JP2019081301A - Joined body and manufacturing method of joined body - Google Patents

Abstract

To eliminate a risk in a conventional art in which burrs generated in a large amount may become an obstacle to cause a gap between to-be-joined members when applying an energy director to ultrasonic spot welding.SOLUTION: A joined body A in which to-be-joined members 1, 2 composed of a fiber reinforced resin having a thermoplastic resin as a base material are joined by ultrasonic bonding has: plural first welded parts B1 in which the to-be-joined members 1, 2 are mutually welded locally; and a linear second welded part B2 in which the to-be-joined members 1, 2 are mutually welded in a state where the first welded parts B1 are connected to each other. Thereby, the joined body A is made high quality in which the pair of to-be-joined members 1, 2 are joined without a gap, and improvement in water tightness and mechanical strength is realized.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a joined body in which members to be joined made of a fiber reinforced resin (FRTP) having a thermoplastic resin as a base material are joined by ultrasonic bonding and a method of manufacturing the joined body.

  As a conventional method of joining members to be joined, there is, for example, one described in Patent Document 1. The bonding method described in Patent Document 1 is a method of bonding two members to be bonded (cabinet pieces) by ultrasonic bonding, and a protruding rib called an energy director is formed on the bonding surface of one of the members to be bonded. Continuously. Moreover, in said joining method, the ultrasonic bonding apparatus provided with the horn to which ultrasonic vibration is given is used. In this case, in the horn, the portion in contact with the members to be joined corresponds to the shape of the joining surface (arrangement of the projecting ribs).

  Then, in the above-described bonding method, the two members to be bonded are put on top of each other, and the horn is pressed against one of the members to be bonded to apply ultrasonic vibration energy. Thereby, in said joining method, frictional heat is generated on the joining surface of to-be-joined members, a contained resin is fuse | melted, and both to-be-joined members are joined (welding). Under the present circumstances, in said joining method, it is made to produce intensive expansion-contraction movement in a projecting rib, to make it heat-generate to resin melting temperature in a short time, and welding is performed efficiently.

  In the bonding method as described above, a dedicated horn corresponding to the shape of the bonding surface (arrangement of the projecting ribs) is required. On the other hand, as a method of bonding resin-made members to be joined, there is ultrasonic spot welding in which members to be joined are joined at a predetermined interval using an ultrasonic bonding apparatus provided with a small-sized horn having a simple shape. This ultrasonic spot welding is excellent in versatility because the form of the horn does not depend on the shape of the bonding surface.

Patent No. 5052805 gazette

  However, when trying to apply the projecting rib described in Patent Document 1 to the above-described ultrasonic spot welding, when the horn is pushed into the member to be joined, the molten resin flows out and a large amount of burrs are generated. . For this reason, the protruding rib is not sufficiently melted at a position separated from the horn because the burr is an obstacle, and as a result, a gap is generated between the members to be joined between adjacent welds, resulting in water tightness and machinery There was a risk that the target strength would decrease.

  The present invention is made in view of the above-mentioned conventional situation, and in a joined body in which members to be joined made of fiber reinforced resin (FRTP) having a thermoplastic resin as a base material are joined by ultrasonic bonding, An object of the present invention is to provide a high quality joined body in which a pair of members to be joined are joined without a gap.

  The joined body according to the present invention is one in which members to be joined made of a fiber reinforced resin having a thermoplastic resin as a base material are joined by ultrasonic bonding. The joined body includes a plurality of first welded portions obtained by locally welding the members to be joined, and a linear second welded portion obtained by welding the members to be joined in a state of connecting the first welded portions. It is characterized by having.

  In the method of manufacturing a joined body according to the present invention, a horn for ultrasonic bonding is used when producing the above-mentioned joined body, and the second welded portion is formed on the joining surface of one of the members to be joined. The rib-like convex portion is provided in a discontinuous state. Then, in the above manufacturing method, after overlapping one bonded member and the other bonded member, in the non-continuous region of the rib-like convex portion in plan view from the one bonded member side, By pressing the horn to which ultrasonic vibration has been applied to one of the members to be joined, the first welded portion and the second welded portion continuous to the first welded portion are formed to join the members to be joined. It is characterized.

