JP2009119832A - 樹脂材の溶着方法及び溶着装置 - Google Patents

樹脂材の溶着方法及び溶着装置 Download PDF

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Publication number
JP2009119832A
JP2009119832A JP2007299427A JP2007299427A JP2009119832A JP 2009119832 A JP2009119832 A JP 2009119832A JP 2007299427 A JP2007299427 A JP 2007299427A JP 2007299427 A JP2007299427 A JP 2007299427A JP 2009119832 A JP2009119832 A JP 2009119832A
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Prior art keywords
resin material
laser light
irradiation
resin
welding
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JP2007299427A
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JP4682179B2 (ja
Inventor
Shinsuke Asada
晋助 浅田
Chikafumi Hara
京史 原
Seizo Fujimoto
晴三 藤本
Kimiaki Taruya
公昭 樽谷
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Mitsubishi Electric Corp
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Mitsubishi Electric Corp
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Priority to JP2007299427A priority Critical patent/JP4682179B2/ja
Priority to KR1020080026709A priority patent/KR100955564B1/ko
Priority to US12/100,086 priority patent/US8110062B2/en
Priority to DE102008018286.9A priority patent/DE102008018286B4/de
Publication of JP2009119832A publication Critical patent/JP2009119832A/ja
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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
    • 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
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • 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
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B29C65/782—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined
    • B29C65/7823—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint
    • B29C65/7829—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint said distance pieces being integral with at least one 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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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
