CN1883925A - 树脂成形体的结合方法 - Google Patents

树脂成形体的结合方法 Download PDF

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CN1883925A
CN1883925A CNA2005100794045A CN200510079404A CN1883925A CN 1883925 A CN1883925 A CN 1883925A CN A2005100794045 A CNA2005100794045 A CN A2005100794045A CN 200510079404 A CN200510079404 A CN 200510079404A CN 1883925 A CN1883925 A CN 1883925A
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molded body
resin molded
laser
resin
cellulose fibre
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板仓雅彦
相根弘
大江裕一
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DAICEL HIGH POLYMER Inc
Daicel Polymer Ltd
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Abstract

本发明提供一种树脂成形体的熔接结合方法，该方法可以以高熔接强度结合2个树脂成形体、使用激光熔接法的结合方法。详细地，是一种使用激光熔接方法，将2个热塑性树脂成形体结合的方法，第1树脂成形体是含有热塑性树脂以及α－纤维素含量在80％或80％以上的纤维素纤维的激光透过性成形体，第2树脂成形体是含有热塑性树脂和着色材料的激光吸收性成形体，是从第1树脂成形体一侧照射激光，将第1树脂成形体和第2树脂成形体熔接结合的方法。

Description

树脂成形体的结合方法
技术领域
本发明涉及使用激光熔接法结合2个热塑性树脂成形体的方法。
背景技术
作为解决作为树脂成形体的结合方法而广泛使用的超声波熔接法、热板熔接法、胶粘剂结合法、螺钉紧固连接法等存在的问题的方法，激光熔接法受到关注。使用激光熔接法时，存在只适用于需要结合的2种树脂成形体的颜色不同的情况的问题(JP-B 62-49850)，作为解决这个问题的方法，已知有JP-A 2001-71384。
在JP-A 2001-71384中，公开了将第一树脂构件和第二树脂构件用激光熔接的技术，在实施例中，公开了使用广泛使用的染料和炭黑着色的黑色树脂构件间熔接的方法。
但是，记载中，第一树脂构件优选对于照射的激光具有95％或95％以上穿透率，第二树脂构件是对于激光具有充分吸收性的树脂，可以配合包含无机或有机物的填料等。这样，为维持高的激光穿透率，在第一树脂构件中就不能配合无机以及有机的填充剂等，这便成为限制了应用于广泛用途的主要原因。
发明内容
如上所述，在使用激光熔接法时，不能在第一树脂构件中配合无机或有机填充剂等的情况则成为限制用途的主要原因，再有，从废弃物处理的观点来看，在焚烧处理分别回收再利用后的废弃物时，为了不会产生燃烧残渣，因此希望配合有机填充剂。但是，作为有机填充剂，众所周知的纤维素纤维向树脂成形体中的分散性差，这就给熔接强度带来不良影响，且有损害成形体外观等问题。
作为本发明的课题，提供一种适用于激光熔接法的结合方法，该结合方法即使是在位于激光照射侧的成形体中配合纤维素纤维时，也能够使2个树脂成形体牢固地结合。
本发明提供一种结合方法，该方法是作为解决课题的措施，使用激光熔接法结合2种热塑性树脂成形体的方法，其中
第1树脂成形体是合有热塑性树脂以及α-纤维素含量在80％或80％以上的纤维素纤维的激光透过性成形体，
第2树脂成形体是含有热塑性树脂和着色材料的激光吸收性成形体
从第1树脂成形体的一侧照射激光，使第1树脂成形体和第2树脂成形体熔接的结合方法。
在本发明的结合方法中，第1树脂成形体(或者第1和第2树脂成形体)优选在热塑性树脂与纤维素纤维混合时，纤维素纤维解纤，分散于热塑性树脂后成形得到的成形体。
在本发明中，所谓的“激光透过性”以及“激光吸收性”是通过实施例记载的方法求得的。