  Since the joined body according to the present invention adopts the above-mentioned configuration, the pair of members to be joined are joined without a gap by the planar first welded portion and the linear second welded portion, and the water tightness and mechanical strength are obtained. Can be realized.

  According to the method of manufacturing a joined body according to the present invention, since the horn and the rib-like convex portion do not overlap in the thickness direction of the members to be joined, generation of burrs in the first welded portion is reduced, and the second Since the welds are not affected by burrs, the members to be joined are securely joined by the planar first welds and the linear second welds. Thereby, in the manufacturing method of said joined body, the high quality joined body to which a pair of to-be-joined member was joined without a clearance gap can be obtained.

They are a top view (A) and a longitudinal cross-sectional view (B) of an important section explaining a 1st embodiment of a joined object concerning the present invention. It is a figure explaining the manufacturing method of the joined body shown in Drawing 1, and is the cross section (A) and the longitudinal section before joining which omitted one side. It is a figure explaining the manufacturing method of the joined body shown in Drawing 1, and is a top view before junction which omitted one side. It is the cross-sectional view (A) and longitudinal cross-sectional view after joining which abbreviate | omitted one side following FIG. It is a photograph which shows the plane of a joined object of an example, a longitudinal section (A, B), and a transverse section (1-7), and a photograph which shows a transverse section (1, 3-7) of a comparative example. It is a table showing a test result of a water leak.

First Embodiment
FIG. 1 is a view showing the main part of a bonded structure according to the present invention. The illustrated joined body A is one in which members to be joined 1 and 2 made of fiber reinforced resin (FRTP) having a thermoplastic resin as a base material are joined by ultrasonic bonding. In addition, although it is possible to make the joined body A into various forms as a whole, the main part of the strip-shaped to-be-joined members 1 and 2 was illustrated for the sake of making it easy to understand easily.

  The thermoplastic resin which is the base material of the members to be joined 1 and 2 is not particularly limited, and, for example, a polyolefin resin, a polyamide resin, and a polyester resin can be used.

  The reinforcing fibers of the members to be joined 1 and 2 are not particularly limited, but for example, carbon fibers or carbon-containing fibers which are high in strength and light in weight are suitable for use as structural materials for automobiles. In this case, the material of the members to be joined 1 and 2 is a carbon fiber reinforced resin (CFRTP) having a thermoplastic resin as a base material.

  The above joined body A welds the members to be joined 1 and 2 with the plurality of first welded portions B1 where the members to be joined 1 and 2 are locally welded and the first welded portions B1 and B1 are connected to each other And a linear second welded portion B2. The joined body A of the illustrated example has the first welded portions B1 at predetermined intervals in the longitudinal direction of the strip-like members to be joined 1 and 2, and the two linear second welded portions B2 and B2 are parallel to each other. Have to.

  The end of the second welded portion B2 is continuous with the first welded portion B1. In addition, although 2nd welding part B2 may be numbers other than two, in the case of two, making the bonded state of both the to-be-joined members 1 and 2 more stable with a necessary minimum number is more preferable Can. Further, the second welded portion B2 is not limited to the parallel arrangement, but may be in a form other than a linear shape, such as a curved shape.

  Furthermore, in the joined body A, the length Lb of the first welded portion B1 and the second welded portion B2 shown in FIG. 1 is 10 to 150 mm, and more preferably, the lengths of the first welded portion B1 and the second welded portion B2 Lb is 40 to 100 mm. This is because, when the length Lb is less than 10 mm, the advantage of spot welding is hardly exhibited substantially without much difference from the bonding of only the first welded portion B1. Moreover, it is because there exists a possibility that welding in the center part of 2nd welding part B2 may become inadequate, when said length Lb exceeds 150 mm.

  Therefore, by setting the length Lb to 10 to 150 mm, it is possible to sufficiently join the entire second welded portion B2 after making the advantage of spot welding possible, and it is more preferable. Is more effective by setting the length Lb to 40 to 100 mm.