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    • 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
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    • 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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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
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    • B29C66/53461—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

【課題】溶着後の両樹脂材の寸法精度が確保でき、なおかつ過剰なレーザ光照射による接合強度の低下を防止できる樹脂材の溶着方法および溶着装置を提供する。
【解決手段】レーザ光９に対して透過性のある樹脂材１と、レーザ光９に対して吸収性のある樹脂材２とを重ね合わせると共に、前記レーザ光透過性の樹脂材側１よりレーザ光９を照射して前記樹脂材同士を溶着する方法において、前記レーザ光９の照射中における前記両樹脂材１，２の接近速度の低下に基づいて、前記レーザ光９の照射を終了させる。
【選択図】図２

Description

本発明は、レーザ光に対して透過性を有する樹脂材と、レーザ光に対して吸収性を有する樹脂材を、レーザ光を用いて接合する溶着方法および溶着装置に関する。
所定の波長のレーザ光に対して透過性を有する樹脂材と、同波長のレーザ光に対して吸収性を有する樹脂材を重ね合わせて、レーザ光透過性の樹脂材側からレーザ光を照射することで両者を溶着する工法は、特許文献１等に示されるようによく知られている。
本工法の原理を簡単に説明する。レーザ光はレーザ光透過性の樹脂中をほとんど吸収されずに通過し、レーザ光吸収性の樹脂材の表面付近で吸収される。吸収されたレーザ光のエネルギーは熱に変換され、レーザ光吸収性の樹脂材の表面を加熱する。レーザ光吸収性の樹脂材の表面と接したレーザ光透過性部材の樹脂の表面近傍も、熱伝達により加熱される。その結果、レーザ光透過性の樹脂材とレーザ光吸収性の樹脂材の接触面において溶融層が形成され、溶着に至る。溶着においては、レーザ光透過性の樹脂材とレーザ光吸収性の樹脂材との密着性を確保するために、重ねた方向に荷重を加え、溶着面において加圧した状態でレーザ光の照射を行う。このため、溶融層の一部は外部へ排斥され、溶着後の部材は溶着前よりも接近する。
特開２００２−３３７２３６号公報
従来のレーザ光溶着方法では、所定のレーザ光を照射した時間に対する両樹脂材の接近距離にばらつきが存在するため、溶着体としての寸法精度を損ねる原因になっていた。このばらつきは様々な要因で発生するが、一例としてレーザ光パワーの不安定性や、レーザ光透過性樹脂の透過率の個体ばらつきなどが挙げられる。これに対し、特許文献１に提案されている方法であれば、所定の接近距離に至った時点で溶着を終了する管理方法であるため、接近距離のばらつきは低減する。
しかし、所定の接近距離に達したことを検知してから溶着を停止するまでの制御上の遅れ時間の間にも接近は進行する。この間の接近距離もばらつくため、接近距離のばらつきは残存する。
溶着体の寸法精度を確保するには、溶着中の両樹脂材が溶着部以外の箇所で互いに突き当たる構造を採用することが確実である。両樹脂材が突き当たった位置で所定の位置精度を発現するように設計しておけば、溶着における接近距離のばらつきの影響を排除できる。この場合、当然、両樹脂材が突き当たるまでの時間についても個々にばらつく。全ての個体が確実に突き当たるためには、レーザ光照射時間をばらつき範囲よりも長く設定する必要がある。このため、突き当たるまで時間が短い個体に対しては、突き当たってからのレーザ光照射時間が過剰になり、溶着部の接合強度が低下する問題がある。強度低下は次のような原因で生じる。両樹脂材が突き当たるまでは、溶着部は加圧された状態であるから、溶融樹脂は順次外部に排斥されてゆき、溶融層が過剰に加熱されることはない。しかし突き当たった後は、突き当て部が荷重を受け止めるため、溶着部に加圧力が作用しなくなる。その結果、溶融層の排斥は停止する。この状態でさらにレーザ光照射が継続されると溶融層の温度が上昇し、ボイドの発生や熱分解が引き起こされ、接合強度が低下する。
