JP2016078113A - 超音波ウェルダー及び超音波ホーン - Google Patents

超音波ウェルダー及び超音波ホーン Download PDF

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Publication number
JP2016078113A
JP2016078113A JP2014215652A JP2014215652A JP2016078113A JP 2016078113 A JP2016078113 A JP 2016078113A JP 2014215652 A JP2014215652 A JP 2014215652A JP 2014215652 A JP2014215652 A JP 2014215652A JP 2016078113 A JP2016078113 A JP 2016078113A
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Japan
Prior art keywords
ultrasonic horn
ultrasonic
vibration
line
horn
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Pending
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JP2014215652A
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English (en)
Inventor
智將 今井
Tomomasa Imai
智將 今井
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Nippon Avionics Co Ltd
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Nippon Avionics Co Ltd
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Priority to JP2014215652A priority Critical patent/JP2016078113A/ja
Publication of JP2016078113A publication Critical patent/JP2016078113A/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
    • B29C66/05—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
    • 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
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7441—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc for making welds and cuts of other than simple rectilinear form
    • 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
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7443—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc by means of 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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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
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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
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • 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
    • B29C66/729—Textile or other fibrous material made from plastics
    • B29C66/7294—Non woven mats, e.g. felt
    • 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
    • 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
    • B29C66/81411—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 characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81415—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 characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being bevelled
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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
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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
    • 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
    • B29C66/81411—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 characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81415—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 characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being bevelled
    • B29C66/81419—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 characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being bevelled and 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
    • B29C66/80—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
    • B29C66/8145—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 constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • 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
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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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
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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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    • 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
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Abstract

【課題】対称性を有する幾何学形状の接合及び型抜きを一回で実現する超音波ホーンと、これを用いる超音波ウェルダーを提供する。
【解決手段】本実施形態に係る超音波ホーン１０３は、多角形のフレーム形状に形成する。そして、超音波ホーン１０３の上面において、線対称になる箇所に最低限二つの振動ユニット１０２の配置を必要とし、更に振動ユニット１０２は同一位相、同一振幅で駆動する必要がある。本実施形態の超音波ホーン１０３は、フレーム形状に形成することにより、振動に乱れがなく、軽量になる。本実施形態に係る超音波ホーン１０３を用いる超音波ウェルダー１０１は、切断と溶着を一度に実現できる。
【選択図】図１