  Furthermore, in the joined body A, the first welded portion B1 has the recess 3 as a joining tool mark opened to the one side of the joined member 1 side, and in plan view from the one side of the joined member 1 side The recess 3 and the second welded portion B2 are disposed in proximity to each other. The recessed part 3 of the example of illustration is circular in planar view, penetrates one to-be-joined member 1, and forms the bottom part in the other to-be-joined member 2. As shown in FIG.

  Here, the first welded portion B1 is formed in the region on the outer peripheral side of the recess 3 by a manufacturing method described later. The second welded portions B2 parallel to each other are disposed at an interval S smaller than the diameter R of the recess 3. Each end of the second welded portion B2 is continuous with the first welded portion B1 formed in the area on the outer peripheral side of the recess 3.

  As shown in FIG. 2 and FIG. 3, the pair of members 1 and 2 constituting the above-mentioned joined body A is a bonding surface of one member 1 to be bonded with the other member 2 (in the figure) On the upper surface, rib-like convex part 4 for forming the 2nd welding part B2 is discontinuously provided, and in the example of illustration, it has two rib-like convex parts 4 and 4 mutually parallel. There is.

  The rib-like convex portion 4 is a so-called energy director, and is disposed except for the portion corresponding to the horn H used in the manufacturing method described later. Thereby, the rib-like convex part 4 is a discontinuous state which made the part corresponding to the horn H the discontinuous area | region (non-formation area | region) on the straight line covering the full length of the to-be-joined member 1. FIG.

  Here, the above-mentioned recessed part 3 is a welding tool mark by the horn H. Two rib-shaped convex portions 4 4 parallel to each other are disposed at an interval S smaller than the diameter R of the recess 3 and, in the cross section shown in FIG. 2A, within the diameter Rh of the horn H It is arranged in the area.

  Further, the height of the rib-like convex portion 4 is 0.3 to 3 mm, and more preferably 0.5 to 1.5 mm. If the height of the rib-like convex portion 4 is less than 0.3 mm, the volume may be insufficient and the function as an energy director may be deteriorated. Furthermore, when the height of the rib-like convex portion 4 exceeds 3 mm, the members to be joined 1 and 2 are separated too much, and there is a possibility that the volume becomes large and the generation amount of burrs increases.

  Therefore, by setting the height of the rib-like convex portion 4 to 0.3 to 3 mm, the rib-like convex portion 4 can exhibit the function as an energy director and can reduce the amount of burr generation, and more preferably, the height While being able to exhibit the function as an energy director more by setting it as 0.5-1.5 mm, the generation amount of a burr | flash can be suppressed further.

  Furthermore, the rib-like convex portion 4 has at least one of a cross section orthogonal to the longitudinal direction as a triangular shape whose top is a tip, a square shape whose one end is a tip, and a semicircular shape whose tip is an arc center. There is. The rib-like convex portion 4 of this embodiment is triangular in cross section, but from the viewpoint of concentrating energy at the time of joining, it is preferable that the contact area to the other member 2 to be joined be small. It does not matter to change the shape.

Next, a method of manufacturing the joined body A using the above-mentioned members to be joined 1, 2 as constituent members will be described.
In the method of manufacturing the joined body A, the horn H for ultrasonic bonding is used, and as described above, the rib-like convex portion 4 for forming the second welded portion B2 on the joint surface of one joined member 1 In the non-continuous state.

  Further, in the above manufacturing method, the outer peripheral portion of the horn H and the end portion of the rib-like convex portion 4 are disposed in contact with each other. That is, although the horn H and the rib-like convex part 4 are arrangement | positioning which does not overlap in planar view, it is the arrangement which made the edge part of the rib-like convex part 4 as close as possible to the outer peripheral part of the horn H.

  The ultrasonic bonding apparatus used for this manufacturing method is not shown, but performs spot welding, and applies ultrasonic vibration to a mechanism for raising and lowering a head mounted with a cylindrical horn H, and the horn H. It is good also as composition provided with a booster etc. and a mechanism which holds the back side (opposite side of horn H) of members 1 and 2 to be joined.

