JP2007283677A - 樹脂積層体およびその製造方法 - Google Patents
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Abstract
【解決手段】溝状の流路を有する樹脂板2〜4を積層してなり、溝状の流路3b等を組み合わせて構成される管状の流路を有する樹脂積層体1であって、上記積層された樹脂板は、少なくとも各樹脂板の溝状の流路を囲む部位で超音波溶着等により溶着して相互に接合され、超音波溶着される接合部の断面は、一方が凸形状で、他方が凸形状の凸部に嵌合できる凹形状で、かつ凸形状の凸部先端幅が凹形状の凹部底面幅よりも大きい形状で嵌合されつつ該凸部の側面で超音波溶着されてなる。
【選択図】図1
Description
また、積層体全体として十分な接合強度が得られていても、流路周囲の箇所で十分な接合がなされていないと上記流体の漏れ等の問題が起こりやすい。特に、燃料電池のエンドプレートでは、流路を通過する反応ガスのガス圧が高く、水素ガス等は分子量が小さいため、わずかな隙間からでも漏れやすいという問題がある。また、マイクロアレイでは接合隙間から、わずかでも物質が漏れたり、気泡等が混入すると正確な同定・検出を行なうことができないという問題がある。
また、上記凹形状の凹部内側面の少なくとも一方の側面に凹部底面幅を凹部上面幅よりも狭くする方向の傾斜面を有することを特徴とする。
各樹脂板の溝状の流路は、相互に積層される任意の2つの樹脂板において、それぞれの積層面の溝状流路を組み合わせて所望の管状流路となるように形成する。溝状流路の形状としては、樹脂板表面に形成される、断面長方形や断面半円形等の凹形状、樹脂板を貫通する円孔形状等が挙げられる。
積層された複数枚の樹脂板は、少なくとも各樹脂板の溝状の流路を囲む部位で溶着して相互に接合されて樹脂積層体が形成される。また、樹脂板同士の接合強度をさらに必要とする場合には、流路周囲以外の部位も同時に溶着する。
上記樹脂溶着手段の中で、後述する接合形状と組み合わせることにより溶融バリの発生がなく、寸法精度および外観形状にも優れるとともに、多種の樹脂材料において溶着が可能であり樹脂板が相互に強固に溶着され樹脂積層体の接合強度、気密性等に優れることから、超音波溶着を用いることが好ましい。
本発明の樹脂積層体を燃料電池用のエンドプレートとして利用する場合、耐薬品性、ガスバリア性および機械的強度等に優れることから、PPS樹脂、PEEK樹脂、PVDF樹脂等を用いることが好ましい。
本発明の樹脂積層体をマイクロアレイ用基板として利用する場合、透明性等が要求されることから、ポリオレフィン樹脂、PC樹脂、PSF樹脂、PES樹脂等を用いることが好ましい。
図1に示すように、燃料電池用エンドプレート1は、3個の樹脂板2〜4を積層して形成されている。樹脂板2の表面2c側に、単位セル同士がセパレータを介して積層されたセルスタックが配置される。
樹脂板2〜4には、それぞれ溝状の流路が形成されており、これらの溝状の流路が組み合わされてエンドプレート1内部に管状流路が形成されている。具体的には次のような流路が形成される。樹脂板2の溝状流路2aは、樹脂板3の溝状流路3aと繋がり、該流路3aは樹脂板3の側口3bと繋がっている(図中流路a)。また、樹脂板2の溝状流路2bは、樹脂板3の溝状流路3bと繋がり、該流路3bは樹脂板4の溝状流路4aと繋がり、さらに該流路4aは樹脂板4の側口4bと繋がっている(図中流路b)。
以上のような管状流路を介して、エンドプレート1からセルスタック内に、またはセルスタック内からエンドプレート外側に、水素ガスや酸素ガス等の反応ガスが供給・排出される。
図2および図3に示すように、超音波溶着される接合部5の断面は、一方(樹脂板2側)が凸形状で、他方(樹脂板3側)が凸形状の凸部に嵌合できる凹形状であり、該凸部または凹部が溝状の流路の周囲に形成される。この凸部側面または凹部側面に超音波振動を与えながら加圧して、相互に圧入して溶着する。このように少なくとも流路を囲む部位(接合部5)で樹脂板同士を溶着することで、該溝状流路を組み合わせて構成された管状流路6の気密性に優れる。
