JP2016175244A - 樹脂接合体、樹脂接合体の製造方法及び車両用構造体 - Google Patents

樹脂接合体、樹脂接合体の製造方法及び車両用構造体 Download PDF

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Publication number
JP2016175244A
JP2016175244A JP2015056373A JP2015056373A JP2016175244A JP 2016175244 A JP2016175244 A JP 2016175244A JP 2015056373 A JP2015056373 A JP 2015056373A JP 2015056373 A JP2015056373 A JP 2015056373A JP 2016175244 A JP2016175244 A JP 2016175244A
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Japan
Prior art keywords
resin
thermoplastic resin
joined body
welding
thermosetting resin
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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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JP2015056373A
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JP6179542B2 (ja
Inventor
吉宏 岩野
Yoshihiro Iwano
吉宏 岩野
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Toyota Motor Corp
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Toyota Motor Corp
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Application filed by Toyota Motor Corp filed Critical Toyota Motor Corp
Priority to JP2015056373A priority Critical patent/JP6179542B2/ja
Priority to KR1020160028732A priority patent/KR101804661B1/ko
Priority to BR102016005457A priority patent/BR102016005457A2/pt
Priority to EP16160551.4A priority patent/EP3069852A1/en
Priority to MYPI2016700937A priority patent/MY174015A/en
Priority to US15/073,320 priority patent/US20160271906A1/en
Priority to RU2016109624A priority patent/RU2635223C2/ru
Priority to ZA2016/01942A priority patent/ZA201601942B/en
Priority to CN201610157460.4A priority patent/CN105984120B/zh
Publication of JP2016175244A publication Critical patent/JP2016175244A/ja
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Publication of JP6179542B2 publication Critical patent/JP6179542B2/ja
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    • 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