Description

本発明は、超音波ウェルダー及び超音波ホーンに関する。
超音波ウェルダーは、製品の量産工程において、接着剤を用いず、短時間で確実な熱可塑性樹脂の接着を実現する。超音波ウェルダーは、接着する二つの部材に強い圧力で接触させた上で、概ね１５ｋＨｚ以上の強い超音波振動を与える。すると、樹脂の、圧力を加えられて接触している面同士が溶けて、二つの部材は溶着する。
特許文献１には、入力面に縦振動を加えると、放射面では、複合振動が得られるようにした、超音波ウェルダーに用いられる複合振動用工具ホーンが開示されている。
特開平６−８８１号公報
従来の超音波ホーンは、形状の制約から特許文献１にもあるような一直線状の形状しか実用されていなかった。このため、正方形あるいは長方形形状の物品の接合を行う場合、四辺のそれぞれに直線形状のホーンを用いて接合を四回行う必要があった。
本発明は係る課題を解決し、対称性を有する幾何学形状の接合及び型抜きを一回で実現する超音波ホーンと、これを用いる超音波ウェルダーを提供することを目的とする。
上記課題を解決するため、本発明の超音波ホーンは、上面から見て線対称であり、且つ重心が線対称の線と一致する、中空形状の多角形の角柱であり、厚みが全て辺毎に等しく形成されている。
本発明により、対称性を有する幾何学形状の接合及び型抜きを一回で実現する超音波ホーンと、これを用いる超音波ウェルダーを提供できる。
超音波ウェルダーの概略的な外観図である。 超音波ホーンの外観斜視図である。 超音波ホーンの上面図と、短辺方向の側面図と、長辺方向の側面図と、底面図である。 振動ユニットと、超音波ホーンと支持体と、打ち抜き加工で形成される加工品の概略的な外観図である。 超音波ホーンと支持体と、打ち抜き加工で形成される加工品の、一部拡大断面図である。 超音波ホーンの動作原理を説明する模式図である。 本実施形態の超音波ホーンを構成する際の原理図である。 超音波ホーンの別の実施形態を示す外観斜視図である。
図１は、超音波ウェルダー１０１の概略的な外観図である。
超音波ウェルダー１０１の主要な構成要素は、振動ユニット１０２と、超音波ホーン１０３と、支持体１０４である。振動ユニット１０２は更に、振動子１０５とブースタ１０６よりなる。
図１中、四つの振動子１０５はやぐら１０７に取り付けられている。やぐら１０７はフレーム１０８から懸架されるエアシリンダ１０９によって上下に移動可能に懸架されている。
振動子１０５は圧電素子である。この圧電素子に図示しない発振器で高電圧の交流を印加することで、振動子１０５に強い超音波振動を発生させる。
振動子１０５の直下には円錐状のブースタ１０６が装着されており、ブースタ１０６によって振動子１０５から発生する振動の振幅が増幅される。
ブースタ１０６の先端には超音波ホーン１０３が装着される。超音波ホーン１０３はその直下の土台１１０に設けられる支持体１０４と共に、接着及び／又は切断する二つの対象物同士を接触させ、密着させる。超音波ホーン１０３はブースタ１０６と同様の、振動の振幅を増幅する効果と、振動を対象物の密着部分に伝達させる機能を備える。
超音波ホーン１０３と支持体１０４のいずれか一方は、超音波振動を接着箇所に集中させるためのブレード形状になる。
本実施形態の超音波ホーン１０３の場合は、超音波ホーン１０３の底面が平面であり、超音波ホーン１０３の底面に当接する支持体１０４がブレード形状である。
図２は、超音波ホーン１０３の外観斜視図である。
図３Ａは、超音波ホーン１０３の上面図である。
図３Ｂは、超音波ホーン１０３の短辺方向の側面図である。
図３Ｃは、超音波ホーン１０３の長辺方向の側面図である。
図３Ｄは、超音波ホーン１０３の底面図である。
超音波ホーン１０３は、鉄、アルミニウム、真鍮等の金属を削り出すことで形成される。図２、図３Ａ、図３Ｂ、図３Ｃ及び図３Ｄを見て判るように、超音波ホーン１０３は、上面及び下面から見て、全長に亘って高さが等しい、長方形の枠として形成されている。すなわち、超音波ホーン１０３は上下方向において中空形状の四角柱である。
この超音波ホーン１０３の上面には、短辺部分の中心に第一クランプ穴２０１ａと第二クランプ穴２０１ｂが、長辺部分の中心に第三クランプ穴２０１ｃと第四クランプ穴２０１ｄが、それぞれ設けられている。なおこれ以降、第一クランプ穴２０１ａ、第二クランプ穴２０１ｂ、第三クランプ穴２０１ｃ及び第四クランプ穴２０１ｄを区別しない場合は、単にクランプ穴２０１と呼ぶ。
これらのクランプ穴２０１には、図１及び図３Ｃで示されるように、振動ユニット１０２が装着される。なお、四つのクランプ穴２０１には、振動ユニット１０２が全て装着される場合と、二つの振動ユニット１０２と振動体を持たない二つの支持ユニットが装着される場合がある。この振動ユニット１０２と支持ユニットの配置関係については後述する。
超音波ホーン１０３は上下方向から見て、短辺側の幅Ｄ１と長辺側の幅Ｄ２は同一である。すなわち、超音波ホーン１０３の厚みは短辺側と長辺側において均一である。また、超音波ホーン１０３は側面から見て、短辺側に二つ、長辺側に四つのスリット２０２が設けられている。このスリット２０２は、超音波ホーン１０３の上下振動を安定化させる効果と、若干の軽量化の効果を奏する。
図４は、振動ユニット１０２と、超音波ホーン１０３と支持体１０４と、打ち抜き加工で形成される加工品４０１の概略的な外観図である。
図５は、超音波ホーン１０３と支持体１０４と、打ち抜き加工で形成される加工品４０１の、一部拡大断面図である。
支持体１０４は、超音波ホーン１０３の底面の形状に合致する長方形形状の枠を形成する。この支持体１０４は、図５を参照して判るように頂上部分が鋭角なブレード５０１を形成し、このブレード５０１が超音波ホーン１０３の底面に当接する。
図４及び図５に示される加工品４０１は、ナイロン（ポリアミド）やポリエステル等の熱可塑性合成繊維で形成される不織布を二枚重ねて、長方形の袋を形成する。
先ず、支持体１０４に一枚目の不織布である第一不織布５０２を敷き、支持体１０４の中心部分に必要な粉体５０３を配置する。粉体５０３は例えば防虫剤、殺虫剤、使い捨てカイロの材料となる鉄粉及び酸化薬剤等、加工品４０１の用途により様々である。
次に、粉体５０３が載置された第一不織布５０２の上に、二枚目の不織布である第二不織布５０４を被せる。