本発明は、このような課題に鑑みてなされたものであって、溶着された部品の寸法精度と溶着強度とを両立させた樹脂材の光溶着方法および溶着装置を提供することを目的とする。
本発明は、レーザ光に対して透過性のある樹脂材と、レーザ光に対して吸収性のある樹脂材とを重ね合わせると共に、前記レーザ光透過性の樹脂材側よりレーザ光を照射して前記樹脂材同士を溶着する方法において、前記レーザ光の照射中における前記両樹脂材の接近速度の低下に基づいて、前記レーザ光の照射を終了させるようにした。
また、本発明は、レーザ光に対して透過性のある樹脂材と、レーザ光に対して吸収性のある樹脂材とを重ね合わせると共に、前記レーザ光透過性の樹脂材側よりレーザ光を照射して前記樹脂材同士を溶着する樹脂材の溶着装置において、前記レーザ光の照射中に一方の樹脂材またはこれを保持する保持治具の他方の樹脂材に対する速度を測定する速度測定部と、前記速度測定部からの出力信号に基づいて、前記両樹脂材の接近速度の低下を判定し、前記レーザ光の照射を終了させる制御部とを備えたものである。
本発明の樹脂材の溶着方法によれば、溶着後の両樹脂材の寸法精度が確保でき、なおかつ過剰なレーザ光照射による接合強度の低下を防止することができる。
また、本発明の樹脂材の溶着装置によれば、溶着後の両樹脂材の寸法精度が確保でき、なおかつ過剰なレーザ光照射による接合強度の低下を防止した溶着方法を実施することができる。
実施の形態１．
図１に示す２つの樹脂材を溶着して密閉容器を製造する方法を例として説明する。
樹脂材１は溶着に用いるレーザ光に対して透過性を有する樹脂からなる蓋体である。材質の一例として、ポリブチレンテレフタレート（ＰＢＴ）、ポリエチレンテレフタレート（ＰＥＴ）、ポリフェニレンスルフィド（ＰＰＳ）、ポリエーテルエーテルケトン（ＰＥＥＫ）、ポリカーボネート（ＰＣ）、ポリアミド(ＰＡ)、ポリエチレン(ＰＥ)などが挙げられる。染料や顔料を全く含まないか、レーザ光の波長に対する透過性を阻害しない範囲で染料や顔料で着色されている。
樹脂材２は溶着に用いるレーザ光の波長に対して吸収性を有するケースである。こちらも材質の例としては、透過性の樹脂と同様であるが、透過性の樹脂材料よりも透過率の低い材料を選択するか、カーボンブラックなどの吸収性を高める顔料や染料を混合したものを用いる。
これらの樹脂材はそれぞれ射出成形法や押し出し成形法、ブロー成形法、熱成形法など各種の樹脂成形法で成形されたものであり、金属部品や別の樹脂部品等がインサート成形される場合もある。溶着にかかわる箇所のみが上記のレーザ光透過性を有する樹脂とレーザ光吸収性を有する樹脂の組合せであれば良い。
図２は、本発明の実施の形態１における樹脂材の溶着装置の構成を示す図である。
この溶着装置は、レーザ光照射装置３と、樹脂材１と樹脂材２をそれぞれ保持する保持治具４、５と、これらを介して溶着対象に荷重を印加する加圧装置（図示せず）と、樹脂材１と樹脂材２との接近速度を測定する速度測定部６と、速度測定部６の測定値に基づいてレーザ光照射の終了タイミングを判断し、レーザ光照射装置３にレーザ光照射終了命令を与える制御部７とを備える。
樹脂材２を保持する保持治具５は固定であるのに対して、樹脂材２を保持する保持治具４は樹脂材１に追従して荷重方向に可動である。
速度測定部６は例えば樹脂材１と樹脂材２、樹脂材１と保持治具５、保持治具４と樹脂材２、或いは保持治具４と保持治具５の相対変位量を検出する変位センサ６１と、一定時間毎に測定された変位量から樹脂材１と樹脂材２、樹脂材１と保持治具５、保持治具４と樹脂材２、或いは保持治具４と保持治具５の接近速度を演算する速度演算部６２から構成されている。
制御部７は、速度測定部６で測定された接近速度が入力される速度入力部７１と、判定条件保持部７２に保持された判定条件に基づいてレーザ照射終了のタイミングを判定する終了判定部７３と、レーザ照射装置３に照射終了信号を出力する終了信号出力部７４とで構成されている。終了判定部７３における判定動作は制御クロックによって定められた一定時間間隔毎に行われる。
図３は、本発明の実施の形態１における溶着方法の各段階における溶着状態を示す断面図である。図４は、レーザ光照射開始からの両樹脂材１，２の接近速度の時間変化の一例を示す図である。
図３（ａ）に示す第一の段階として、樹脂材１と樹脂材２を重ね合わせ、荷重を加える。この段階においては、荷重が主に溶着部８に作用している。