    • B29C65/022—Particular heating or welding methods not otherwise provided for
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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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
    • 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
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  • Engineering & Computer Science (AREA)
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  • Chemical & Material Sciences (AREA)
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  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Architecture (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Structural Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
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  • Body Structure For Vehicles (AREA)

Abstract

【課題】熱可塑性樹脂と熱硬化性樹脂硬化物とが接合された樹脂接合体及びその製造方法並びにこの樹脂接合体を用いた車両用構造体の提供。
【解決手段】繊維を含む熱可塑性樹脂と、前記熱可塑性樹脂の融解温度よりも低い融解温度を有し繊維を含む熱硬化性樹脂硬化物と、が溶着により接合した樹脂接合体及び前記樹脂接合体を有する車両用構造体並びに繊維を含む熱可塑性樹脂と、前記熱可塑性樹脂の融解温度よりも低い融解温度を有し繊維を含む熱硬化性樹脂硬化物と、を溶着して接合する接合工程を含む樹脂接合体の製造方法。
【選択図】なし

Description

本発明は、樹脂接合体、樹脂接合体の製造方法及び車両用構造体に関する。
次世代の車両用車体には、樹脂製部品の採用の拡大が予想されている。そのため、樹脂製部品同士の結合方法の確立が急務となっている。
繊維強化熱可塑性樹脂同士を接合するため、繊維強化熱可塑性樹脂の間に配置した熱可塑性樹脂シートを介して繊維強化熱可塑性樹脂同士を接合する接合方法が開示されている（例えば、特許文献１参照。）。
また、熱硬化性樹脂硬化物を用いた樹脂製部品と熱可塑性樹脂を用いた樹脂製部品との接合には、接着剤を用いた接合又はリベット等の締結部材を用いた固定が一般的である。
なお、熱硬化性樹脂と熱可塑性樹脂とを含む繊維強化複合材料板については知られている（例えば、特許文献２参照。）。
特開２０１４−０７６５６５号公報 特開２００８−２３０２３８号公報
しかし、特許文献１に記載の技術は、可塑性を示す熱可塑性樹脂同士の接合に用いられるものであり、熱可塑性樹脂と既に硬化反応が完了して可塑化しにくい熱硬化性樹脂硬化物との接合には適用できない。また、熱硬化性樹脂硬化物を用いた樹脂製部品と熱可塑性樹脂を用いた樹脂製部品との接合に接着剤又はリベット等の締結部材を用いると、質量又はコストの増加の一因となり、望ましくない。特に、接着剤を用いて熱可塑性樹脂と熱硬化性樹脂硬化物とを接合した場合、接着剤の強度で接合部の強度が決定されるため、樹脂製部品自身の材料強度を生かすことができない場合がある。さらには、特許文献２に記載の技術は熱可塑性樹脂と未だ未硬化の熱硬化性樹脂とを用いた繊維強化複合材料板の製造に適用されるものであり、既に硬化反応が完了している熱硬化性樹脂硬化物と熱可塑性樹脂との接合には適用できない。
本発明は、上記従来の問題点に鑑みてなされたものであり、熱可塑性樹脂と熱硬化性樹脂硬化物とが接着剤又はリベット等の締結部材を用いることなく接合された樹脂接合体及びその製造方法並びにこの樹脂接合体を用いた車両用構造体を提供することを目的とする。
