JP2019111835A - Ultrasonic welding member and ultrasonic welding method - Google Patents
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- 238000003466 welding Methods 0.000 title claims abstract description 498
- 238000000034 method Methods 0.000 title claims abstract description 25
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 63
- 238000005304 joining Methods 0.000 claims description 41
- 239000004696 Poly ether ether ketone Substances 0.000 claims description 13
- JUPQTSLXMOCDHR-UHFFFAOYSA-N benzene-1,4-diol;bis(4-fluorophenyl)methanone Chemical compound OC1=CC=C(O)C=C1.C1=CC(F)=CC=C1C(=O)C1=CC=C(F)C=C1 JUPQTSLXMOCDHR-UHFFFAOYSA-N 0.000 claims description 13
- 229920002530 polyetherether ketone Polymers 0.000 claims description 13
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims description 5
- 229920001652 poly(etherketoneketone) Polymers 0.000 claims description 5
- 229920000728 polyester Polymers 0.000 claims description 5
- 229920000069 polyphenylene sulfide Polymers 0.000 claims description 5
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 5
- 230000015572 biosynthetic process Effects 0.000 abstract description 16
- 239000011800 void material Substances 0.000 abstract description 7
- 230000014759 maintenance of location Effects 0.000 abstract 1
- 239000000463 material Substances 0.000 description 19
- 238000004519 manufacturing process Methods 0.000 description 16
- 229920005989 resin Polymers 0.000 description 14
- 239000011347 resin Substances 0.000 description 14
- 230000000052 comparative effect Effects 0.000 description 10
- 238000013461 design Methods 0.000 description 8
- 239000002759 woven fabric Substances 0.000 description 5
- 239000002131 composite material Substances 0.000 description 4
- 239000004744 fabric Substances 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 238000002844 melting Methods 0.000 description 4
- 230000008018 melting Effects 0.000 description 4
- 229920000049 Carbon (fiber) Polymers 0.000 description 3
- 239000004917 carbon fiber Substances 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 238000001746 injection moulding Methods 0.000 description 3
- 230000010485 coping Effects 0.000 description 2
- 238000005242 forging Methods 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 238000009825 accumulation Methods 0.000 description 1
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
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Abstract
Description
本発明は、超音波溶着用部材および超音波溶着方法に関する。さらに詳細には、本発明は、溶着対象の第１部材および第２部材とは独立した超音波溶着用部材、ならびに、これを用いた超音波溶着方法に関する。 The present invention relates to an ultrasonic welding member and an ultrasonic welding method. More particularly, the present invention relates to an ultrasonic welding member independent of the first and second members to be welded, and an ultrasonic welding method using the same.
熱可塑性樹脂を対象部材とする２つの部材の溶着方法として、超音波振動を付与することによって溶着を行う超音波溶着法が広く用いられている。この際、溶着対象である熱可塑性樹脂のいずれか一方に、リブを予め一体に成形しておき、超音波振動を与えた際の溶着起点としてこのリブ形状を利用する方法が一般的に知られている。
しかし、溶着対象である熱可塑性樹脂の部材のいずれか一方にリブ状の突起を予め一体に成形するための方法としては、射出成形等の成形法に限定されるところ、溶着対象の部材の表面形状が複雑である場合には、リブ状の突起の付加は非常に困難である。
The ultrasonic welding method which welds by giving an ultrasonic vibration as a welding method of two members which make a thermoplastic resin an object member is used widely. At this time, a method is generally known in which a rib is integrally formed in advance in any one of thermoplastic resins to be welded, and this rib shape is used as a welding starting point when ultrasonic vibration is applied. ing.
However, as a method for forming the rib-like projections integrally in advance on any one of the members of the thermoplastic resin to be welded is limited to a molding method such as injection molding, the surface of the member to be welded is If the shape is complex, the addition of rib-like projections is very difficult.
また、近年においては、航空機や船舶を含む輸送機器等の高度な機械的強度が要求される技術分野では、炭素繊維等の繊維および樹脂の複層構造を有する複合材料等の開発が盛んに行われている。このような複合材料は、樹脂層が一般的に薄いので、射出成形によってリブ状の突起を形成すれば樹脂層が剥げて繊維が毛羽立つため、実質的にリブ状の突起形成が不可能であるという不都合がある。 In recent years, in technical fields where high mechanical strength is required, such as transportation equipment including aircraft and ships, development of composite materials having a multilayer structure of fibers such as carbon fibers and resins, etc. has been brisk. It is In such a composite material, since the resin layer is generally thin, if the rib-like projections are formed by injection molding, the resin layer peels off and the fibers become fluffed, so that substantially no rib-like projections can be formed. There is a disadvantage.