  Then, as shown in FIG. 2, the method of manufacturing the joined body A is one joined member 1 after the one (upper side) joined member 1 and the other (lower side) joined member 2 are overlapped. In a plan view from the side, the horn H to which ultrasonic vibration has been applied is pressed against one of the members to be joined 1 in the discontinuous region of the rib-like convex portion 4. That is, ultrasonic vibration energy is applied to the members 1 and 2 to be bonded.

  Then, in the manufacturing method, the contained resin is melted by the frictional heat due to the ultrasonic vibrational energy of the horn H, and as shown in FIG. 4, the horn H penetrates one joined member 1 and the other joined member 2 Pushed into. Thereby, in the said manufacturing method, contained resin fuse | melts in the interface of both the to-be-joined members 1 and 2, and 1st weld part B1 which is a planar weld part is formed in the area | region of the outer peripheral side of horn H.

  Further, in the manufacturing method, a concentrated expansion and contraction motion is caused in the rib-like convex portion 4 of one of the members to be joined 1 almost simultaneously with the formation of the first welded portion B1 to generate heat in a short time to the resin melting temperature A second welding portion B2 which is a linear welding portion is formed.

  Thus, in the method of manufacturing the joined body A, the first welded portion B1 and the second welded portion B2 continuous to the first welded portion B1 are formed, and the joined body A in which the members 1 and 2 to be joined are welded is obtained. At this time, in the joined body A, the first welded portion B1 and the end portion of the second welded portion B2 are continuous, and the recess 3 as a bonding tool mark (horn mark) is formed by detachment of the horn H after bonding. Be done.

  The joined body A manufactured as described above has few occurrences of burrs in the first welded portion B1, and the second welded portion B2 is not affected by the burrs, so the planar first welded portion B1 and the linear welded portion B1 are produced. The to-be-joined members 1 and 2 are reliably joined in 2nd welding part B2.

  As a result, the joined body A is of high quality in which the pair of members to be joined 1 and 2 are joined without a gap, and along with this, improvement of water tightness and mechanical strength can be realized. Further, it is apparent that the above-mentioned joined body A can adopt ultrasonic spot welding with high versatility and an energy director which realizes improvement of joining efficiency in its production.

  Further, since the joined body A has the two second welded portions B2 and B2 between the first welded portions B1 and B1, the pair of members to be joined 1 and 2 are parallel without tilting. It becomes a stably joined state, and further improvement of water tightness and mechanical strength can be realized.

  Furthermore, the above-mentioned joined body A has the length of the first welded portion B1 and the second welded portion B2 of 10 to 150 mm, so that the advantage of spot welding can be exhibited, and the second welded portion The entire B2 can be joined more reliably.

  Furthermore, since the first welded portion B1 has the concave portion 3 as a welding tool mark opened to the side of one joined member 1 in the above joined body A, the first welding is wide in the region on the outer peripheral side of the concave portion 3 Part B1 is secured, which can contribute to further improvement of mechanical strength and the like. In addition, according to the thickness etc. of the to-be-joined members 1 and 2, although there may also be a structure without the recessed part 3 in any case, a pair of to-be-joined members 1 and 2 comrades mutually join It will be in the welding state where there is no interface in the part.

  Furthermore, in the above-mentioned joined body A, since the concave portion 3 and the second welded portion B2 are disposed close to each other in a plan view from the side of one joined member 1, the first welded portion B1 and the second welded portion Thus, the end portions of the portion B2 are reliably continued, and the pair of members 1 and 2 are joined without a gap, thereby achieving further improvement of water tightness and mechanical strength.

  Further, the pair of members to be joined 1 and 2 forming the joined body A is for forming the second welded portion B2 on the joining surface of one member to be joined 1 with the other member to be joined 2. Since the rib-like convex part 4 is in a discontinuous state, the rib-like convex part 4 functions as an energy director, and efficient bonding can be performed, which can contribute to shortening of bonding time and the like.