前記課題を達成するための具体的手段は以下の通りである。
＜１＞ 繊維を含む熱可塑性樹脂と、前記熱可塑性樹脂の融解温度よりも低い融解温度を有し繊維を含む熱硬化性樹脂硬化物と、が溶着により接合した樹脂接合体。
＜２＞ 前記熱硬化性樹脂硬化物に含まれる繊維が、織布である＜１＞に記載の樹脂接合体。
＜３＞ 前記熱可塑性樹脂に含まれる繊維が、不織布である＜１＞又は＜２＞に記載の樹脂接合体。
＜４＞ 前記熱可塑性樹脂の融解温度と前記熱硬化性樹脂硬化物の融解温度との差が５０℃以上である＜１＞〜＜３＞のいずれか１項に記載の樹脂接合体。
＜５＞ 繊維を含む熱可塑性樹脂と、前記熱可塑性樹脂の融解温度よりも低い融解温度を有し繊維を含む熱硬化性樹脂硬化物と、を溶着して接合する接合工程を含む樹脂接合体の製造方法。
＜６＞ 前記接合工程における溶着が、振動溶着である＜５＞に記載の樹脂接合体の製造方法。
＜７＞ ＜１＞〜＜４＞のいずれか１項に記載の樹脂接合体を有する車両用構造体。
本発明によれば、熱可塑性樹脂と熱硬化性樹脂硬化物とが接着剤又はリベット等の締結部材を用いることなく接合された樹脂接合体及びその製造方法並びにこの樹脂接合体を用いた車両用構造体が提供される。
本実施形態に係る樹脂接合体の接合部の断面写真の一例である。 図１の記号Ａを付された楕円で囲まれた付近の拡大写真である。
以下、本発明の樹脂接合体、樹脂接合体の製造方法及び車両用構造体の実施形態について詳細に説明する。
＜樹脂接合体及びその製造方法＞
本実施形態に係る樹脂接合体は、繊維を含む熱可塑性樹脂と、前記熱可塑性樹脂の融解温度よりも低い融解温度を有し繊維を含む熱硬化性樹脂硬化物と、が溶着により接合したものである。本実施形態に係る樹脂接合体は、繊維を含む熱可塑性樹脂と繊維を含む熱硬化性樹脂硬化物とが接着剤又はリベット等の締結部材を用いることなく溶着により接合されているため、繊維を含む熱可塑性樹脂と繊維を含む熱硬化性樹脂硬化物を接合する際の接着剤又はリベット等の締結部材の使用による質量増加が抑制される。さらに、接着剤の強度で接合部の強度が決定されることがなく、適切な樹脂を選択することにより樹脂接合体の接合強度を向上させることができる。また、リサイクル性、ハイサイクル性に優れる熱可塑性樹脂の採用可能範囲を拡大することが可能となる。
本実施形態において用いられる熱可塑性樹脂は特に限定されるものではなく、目的に応じて公知の各種熱可塑性樹脂を使用可能である。本実施形態において用いられる熱可塑性樹脂としては、例えば、ポリカーボネート樹脂、ポリアミド（ＰＡ）樹脂、ポリウレタン（ＰＵ）樹脂、ポリ塩化ビニル樹脂、アクリロニトリル−ブタジエン−スチレン共重合体（ＡＢＳ）樹脂及びポリプロピレン（ＰＰ）樹脂が挙げられる。これらの中でも、ＰＡ樹脂及びＰＰ樹脂が好ましい。
本実施形態において用いられる熱硬化性樹脂硬化物は、熱硬化性樹脂を熱硬化させた後の硬化物である。熱硬化性樹脂硬化物の形成に用いられる熱硬化性樹脂は特に限定されるものではなく、目的に応じて公知の各種熱硬化性樹脂を使用可能である。本実施形態において用いられる熱硬化性樹脂としては、例えば、ビニルエステル樹脂、不飽和ポリエステル樹脂、フェノール樹脂、エポキシ樹脂及びウレタン樹脂が挙げられる。これらの中でも、エポキシ樹脂が好ましい。
本実施形態において用いられる繊維の種類は特に限定されるものではなく、目的に応じて公知の各種繊維を使用可能である。本実施形態において用いられる繊維の種類としては、例えば、アラミド繊維、セルロース繊維、ナイロン繊維、ビニロン繊維、ポリエステル繊維、ポリオレフィン繊維、レーヨン繊維等の樹脂繊維、炭素繊維、ガラス繊維、金属繊維などが挙げられる。これらの中でも、高い機械的強度を実現可能な炭素繊維が望ましい。
熱可塑性樹脂と繊維とを複合化させる方法については、特に限定されるものではなく、目的に応じて公知の各種方法を使用可能である。例えば、繊維に熱可塑性樹脂の溶液または融液を含浸させ、必要に応じて乾燥してシート状に成型する方法、繊維と熱可塑性樹脂フィルムとを交互に積層した後に加熱加圧成形する方法が挙げられる。
熱硬化性樹脂と繊維とを複合化させる方法についても、特に限定されるものではなく、目的に応じて公知の各種方法を使用可能である。熱硬化性樹脂と繊維とを複合化させてプリプレグを形成してもよい。
本実施形態において用いられる繊維の状態は特に限定されるものではなく、目的に応じて公知の形状の繊維を使用可能である。本実施形態において用いられる繊維の状態としては、例えば、織布及び不織布が挙げられる。
