JP2004209884A - Method for welding resin molded article - Google Patents

Method for welding resin molded article Download PDF

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Publication number
JP2004209884A
JP2004209884A JP2003001365A JP2003001365A JP2004209884A JP 2004209884 A JP2004209884 A JP 2004209884A JP 2003001365 A JP2003001365 A JP 2003001365A JP 2003001365 A JP2003001365 A JP 2003001365A JP 2004209884 A JP2004209884 A JP 2004209884A
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JP
Japan
Prior art keywords
heating element
welding
molded article
heating
molded
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.)
Pending
Application number
JP2003001365A
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Japanese (ja)
Inventor
Kenji Watanabe
健二 渡辺
Susumu Koshiji
晋 越路
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Showa Denko Materials Co Ltd
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Hitachi Chemical Co Ltd
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Filing date
Publication date
Application filed by Hitachi Chemical Co Ltd filed Critical Hitachi Chemical Co Ltd
Priority to JP2003001365A priority Critical patent/JP2004209884A/en
Publication of JP2004209884A publication Critical patent/JP2004209884A/en
Pending legal-status Critical Current

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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
    • B29C66/70—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
    • 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
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3404—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint
    • B29C65/342—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint comprising at least a single wire, e.g. in the form of a winding
    • 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
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3468—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the means for supplying heat to said heated elements which remain in the join, e.g. special electrical connectors of windings
    • 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
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3472—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint
    • B29C65/3476—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being metallic
    • 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
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • 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
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove 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
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2424—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain
    • B29C66/24243—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a quadrilateral
    • B29C66/24244—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a quadrilateral forming a rectangle
    • 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
    • B29C66/30223—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 rib-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
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/322—Providing cavities in the joined article to collect the burr
    • 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
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular 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
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • 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
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • 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