特開平８−１５０６６９号公報（特許第３５３６３８５号）には、リブ状の突起形成を回避した超音波溶着手段として、図１に示されるような超音波溶着用ネットおよびこれを用いる超音波溶着方法が開示されている（特許文献１）。図中、１は超音波溶着用ネットであり、２はネットを形成する線条を示す。対象の溶着部材間に超音波溶着用ネットを挿入して超音波溶着を行うものであり、射出成形によるリブ状の突起形成が不可能な対象部材であっても、高い自由度を持って溶着を行うことができる。しかし、この超音波溶着用ネットは、線条の断面の長径がネット厚み方向であり、線条の全体を溶着部材の表面に一致させるように構成されている。このような超音波溶着用ネットは、生産性が低いため製造コストが高くなる。さらには、ネットの構造が平面的であるために、溶着部に空気が閉じ込められ、ボイドが残りやすくなり、その結果、溶着強度が低くなり、外観も損なわれるという不都合が生じる。 In JP-A-8-150669 (Patent No. 3536385), an ultrasonic welding net as shown in FIG. 1 and an ultrasonic welding method using the same as ultrasonic welding means avoiding formation of rib-like projections Is disclosed (Patent Document 1). In the figure, 1 is a net for ultrasonic welding, and 2 is a filament forming a net. Ultrasonic welding is performed by inserting an ultrasonic welding net between the welding members to be treated and ultrasonic welding is performed, and even if the target member can not form a rib-like projection by injection molding, welding is performed with a high degree of freedom. It can be performed. However, in this ultrasonic welding net, the major axis of the cross section of the filament is in the thickness direction of the net, and the entire filament is made to coincide with the surface of the welding member. Such ultrasonic welding nets have high productivity because they have low productivity. Furthermore, since the structure of the net is flat, air is trapped in the weld and a void is likely to remain, resulting in a disadvantage that the weld strength is reduced and the appearance is lost.
上で説明した諸々の不都合に鑑み、本発明が解決すべき課題は、リブ状の突起を予め設ける必要性がなく、製造が容易であると共に、溶着部にボイドが残りにくく、十分な溶着強度を確保可能な超音波溶着用部材およびこれを用いた超音波溶着方法を提供することである。 In view of the various disadvantages described above, the problem to be solved by the present invention is that there is no need to provide a rib-like protrusion in advance, which is easy to manufacture, and voids are not easily left in the welded portion, and sufficient welding strength It is an object of the present invention to provide an ultrasonic welding member capable of securing an ultrasonic welding method and an ultrasonic welding method using the same.
本発明者らは、鋭意研究を進めた結果、溶着対象の２つの部材とは独立した超音波溶着用部材を用い、この超音波溶着用部材と溶着対象表面との接合箇所が少なくとも一部において非連続的に存在するようにし、非接合箇所が空気通路を確保するように外部に開放されており、かつ、接合箇所と非接合箇所の面積比を所定範囲内に調整することによって、上記課題が解決され得ることを見出した。 As a result of intensive studies, the present inventors have used ultrasonic welding members independent of the two welding target members, and at least a part of the joint between the ultrasonic welding member and the surface to be welded is The above problem is achieved by making the non-consecutively exist, the non-joined part be open to the outside so as to secure the air passage, and adjusting the area ratio of the joined part and the non-joined part within a predetermined range. Found that can be resolved.