本実施形態において、熱可塑性樹脂に含まれる繊維の含有率としては、５質量％〜５０質量％が好ましく、より好ましくは１０質量％〜５０質量％である。
本実施形態において、熱硬化性樹脂硬化物に含まれる繊維の含有率としては、５質量％〜５０質量％が好ましく、より好ましくは１０質量％〜５０質量％である。
本実施形態に係る樹脂接合体においては、熱硬化性樹脂硬化物の融解温度は熱可塑性樹脂の融解温度よりも低い。熱硬化性樹脂硬化物の融解温度と熱可塑性樹脂の融解温度との差は特に限定されるものではない。熱硬化性樹脂硬化物の融解温度と熱可塑性樹脂の融解温度との差の下限値としては、例えば、５０℃以上が好ましく、１００℃以上がより好ましく、１５０℃以上が更に好ましい。熱硬化性樹脂硬化物の融解温度と熱可塑性樹脂の融解温度との差の上限値は特に限定されるものではないが、樹脂の入手容易性の観点から２５０℃以下とされる。
本実施形態において、熱硬化性樹脂硬化物及び熱可塑性樹脂の融解温度の測定は、ＪＩＳ Ｋ７１２１−２０１２（プラスチックの転移温度測定方法）に基づき、示差走査熱量測定（ＤＳＣ）により測定された値をいう。
なお、熱硬化性樹脂硬化物に含まれる繊維は、織布であることが好ましい。熱硬化性樹脂硬化物に含まれる繊維として織布を用いることで、織布を構成する繊維に熱可塑性樹脂に含まれる繊維が絡みやすくなり、熱可塑性樹脂と熱硬化性樹脂硬化物との間により大きな接合強度が生じやすくなるものと推察される。
また、熱可塑性樹脂に含まれる繊維は、不織布であることが好ましい。熱可塑性樹脂に含まれる繊維として不織布を用いることにより、熱硬化性樹脂硬化物に含まれる繊維と熱可塑性樹脂に含まれる繊維とが絡みやすくなり、熱可塑性樹脂と熱硬化性樹脂硬化物との間により大きな接合強度が生じやすくなるものと推察される。
さらには、熱硬化性樹脂硬化物に含まれる繊維が織布であり、熱可塑性樹脂に含まれる繊維が不織布であることがより好ましい。熱可塑性樹脂よりも融解温度の低い熱硬化性樹脂硬化物が溶着の際に先に溶融するか又は燃焼により消失しやすいため、熱硬化性樹脂硬化物に含まれる織布がむき出しになりやすい。このむき出しになった織布における繊維の網目に不織布が入り込むことで、織布には不織布がより絡み合いやすい。そのため、強固な結合が生じやすい。その結果、熱可塑性樹脂と熱硬化性樹脂硬化物との間により大きな接合強度が生じやすくなると推察される。
本実施形態に係る樹脂接合体は、繊維を含む熱可塑性樹脂と、前記熱可塑性樹脂の融解温度よりも低い融解温度を有し繊維を含む熱硬化性樹脂硬化物と、を溶着して接合する接合工程を含む樹脂接合体の製造方法を経て製造されたものであってもよい。
本実施形態においては、熱可塑性樹脂の融解温度よりも熱硬化性樹脂硬化物の融解温度の方が低いことから、接合工程において溶着により当該樹脂同士を接合する際に、熱可塑性樹脂よりも先に熱硬化性樹脂硬化物が溶融するか又は燃焼により消失しやすい。熱硬化性樹脂硬化物が先に溶融するか又は燃焼により消失することで、熱硬化性樹脂硬化物に含まれる繊維がむき出しになる。むき出しになった熱硬化性樹脂硬化物に含まれる繊維に、熱可塑性樹脂及びこれに含まれる繊維が絡み合うことで、熱可塑性樹脂と熱硬化性樹脂硬化物との間に接合強度が生ずる。そのため、本実施形態に係る樹脂接合体は、熱可塑性樹脂と熱硬化性樹脂硬化物とを、接着剤又はリベット等の締結部材を用いることなく接合可能になるものと推察される。
前記接合工程における溶着は特に限定されるものではなく、公知の各種溶着方法を使用可能である。本実施形態において用いることのできる溶着方法としては、例えば、超音波溶着、振動溶着、誘導溶着、高周波溶着、レーザー溶着、熱溶着及びスピン溶着が挙げられる。これらの中でも、超音波溶着及び振動溶着が好ましい。
図１は、熱硬化性樹脂硬化物に含まれる繊維を織布とし、熱可塑性樹脂に含まれる繊維を不織布とした本実施形態に係る樹脂接合体の接合部の断面写真の一例である。図１の断面写真において、上側が熱可塑性樹脂であり下側が熱硬化性樹脂硬化物である。下側の熱硬化性樹脂硬化物には、織布由来の規則的な繊維の断面が観察されている。
図２は、図１の記号Ａを付された楕円で囲まれた付近の拡大写真である。図２の溶着面において、熱可塑性樹脂（図２中「熱可塑」と表記されたもの）に含まれる不織布と熱硬化性樹脂硬化物（図２中「熱硬化」と表記されたもの）に含まれる織布とが絡み合った部分（繊維絡み部）が存在することがわかる。
