JP2012121156A - 振動溶着方法 - Google Patents

振動溶着方法 Download PDF

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Publication number
JP2012121156A
JP2012121156A JP2010271539A JP2010271539A JP2012121156A JP 2012121156 A JP2012121156 A JP 2012121156A JP 2010271539 A JP2010271539 A JP 2010271539A JP 2010271539 A JP2010271539 A JP 2010271539A JP 2012121156 A JP2012121156 A JP 2012121156A
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Japan
Prior art keywords
vibration
welding
welded
pressure
pair
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JP2010271539A
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Inventor
Shuji Kanemoto
周二 金本
Ryutaro Nishibori
隆太郎 西堀
Takaaki Nagata
高章 永田
Hisashi Masuda
久 増田
Masato Tanaka
正人 田中
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Honda Motor Co Ltd
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Honda Motor Co Ltd
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Priority to JP2010271539A priority Critical patent/JP2012121156A/ja
Priority to US13/310,274 priority patent/US20120168057A1/en
Priority to CN2011104618512A priority patent/CN102555211A/zh
Publication of JP2012121156A publication Critical patent/JP2012121156A/ja
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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/343—Making tension-free or wrinkle-free 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
    • 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
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/0609—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding characterised by the movement of the parts to be joined
    • B29C65/0618—Linear
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • 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
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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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    • B29C66/11—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
    • B29C66/114—Single butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
    • 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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    • B29C66/3022—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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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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    • B29C66/00—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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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • 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
    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • 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
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    • B29C66/91443—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91931—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one 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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    • B29C66/91951—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to time, e.g. temperature-time diagrams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/92441—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 by controlling or regulating the pressure, the force or the mechanical power the pressure, the force or the mechanical power being non-constant over time
    • B29C66/92443—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 by controlling or regulating the pressure, the force or the mechanical power the pressure, the force or the mechanical power being non-constant over time following a pressure-time profile
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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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    • 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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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • High Energy & Nuclear Physics (AREA)
  • Plasma & Fusion (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

【課題】 振動溶着において樹脂製の一対の被溶着物を溶着する際、溶着後の製品にひずみが発生するのを抑制し、外観品質が低下するのを防止する。
【解決手段】 一対の樹脂製の被溶着物１、２の溶着面同士を対面させ、加圧力を加えて一対の被溶着物１、２を圧接させると同時に振動を付加して摩擦熱を発生させることで溶着面の融着部を溶融させ、所定の押し込み量に達した時点で振動を停止して溶融部を冷却させることで溶融部を溶着するようにした振動溶着方法において、振動工程が終了すると直ちに圧接力を所定圧力まで低下させて冷却固化させる。
【選択図】 図２

