JP2015205420A - ガス透過部材及びその製造方法 - Google Patents

ガス透過部材及びその製造方法 Download PDF

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Publication number
JP2015205420A
JP2015205420A JP2014085993A JP2014085993A JP2015205420A JP 2015205420 A JP2015205420 A JP 2015205420A JP 2014085993 A JP2014085993 A JP 2014085993A JP 2014085993 A JP2014085993 A JP 2014085993A JP 2015205420 A JP2015205420 A JP 2015205420A
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Japan
Prior art keywords
gas permeable
welding
working surface
permeable member
resin
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.)
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JP2014085993A
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English (en)
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JP6486014B2 (ja
Inventor
恭子 石井
Kyoko Ishii
恭子 石井
陽三 矢野
Yozo Yano
陽三 矢野
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Nitto Denko Corp
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Nitto Denko Corp
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Priority to JP2014085993A priority Critical patent/JP6486014B2/ja
Application filed by Nitto Denko Corp filed Critical Nitto Denko Corp
Priority to EP15779897.6A priority patent/EP3132915B1/en
Priority to KR1020227031594A priority patent/KR20220129677A/ko
Priority to US15/304,788 priority patent/US10300665B2/en
Priority to CN201580020284.3A priority patent/CN106232325B/zh
Priority to PCT/JP2015/001987 priority patent/WO2015159515A1/ja
Priority to KR1020167028176A priority patent/KR20160147737A/ko
Priority to TW104112018A priority patent/TWI674188B/zh
Publication of JP2015205420A publication Critical patent/JP2015205420A/ja
Application granted granted Critical
Publication of JP6486014B2 publication Critical patent/JP6486014B2/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
    • 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
    • B29C66/81433—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 being toothed, i.e. comprising several teeth or pins, or being patterned
    • 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
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • 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
    • B29C66/11—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
    • B29C66/112—Single lapped 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
    • B29C66/11—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
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/05—Particular design of joint configurations
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    • 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