すなわち、上記課題を解決する本発明の構成は、以下のとおりである。
［１］．熱可塑性樹脂を含んでなる第１部材の溶着対象表面と、これに対して平行または嵌合する形状を有する熱可塑性樹脂を含んでなる第２部材の溶着対象表面との超音波溶着に先立って、これらの溶着対象表面の間に挟持させるための、第１部材および第２部材とは独立した超音波溶着用部材であって、
この超音波溶着用部材は、熱可塑性樹脂を含んでなり、
超音波溶着用部材は、第１部材の溶着対象表面および第２部材の溶着対象表面の間に挟持させたときに、超音波溶着用部材と第１部材の溶着対象表面との接合箇所および／または超音波溶着用部材と第２部材の溶着対象表面との接合箇所が、少なくとも一部において非連続的に存在するように形成されてなり、
かつ、超音波溶着用部材は、第１部材の溶着対象表面および第２部材の溶着対象表面の間に挟持させたときに、超音波溶着用部材と第１部材の溶着対象表面との非接合箇所および／または超音波溶着用部材と第２部材の溶着対象表面との非接合箇所の全てが、超音波溶着用部材の外部に対して開放されるように形成されてなり、
かつ、超音波溶着用部材を第１部材の溶着対象表面および第２部材の溶着対象表面の間に挟持させたとき、超音波溶着用部材と第１部材の溶着対象表面との非接合箇所の合計面積に対する、超音波溶着用部材と第１部材の溶着対象表面との接合箇所の合計面積の比率が１未満になり、および／または、超音波溶着用部材と第２部材の溶着対象表面との非接合箇所の合計面積に対する、超音波溶着用部材と第２部材の溶着対象表面との接合箇所の合計面積の比率が１未満になる、
上記超音波溶着用部材。
［２］．超音波溶着用部材が、少なくとも一部において、複数の線条を含んでなることを特徴とする、上記［１］項に記載の超音波溶着用部材。
［３］．超音波溶着用部材が、少なくとも一部において、略格子状の織物又は編物のメッシュであり、超音波溶着用部材を第１部材の溶着対象表面および第２部材の溶着対象表面の間に挟持させたとき、メッシュの糸の交差部が、超音波溶着用部材と第１部材の溶着対象表面との接合箇所および超音波溶着用部材と第２部材の溶着対象表面との接合箇所を形成することを特徴とする、上記［２］項に記載の超音波溶着用部材。
［４］．超音波溶着用部材が、少なくとも一部において、略等間隔にまたは不規則的に配された複数のドット状であることを特徴とする、上記［１］〜［３］項のいずれか１項に記載の超音波溶着用部材。
［５］．超音波溶着用部材に含まれる熱可塑性樹脂が、ＰＰ、ＰＡ６、ＰＡ６６、ＰＣ、ＰＳ、ＰＶＣ、ポリエステル、ＡＢＳ、ＰＰＳ、ＰＥＥＫ、およびＰＥＫＫからなる群から選択されることを特徴とする、上記［１］〜［４］項のいずれか１項に記載の超音波溶着用部材。
［６］．熱可塑性樹脂を含んでなる第１部材の溶着対象表面と、これに対して平行または嵌合する形状を有する熱可塑性樹脂を含んでなる第２部材の溶着対象表面との間に、第１部材および第２部材とは独立した超音波溶着用部材を挟持させる工程、ならびに、
超音波溶着用部材に超音波振動を与えて、第１部材および第２部材を溶着させる工程を含む超音波溶着方法であって、
この超音波溶着用部材は、熱可塑性樹脂を含んでなり、
第１部材の溶着対象表面と第２部材の溶着対象表面との間に超音波溶着用部材を挟持させる工程において、
超音波溶着用部材と第１部材の溶着対象表面との接合箇所および／または超音波溶着用部材と第２部材の溶着対象表面との接合箇所が、少なくとも一部において非連続的に存在するように、超音波溶着用部材を配置し、
かつ、超音波溶着用部材と第１部材の溶着対象表面との非接合箇所および／または超音波溶着用部材と第２部材の溶着対象表面との非接合箇所の全てが、超音波溶着用部材の外部に対して開放されるように、超音波溶着用部材を配置し、
かつ、超音波溶着用部材と第１部材の溶着対象表面との非接合箇所の合計面積に対する、超音波溶着用部材と第１部材の溶着対象表面との接合箇所の合計面積の比率が１未満になり、および／または、超音波溶着用部材と第２部材の溶着対象表面との非接合箇所の合計面積に対する、超音波溶着用部材と第２部材の溶着対象表面との接合箇所の合計面積の比率が１未満になるように、超音波溶着用部材を配置する、
上記超音波溶着方法。
［７］．超音波溶着用部材が、少なくとも一部において、複数の線条を含んでなることを特徴とする、上記［６］項に記載の超音波溶着方法。
［８］．超音波溶着用部材が、少なくとも一部において、略格子状の織物又は編物のメッシュであり、超音波溶着用部材を第１部材の溶着対象表面および第２部材の溶着対象表面の間に挟持させたとき、メッシュの糸の交差部が、超音波溶着用部材と第１部材の溶着対象表面との接合箇所および超音波溶着用部材と第２部材の溶着対象表面との接合箇所を形成することを特徴とする、上記［７］項に記載の超音波溶着方法。
［９］．超音波溶着用部材が、少なくとも一部において、略等間隔に配された複数のドット状であることを特徴とする、上記［６］〜［８］項のいずれか１項に記載の超音波溶着方法。
［１０］．超音波溶着用部材に含まれる熱可塑性樹脂が、ＰＰ、ＰＡ６、ＰＡ６６、ＰＣ、ＰＳ、ＰＶＣ、ポリエステル、ＡＢＳ、ＰＰＳ、ＰＥＥＫ、およびＰＥＫＫからなる群から選択されることを特徴とする、上記［６］〜［９］項のいずれか１項に記載の超音波溶着方法。
なお、超音波溶着用部材に係る本発明（上記項目［１］〜［５］）の対象は、当該部材自体である。第１部材および第２部材は、超音波溶着用部材に係る本発明の範囲に含まれない。
That is, the configuration of the present invention for solving the above problems is as follows.