使用本发明的结合方法得到的树脂成形体，不受是否配合纤维素纤维的限制，但是除所谓的白点少，外观优美以外，由于含有纤维素纤维，与不含有纤维素纤维等填充剂的成形体相比较，弯曲弹性模量等机械性质优异，因此，与原有的相比，可以使用于更为广泛的用途。
再有，使用纤维素纤维时，除了对成形体可赋予高激光穿透率和高弯曲弹性模量的良好平衡外，还在燃烧后不会产生残渣这点上，也是优异的。
附图的简单说明
图1是树脂成形体的结合方法的说明图。而且，图中的符号1表示聚丙烯成形体，2表示热塑性树脂成形体。
发明的详细说明
以下，对本发明的结合方法按照工序顺序进行说明，但工序的顺序和操作方法并不限定于以下说明，可以适当改变。
[第1工序]
首先将作为结合对象的第1树脂成形体和第2树脂成形体重合后，通过夹持器等固定装置进行固定。这里，第1树脂成形体和第2树脂成形体的部分接触面或全部接触面被熔接成为结合部分。
第1树脂成形体是含有热塑性树脂以及α-纤维素含量在80％或80％以上的纤维素纤维(以下，只记做“纤维素纤维”)的激光透过性成形体。
在能够解决本发明的课题的范围，可以在第1树脂成形体中配合少量的无机填充剂，在全部填充剂中，优选纤维素纤维含量在50质量％或50质量％以上，较为优选70质量％或70质量％以上，更为优选85质量％或85质量％以上，但是特别优选实质上为100质量％的纤维素纤维。
第1树脂成形体的激光穿透率优选10％或10％以上，较为优选15％或15％以上，更优选20％或20％以上。
第1树脂成形体的形状、大小、厚度等可以按结合后的用途以及在满足上述激光穿透范围适当设定。但是，即使是激光穿透率低的材料，通过使成形体的厚度变薄，可以抑制熔接性的降低，为此，视用途，在熔接厚度比较薄的成形体时，也可以使用激光穿透率比较低的成形体。
作为热塑性树脂，可以举出，烯烃类树脂(优选聚丙烯)、苯乙烯类树脂(均聚物、AS树脂、HIPS等)、含有橡胶的苯乙烯类树脂(ABS树脂、AES树脂、ABSM树脂、AAS树脂等)、聚酰胺树脂、聚乙烯树脂、聚丙烯树脂、聚对苯二甲酸丁二醇酯树脂、聚苯硫醚树脂、聚醚醚酮树脂、聚对苯二甲酸乙二醇酯树脂、聚对苯二甲酸丁二醇酯树脂、聚苯硫醚树脂、聚碳酸酯树脂、非结晶(透明)尼龙、液晶聚合物、(甲基)丙烯酸类树脂、聚缩醛树脂、聚苯醚树脂、丙烯腈·苯乙烯共聚树脂等，这些热塑性树脂可以单独使用也可以2种或2种以上混合使用。另外，以这些聚合物为主体的共聚物或混合物也可以举出，向它们中配合橡胶或橡胶状树脂等的弹性体的热塑性树脂以及含有这些树脂10重量％或10重量％以上的聚合物合金等。
聚丙烯优选均聚物，但和乙烯之类的其他烯烃单体、(甲基)丙烯酸酯等其他单体的共聚物也可以。在制成共聚物时，优选聚丙烯以外的单体使用量(原料基准)不足50质量％。
纤维素纤维是α-纤维素含量在80％或80％以上，优选85％或85％以上，α-纤维素不足80％的，如众所周知的洋麻纤维和黄麻纤维，不能用来解决本发明的课题。
平均纤维径优选0.1～1000μm、较为优选100μm或100μm以下，更为优选10～50μm，特别优选20～30μm。
平均长度优选0.1～1000mm、较为优选0.2～500mm，更为优选0.3～50mm，特别优选0.5～5mm。
纤维素纤维的配合量相对于热塑性树脂100质量份为1～500质量份、优选5～300质量份、较为优选5～100质量份，更为优选10～50质量份。
得到适用于本发明的第1树脂成形体的场合，纤维素纤维向热塑性树脂中的分散性是很重要的。这种分散性不充分时，就会在成形体表面散布有被称作所谓“白点”的大的纤维素纤维块，成为有损外观的主要原因。这些“白点”的产生，用一般的双螺杆挤出机是不能充分解决的，
在本发明中，为抑制这样的“白点”发生，可以使用如下方法得到第1树脂成形体，即在混合热塑性树脂和纤维素纤维时，将纤维素纤维解纤，分散于热塑性树脂中后，进行成形。另外，解纤、分散时，包含解纤后分散的方法和解纤与分散同时进行的方法。下面，说明该方法(解纤和分散的方法)的优选实施方案。
(方法1)
在上述比例范围使用热塑性树脂以及纤维素纤维(最好事先予混)，将其投入亨舍尔混合器(例如，三井矿山社制，带加热器)中，边搅拌边加温。此时的条件如下：
将热塑性树脂以及纤维素纤维共1000～3000g投入到混合槽容量为20L的混合器内，在所用树脂的熔融温度附近、以10～50m/sec的圆周速度，混炼10～30分钟。
(方法2)