    • 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
    • B29C66/23—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
    • 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
    • B29C66/2422—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 circular, oval or elliptical
    • B29C66/24221—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 circular, oval or elliptical being circular
    • 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
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
    • 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
    • B29C66/53—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
    • B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • 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
    • B29C66/71—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 composition of the plastics material of the parts to be joined
    • 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
    • B29C66/71—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 composition of the plastics material of the parts to be joined
    • B29C66/712—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 composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
    • 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
    • B29C66/72—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 structure of the material of the parts to be joined
    • B29C66/727—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 structure of the material of the parts to be joined being porous, e.g. foam
    • 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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B29C66/73116—Melting point of different melting point, i.e. the melting point of one of the parts to be joined being different from the melting point of the other part
    • 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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
    • B29C66/7318—Permeability to gases or liquids
    • B29C66/73181—Permeability to gases or liquids permeable
    • B29C66/73182—Permeability to gases or liquids permeable to gases
    • 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
    • B29C66/70—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
    • B29C66/735—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 extensive physical properties 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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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • 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
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • 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
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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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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Engineering & Computer Science (AREA)
  • Thermal Sciences (AREA)
  • Fluid Mechanics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

【課題】樹脂部品と樹脂膜との間の溶着強度を高める。【解決手段】加工対象に接するべき作用面（６２ｐ）に凸部（６２ｔ）が設けられた溶着ホーン（６２）を使用して、フッ素樹脂で作られたガス透過性のフッ素樹脂多孔質膜（４）を熱可塑性樹脂で作られた樹脂部品（２）に溶着する。溶着ホーン（６２）の作用面（６２ｐ）には、例えば、複数の凸部（６２ｔ）が設けられている。複数の凸部（６２ｔ）は、作用面（６２ｐ）において格子状に並んでいてもよい。【選択図】図２

Description

本発明は、通気部材、防水通音部材などのガス透過部材及びその製造方法に関する。
ランプ、センサ、ＥＣＵ（electronic control unit）などの自動車の電気部品を収容するための筐体には、筐体の内部と外部との通気を確保しつつ、筐体の内部への異物の侵入を阻止するための通気部材が取り付けられている。例えば、特許文献１には、車両用ランプハウジングの開口部にガス透過膜を接着又は溶着することが記載されている。
ガス透過膜をランプハウジングなどの樹脂部品に固定する方法として、特許文献１は、接着及び溶着を開示している。接着は、簡単な方法であるが、生産性があまりよくないこと、接着強度が経時的に低下することなどの問題を抱えている。一方、溶着は、材料の相性の問題を抱えている。特に、ガス透過膜がフッ素樹脂で作られ、樹脂部品が熱可塑性樹脂で作られているとき、ガス透過膜を樹脂部品に溶着することは容易ではない。そのため、従来の樹脂部品の表面には、溶着リブが設けられている。樹脂部品の表面の溶着リブにガス透過膜を押し付けながら溶着リブを溶融及び固化させることによって、樹脂部品とガス透過膜との間の溶着強度を高めることができる（特許文献２）。
特開２００６−３２４２６０号公報 特開２００９−０７８８６６号公報
特許文献２の方法によれば、溶着強度の向上を期待できるものの、樹脂部品に溶着リブが不可欠となる。溶着リブに頼らず、十分な溶着強度を達成できる技術が望まれている。
本発明の目的は、樹脂部品と樹脂膜との間の溶着強度を高めることにある。
すなわち、本開示は、
加工対象に接するべき作用面に凸部が設けられた溶着ホーンを使用して、フッ素樹脂で作られたガス透過性のフッ素樹脂多孔質膜を熱可塑性樹脂で作られた樹脂部品に溶着する工程を含む、ガス透過部材の製造方法を提供する。
別の側面において、本開示は、
熱可塑性樹脂で作られた樹脂部品と、
前記樹脂部品に取り付けられ、フッ素樹脂で作られたガス透過性のフッ素樹脂多孔質膜と、
を備え、
前記フッ素樹脂多孔質膜は、加工対象に接するべき作用面に凸部が設けられた溶着ホーンを使用して前記樹脂部品に溶着されている、ガス透過部材を提供する。
上記の技術では、樹脂部品にガス透過性のフッ素樹脂多孔質膜が溶着される。溶着ホーンの作用面には凸部が設けられている。そのため、フッ素樹脂多孔質膜と樹脂部品との界面に溶着ホーンからの荷重を集中させやすい。その結果、樹脂部品とフッ素樹脂多孔質膜との間の溶着強度を容易に高めることができる。
本発明の第１実施形態に係る通気部材の縦断面図 図１に示す通気部材の製造に使用される超音波溶着装置の構成図 溶着ホーンの作用面の平面図 他の溶着ホーンの断面図及び平面図 本発明の第２実施形態に係る通気部材（ガス透過膜が設けられた蓋部分）を備えた筐体の斜視図 図５Ａに示す筐体の部分断面図
以下、本発明の実施形態について、図面を参照しながら説明する。本発明は、以下の実施形態に限定されない。
（第１実施形態）
図１に示すように、本実施形態に係る通気部材１０は、支持体２、ガス透過膜４、カバー６及びシールリング８を備えている。通気部材１０は、例えば、筐体２０（詳細には、筐体の蓋部分）の開口部２０ｈに取り付けられている。通気部材１０及び筐体２０によって通気構造１００が形成されている。
筐体２０は、電気部品及び／又は機械部品を収容するために使用される筐体である。筐体２０は、典型的には、ランプ、モータ、センサ、スイッチ、ＥＣＵ、ギアボックスなどの自動車部品の筐体である。筐体２０は、電光掲示板、道路標識などの自動車部品以外の部品を収容するための筐体としても使用されうる。通気部材１０は、液体及び固体の侵入を防ぎつつ、筐体２０の内部の換気を行うための部材である。ガス透過膜４は、筐体２０の内部空間２２と外部空間２４との間の気体の流通を許容する一方、液体及び固体が内部空間２２に侵入することを防ぐ。
本実施形態において、支持体２は、熱可塑性樹脂で作られた樹脂部品である。ガス透過膜４は、フッ素樹脂で作られたガス透過性のフッ素樹脂多孔質膜である。本実施形態において、ガス透過膜４は、補強材などを有さず、フッ素樹脂多孔質膜のみで構成されている。熱可塑性樹脂は相対的に低い融点を有し、フッ素樹脂は相対的に高い融点を有する。支持体２は、通気経路としての貫通孔２ｈを有する。貫通孔２ｈを塞ぐように、支持体２の上面にガス透過膜４が溶着されている。支持体２とガス透過膜４との間には、支持体２を構成する熱可塑性樹脂が溶融及び固化することによって形成された溶着部１４が形成されている。溶着部１４は、例えば、平面視で環形状である。