溶着方法として振動溶着を用いることにより、樹脂接合体の強度がより向上する。一方、溶着方法として超音波溶着を用いることにより、接合される熱可塑性樹脂及び熱硬化性樹脂硬化物の設計及び構造の自由度が高くなる。
本実施形態においては、溶着方法として、熱硬化性樹脂硬化物が溶着の際に溶融するか又は燃焼により消失しやすい振動溶着を用いることがより好ましい。
振動溶着は、溶着させる熱可塑性樹脂及び熱硬化性樹脂硬化物に対してプレス機等を用いて荷重をかけた状態で、熱可塑性樹脂及び熱硬化性樹脂硬化物の一方を熱可塑性樹脂及び熱硬化性樹脂硬化物の接触面に対して水平方向に振動させ、それによって発生する摩擦熱を利用して溶着する方法である。
一方、超音波溶着は、超音波発振器によって電気エネルギーを振動エネルギーに変換し、この振動エネルギーを接触させた状態の熱可塑性樹脂及び熱硬化性樹脂硬化物の接触面に付与することで当該接触面に発生した摩擦熱を利用して溶着する方法である。
溶着方法として振動溶着を用いる場合、振動溶着の諸条件は、熱可塑性樹脂及び熱硬化性樹脂硬化物の形状、融解温度、接合面の面積等により選択され得る。例えば、振動の周波数は１００Ｈｚ〜３００Ｈｚが好ましく、２１０Ｈｚ〜２６０ＨＺがより好ましい。また、熱可塑性樹脂及び熱硬化性樹脂硬化物に対する荷重としては、０．１ＭＰａ〜５ＭＰａが好ましく、０．１ＭＰａ〜２ＭＰａがより好ましく、０．１ＭＰａ〜１ＭＰａが更に好ましい。また、振動振幅は０．５ｍｍ〜５ｍｍが好ましく、１ｍｍ〜３ｍｍがより好ましく、１．５ｍｍ〜２．５ｍｍが更に好ましい。
溶着方法として超音波溶着を用いる場合、超音波溶着の諸条件は、熱可塑性樹脂及び熱硬化性樹脂硬化物の形状、融解温度、接合面の面積等により選択されうる。例えば、超音波を発生させる超音波発生装置を構成するホーンのホーン加圧力は１００Ｎ〜２０００Ｎが好ましく、３００Ｎ〜１０００Ｎがより好ましく、５００Ｎ〜８００Ｎが更に好ましい。超音波振動の振幅としては、１０μｍ〜１００μｍが好ましく、１５μｍ〜５０μｍがより好ましい。熱可塑性樹脂及び熱硬化性樹脂硬化物に対する加圧としては、０ｋＮ〜５ｋＮが好ましく、０ｋＮ〜３ｋＮがより好ましく、０ｋＮ〜１ｋＮが更に好ましい。
＜車両用構造体＞
本実施形態に係る車両用構造体は、上述した本実施形態に係る樹脂接合体を有するものである。本実施形態に係る車両用構造体の種類は特に限定されるものではなく、例えば、サイドドア、フード、ルーフ、バックドア、ラゲージドア、バンパ及びクラッシュボックスが挙げられる。
本実施形態に係る車両用構造体においては、繊維を含む熱可塑性樹脂及び繊維を含む熱硬化性樹脂硬化物は、各々、プレス成形、射出成形、トランスファー成形等、用途に応じた成形法により、成形品とした状態で溶着により接合してもよい。
一般に、熱可塑性樹脂に比較して熱硬化性樹脂硬化物の方が表面平滑性に優れるため、例えば、本実施形態に係る樹脂接合体を用いて車両用構造体としてドアを形成する場合、樹脂接合体のうちの熱硬化性樹脂硬化物でドアの表側が構成されることが好ましい。
本実施形態に係る車両用構造体によれば、要求される特性に応じて部分毎に好適な樹脂材料を組み合わせて樹脂製の車両用構造体を構成することが可能となる。そのため、本実施形態に係る車両用構造体によれは、複数種の樹脂（マルチマテリアル）を併用する次世代の車両を実現可能となる。
以下、実施例および比較例を挙げ、本実施形態をより具体的に説明するが、本実施形態は以下の実施例に限定されるものではない。
（試験片の準備）
炭素繊維強化熱可塑性樹脂（ＣＦＲＴＰ、ポリアミド樹脂と炭素繊維（不織布）との複合材料、融解温度２４０℃）、炭素繊維強化熱硬化性樹脂硬化物（ＣＦＲＰ、エポキシ樹脂硬化物と炭素繊維（織布）との複合材料、融解温度１４０℃）、アルミニウム板（表面未処理）、アルミニウム板（＃６０サンディング）及び鉄板（表面カチオン電着塗装処理）を試験片として用いた。なお、ＣＦＲＰについては、樹脂を熱硬化した際のプリプレグによる型面側とフィルム面側とを区別して使用した。
試験片の大きさは、長さ１７５ｍｍ、幅２５ｍｍ、厚み３ｍｍとした。
試験片は、研削盤を用いて前記サイズにカットして準備した。ＣＦＲＰの型面側及びフィルム面側表面、アルミニウム板の表面並びにＣＦＲＴＰの表面は脱脂処理した。
試験片を２５±２℃に管理された部屋で１０日以上保管後、溶着試験に供した。
（振動溶着）