Description

本発明は、例えば車両用のエアバッグカバーをインストルメントパネルに振動溶着する際に脆弱部等にひずみが発生するのを抑制するのに有効な技術に関する。
従来、車両の乗員を保護するためのエアバッグを収容する樹脂製の収容ケースとエアバッグカバー本体とを接合するような場合に、両者の接合面を当接させ加圧力を付与した状態で相対振動を与え、当接部分を摩擦熱で溶融させて溶着する振動溶着が行われることがある。このような振動溶着の技術として、例えば被溶着物の一方側の形状が湾曲しているような場合でも確実に溶着できるよう、振動溶着に用いる一方側の被溶着物の溶着用リブの先端の当接領域を、他方側の接合部の延在面形状に対応する面にするような技術が知られている。（例えば、特許文献１参照。）
また、振動溶着時の溶着強度を高めるため、第１圧接圧力で加圧した状態で振動を付加し、振動を付加した後、直ちに圧接圧力を連続的に低下させて所定時間（０．５〜５秒）内に第２圧接圧力（第１圧接圧力の４／５〜１／５）に到達させ、この状態で圧接を継続しつつ振動の付加を所定時間継続して溶着するような技術（例えば、特許文献２参照。）や、振動溶着において当接面が溶融する前に発生する磨耗粉を抑制するための技術（例えば、特許文献３参照。）なども知られている。
特開２００８−１１４７４７号公報 特許第３２１１７１２号公報 特開２０１０−１４９４２４号公報
ところが、従来の技術の場合、振動を停止した後、加圧力を保持したまま冷却して溶融部を固化させるようにしているため、溶融部における溶着強度は十分得られるものの、例えば被溶着物として、所定箇所にカバー開裂用の薄肉のティアラインが形成されているエアバッグカバーなどの場合には、このようなティアラインなどの脆弱部分に応力が集中してひずみが発生するという問題があった。そして、このようなひずみが残ったまま固化すると、ひずみ跡が凹凸となって外観に現れ、見栄えが悪くなるという不具合があった。
また、上記特許文献２のように、振動工程の途中で圧接力を第２圧接圧力に低下させる技術でも、被溶着物が脆弱部を有する場合には、脆弱部のひずみを解消することはできなかった。
そこで本発明は、振動溶着において一対の被溶着物を溶着する場合に、溶着後の製品にひずみが発生するのを抑制し、外観品質が低下するのを防止することを目的とし、特に、被溶着物として、薄肉の脆弱部を有するものであってもひずみが生じないようにする。
上記目的を達成するため本発明は、溶着すべき一対の被溶着物の溶着面同士を対面させる工程と、圧接力を加えて前記一対の被溶着物を圧接させると同時に振動によって両者の間に相対運動を起こさせることで溶着面の融着部を溶融させる振動工程と、振動を停止して溶融部を冷却させることで溶融部を溶着する冷却工程からなる振動溶着方法において、前記振冷却工程において、前記圧接力を所定圧力まで低下させるようにした。
このように、振動によって溶着面の溶着部を摩擦熱で溶融させ、例えば加圧側の被溶着物の押し込み量が所定量に達した時点で振動工程を終了し、冷却工程に移行するが、振動工程中は、当初の圧接力が保持されるため、効率的に摩擦熱を高めることができる。また、冷却工程において圧接力を所定圧力まで低下させることにより、ひずみを生じにくくすることができる。
この際、圧接力を低下させる程度としては、例えば、振動工程中の圧接力が０．４４ＭＰａ程度であれば、０．０５〜０．３５Ｍｐａ程度が好適である。
この際、圧接力の低下は、振動工程が終了したら直ちに行われることがより好ましい。
ここで、「振動工程が終了したら直ちに圧接力を低下させる」とは、溶融部の温度が融点に達するまでに、圧接力が振動時の圧接力以下に下がり初めていればよく、融点に達するまでに所望の圧接力まで下がりきっている必要はない。
これは、摩擦熱が無くなった状態で圧接力を長い時間保持すると、圧縮方向のひずみが大きくなって、結果的に溶融部が凝固した時の最終的なひずみが大きくなるからである。
また、このような冷却工程における圧接力の低下は、特に、被溶着物の少なくともいずれか一方が、薄肉による脆弱部を有するものであるときに、ひずみ防止に有効である。
振動溶着方法において、振動工程が終了した冷却工程において圧接力を低下させることにより、ひずみの発生による外観品質の低下を抑制することができる。
この際、振動工程が終了すると直ちに圧接力を低下させることで、より効果的にひずみの発生を抑制でき、また、被溶着物として少なくともいずれか一方に、薄肉による脆弱部が形成されるものであるときには効果的である。
一般的な振動溶着方法を説明するための説明図である。 本発明に係る振動溶着方法を説明する説明図である。 冷却時の脆弱部のひずみ量を測定した実験データの説明図である。 冷却時の圧接力と溶着強度の関係を示す説明図である。
本発明に係る振動溶着方法は、例えば、車両の乗員を保護するためのエアバッグ関連部品を振動溶着で組付けるにあたり、溶着後の製品にひずみが発生するのを抑制し、外観品質が低下するのを防止できるようにされ、特に、ティアライン等の薄肉の脆弱部を有する場合であっても、脆弱部に応力が集中してひずみが生じることがないようにされている。
振動溶着の一般的要領の概要について図１に基づき説明すると、（ａ）に示すように、一対の被溶着物１、２の溶着面同士を対面させ、振動溶着機の上治具３と、下治具４で挟み込んで型締め・クランプする。