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for welding a thermoplastic resin molded article with a high-strength reliability at low cost. <P>SOLUTION: In the method for welding two or more halves of the thermoplastic resin molded article by energizing and heating a member which serves as a heating element, the member which serves as a heating element is included beforehand into at least one half of the molded article and a protrusion formed on another half of the molded article in contact with the former, is pressurized against the heating element. Thus, the mating halves of the molded article can be welded together by energizing and heating the heating element. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は，自動車部品及び家電製品用途の成形品の溶着方法に関する。
【０００２】
【従来の技術】
従来より、樹脂成形品の溶着工法としては、幾つかの工法が挙げられるが、従来より使用される熱板加熱、熱風加熱、超音波加熱と言った加熱方法で樹脂の表面を加熱した後に樹脂同士を加圧する方法が一般的である。しかし、溶着により高い剛性が要求される場合などは振動溶着法、熱線溶着工法と言った連続した溶着面が設けられる溶着工法が用いられる。振動溶着工法は各成形品を相互に振動、加圧させることで樹脂が溶融し密着する工法であるが、特殊な溶着装置と製品を固定する治具が必要となり、投資額が大きく、コスト的に十分な量産数量が必要となる場合がある。特に大型製品になるに従い装置コスト及び治具コストが高価となる問題がある。一方、熱線溶着工法は、各成形品の間に発熱線を挟んで、加圧と同時に発熱体に通電し加熱することで樹脂を溶融密着させる工法であり、電気的制御装置と電極及び各成形品の位置決めし加圧する治具が必要となるが、これらの費用は振動溶着に比べ安価である。特に成形品が１５００ｃｍ２以上の大型成形品の場合は、この投資額の差が更に大きくなることが考えられる。
【０００３】
【発明が解決しようとする課題】
上記の熱線溶着工法は装置や治具の投資額が小さくなる一方で種々の問題点がある。まず、発熱体の固定や成形品の合わせに難があり、大型成形品では工数や信頼性に問題があった。又、振動溶着、熱線溶着共に溶着部の幅が溶着強度に寄与するのに対して、熱線溶着の場合は発熱体に断面を奪われる為に溶着部幅をより大きく取る必要があった。つまり、同じスペースで確保できる強度が小さいという問題があった。この問題は大型成形品に限ることではなく、すべてのサイズで同じ事が言える。
【０００４】
更に熱線溶着工法では熱線が製品内に残るために若干の問題が残る場合がある。実際の製品では単一材料で部品が構成されることは殆ど無いためリサイクル上は大きな影響はないが、例えば重量の問題や金属の介在が通信等の電波の阻害要因となる場合が考えられる。
本発明はかかる状況に鑑みなされたもので、低コストで溶着強度の高い溶着方法を提供するものである。
【０００５】
【課題を解決するための手段】
本発明は、次のものに関する。
（１）複数の熱可塑樹脂製成形品を、発熱体となる部材に通電し加熱することで、溶着する方法において、少なくとも片側の成形品に予め発熱体となる部材を内在させておき、これと当接する成形品に設けた凸部で発熱体に向けて加圧し、同時に発熱体に通電し加熱することで当接しあう成形品を溶着させることを特徴とする溶着方法。
（２）発熱体を内在させた成形品には、両端を成形品に固定されて発熱体が露出した電極部を有していることを特徴とする（１）の溶着方法。
【０００６】
【発明の実施の形態】
本発明の熱可塑樹脂製成形品の材料は、熱可塑性樹脂であれば特に限定されるものではないが、溶着しあう複数の成形品については相互が相溶性を持つことが望ましい。特に請求項１の場合は相溶性を持つことが必須となる。成形品の形状とサイズは限定するものでは無いが相互に当接しあう面を有し、この面に対し垂直方向に加圧力が加えられることが必要である。この面とはリブの先端面も含めて表現されるものである。
【０００７】
例えば片方の成形品に設けられたリブの先端が相手成形品の面に当接し、この面がリブに対して９０°〜３０°程度で有れば、溶着に必要な垂直方向の面圧は確保できる。発熱体の材料としては、導電性材料であれば特に限定するものではないが、金属材料が望ましく、鋼線又はステンレス線がより望ましい。形状は配策や溶着に適するものであれば良いが、一般には円形断面を有する線材が使用し易い。又、発熱体はフォーミングする場合も少なくは無く、この場合は平板材や帯状材料の方が打ち抜きやプレス加工に適しており、より有効なことがある。本発明の発熱体は成形品の中に埋め込まれる必要があり、インサート成形によりこれを行う。前述の複数の成形品うち少なくとも片側の成形品にはこの発熱体をインサート成形することになる。成形方法は熱可塑性樹脂の成形方法であれば加工可能であり、射出成形、プレス成形等で行うことができる。
【０００８】
例えば射出成形の場合は、射出成形金型に発熱体となる部材を型内に固定した後に樹脂を型内に充填し成形する工程をとる。尚、発熱体となる部材は、発熱部の両端に電極となる露出部を設ける必要があるが、本発明においては、成形型で発熱体を挟持する構造をとることで、成形品から発熱体が露出した部分を設けることができる。これにより両端を成形品に固定されて発熱体が露出した電極部を設けることができる。
【０００９】
一方、発熱体を内在する部分に当接する相手側部分に対しては、凸部を設けておく。そして各成形品には発熱体を内在する部分に凸部が正確に位置決めされるよう、当てリブ等を設けておくことも好ましい。ただし溶着時に製品固定用治具を用いる場合は、必ずしも当てリブは必要ではない。ここで、発熱体がインサートされる成形品と凸部を有する成形品は別々の成形品である必要はなく、各成形品が発熱体インサート部と凸部を持ち合わせていて相互の発熱体インサート部と凸部が当接し合う構造も可能である。凸部の幅は発熱体の幅よりも大きくとることが好ましい。凸部の高さは溶着代に関連するが、溶着代を管理するために凸部の両脇又は片脇に或いは発熱体を内在する部分の両脇又は片脇に別の当て凸部を設けて溶着代を制御することが好ましい。この場合、凸部と当て凸部の高さの差が溶着代となり、この溶着代を一般的に０．５〜２ｍｍ程度に設定すれば良い。
【００１０】
本発明の請求項２及び３の場合は、これ以上の高さにすることが考えられるが、発熱体の厚みの０．５〜２倍とするのが好ましい。発熱体を内在する成形品と凸部を有した成形品を当接させ、加圧する場合は、一般には成形品の固定治具を用意しておき、生産性を上げると同時に、不適な変形やひずみを避けたり精度を確保できるようにする。又、集中的に溶着部を加圧できるように、発熱体付近或いは凸部の背面部に対して治具側から凸形状で押すことも効果的である。加圧方法はクランプのように樹脂やゴムの弾性変形による応力を利用する方法もあるが、圧力シリンダーを用いる方法が連続した加圧や加熱タイミングとの同調制御には適している。通電は電圧と電流の印加を制御できる装置を介して、前述の電極部から行われる。
【００１１】
この通電により発熱部が発熱し、続いて周辺樹脂が溶融していき、加圧力により凸部が接合面付近で流動し融合し合い、さらに連続する加圧により、発熱体を押し込む力となり、凸部が相手成形品に入り込む形態をとることができる。ここで樹脂圧が逃げないように発熱体の両脇に壁となる凸部を設けておくことが好ましい。この凸部は前述の当て凸部と兼ねることができるので、この当て凸部は溶着安定性と高強度溶着の両方に有効となる。以上により接合部の溶融と加圧が十分となったと略同時に通電及び通電制御を停止することで、溶融部が冷却硬化し溶着強度が得られる。
【００１２】
【実施例】
以下，本発明を実施例に基づいて説明するが，本発明はこれに限定されるものではない。
実施例１
まず、発熱体は軟鋼線のφ２をプレス加工にて予め図のようにフォーミングしておき、これを射出成形型にインサートしてガラス入りＰＰ樹脂で射出成形することで成形品Ａを得る。発熱体の端末はａ及びｂで成形品から露出した状態としておき、この部分を電極とした。この成形品Ａには当て凸部ｃを設けてあり、溶着高さ一定にできるようにしてある。又、この凸部の高さは１．５ｍｍとした。次に相手側の凸部ｄを有する成形品Ｂを成形品Ａと同じガラス入りＰＰ樹脂で射出成形により得る。この凸部ｄの高さは３ｍｍ、幅は３ｍｍとした。続いて成形品ＡとＢを当接させるが、このとき、各成形品を固定する治具を用意しておき、さらにこの治具は加圧できるようにプレス機にセッティングしておいた。又この固定治具は溶着部が先当たりする形状とした。この後、プレス機で加圧を行うと同時に電極ａとｂから電圧と電流の印加を制御できる装置を介して、通電した。加熱は制御装置によりＰＰの分解温度を超えない加熱状態を継続させ、凸部ｄが溶融し沈み込み、当て凸部ｃが相手成形品に突き当たる時点で停止し、冷却後に加圧を停止した。治具より取り出し、成形品ＡとＢが溶着部全周に渡って同じ溶着高さの強度の高い溶着品を得た。
