了喷砂修整的模具表面的转移，形成所述橡胶接合粗糙面。
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