図4の拡大図に示すように、接合部5の断面は、樹脂板2の接合部断面が凸形状2cで、樹脂板3の接合部断面が凹形状3cであり、相互に嵌合できる形状をしており、かつ凸部先端幅Dが凹形状の凹部底面幅d2よりも大きい形状である。
詳細には、樹脂板3の凹形状3cが、内側面3dおよび3eと、凹部底面3fとから構成され、内側面3dに凹部の上部内幅d1を狭くする方向の傾斜面3gを有している。傾斜面3gを有する凹形状3cに凸形状2cを嵌合して超音波振動を印加することにより、接触部における変形歪の発熱が傾斜面3gと凸形状2cの端面および側面2dとで発生し該部位で溶着される。
具体的工程としては、樹脂板2の凸形状2cと樹脂板3の凹形状3cとを嵌合させ、超音波振動を発生させながら加圧して、相互に圧入する。この工程により、凹形状の凹部側面で超音波溶着する。ここで超音波溶着条件は、樹脂材料、凹凸形状等によって異なるが、超音波振動ホーンの振幅は、凹凸形状の嵌合上下方向に 25〜50μm 、周波数は、15〜40 kHz で行なうのが溶着強度および気密度を高めるので好ましい。なお、相互に接合する樹脂板のどちらに凹形状または凸形状を設けるかは任意に決定できる。
接合体の外観形状を維持するため、凹形状3cの深さを凸形状2cの長さより、余剰溶融物が溢れでない程度深くすることが好ましい。また、凸部の嵌合を容易とするため、凹部上部入口にテーパーを設けることが好ましい。
凸形状2cの形状は、その先端幅Dを凹部の上部内幅d1よりも約0.05mm程度のクリアランスをもたせた形状とすることが好ましい。該形状とすることにより、溶着振動をかける前に嵌合先端部の凹凸を誘い込ませて樹脂板2と樹脂板3とを押えて変形などを矯正させることができる。その押えを保持しながら溶着振動をかけることによって、流路を囲む全周を均一に溶着することが可能となる。
図1に示す形状の燃料電池用エンドプレート(寸法:210×100×60mm)を、PPS樹脂製の樹脂板を3個積層し超音波溶着により接合して作製した。なお接合部断面は図4に示す形状とした。超音波溶着は、超音波溶着機としてBRANSON2000シリーズを使用し、周波数 15 kHz、振幅 50 μm、溶着時間 1.0秒の条件下で行なった。
得られた積層体について、流路全てに蓋をして水中でガスを加圧(0.3MPa)充填し、ガスの漏れを確認する気密確認試験を行なった。試験の結果、水素ガスの漏れは認められなかった。
2〜4 樹脂板
5 接合部
6 管状流路
Claims (7)
- 溝状の流路を有する樹脂板を複数枚積層してなり、前記溝状の流路を組み合わせて構成される管状の流路を有する樹脂積層体であって、
前記積層された複数枚の樹脂板は、少なくとも各樹脂板の溝状の流路を囲む部位で溶着して相互に接合されることを特徴とする樹脂積層体。 - 前記溶着は、超音波溶着であることを特徴とする請求項1記載の樹脂積層体。
- 前記超音波溶着される接合部の断面は、一方が凸形状で、他方が前記凸形状の凸部に嵌合できる凹形状で、かつ前記凸形状の凸部先端幅が前記凹形状の凹部底面幅よりも大きい形状で嵌合されつつ該凸部の側面で超音波溶着されてなることを特徴とする請求項2記載の樹脂積層体。
- 前記凹形状の凹部内側面の少なくとも一方の側面に凹部底面幅を凹部上面幅よりも狭くする方向の傾斜面を有することを特徴とする請求項3記載の樹脂積層体。
- 前記樹脂積層体が、燃料電池用のエンドプレートであることを特徴とする請求項1ないし請求項4のいずれか一項記載の樹脂積層体。
- 前記樹脂積層体が、マイクロアレイ用基板であることを特徴とする請求項1ないし請求項4のいずれか一項記載の樹脂積層体。
- 溝状の流路を有する樹脂板を複数枚積層し、各樹脂板を相互に接合する積層工程を備えてなる樹脂積層体の製造方法であって、
前記積層工程は、少なくとも各樹脂板の溝状の流路を囲む部位で、各樹脂板同士を溶着により相互に接合して、前記溝状の流路を組み合わせて管状の流路を形成する工程であることを特徴とする樹脂積層体の製造方法。
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