【００１３】
実施例２
まず、実施例１において発熱体はプレス加工にて予め図のようにフォーミングしておき、これを射出成形型でインサート成形するときに矢視Ｄの個所で発熱体を露出する形状としておいた。これにより電極が固定され、プローブ接触等の生産的接点を得られると同時に製品上の発熱体露出の製品安全性や外観的問題を解決できる。即ち線材の端末がエッジとなった状態で製品から突出することを回避することができるため傷つけたり外観を損なうことが無い。勿論、これを避けるために伴う後加工が発生することが無い。
【００１４】
【発明の効果】
本発明により、低コストで信頼性が高く、溶着強度の高い、熱可塑性樹脂成形品の溶着が可能となった。熱可塑性樹脂が多用される家電製品及び自動車部品で、特に設備投資の大きい大型成形品の溶着分野において多大な効果をもたらす。
【図面の簡単な説明】
【図１】本発明実施例１の発熱体
【図２】本発明実施例１の成形品Ａ
【図３】本発明実施例１の成形品Ｂ
【図４】本発明実施例１の加圧、通電構造の概要
【図５】本発明実施例１の電極部断面
【図６】本発明実施例２の発熱体
【図７】本発明実施例２の成形品
【図８】本発明実施例２の電極部断面（電極ｅ断面）
【図９】本発明実施例２の電極部側面図
【符号の説明】
１．発熱体ａ ２．成形品Ａ
３．成形品Ｂ ４．電極ｃ
５．電極ｄ ６．凸部
７．当て凸部 ８．固定治具Ａ
９．固定治具Ｂ １０．加圧シリンダ
１１．装置側電極端子ｆ １２．通電制御装置
１３．成形品Ｃ １４．発熱体ｂ
１５．電極ｅ １６．装置側電極端子ｇ[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for welding molded articles for use in automobile parts and home electric appliances.
[0002]
[Prior art]
Conventionally, as a welding method of a resin molded product, there are several methods, but a heating method such as a hot plate heating, a hot air heating, and an ultrasonic heating, which is conventionally used, is used to heat the resin surface. A method of pressurizing each other is common. However, when high rigidity is required by welding, a welding method in which a continuous welding surface is provided, such as a vibration welding method or a hot-wire welding method, is used. The vibration welding method is a method in which the resin melts and adheres to each other by vibrating and pressing each molded product mutually.However, a special welding device and a jig for fixing the product are required, and the investment amount is large and cost In some cases, sufficient mass production is required. In particular, there is a problem that the cost of the apparatus and the cost of the jig become higher as the product becomes larger. On the other hand, the hot-wire welding method is a method in which a heating wire is sandwiched between molded products, and the resin is melted and adhered by applying heat to the heating element and heating at the same time as applying pressure. A jig for positioning and pressing the product is required, but these costs are lower than vibration welding. In particular, when the molded product is a large molded product having a size of 1500 cm 2 or more, the difference in the investment amount may be further increased.
[0003]
[Problems to be solved by the invention]
The above-mentioned hot-wire welding method has various problems while reducing the investment amount of equipment and jigs. First, there is a difficulty in fixing the heating element and aligning the molded products, and large-sized molded products have problems in man-hour and reliability. In addition, while the width of the welded portion contributes to the welding strength in both the vibration welding and the hot wire welding, in the case of the hot wire welding, the cross section is taken away by the heating element, so that the welded portion width needs to be made larger. That is, there is a problem that the strength that can be secured in the same space is small. This problem is not limited to large molded products, but the same can be said for all sizes.
[0004]
Further, in the hot wire welding method, some problems may remain because the hot wire remains in the product. In actual products, parts are hardly constituted by a single material, so there is no significant effect on recycling. However, for example, a problem of weight or the presence of a metal may be a factor of inhibiting radio waves for communication or the like.
The present invention has been made in view of such circumstances, and provides a welding method that is low in cost and has high welding strength.
[0005]
[Means for Solving the Problems]
The present invention relates to the following.