  Furthermore, by setting the height of the rib-shaped convex part 4 to 0.3 to 3 mm, the member 1 to be joined can sufficiently exhibit the function as an energy director and reduce the amount of generation of burrs.

  Furthermore, the member 1 to be joined has a cross section orthogonal to the longitudinal direction of the rib-like convex portion 4, a triangular shape with the top as a tip, a square shape with one side as a tip, and a semicircular shape with an arc center as a tip. The function as an energy director can fully be exhibited by setting it as at least one of these. In particular, if the rib-like convex portion 4 has a triangular cross-sectional shape or a semi-circular cross-sectional shape, the contact area with the other member 2 to be joined is reduced, and ultrasonic vibration energy is concentrated by that amount, which is efficient. Bonding is possible.

  Further, according to the manufacturing method of the joined body A, since the horn H and the rib-like convex portion 4 do not overlap in the thickness direction of the members to be joined 1 and 2, generation of burrs in the first welded portion B1 As the second welded portion B2 is not affected by burrs, the members to be joined are reliably joined at the first welded portion B1 and the second welded portion B2. Thereby, in the manufacturing method of said joined body, the high quality joined body A with which a pair of to-be-joined members 1 and 2 joined without gap can be obtained.

  Furthermore, in the above manufacturing method, the planar first welded portion B1 and the linear second welded portion B2 are formed by arranging the outer peripheral portion of the horn H and the end portion of the rib-like convex portion 4 to be in contact with each other. . That is, in the above manufacturing method, the horn H and the rib-like convex portion 4 do not overlap in plan view, but the end of the rib-like convex portion 4 is brought close to the outer periphery of the horn H as much as possible. Thus, in the above manufacturing method, the first welded portion B1 and the end portion of the second welded portion B2 can be integrated more reliably, and the water tightness between the pair of members 1 and 2 to be joined and the like To realize further improvement of mechanical strength.

  In addition, when manufacturing the joined body A by the above-mentioned manufacturing method, it is not impossible to press the individual horns H on a plurality of discontinuous regions of the rib-like convex portion 4 and apply ultrasonic vibration, Spot welding with the horn H can be sequentially performed on a plurality of discontinuous regions as if spot welding is performed.

  That is, the above-described manufacturing method can achieve both the versatility of spot welding and the function of the rib-like convex portion 4 as an energy director while suppressing the occurrence of burrs, which has been a problem in the prior art, Is very expensive. Moreover, since manufacture by spot welding is possible, a small and simple-shaped horn H can be adopted.

  However, when the first and second welded portions B1 and B2 are formed by pressing the horn H against one discontinuous region, movement of the members 1 and 2 in the in-plane direction (direction along the bonding surface) is obtained. It may be insufficient. Therefore, in the case where the joined body A is manufactured by spot welding, it is more preferable to apply longitudinal ultrasonic vibration in the thickness direction of the members 1 and 2 to the horn H. Thereby, it is possible to stably join all the junctions under the same joining condition.

  FIG. 5: the photograph which shows the plane of the joined body A manufactured based on the said embodiment, a longitudinal cross-section (A, B), and a cross section (1-7), and the cross section (1, 3-7) of a comparative example It is a photograph showing. In the embodiment, the rib-like convex portion 4 in a discontinuous state is provided on one of the members to be joined 1, and the horn H (concave portion 3) and the rib-like convex portion 4 are provided in the thickness direction of the members to be joined 1 and 2. Are not overlapping. On the other hand, in the comparative example, the rib-like convex portion 4 is provided over the entire length of the member to be joined 1, and the horn H (concave portion 3) and the rib-like convex portion 4 overlap in the thickness direction of the members to be joined 1 and 2. It is an arrangement.

  As apparent from the photograph of FIG. 5, in the joined body of the comparative example, since the rib-like convex portion 4 is on the lower side of the horn H, the molten resin flows out on the lower side of the horn H and a large amount of burrs Occurred. For this reason, in the comparative example, the rib-like convex portion 4 is not sufficiently melted at a position separated from the horn due to the burr, and particularly as shown in the cross sections (3 to 5) A gap was generated between two (protruding ribs 4).