図３（ｂ）に示す第二の段階として、樹脂材１の中を透過させて溶着部８にレーザビーム９を照射する。レーザビーム９の照射方法は特に指定するものではないが、例えば、スポット状に集光したレーザビームを溶着部８に従って順次走査する方式や、光学素子やマスクなどを用いて溶着部８に従った形状に成形したレーザビームを接合部に対して一括で照射する方式などが挙げられる。
レーザ光照射装置３のレーザ光源についても特に指定するものではないが、多くの樹脂に対して透過性を有する近赤外の波長を有するダイオードレーザや、ＹＡＧレーザが好適であり、この他にＣＯ２レーザなども選択できる。
レーザビーム９の照射開始と同時に、速度測定部６によって、両樹脂材１，２の接近速度の測定を開始する。レーザビームの照射を開始してからしばらく経つと溶着部８に溶融層１０が形成され、その後溶融層１０の一部が溶着部外部へ押し出されることにより、樹脂材１と樹脂材２は接近する。溶融層１０が形成されるまではほとんど接近が進まないのでレーザビームの照射直後の接近速度は小さいが、一旦溶融層が形成された後は、順次押し出されていくため、ほぼ一定の接近速度を示す。図４に示すとおりである。
図３（ｃ）に示す第三の段階として、両樹脂材１，２が溶着部以外に設けられた突き当て部１１にて突き当たり、これに伴って図４に示すように接近速度は急激に低下する。
制御部７においてこの接近速度の低下を検知すると、レーザ光照射装置３にレーザ光照射の終了を命令し、レーザ光照射は終了される。接近速度の急激な低下を検知する制御上の判定方式は特に指定するものではないが、接近速度が予め定めた閾値を下回ったことを判定する方式が最も簡便である。
以上では、樹脂材同士に突き当て部を設けた場合について説明したが、突き当て部１１は図５に示すように樹脂材１と保持治具５との間に設けてもよく、図６に示すように、保持治具４と保持治具５との間に設けてもよい。当然ながら保持治具４と樹脂材２との間に設けてもよい。このようにすれば、突き当たってからの過剰なレーザ光照射を防止でき、溶融層の過剰温度上昇による接合強度の低下を防止することができる。
図７は、実施の形態１における制御方法の処理手順の一例を示すフローチャートである。まず、両樹脂材１，２の間の接近速度が急激に低下する際に、個体のばらつきに拘わらず必ず通過する第１の速度Ｖ１を第１の閾値として定め、更に第１の速度Ｖ１以上で、個体のばらつきに拘わらず必ず通過する第２の速度Ｖ２を第２の閾値として定める。
レーザ光照射開始後、まず接近速度Ｖと第２の閾値Ｖ２の大小が制御クロックで定められた時間間隔毎に判定される。判定条件Ｖ＞Ｖ２を満足した後に、接近速度Ｖと第１の閾値Ｖ１の大小が制御クロックで定められた時間間隔毎に判定される。判定条件Ｖ≦Ｖ１を満足した時点で、接近速度Ｖの急激な低下と判定し、レーザ光照射を終了する。
なお、判定条件Ｖ＞Ｖ２の判定は、この判定条件を満足するときのレーザ光照射開始後の経過時間があらかじめ分かっている場合は、これらで代用してもよい。
実施の形態２．
図８は、実施の形態２における制御方法の処理手順の一例を示すフローチャートである。実施の形態２においては、判定条件Ｖ≦Ｖ１を満足した時点で、接近速度Ｖの低下の判定をしてから、更に所定時間レーザ光照射を継続した後に、レーザ光照射を終了する。
このレーザ光照射の継続時間は、溶着部８にボイドや熱分解が生じる時間領域よりも短い範囲で設定する。このようにすれば、即座にレーザ光照射を停止するよりも、溶融層１０の厚みが増すので、より強固な接合を得ることができる。
実施の形態３．
図９及び１０は実施の形態３における制御方法の処理手順の異なる例を示すフローチャートである。実施の形態３においては、実施の形態１における第二の段階の途中において溶着部８に照射されるレーザ光のパワーを低下させるようにしたもので、レーザ光のパワーを低下させる第３の速度Ｖ３を第３の閾値として定めている。
図９は、判定条件Ｖ＞Ｖ２を満足した後に、接近速度Ｖと第３の閾値Ｖ３の大小が制御クロックで定められた時間間隔毎に判定され、判定条件Ｖ＞Ｖ３を満足した時点で、レーザ光のパワーを低下させた後、第１の閾値Ｖ１による判定を行うようにしたものである。
図１０では、第３の閾値Ｖ３が第２の閾値Ｖ２以下の場合の例を示したもので、最初に接近速度Ｖと第３の閾値Ｖ３の大小を制御クロックで定められた時間間隔毎に判定し、判定条件Ｖ＞Ｖ３を満足した段階でレーザ光のパワーを低下させ、その後第２の閾値Ｖ２及び第１の閾値Ｖ１による判定を順次行うようにしたものである。