(1) In a method of welding a plurality of molded articles made of a thermoplastic resin by energizing and heating a member serving as a heating element, a member serving as a heating element is previously included in at least one of the molded articles. A welding method characterized by applying pressure to a heating element at a convex portion provided on a molded article in contact with the heating element, and simultaneously applying heat to the heating element and heating to weld the molded articles in contact with each other.
(2) The welding method according to (1), wherein the molded article having the heating element therein has an electrode portion having both ends fixed to the molded article and exposing the heating element.
[0006]
BEST MODE FOR CARRYING OUT THE INVENTION
The material of the molded article made of the thermoplastic resin of the present invention is not particularly limited as long as it is a thermoplastic resin, but it is desirable that a plurality of molded articles to be welded have mutual compatibility. In particular, in the case of claim 1, it is essential to have compatibility. The shape and size of the molded product are not limited, but they have surfaces that abut each other, and it is necessary that a pressing force be applied to this surface in the vertical direction. This surface is expressed including the tip surface of the rib.
[0007]
For example, if the tip of the rib provided on one molded product abuts against the surface of the counterpart molded product, and this surface is about 90 ° to 30 ° with respect to the rib, the vertical surface pressure required for welding is Can be secured. The material of the heating element is not particularly limited as long as it is a conductive material, but a metal material is desirable, and a steel wire or a stainless steel wire is more desirable. The shape may be any shape suitable for arrangement and welding, but in general, a wire having a circular cross section is easily used. Further, the heating element is often formed, and in this case, a flat plate or a band-shaped material is more suitable for punching and pressing, and may be more effective. The heating element of the present invention needs to be embedded in a molded article, and this is performed by insert molding. The heating element is insert-molded on at least one of the plurality of molded products described above. Any molding method can be used as long as it is a thermoplastic resin molding method, and it can be performed by injection molding, press molding, or the like.
[0008]
For example, in the case of injection molding, a step of fixing a member to be a heating element in an injection molding die, filling the resin with the resin, and molding. In addition, it is necessary to provide an exposed portion serving as an electrode at both ends of the heat generating portion for the member serving as the heat generating member. Can be provided. In this way, it is possible to provide an electrode portion having both ends fixed to the molded product and the heating element exposed.
[0009]
On the other hand, a convex portion is provided for a counterpart portion that comes into contact with the portion where the heating element is present. It is also preferable that each molded product is provided with a contact rib or the like so that the convex portion is accurately positioned at a portion where the heating element is present. However, when a jig for fixing the product is used at the time of welding, the contact rib is not necessarily required. Here, the molded product into which the heating element is inserted and the molded product having the convex portion do not need to be separate molded products, and each molded product has the heating element insert portion and the convex portion, and the mutual heating element insert portion is formed. It is also possible to adopt a structure in which the projection and the projection come into contact with each other. It is preferable that the width of the projection is larger than the width of the heating element. The height of the projection is related to the welding allowance, but another contact projection is provided on both sides or one side of the projection or on both sides or one side of the part where the heating element is included to manage the welding allowance. It is preferable to control the welding allowance. In this case, the difference in height between the convex portion and the contact convex portion is a welding margin, and the welding margin may be generally set to about 0.5 to 2 mm.