支持体２を構成する熱可塑性樹脂としては、ポリプロピレン、ポリブチレンテレフタレート、アクリロニトリル−ブタジエン−スチレン共重合体、ポリカーボネートなどが挙げられる。これらの熱可塑性樹脂の融点は、概ね１００〜２００℃である。支持体２を構成する熱可塑性樹脂には、ガラスファイバーなどの添加剤が含まれていてもよい。ガス透過膜４を構成するフッ素樹脂としては、ポリテトラフルオロエチレン（ＰＴＦＥ）、ポリクロロトリフルオロエチレン、テトラフルオロエチレン−ヘキサフルオロプロピレン共重合体、テトラフルオロエチレン−エチレン共重合体などが挙げられる。これらのフッ素樹脂の融点は、概ね２５０〜３５０℃である。ガス透過膜４の厚さは特に限定されず、例えば、０．１〜０．５ｍｍである。第２実施形態のように、ガス透過膜４がカバーなどで保護されていない場合、ガス透過膜４が比較的厚いこと（例えば、０．２〜０．４ｍｍ）が推奨される。薄いフッ素樹脂膜又は薄いフッ素樹脂膜と補強材とで構成された膜のような薄いガス透過膜４は、熱及び振動を伝えやすいので、溶着しやすい。一方、厚いガス透過膜４は、熱及び振動を伝えにくく、溶着しにくいので、本明細書に記載された技術を適用することが特に推奨される。
カバー６は、ガス透過膜４を保護するように支持体２に取り付けられている。カバー６は、支持体２と同じ材料で作られていてもよいし、支持体２とは別の材料で作られていてもよい。
支持体２は、複数の脚部１２を有する。通気構造１００において、支持体２の脚部１２は、筐体２０の開口部２０ｈに嵌められている。脚部１２は、筐体２０の内面に係合している。これにより、通気部材１０が筐体２０に固定されている。シールリング８は、支持体２の下面と筐体２０の外面との間に配置されている。シールリング８によって、支持体２と筐体２０との間の隙間が封じられている。シールリング８は、例えば、ニトリルゴム、エチレン−プロピレンゴム、シリコーンゴム、フッ素ゴム、アクリルゴム、水素化ニトリルゴムなどのエラストマーで作られている。
筐体２０は、複数の部分、例えば、蓋部分と底部分とで構成されている。通気部材１０を取り付けるための開口部２０ｈは、どの部分に形成されていてもよい。筐体２０は、例えば、樹脂で作られている。ただし、本実施形態において、筐体２０の材料は限定されない。筐体２０は金属で作られていてもよい。
次に、図１に示す通気部材１０の製造方法を説明する。
まず、支持体２、ガス透過膜４及びカバー６を準備する。支持体２及びカバー６は、射出成形法などの公知の樹脂成形方法によって作製されうる。ガス透過膜４としてのフッ素樹脂膜は、延伸法、抽出法などの公知のフッ素樹脂成形方法によって作製されうる。ガス透過膜４として好適なＰＴＦＥ多孔質膜は、例えば、日東電工社より入手できる。
次に、ガス透過膜４を支持体２に溶着する。この工程では、図２に示す溶着装置３００を使用できる。本実施形態において、溶着装置３００は、超音波溶着装置であり、固定台６０、溶着ホーン６２、超音波振動子６４、シリンダ６５、エアコンプレッサ６６、超音波発振器６７及び制御器６８を備えている。つまり、溶着ホーン６２は、超音波溶着用の溶着ホーンでありうる。超音波溶着は、高強度の溶着を高い生産性で達成できる。溶着装置３００の構成は、溶着ホーン６２を除き、市販されている超音波溶着装置と同じである。
固定台６０には、ガス透過膜４が溶着されるべき支持体２（樹脂部品）が配置されている。シリンダ６５は、エアコンプレッサ６６で生成された圧縮空気を利用して、溶着ホーン６２及び超音波振動子６４をガス透過膜４に接近させるとともに、溶着ホーン６２からガス透過膜４に印加される圧力を調節する。制御器６８は、超音波発振器６７を制御し、超音波振動子６４を介して溶着ホーン６２に印加されるべき超音波振動の周波数を調節する。
本実施形態において、溶着ホーン６２は、加工対象であるガス透過膜４に接するべき作用面に凸部６２ｔが設けられた溶着ホーンである。そのため、ガス透過膜４と支持体２との界面に溶着ホーン６２からの荷重を集中させやすい。その結果、支持体２とガス透過膜４との間の溶着強度を容易に高めることができる。溶着ホーン６２は、例えば、アルミニウム合金、チタン合金などの金属で作られている。
図３に示すように、溶着ホーン６２の作用面６２ｐは、平面視で環状である。作用面６２ｐには、複数の凸部６２ｔが設けられている。複数の凸部６２ｔは、作用面６２ｐにおいて格子状（あやめ状）に並んでいる。１つ１つの凸部６２ｔは、四角錘の形状を有している。言い換えれば、凸部６２ｔは、平面視で正方形の形状を有している。このような凸部６２ｔが作用面６２ｐに隙間なく（最密に）並べられている。このような構成によれば、ガス透過膜４と支持体２との界面に溶着ホーン６２からの荷重を集中させやすい。また、支持体２とガス透過膜４との間の溶着強度を容易に高めることができる。
図３に示す溶着ホーン６２に代えて、図４に示す溶着ホーン７２も使用できる。溶着ホーン７２の作用面７２ｐは、平面視で環状（円環状）である。作用面７２ｐには２つの凸部７２ｔが設けられている。各凸部７２ｔは、平面視で、作用面７２ｐと同心状の環状である。このような凸部７２ｔによっても、ガス透過膜４と支持体２との界面に溶着ホーン７２からの荷重を集中させやすい。凸部７２ｔの数は２つに限定されない。凸部７２ｔが作用面７２ｐに１つのみ設けられていてもよいし、３つ以上設けられていてもよい。
図３及び図４の例から理解できるように、ガス透過膜４の厚さ、支持体２の樹脂の種類などに応じて、溶着ホーンの作用面における凸部の形状を適宜変更することができる。