振動溶着機として、ブランソン ＭＩＣＲＯ ＰＰＬ（日本エマソン株式会社）を用いた。ワーク（固定側）及びワーク（加振側）に表１に示す組合せで上記試験片を装着し、振動溶着を実施し、樹脂接合体を作製した。溶着条件としては、振動振幅を１．８ｍｍとし、加圧を０．７５ＭＰａとし、溶け込み寸法を０．３ｍｍとした。
（せん断強度測定）
株式会社島津製作所製 オートグラフ ＡＧ−Ｘ１００ＫＮを用い、せん断試験を実施した。得られた結果を表１に示す。なお、得られた結果は、２回の試験を行った結果の平均値である。
表１においてせん断強度が「−」とは、せん断強度が測定限界以下であったことを表す。
表１から、ＣＦＲＴＰとＣＦＲＰとの間で溶着による接合状態が形成されていることがわかる。また、そのせん断強度は１９．５ＭＰａであり、ＣＦＲＴＰ同士を溶着した場合（２６．０ＭＰａ）と遜色のないものであった。
ＣＦＲＴＰとＣＦＲＰとの間で形成された接合の破断面を観察すると、ＣＦＲＴＰ側にＣＦＲＰ側の炭素繊維が付着していた。このことから、振動発熱時にＣＦＲＰのエポキシ樹脂硬化物が破壊され、エポキシ樹脂硬化物が取り除かれた箇所に熱可塑性樹脂が流れ込み、ＣＦＲＰ側の炭素繊維とＣＦＲＴＰとが接合したものと考えられる。
なお、ＣＦＲＰの型面とフィルム面とでせん断強度に差が生じた。型面とフィルム面との表面凹凸の差は１０μｍ程度しかないため、今回の評価においては表面凹凸によるせん断強度への影響は少ないと考えられる。しかし、型面とフィルム面とでは使用されている離型剤の種類が異なるため、フィルム面に離型剤が多く残留（溶着前に脱脂済み）していることによる影響が強いと考えられる。そのため、フィルム面側では、せん断強度のばらつき（１７．３ＭＰａ及び１４．０ＭＰａ）が大きくなったと考えられる。
一方、アルミニウム板及び鉄板を試験片として用いた場合、接合効果がほとんど見られなかった。これは、振動溶着の原理より、試験片の接触面同士の摩擦により生ずる熱により試験片が溶着するため、金属表面に凹凸を設けても凹凸がすりつぶされるため接触面に樹脂等をコーティングしない限りは金属と熱可塑性樹脂との接合は困難と考えられる。また、表面カチオン電着塗装処理など極めて樹脂の膜厚が薄い場合には、振動溶着によりこの樹脂が剥がし取られる可能性が高いため、せん断強度を得るには金属表面にある程度の樹脂厚みが必要と考えられる。
（超音波溶着）
超音波溶着機として、ブランソン ２０００Ｘｄｔ（日本エマソン株式会社）を用いた。超音波溶着機による溶着条件を表２に示すように設定し、超音波溶着試験を実施し、樹脂接合体を作製した。また、超音波溶着された試験片のせん断強度の測定を、振動溶着による試験の場合と同様にして実施した。得られた結果を表２に示す。試験片としては、ＣＦＲＴＰ及びＣＦＲＰを使用した。
表２において、１）はホーン径φ１５で算出された強度であり、２）は実溶着面積で算出された強度である。
表２より、基準溶着条件が最も高強度（約５０ＭＰａ）であった。つまり、試験片を押さえ込むこと（試験片加圧）による強度の向上は見られなかった。試験片加圧は少ない方がせん断強度に優れる。これは、超音波溶着は試験片の接触面に対して上下の動きにより試験片を振動させるため、試験片同士を強く押し付けすぎると試験片中の繊維の絡みが少なくなるためと考えられる。
また、振幅を約３μｍ（制御上は約５％）増減することで溶着強度に大きな変化（相異）が発生した。

Claims (7)

  1. 繊維を含む熱可塑性樹脂と、前記熱可塑性樹脂の融解温度よりも低い融解温度を有し繊維を含む熱硬化性樹脂硬化物と、が溶着により接合した樹脂接合体。
  2. 前記熱硬化性樹脂硬化物に含まれる繊維が、織布である請求項１に記載の樹脂接合体。
  3. 前記熱可塑性樹脂に含まれる繊維が、不織布である請求項１又は請求項２に記載の樹脂接合体。
  4. 前記熱可塑性樹脂の融解温度と前記熱硬化性樹脂硬化物の融解温度との差が５０℃以上である請求項１〜請求項３のいずれか１項に記載の樹脂接合体。
  5. 繊維を含む熱可塑性樹脂と、前記熱可塑性樹脂の融解温度よりも低い融解温度を有し繊維を含む熱硬化性樹脂硬化物と、を溶着して接合する接合工程を含む樹脂接合体の製造方法。
  6. 前記接合工程における溶着が、振動溶着である請求項５に記載の樹脂接合体の製造方法。
  7. 請求項１〜請求項４のいずれか１項に記載の樹脂接合体を有する車両用構造体。
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