[0010]
In the case of claims 2 and 3 of the present invention, it is conceivable to make the height higher than this, but it is preferable to set the thickness to 0.5 to 2 times the thickness of the heating element. When a molded product with a heating element and a molded product with a convex part are brought into contact with each other and pressurized, generally, a fixture for fixing the molded product is prepared to improve productivity, Avoid distortion and ensure accuracy. It is also effective to press the welding portion in a convex shape from the jig side to the vicinity of the heating element or the back surface of the convex portion so that the welded portion can be concentratedly pressed. As a pressing method, there is a method using a stress due to elastic deformation of resin or rubber like a clamp. However, a method using a pressure cylinder is suitable for continuous control of pressure and synchronization with heating timing. Energization is performed from the above-described electrode unit via a device capable of controlling the application of voltage and current.
[0011]
Due to this energization, the heat-generating portion generates heat, and then the peripheral resin melts, and the pressing force causes the convex portion to flow near the joint surface and fuse together, and further continuous pressurization results in a force for pushing the heat-generating element. It is possible to adopt a form in which the part enters the counterpart molding. Here, it is preferable to provide convex portions serving as walls on both sides of the heating element so that the resin pressure does not escape. Since this convex portion can also serve as the above-mentioned convex portion, this convex portion is effective for both welding stability and high-strength welding. By stopping the energization and the energization control at substantially the same time as the melting and pressurization of the joint become sufficient as described above, the fusion part is cooled and hardened, and the welding strength is obtained.
[0012]
【Example】
Hereinafter, the present invention will be described based on examples, but the present invention is not limited thereto.
Example 1
First, as a heating element, φ2 of a mild steel wire is previously formed by press working as shown in the figure, and this is inserted into an injection molding die and injection molded with glass-containing PP resin to obtain a molded product A. The terminal of the heating element was exposed from the molded product in a and b, and this portion was used as an electrode. This molded product A is provided with a contact convex portion c so that the welding height can be made constant. Also, the height of the projection was 1.5 mm. Next, a molded product B having the convex part d on the other side is obtained by injection molding with the same glass-containing PP resin as that of the molded product A. The height of the projection d was 3 mm, and the width was 3 mm. Subsequently, the molded products A and B are brought into contact with each other. At this time, a jig for fixing each molded product is prepared, and the jig is set on a press machine so that the jig can be pressurized. Further, this fixing jig was shaped so that the welded portion comes into contact. Thereafter, pressure was applied by a press machine, and at the same time, electricity was supplied through a device capable of controlling the application of voltage and current from the electrodes a and b. The heating was continued by the control device so that the heating state did not exceed the decomposition temperature of PP, the projection d was melted and sinked, and stopped when the contact projection c hit the mating molded product, and after cooling, pressurization was stopped. The molded products A and B were taken out from the jig to obtain a high-strength welded product having the same welding height over the entire periphery of the welded portion.