  On the other hand, in the joined body A of the example, the members 1 and 2 to be joined were joined without any gap in any cross section (1 to 7), and were joined in the entire longitudinal direction. Thereby, it was confirmed that the joined body A of the example is excellent in mechanical strength in water tightness as compared with the comparative example.

  FIG. 6 is a table showing test results of water leak (water tightness). In Conventional Example 1, one of the members to be joined has no rib-like convex portion. In Conventional Example 2, the horn H and one rib-shaped convex portion 4 are arranged to overlap. In Conventional Example 3, the horn H and the two rib-like convex portions 4 are arranged to overlap. An example is the composition of the joined object of the present invention in which a horn and two discontinuous rib-like convex parts do not overlap. Furthermore, in the comparative example, the rib-like convex portions of the continuous bodies on both sides of the horn are disposed, and both are not overlapped.

  In the water leak test, after producing the bonded body of each example by ultrasonic welding, 3-5 mL of water is vigorously injected into the gap between both members 1 and 2 with a syringe, and the water leak from the opposite side Confirmed the presence of As a result, in the conventional examples 1 to 3 and the comparative example, although the bonding strength, the inclination of the members to be joined, and the adhesion were partially good, water leakage was observed at all, and the comprehensive evaluation was poor. .

  On the other hand, in the examples, all of the bonding strength, the sealability, the inclination of the members to be joined, and the adhesion were good, and no water leakage was observed. As a result, it was confirmed that the examples were good in the comprehensive evaluation, and that the water tightness and the mechanical strength were clearly superior as compared with the conventional examples 1 to 3 and the comparative example.

  The details of the configuration of the bonded structure and the method of manufacturing the same according to the present invention are not limited to the above embodiment, and, for example, the form of members to be joined, the number, shape and arrangement of rib-like convex portions, horns It is possible to change suitably in the range which does not deviate from the gist of the present invention, such as the form of.

A joined body B1 first welded portion B2 second welded portion H horn 1 one to-be-joined member 2 other to-be-joined member 3 concave portion 4 rib-like convex portion

Claims (8)

A bonded body in which members to be joined made of fiber reinforced resin having a thermoplastic resin as a base material are joined by ultrasonic bonding,
Having a plurality of first welding parts in which the members to be joined are locally welded and a linear second welding part in which the members to be joined are welded in a state in which the first welding parts are connected to each other Characteristic junction body.   The joined body according to claim 1, wherein two of the second welded portions are provided between the first welded portions.   The joined body according to claim 1 or 2, wherein lengths of the first welded portion and the second welded portion are 10 to 150 mm.   The joined body according to any one of claims 1 to 3, wherein the first welding portion has a concave portion as a welding tool mark opened to the side of one joined member. It is a pair of to-be-joined member which comprises the joined body of any one of Claims 1-4, Comprising:
A to-be-joined member characterized by having a rib-like convex part for forming said 2nd welding part in a discontinuous state on the joined surface with one to-be-joined member of another to-be-joined member.   The cross section orthogonal to the longitudinal direction of the rib-like convex portion is at least one of a triangular shape with the top as a tip, a square shape with one side as the tip, and a semicircular shape with the center of the arc as the tip The to-be-joined member of Claim 5 characterized by the above-mentioned. When manufacturing the joined body of any one of Claims 1-4,
Using a horn for ultrasonic bonding, a rib-like convex portion for forming the second welded portion is provided in a discontinuous state on the bonding surface of one of the members to be bonded,
After overlapping one of the members to be joined and the other member to be joined,
In a plan view from one of the members to be joined, pressing the horn to which ultrasonic vibration is applied to the discontinuous region of the rib-like convex portion against the one member to be joined allows the first welded portion to be formed. A method of manufacturing a joined body, comprising forming the second welded portion continuous to this and joining the members to be joined.   8. The joined body according to claim 7, wherein the first welded portion and the second welded portion are formed such that the outer peripheral portion of the horn and the end portion of the rib-like convex portion are in contact with each other. Production method.

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