そして、第二不織布５０４の上に超音波ホーン１０３をあてがう。そして、超音波ホーン１０３の自重と、必要に応じて任意の与圧機構を追加して第二不織布５０４に圧力を掛け、その上で振動ユニット１０２を駆動させ、超音波を発生させる。すると、不織布の支持体１０４のブレード５０１と接触している箇所で熱が生じる。この熱が、支持体１０４のブレード５０１と超音波ホーン１０３の当接している部分で第一不織布５０２と第二不織布５０４を切断し、支持体１０４のランド５０５で不織布同士が溶着する。
すなわち、切断と溶着が同時に行われ、柔らかい不織布でも、抜き型で製品を整形したに等しい効果を実現することができる。
上述したように、不織布に切断と溶着を同時に実施して、長方形形状の袋を形成するためには、超音波ホーン１０３の底面を均一に振動させる必要がある。つまり、超音波ホーン１０３の重心を、垂直に駆動する必要がある。このため、超音波ホーン１０３の上面に据え付けられる四つの振動ユニット１０２が、同じ位相及び振幅で振動することと、振動ユニット１０２同士を結ぶ線に超音波ホーン１０３の重心が存在していることが必要である。したがって、特に図示はしないが、四つの振動ユニット１０２は共通の駆動源で駆動されることが望ましい。例えば、四つの振動ユニット１０２を並列接続して単一の発振装置で駆動するか、或は四つの発振装置を位相同期させる等の工夫をすることが必要となる。
超音波ホーン１０３の重心を垂直に駆動するには、必ずしも四つのクランプ穴２０１の全てに、振動ユニット１０２が全て装着される必要はない。超音波ホーン１０３の重心において点対称の位置にある第一クランプ穴２０１ａと第二クランプ穴２０１ｂに振動ユニット１０２を設け、第三クランプ穴２０１ｃと第四クランプ穴２０１ｄに振動体を持たない支持ユニットを設けてもよい。逆に、第一クランプ穴２０１ａと第二クランプ穴２０１ｂに振動体を持たない支持ユニットを設け、第三クランプ穴２０１ｃと第四クランプ穴２０１ｄに振動ユニット１０２を設けてもよい。このような振動ユニット１０２と支持ユニットの配置は、振動ユニット１０２同士を結ぶ線と支持ユニット同士を結ぶ線がそれぞれ線対称の線を形成することに起因する。
図６は、超音波ホーンの動作原理を説明する模式図である。
直線形状の超音波ホーン６０１に、その上面から超音波振動を与えると、超音波ホーン６０１は振動によって伸縮する。その伸縮による超音波ホーン６０１の変形は、実際には肉眼では見えないが、概ね図６に示すような形状の変化が生じる。超音波ホーン６０１の幅と高さは、溶着及び／又は切断する対象物に応じて、一義的に算出される。
図７は、本実施形態の超音波ホーン１０３を構成する際の原理図である。
もし、超音波ホーン１０３の中心部分が中空形状でなく、超音波ホーン１０３を構成する金属で充填されていると、図６に示したような二次元の振動が生じなくなり、代わりに複雑な三次元の振動が超音波ホーン１０３全体で発生してしまう。そのような複雑な振動はエネルギーロスとなり、超音波ホーン１０３本来の溶着及び／又は切断の性能を発揮できなくなってしまう。また、超音波ホーン１０３自体の重量が必要以上に重くなってしまい、取り扱いが困難になってしまう。
そこで、本実施形態の超音波ホーン１０３は、長方形形状の対象物の四辺に対し、溶着と切断を同時に行うために、直線形状の超音波ホーン６０１を対象物の形状に合わせて合成する形状にした。
本実施形態は以下のような応用が可能である。
（１）クランプ穴２０１の配置は、長方形の四隅であってもよい。
図８は、超音波ホーン１０３の別の実施形態を示す外観斜視図である。
図８の超音波ホーン８０１の、図２及び図３に示した超音波ホーン１０３との相違点は、クランプ穴８０２が超音波ホーン８０１の角に設けられている点である。但し、図８の超音波ホーン８０１の場合、四つのクランプ穴８０２には全て振動ユニット１０２を装着しなければならない。何故ならば、振動ユニット１０２同士を結び重心を通る線において線対称にならないからである。
（２）また、平行四辺形の場合においても、超音波ホーン１０３を形成可能である。平行四辺形の場合、クランプ穴が平行四辺形の辺の中心、平行四辺形の四隅の、何れの場合でも、四つのクランプ穴全てに振動ユニット１０２を装着しなければならない。
但し、平行四辺形の特殊形態として、菱形の場合は、クランプ穴が菱形の角に形成されている場合に、振動ユニット１０２と支持ユニットを混在可能である。
（３）超音波ホーン１０３の形状は、四角形に限らず、三角以上で、線対称であり、且つ重心が線対称の線と一致する多角形の角柱であれば、実施可能である。例えば三角形の場合、二等辺三角形はこの条件に合致する。四角形の場合、平行四辺形はこの条件に合致せず、台形は線対称でない限り合致しない。これらの様々な形状の超音波ホーンは、図３Ｄに示したように、その幅（厚み）が全て辺毎に等しく形成される必要がある。
また、多角形の角を丸めても、その幅（厚み）が全て辺毎に等しく形成されていれば、本実施形態の超音波ホーンとして実施可能である。
更に、円形や楕円形でも、本実施形態の超音波ホーンは実施可能である。その際、クランプ穴の配置は本実施形態の超音波ホーン１０３に準ずる。
これらの態様に共通する特徴として、振動ユニット１０２を装着するためのクランプ穴は多角形の重心を通過する線上に二つ設けられる、という点が挙げられる。更に、その重心を通過する線が線対称の線と一致していれば、他のクランプ穴は支持ユニットを装着して、振動ユニット１０２を省略してもよい。
本実施形態では、超音波ウェルダー１０１と、これに用いる超音波ホーン１０３を開示した。
本実施形態に係る超音波ホーン１０３は、多角形のフレーム形状に形成する。そして、超音波ホーン１０３の上面において、線対称になる箇所に最低限二つの振動ユニット１０２の配置を必要とし、更に振動ユニット１０２は同一位相、同一振幅で駆動する必要がある。
本実施形態の超音波ホーン１０３は、フレーム形状に形成することにより、振動に乱れがなく、軽量になる。
本実施形態に係る超音波ホーン１０３を用いる超音波ウェルダー１０１は、切断と溶着を一度に実現できる。
以上、本発明の実施形態について説明したが、本発明は上記実施形態に限定されるものではなく、特許請求の範囲に記載した本発明の要旨を逸脱しない限りにおいて、他の変形例、応用例を含む。
１０１…超音波ウェルダー、１０２…振動ユニット、１０３…超音波ホーン、１０４…支持体、１０５…振動子、１０６…ブースタ、１０８…フレーム、１０９…エアシリンダ、１１０…土台、２０１…クランプ穴、２０２…スリット、４０１…加工品、５０１…ブレード、５０２…第一不織布、５０３…粉体、５０４…第二不織布、５０５…ランド、６０１…超音波ホーン、８０１…超音波ホーン、８０２…クランプ穴