[0013]
Example 2
First, in Example 1, the heat generating element was formed in advance by press working as shown in the figure, and the heat generating element was formed in such a shape that the heat generating element was exposed at a location indicated by an arrow D when insert-molding the same with an injection mold. As a result, the electrodes are fixed, so that productive contacts such as probe contact can be obtained, and at the same time, the problems of product safety and appearance due to exposure of the heating element on the product can be solved. That is, since the terminal of the wire can be prevented from protruding from the product in the state of the edge, there is no damage or damage to the appearance. Of course, no post-processing is required to avoid this.
[0014]
【The invention's effect】
According to the present invention, it has become possible to weld a thermoplastic resin molded product having low cost, high reliability, and high welding strength. The present invention has a great effect in the field of welding of large-sized molded products, which require large capital investment, in home electric appliances and automobile parts in which a thermoplastic resin is frequently used.
[Brief description of the drawings]
FIG. 1 is a heating element of Example 1 of the present invention. FIG. 2 is a molded article A of Example 1 of the present invention.
FIG. 3 is a molded article B of Example 1 of the present invention.
4 is an outline of a pressurizing and energizing structure according to the first embodiment of the present invention. FIG. 5 is a sectional view of an electrode portion according to the first embodiment of the present invention. FIG. FIG. 8 is a cross-sectional view of an electrode part (a cross-section of an electrode e) according to a second embodiment of the present invention.
FIG. 9 is a side view of an electrode part according to a second embodiment of the present invention.
1. Heating element a2. Molded product A
3. Molded product B 4. Electrode c
5. Electrode d6. Projection 7. Contact convex part 8. Fixing jig A
9. Fixing jig B 10. Pressurized cylinder11. Device-side electrode terminal f12. Energization control device 13. Molded product C14. Heating element b
15. Electrode e16. Device side electrode terminal g

Claims (2)

複数の熱可塑樹脂製成形品を、発熱体となる部材に通電し加熱することで、溶着する方法において、少なくとも片側の成形品に予め発熱体となる部材を内在させておき、これと当接する成形品に設けた凸部で発熱体に向けて加圧し、同時に発熱体に通電し加熱することで当接しあう成形品を溶着させることを特徴とする溶着方法。A plurality of thermoplastic resin molded articles are heated and energized to a member serving as a heating element, and in a welding method, a member serving as a heating element is preliminarily included in at least one of the molded articles and is brought into contact therewith. A welding method characterized by applying pressure to a heating element at a convex portion provided on a molded article, and simultaneously applying a current to the heating element and heating to weld the molded articles in contact with each other. 発熱体を内在させた成形品には、両端を成形品に固定されて発熱体が露出した電極部を有していることを特徴とする請求項１の溶着方法。2. The welding method according to claim 1, wherein the molded article including the heating element includes an electrode portion having both ends fixed to the molded article and exposing the heating element.
JP2003001365A 2003-01-07 2003-01-07 Method for welding resin molded article Pending JP2004209884A (en)

Priority Applications (1)

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Publications (1)

Publication Number Publication Date
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Family

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Country Status (1)

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