将热塑性树脂和纤维素纤维的预先混合物50kg，投入到双螺杆高速混炼型挤出机[例如，希得伊(シ一ティ一イ一)社(CTE公司)制，HTM65，螺杆直径65mm，带热切割器(水中)切割]中，在所用的树脂的熔融温度附近，在螺杆转数200～800r/m下熔融混炼。
通过使用这样的解纤和分散方法得到第1树脂成形体，能够得到外观美观，抑制“白点”产生的成形体。在本发明中，第1树脂成形体中优选成形体表面的每50cm2，最大直径或最大长度为1mm或1mm以上的未解纤或解纤的纤维素纤维的块数在10个或10个以下的，更为优选5个或5个以下的。所谓最大直径，在球的情况下，是指直径，而在椭圆的情况下，是指长径，而在不规则形状的情况下，是指最大长度。
另外，使用α-纤维素含量在80％或80％以上的纤维素纤维时，与使用例如α-纤维素含量不足80％的洋麻纤维或黄麻纤维相比，由于热稳定性好，因此在得到成形体时，模具中几乎没有生成淀积物(纤维的附着物)，也几乎没有发生成形体着色。
视需要，使用无机填充剂时，为不损害激光透过性，优选使用与在第1树脂成形体中使用的热塑性树脂的折射率接近的。例如，使用聚丙烯(均聚物的折射率为1.49；制成共聚物时，希望为与上述折射率接近的值。)时，作为无机填充剂，优选折射率为1.4～1.7的，更为优选折射率为1.45～1.55的。
作为这样的无机填充剂，可以从滑石(折射率1.54～1.59)、云母(折射率1.55～1.59)、重质碳酸钙(折射率1.47～1.69)、轻质碳酸钙(折射率1.47～1.69)、玻璃纤维(折射率1.46～1.56)、玻璃片(折射率1.46～1.56)、玻璃珠(折射率1.46～1.56)、硅灰石(折射率1.63)、硫酸钡(折射率1.64～1.65)、氧化铝(折射率1.56)、氢氧化镁(折射率1.54)、膨润土(折射率1.52)、硫酸钙(2水盐)(折射率1.52～1.53)、碱式碳酸镁(折射率1.50～1.53)水合硅酸钙(折射率1.47～1.50)、湿式法白炭黑(折射率1.44～1.50)中选择的1个或2个或2个以上。
无机填充剂可以使用粒状、纤维状、片状等不定形状的。使用粒状的时候，优选平均粒径为0.01～100μm的。使用纤维状的时候，优选直径为0.1～100μm、长1～100μm的。使用片状的优选最大长度为5000μm或5000μm以下的。
第1树脂成形体中可以配合不损害激光透过性的种类及范围的着色材料。
第2树脂成形体是含有热塑性树脂和着色材料的激光吸收性的成形体。热塑性树脂成形体的激光穿透率优选0％。
作为热塑性树脂，可以举出与上述相同的。作为着色材料，可以举出炭黑、无机颜料、有机颜料、染料等。相对于热塑性树脂的着色材料的配合量根据结合后成形体的用途、与激光的穿透率等的关系来决定，但是，相对于热塑性树脂100质量份，优选0.001～10质量份、较为优选0.01～5质量份、更为优选0.05～5质量份。
在第2树脂成形体中，视需要，可以配合上述纤维素纤维以及无机填充剂，第1树脂成形体和/或第2树脂成形体中，可以视需要配合增色剂、分散剂、稳定剂、增塑剂、改性剂、紫外线吸收剂或者光稳定剂、抗氧剂、防静电剂、润滑剂、脱模剂、结晶促进剂、结晶成核剂以及耐冲击性改良用弹性体等。
向第1树脂成形体中配合染料时，优选上述染料和第2树脂成形体所包含的着色材料为相同色，但黑色不必要，黑色以外的组合也可以配合用途使用。
[第2工序]
接着，对重合的第1树脂成形体和第2树脂成形体的接触部分，从第1树脂成形体侧照射激光，将第1树脂成形体和第2树脂成形体在它们的接触面熔接。
作为在本发明中使用的激光，可以使用具有800～1200nm震荡波长的激光，可以使用YAG激光器、半导体激光器、玻璃激光器、红宝石激光器、He-Ne激光器、氮激光器、鳌合物激光器、染料激光器等已知的激光器。这些激光器的输出功率在5～30W左右即可，但在结合厚的成形体时，可以使用更高输出功率的。
激光器的照射时间以及激光器与被照物体(第1树脂成形体和第2树脂成形体)的间隔考虑激光的输出功率、成形体的厚度、成形体的激光穿透率等进行调整。
对于采用本发明的树脂成形体的结合方法的结合原理进行说明。在将第1树脂成形体和第2树脂成形体重合的状态下，从第1树脂成形体的一侧照射激光时，激光穿透第1树脂成形体后，到达第2树脂成形体的表面。此时，由于在第1树脂成形体上“白点”的产生受到抑制，因此激光的穿透率稳定(成形体内的激光的穿透率的差别小)、对激光器输出功率的高低的依赖性也会变小。
由于第2树脂成形体是激光吸收性的，激光不能穿过第2树脂成形体，则在第1树脂成形体和第2树脂成形体的界面作为能量而滞留。其结果，由于在第1树脂成形体和第2树脂成形体的界面上伴随温度上升而发生熔融，从而使两成形体牢固地结合。