Claims (5)

  1. 上面から見て線対称であり、且つ重心が線対称の線と一致する、中空形状の多角形の角柱であり、厚みが全て辺毎に等しく形成されている、超音波ホーン。
  2. 前記多角形は長方形である、請求項１に記載の超音波ホーン。
  3. 前記上面の辺の中心又は角に、振動ユニット又は支持ユニットが装着されるクランプ穴が形成されている、請求項１に記載の超音波ホーン。
  4. 前記線対称の線上に、振動ユニット又は支持ユニットが装着されるクランプ穴が形成されている、請求項２に記載の超音波ホーン。
  5. 圧電素子を有する振動ユニットと、
    上面から見て線対称であり、且つ重心が線対称の線と一致する、中空形状の多角形の角柱であり、厚みが全て辺毎に等しく形成されており、前記上面に、前記振動ユニットが装着されるクランプ穴が複数形成されている超音波ホーンと、
    前記超音波ホーンの直下に設けられ、前記超音波ホーンと共に材料を挟み込むことで加工品を形成する支持体と
    を具備し、
    前記振動ユニットは前記重心を通過する線上に二つ装着され、共に同じ位相及び振幅で駆動される、超音波ウェルダー。
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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6068926A (ja) * 1983-09-26 1985-04-19 Eiji Mori 超音波溶着機用工具ホ−ン
JPH04201236A (ja) * 1990-11-29 1992-07-22 Seidensha Denshi Kogyo Kk プラスチックの伝達溶着法
US5476570A (en) * 1993-04-28 1995-12-19 Karl Widmann Schweissmaschinen Gmbh Apparatus to make plastic seamed jackets, reinforced jacket structures, and the like
JP2007105610A (ja) * 2005-10-13 2007-04-26 Seidensha Electronics Co Ltd 超音波加工用工具ホーン
JP2010208031A (ja) * 2009-03-06 2010-09-24 Seidensha Electronics Co Ltd 溶着方法、溶着機、溶着した樹脂成形品付きシート状部材

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6068926A (ja) * 1983-09-26 1985-04-19 Eiji Mori 超音波溶着機用工具ホ−ン
JPH04201236A (ja) * 1990-11-29 1992-07-22 Seidensha Denshi Kogyo Kk プラスチックの伝達溶着法
US5476570A (en) * 1993-04-28 1995-12-19 Karl Widmann Schweissmaschinen Gmbh Apparatus to make plastic seamed jackets, reinforced jacket structures, and the like
JP2007105610A (ja) * 2005-10-13 2007-04-26 Seidensha Electronics Co Ltd 超音波加工用工具ホーン
JP2010208031A (ja) * 2009-03-06 2010-09-24 Seidensha Electronics Co Ltd 溶着方法、溶着機、溶着した樹脂成形品付きシート状部材

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