この際、例えば上治具３には、上側の被溶着物１を保持して振動を与えることのできる振動源（不図示）が接続され、下治具４には、保持した下側の被溶着物２を押し上げて、両方の被溶着物１、２間に圧接力を与えることのできる加圧源（不図示）が接続されている。
また、振動が付与される上側の被溶着物１の溶着面には、溶着用リブ１ｒが突起として複数設けられている。
振動溶着機の上治具３と下治具４で被溶着物１、２をクランプすると、（ｂ）に示すように、下治具４で加圧力を加えるとともに、上治具３で上側の被溶着物１を振動させる。すると、上側の被溶着物１の溶着用リブ１ｒの当接部と被溶着物２の当接部との間に摩擦熱が生じ、溶着用リブ１ｒが溶融してきて下側の被溶着物２が上方に押し込まれるようになる。そして、この押し込み量が所定の値に達せると、（ｃ）に示すように、上治具３による振動が停止して溶融部の冷却が始まる。
この（ｃ）の段階における冷却の際、従来では（ｂ）の振動工程中の加圧力をそのまま保持するのが一般的であるが、本発明では、振動が停止すると所定圧まで低下させることを要旨としている。
それでは、図２に基づき本発明に係る振動溶着方法について説明する。
本発明に係る振動溶着方法においては、図２に示すように、一対の樹脂製の被溶着物１、２を上治具３と下治具４で挟み込んで型締めし、圧力をかけてクランプする。
ちなみに、被溶着物の一方がティアラインを有するエアバッグカバーであるような場合の圧接力は、０．４４ＭＰａ程度である。
そして、所定の加圧力がかけられると、この圧力を保持したまま上治具３を介して上側の被溶着物１を振動させる。すると、摺動面の温度が上昇し、溶着用リブ１ｒが溶融し始める。
ちなみに、上側の被溶着物１がティアラインを有するエアバッグカバーであるような場合の樹脂材料としては、融点が１３０度程度のポリプロピレン（ＰＰ）などが使用されている。
そして、溶着用リブ１ｒが溶融することにより上治具３と下治具４が接近し、所定の押し込み量に達した時点で、上治具３による振動付加が停止し、振動工程が終了する。
振動工程が終了すると、従来の場合は図２の破線に示すように、加圧が保持されて冷却が行われるが、本案の場合は、直ちに加圧力を低下させて冷却する。このときの圧接力は、被溶着物の一方としてティアラインを有するエアバッグカバーであるような場合は０．０５〜０．３５ＭＰａにすると、必要な接合強度が得られるとともに、成形後のひずみを抑制できることが確認されている。
すなわち、図２は、エアバッグ関連部品の振動溶着において、ティアラインを有する被溶着物を溶着する際のティアライン上のひずみを測定した実験データの一部を示し、図３は溶着強度の実験データを示すものであるが、冷却時の圧接力として、振動工程時の圧力と同じ０．４４ＭＰａの圧力を保持して冷却固化した場合は、成形後のひずみが大きく、冷却時の圧接力を低下させるほどひずみが小さくなることが判る。
そして、このときの圧接力を０．３５ＭＰａ以下にすれば、ティアライン上のひずみが外観に現れるような不具合を是正できる圧力の上限であることが判った。
また、加圧力を低下させるタイミングについても、振動工程が終了して直ちに低下させると、若干の間をおいて低下させることに較べて、成形後のひずみを小さくできることも確認された。
一方、成形後の溶着部の溶着強度については、図４に示すように、冷却時の圧接力低下に伴って溶着強度も低下するが、０．０５ＭＰａまでは溶着強度要件を満たしており、０．０５ＭＰａ以下になると、溶着強度にばらつきが生じるようになり、場合によっては溶着強度要件を満たさない場合もあることが判った。
以上のようなことから、振動工程終了後加圧力を所定範囲に低下させることで、脆弱部に集中しやすいひずみを解消して良好な外観品質を得ることができ、また、必要な溶着強度も得られることが確認された。
なお、本発明は以上のような実施形態に限定されるものではない。本発明の特許請求の範囲に記載した事項と実質的に同一の構成を有し、同一の作用効果を奏するものは本発明の技術的範囲に属する。
例えば被溶着物の種類等は例示である。
樹脂などの振動溶着において、必要な溶着強度を確保しつつ、ひずみの発生を抑制できるため、特に車両のエアバッグ関連部品などの溶着において広い普及が期待される。
１、２…被溶着物。

Claims (3)

  1. 溶着すべき一対の被溶着物の溶着面同士を対面させる工程と、圧接力を加えて前記一対の被溶着物を圧接させると同時に振動によって両者の間に相対運動を起こさせることで溶着面の融着部を溶融させる振動工程と、振動を停止して溶融部を冷却させることで溶融部を溶着する冷却工程からなる振動溶着方法であって、前記振冷却工程において、前記圧接力を所定圧力まで低下させることを特徴とする振動溶着方法。
  2. 前記圧接力の低下は、前記振動工程が終了したら直ちに行われることを特徴とする請求項１に記載の振動溶着方法。
  3. 前記被溶着物の少なくともいずれか一方は、薄肉による脆弱部を有するものであることを特徴とする請求項１又は請求項２に記載の振動溶着方法。
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