特别在第1树脂成形体中，因为“白点”的产生受到抑制，与在第1树脂成形体和第2树脂成形体的接触面上存在大量“白点”(超过10个/50cm2的数值)的情况相比，由于第1树脂成形体和第2树脂成形体的激光照射前的密合程度提高，因此可以认为用激光照射时容易熔接，并且也提高了熔接的强度。
另外，由于在第1树脂成形体中，配合纤维素纤维，抑制了“白点”的产生，故外观美观，并可以对机械的强度等性质进行调节，因此，能够在更为广泛的领域中使用于各种用途。
根据本发明的结合方法，作为激光穿透一侧的第1树脂成形体中，不管是否配合本来作为激光穿透阻碍的主要原因的纤维素纤维，也可以维持高激光穿透率，其结果，可以牢固地结合2个热塑性树脂成形体。甚至，根据希望，可以对2个热塑性树脂成形体着色为同色或异色。
实施例
(实施例中使用的原料)
·聚丙烯：PMB60A(萨恩亚路玛(サンアロマ一)社制)
·纤维素纤维：使用将溶解纸浆NDT-T(日本制纸社制)的片用撕碎机制成5mm见方的小片(平均纤维径为20～40μm，α-纤维素含量为91％)。
·酸改性聚丙烯：优梅克斯(ユ一メックス)1010(三洋化成工业社制)
(比较例使用的原料)
·纤维素纤维1：洋麻纤维(切段长为5mm的纤维，α-纤维素含量约50％，奈洽特拉斯特(ネイチャ一トラスト)社制)
·纤维素纤维2：黄麻纤维(切段长为3mm的纤维，α-纤维素含量约70％)
·炭黑：商品名  A1-1000 DIC社制
(纤维分散性评价)
在树脂成形体的一面(面积50cm2)使用放大镜(10倍)，对直径1mm或1mm以上的纤维块(白点)进行计数。另外，同样的，对最大直径(最大长度)1mm或1mm以上的纤维块的个数也进行计数(比较例2、3)。
(激光穿透率的测定方法)
对成形体从垂直方向照射激光(波长1064nm，YAG激光器，输出功率1.5W)(Laser Marker(レ一ザ一マ一カ一)，NEC制，马卡恩基(MarkenEngine(マ一カ一エンジン)SL475H)时，通过激光功率记录器(COHERENT制，LASERMATE10)接收通过成形体的激光和不放置成形体时的激光，由连接在激光功率记录器的万用表测定电压(V)，将电压作为激光的强度，通过下式计算。
激光的穿透率(％)
＝[穿透成形体的激光的强度(V)/照射在成形体上激光的强度(V)]×100
(熔接强度)
使用熔接的实验片，用奥里恩得克(オリエンデック)社制的坦锡伦(デンシロン)UCT-1T进行拉伸实验，测定其最大点荷重(单位kg重)。另外，对激光输出功率40W、60W、80W进行测定。
(熔接部分附近的状态观察)
由目测对熔接部分附近进行观察。具体地，观察激光照射时，是否发生树脂或纤维素纤维分解产生气体，固化的气体成分是否附着在熔接部分附近的现象。
实施例1～3、比较例1～4
使用表1所示的成分(除炭黑外，用质量％表示，而炭黑用相对于其他成分合计100质量份的质量份表示)，通过下述方法制得原料颗粒。
<熔融混炼方法等>
方法1(由亨舍尔混合器混合)
将原料成分(第1树脂成形体或者第2树脂成形体的原料成分)合计2000g投入到三井矿山社制的亨舍尔混合器(带加热器，容量20L)，在140℃加热状态下，以3000r/m搅拌20分钟。
聚丙烯开始熔融时，排出到相连接的其他的搅拌机(冷却搅拌机)中，边冷却边搅拌，制得包含聚丙烯和纤维素纤维的造粒物(直径约1cm)。将该造粒物用带有热切器(水中)的单螺杆挤出机(螺杆直径40mm、使用全螺纹型螺杆)进行挤出造粒。
方法2(带有转子的高混炼型挤出机)
将原料成分(第1树脂成形体或者第2树脂成形体的原料成分)均匀混合后，将50kg投入双螺杆高速混炼型挤出机[希得伊社制，HTM65，螺杆直径65mm，带热切器(水中)切割]，在螺杆转数400r/m下熔融连续混炼后，挤出、造粒。
方法3(双螺杆挤出机)
将原料成分(第1树脂成形体或者第2树脂成形体的原料成分)均匀混合后，将10kg投入双螺杆挤出机[日本制钢所社制TEX30，螺杆直径为30mm，带热切器(水中)切割]，在螺杆转数400r/m下熔融混炼后，挤出、造粒。
<第1树脂成形体或者第2树脂成形体的制造>
接着，使用各原料颗粒，在80℃下，热风干燥4小时后，通过注射成形(住友重机社制，SH100，料筒温度200℃)，制得纵10cm、横5cm、厚2mm的板状成形体(树脂成形体1和树脂成形体2)。
<通过激光的结合>