なお、レーザ光パワーを低下させるタイミングは、樹脂材１が樹脂材２に突き当たって接近速度が急激に低下するよりも前であれば任意に設定できるが、レーザ光の照射開始から所定時間経過後、両樹脂材１，２が所定量接近した後、あるいは両樹脂材１，２の接近速度が所定速度に到達した後の何れかであれば良い。
実施の形態３によれば樹脂材１が樹脂材２に突き当たってからの溶融層１０の温度上昇が緩やかになり、第三の段階において接近速度の急激な低下を検知してからレーザ光の照射を終了するまでの猶予時間が拡大する。
この結果、制御が容易になる上、レーザ光照射開始時点から低いパワーで照射しつづける場合に比べて溶着時間を短縮できる利点がある。
なお、以上の実施の形態においては溶着の対象として密閉容器を例としたが、これに限定されるものではない。
本発明によれば溶着体として高い寸法精度が得られるので、精密な電子部品の収納ケース等の製造に適している。
本発明の実施の形態を説明する一例としての密閉容器を示す斜視図である。 本発明の実施の形態１における溶着装置の構成を示す概略構成図である。 本発明の実施の形態１における溶着方法の各段階を示す断面図である。 本発明の実施の形態１における溶着に伴う接近速度の時間変化の一例を示す説明図である。 樹脂材同士に突き当て方法の他の例を示す断面図である。 樹脂材同士に突き当て方法の更に他の例を示す断面図である。 本発明の実施の形態１における制御方法の処理手順の一例を示すフローチャートである。 本発明の実施の形態２における制御方法の処理手順の一例を示すフローチャートである。 本発明の実施の形態３における制御方法の処理手順の一例を示すフローチャートである。 本発明の実施の形態３における制御方法の処理手順の他の例を示すフローチャートである。
符号の説明
１ 樹脂材
２ 樹脂材
３ レーザ光照射装置
４ 保持治具
５ 保持治具
６ 速度測定部
６１ 変位センサ
６２ 速度演算部
７ 制御部
７１ 速度入力部
７２ 判定条件保持部
７３ 終了判定部
８ 溶着部
９ レーザ光ビーム
１０ 溶融層
１１ 突き当て部

Claims (8)

  1. レーザ光に対して透過性のある樹脂材と、レーザ光に対して吸収性のある樹脂材とを重ね合わせると共に、前記レーザ光透過性の樹脂材側よりレーザ光を照射して前記樹脂材同士を溶着する方法において、
    前記レーザ光の照射中における前記両樹脂材の接近速度の低下に基づいて、前記レーザ光の照射を終了させるようにしたことを特徴とする樹脂材の溶着方法。
  2. 前記レーザ光の照射中に前記両樹脂材同士、あるいは前記両樹脂材を保持する保持治具同士、あるいは一方の樹脂材を保持する保持治具と他方の樹脂材との突き当たりによる前記両樹脂材の接近速度の低下を判定し、前記レーザ光の照射を終了させることを特徴とする請求項１記載の樹脂材の溶着方法。
  3. 前記接近速度の低下が生じた後、所定時間経過後に前記レーザ光の照射を終了することを特徴とする請求項１または２記載の樹脂材の溶着方法。
  4. 前記レーザ光の照射終了の契機となる前記接近速度の低下が生じるより前に、前記レーザ光のパワーを低下させることを特徴とする請求項１乃至３の何れか一つに記載の樹脂材の溶着方法。
  5. レーザ光に対して透過性のある樹脂材と、レーザ光に対して吸収性のある樹脂材とを重ね合わせると共に、前記レーザ光透過性の樹脂材側よりレーザ光を照射して前記樹脂材同士を溶着する樹脂材の溶着装置において、
    前記レーザ光の照射中に一方の樹脂材またはこれを保持する保持治具の他方の樹脂材に対する速度を測定する速度測定部と、
    前記速度測定部の測定値に基づいて、前記両樹脂材の接近速度の低下を判定し、前記レーザ光の照射を終了させる制御部とを備えた
    ことを特徴とする樹脂材の溶着装置。
  6. 前記制御部は、前記レーザ光の照射中に両樹脂材同士、あるいは両樹脂材を保持する保持治具同士、あるいは一方の樹脂材を保持する保持治具と他方の樹脂材との突き当たりによる前記両樹脂材の接近速度の低下を判定し、前記レーザ光の照射を終了させることを特徴とする請求項５記載の樹脂材の溶着装置。
  7. 前記接近速度の低下が生じた後、所定時間経過後に前記レーザ光の照射を終了することを特徴とする請求項５または６記載の樹脂材の溶着装置。
  8. 前記制御部は、前記レーザ光の照射開始から所定時間経過後、前記両樹脂材が所定量接近した後、あるいは前記両樹脂材の接近速度が所定速度に到達した後の何れかにおいて前記レーザ光のパワーを低下させることを特徴とする請求項５乃至７のいずれか一つに記載の樹脂材の溶着装置。
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