なお、ガス透過膜４を支持体２に溶着するために、超音波溶着装置３００に代えて、熱溶着装置を使用してもよい。一般に、超音波溶着装置において、樹脂部品（支持体２）の一部は、摩擦熱によって溶かされる。熱溶着装置において、樹脂部品の一部は、溶着ホーンが持っている熱によって溶かされる。超音波振動子６４がヒータに置き換えられ、超音波発振器６７及び制御器６８が温度調節器に置き換えられると、図２は、熱溶着装置の構成を示す。溶着ホーン６２は、熱溶着用の溶着ホーンでありうる。
次に、第２実施形態に係るガス透過部材を説明する。第１実施形態と第２実施形態とで共通する要素には同じ参照符号を付し、それらの説明を省略することがある。すなわち、各実施形態に関する説明は、技術的に矛盾しない限り、相互に適用されうる。さらに、技術的に矛盾しない限り、各実施形態は、相互に組み合わされてもよい。
（第２実施形態）
図５Ａ及び図５Ｂに示すように、ガス透過膜４は、筐体２００に設けられていてもよい。筐体２００は、第一部分２０及び第二部分２６を含む複数の部分で構成されている。例えば、第一部分２０が蓋部分であり、第二部分２６が底部分である。第一部分２０及び第２部分２６は、第１実施形態の通気部材１０における支持体２と同様、熱可塑性樹脂で作られている。本実施形態では、第一部分２０に通気用の開口部２０ｈが形成されている。開口部２０ｈを塞ぐように、第一部分２０にガス透過膜４が溶着されている。通気用の開口部２０ｈは、第二部分２６に形成されていてもよいし、第一部分２０及び第二部分２６の両方に形成されていてもよい。筐体２００の第一部分２０及びガス透過膜４は、液体及び固体の透過を防ぎつつ換気を行うための通気部材３０（ガス透過部材）を形成している。
図５Ｂに示すように、ガス透過膜４と筐体２００の第一部分２０との間には、溶着部１４が形成されている。溶着部１４は、平面視で環状である。本実施形態においても、ガス透過膜４は、図３又は図４を参照して説明した溶着ホーン６２又は７２を使用して、筐体２００の第一部分２０に溶着されている。
（その他）
各実施形態において、ガス透過膜４が溶着される前の樹脂部品（支持体２又は筐体の第一部分２０）の上面には、溶着強度を高めるためのリブが設けられていない。ただし、樹脂部品の上面にそのようなリブが設けられていてもよい。
また、各実施形態において、ガス透過膜４は、筐体の換気及び内圧調整の役割を担っている。つまり、ガス透過膜４は、通気膜である。しかし、ガス透過膜４は、通気膜に限定されない。本明細書に開示された方法によって製造されるべきガス透過部材は、水の透過を防ぎつつ音声を透過させるための防水通音部材であってもよい。ガス透過膜４を含む防水通音部材は、例えば、携帯電話などの通信機器の受話口及び送話口に設けられる。
（実施例）
３０質量％のガラスファイバー及び７０質量％のポリブチレンテレフタレートを含む樹脂材料で作られた筐体部品（ＥＣＵ筐体の蓋部分：図５Ａ参照）を準備した。筐体部品に直径５ｍｍの開口部を形成した後、超音波溶着装置（静電舎社製、小型精密プレスシリーズ）を用い、開口部を塞ぐように、ＰＴＦＥ多孔質膜（日東電工社製、ＮＴＦ８１０Ａ、厚さ０．３ｍｍ、直径１０ｍｍ）を筐体部品に溶着した。超音波の周波数は２８．５ｋＨｚ、溶着時間は０．１６秒、溶着圧力（エアー圧）は０．１５ＭＰａであった。溶着ホーンとして、図２及び図３を参照して説明した構造を有するものを使用した。このようにして、ＰＴＦＥ多孔質膜及び筐体部品で構成された実施例の通気部材を得た。
（比較例）
作用面が平坦な溶着ホーンを使用したことを除き、実施例と同じ条件で筐体部品の開口部にＰＴＦＥ多孔質膜を溶着することを試みた。しかし、ＰＴＦＥ多孔質膜は、筐体部品に溶着されず、筐体部品から簡単に剥がれ落ちた。
［耐水試験］
日本工業規格JIS L 1092（Ｂ法、高水圧法）に基づき、実施例の通気部材の耐水圧を調べた。具体的には、水漏れが発生する水圧（耐水圧）を測定した。結果を表１に示す。表１に示すように、実施例の通気部材は、十分な耐水圧を達成した。なお、実施例のようにＰＴＦＥ多孔質膜を筐体部品に問題なく溶着できた場合、溶着結果を「良」と判断した。比較例のようにＰＴＦＥ多孔質膜を筐体部品に溶着できなかった場合、溶着結果を「否」と判断した。
Figure 2015205420
本明細書に開示された技術は、通気部材、防水通音部材などのガス透過部材の製造に適用できる。
２ 支持体（樹脂部品）
４ ガス透過膜
１０，３０ 通気部材
１４ 溶着部
２０ 筐体の第一部分（樹脂部品）
２０ｈ 開口部
２６ 筐体の第二部分
１００ 通気構造
２００ 筐体

Claims (6)

  1. 加工対象に接するべき作用面に凸部が設けられた溶着ホーンを使用して、フッ素樹脂で作られたガス透過性のフッ素樹脂多孔質膜を熱可塑性樹脂で作られた樹脂部品に溶着する工程を含む、ガス透過部材の製造方法。
  2. 前記溶着ホーンの前記作用面には、前記複数の凸部が設けられ、
    前記複数の凸部は、前記作用面において格子状に並んでいる、請求項１に記載のガス透過部材の製造方法。
  3. 前記作用面は、平面視で環状であり、
    前記凸部は、平面視で、前記作用面と同心状の環状である、請求項１に記載のガス透過部材の製造方法。
  4. 前記溶着ホーンは、超音波溶着用の溶着ホーンである、請求項１〜３のいずれか１項に記載のガス透過部材の製造方法。
  5. 前記ガス透過部材は、（ａ）液体及び固体の透過を防ぎつつ換気を行うための通気部材であるか、（ｂ）水の透過を防ぎつつ音声を透過させるための防水通音部材である、請求項１〜４のいずれか１項に記載のガス透過部材の製造方法。
  6. 熱可塑性樹脂で作られた樹脂部品と、
    前記樹脂部品に取り付けられ、フッ素樹脂で作られたガス透過性のフッ素樹脂多孔質膜と、
    を備え、
    前記フッ素樹脂多孔質膜は、加工対象に接するべき作用面に凸部が設けられた溶着ホーンを使用して前記樹脂部品に溶着されている、ガス透過部材。
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