在第1树脂成形体1和第2树脂成形体2以图1所示的组合状态下，用夹具和支承构件(未图示)固定后，从与接触部分垂直方向(图中箭头方向)，使用法恩得拜斯(ファインデバイス)社制的激光熔接机FD200(半导体激光器)，以10mm/sec照射激光(输出功率40W、60W、80W)。激光的点径为0.6mm，用激光按照描绘出一个直径1cm的圆那样照射。
                                               表1
               实施例                      比较例
    1     2     3   1   2   3     4
第1树脂成形体   聚丙烯     68     68     68   68   68   68     68
  酸改性聚丙烯     2     2     2   2   2   2     2
  溶解纸浆     30     30     30   -   -   -     30
  洋麻     -     -     -   30   -   30     -
  黄麻     -     -     -   -   30   -     -
  熔融混炼法     方法1     方法2     方法1   方法3   方法3   方法1     方法3
  白点数     0     1     0   100以上   100以上   100以上     20
  穿透率(最大)(％)     31     31     31   15以下   15以下   15以下     39
  穿透率(最小)(％)     30     28     30   15以下   15以下   15以下     15以下
第2树脂成形体   聚丙烯     68     68     100   68   68   68     68
  酸改性聚丙烯     2     2     -   2   2   2     2
  溶解纸浆     30     30     -   -   -   -     30
  洋麻     -     -     -   30   -   30     -
  黄麻     -     -     -   -   30   -     -
  炭黑     0.7     0.7     0.7   0.7   0.7   0.7     0.7
  透过率(％)     0     0     0   0   0   0     0
    熔接强度(40W)     111     107     120   25   未熔接   未熔接     未熔接
    熔接强度(60W)     114     110     125   55   25   未熔接     55
    熔接强度(80W)     119     111     130   72   54   58     68
结合附近的状态 良好 良好 良好 良好   有分解气体成分附着   有分解气体成分附着 良好
α
第1树脂成形体，由于适用于方法1或方法2，因此确认可以获得白点数少，穿透率的不均匀小的产品。这意味着纤维素纤维被解纤，均匀分散。
另外，实施例1～3的第1树脂成形体和第2树脂成形体的熔接强度不受激光输出功率的限制，表现出稳定的数值。

Claims (4)

1.一种结合方法，该方法是使用激光熔接法结合两个热塑性树脂成形体的方法，其中
第1树脂成形体是含有热塑性树脂、以及α-纤维素的含量是80％或80％以上的纤维素纤维的激光透过性的成形体，
第2树脂成形体是含有热塑性树脂和着色材料的激光吸收性的成形体，
从第1树脂成形体一侧照射激光，熔接第1树脂成形体和第2树脂成形体。
2.按照权利要求1所记载的结合方法，其中至少第1树脂成形体是在混合热塑性树脂和纤维素纤维时，将纤维素纤维解纤，并分散于热塑性树脂中后进行成形制得的树脂成形体。
3.按照权利要求1或2所记载的结合方法，其中第1树脂成形体中所含的纤维素纤维的平均纤维径为100μm或100μm以下。
4.按照权利要求1或2所记载的结合方法，其中在第1树脂成形体中，成形体表面的每50cm2，最大径或最大长度在1mm或1mm以上的未解纤或解纤的纤维素纤维的块数为10个或10个以下。
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