[1]. Prior to ultrasonic welding of the surface to be welded of the first member comprising a thermoplastic resin, and the surface to be welded of a second member comprising a thermoplastic resin having a shape parallel to or fitted to the first member An ultrasonic welding member independent of the first member and the second member, for sandwiching the surfaces to be welded;
The ultrasonic welding member comprises a thermoplastic resin,
When the ultrasonic welding member is held between the welding target surface of the first member and the welding target surface of the second member, the ultrasonic welding member and the welding point of the welding target surface of the first member and / or Or the joint between the ultrasonic welding member and the welding target surface of the second member is formed so as to be discontinuous at least in part,
And when the ultrasonic welding member is held between the welding target surface of the first member and the welding target surface of the second member, the ultrasonic welding member and the welding target surface of the first member are not joined. All of the portions and / or the non-joining points between the ultrasonic welding member and the welding target surface of the second member are formed to be open to the outside of the ultrasonic welding member,
And when the ultrasonic welding member is held between the welding target surface of the first member and the welding target surface of the second member, the non-joining portion of the ultrasonic welding member and the welding target surface of the first member The ratio of the total area of the bonding points between the ultrasonic welding member and the welding target surface of the first member to the total area is less than 1 and / or the welding target surface of the ultrasonic welding member and the second member The ratio of the total area of the bonding points between the ultrasonic welding member and the surface of the second member to be welded is less than 1 with respect to the total area of the non-bonding points of
The above ultrasonic welding member.
[2]. The member for ultrasonic welding according to the above [1], characterized in that the member for ultrasonic welding comprises a plurality of filaments at least in part.
[3]. The ultrasonic welding member is a mesh of a substantially lattice-like woven or knitted fabric at least in part, and the ultrasonic welding member is held between the welding target surface of the first member and the welding target surface of the second member. Forming a joint between the ultrasonic welding member and the welding target surface of the first member and a joint between the ultrasonic welding member and the welding target surface of the second member. The ultrasonic welding member according to the above [2], characterized in that
[4]. The ultrasonic welding member is in the form of a plurality of dots arranged at substantially equal intervals or irregularly at least in part, any one of the above items [1] to [3]. The member for ultrasonic welding as described in-.
[5]. The thermoplastic resin contained in the member for ultrasonic welding is characterized in that it is selected from the group consisting of PP, PA6, PA66, PC, PS, PVC, polyester, ABS, PPS, PEEK, and PEKK. The ultrasonic welding member according to any one of the items 1] to [4].
[6]. A first member between a welding target surface of a first member comprising a thermoplastic resin and a welding target surface of a second member comprising a thermoplastic resin having a shape parallel to or fitted to the first member And a step of holding the ultrasonic welding member independent of the second member and the second member;
An ultrasonic welding method comprising the steps of: applying ultrasonic vibration to a member for ultrasonic welding to weld a first member and a second member,
The ultrasonic welding member comprises a thermoplastic resin,
In the step of holding the ultrasonic welding member between the welding target surface of the first member and the welding target surface of the second member,
The joint between the ultrasonic welding member and the welding target surface of the first member and / or the joint between the ultrasonic welding member and the welding target surface of the second member are present discontinuously at least in part Place the ultrasonic welding member at
In addition, all the non-joining points between the ultrasonic welding member and the welding target surface of the first member and / or all the non-joining points between the ultrasonic welding member and the welding target surface of the second member are ultrasonic welding members Position the ultrasonic welding member so that it is open to the outside of the
In addition, the ratio of the total area of the bonding portion between the ultrasonic welding member and the welding target surface of the first member to the total area of the non-bonding portion between the ultrasonic welding member and the welding target surface of the first member is less than 1 And / or the total area of the joint between the ultrasonic welding member and the welding target surface of the second member relative to the total area of the non-joining area of the ultrasonic welding member and the welding target surface of the second member. Position the ultrasonic welding member so that the ratio of
The above ultrasonic welding method.
[7]. The ultrasonic welding method according to the above [6], wherein the ultrasonic welding member comprises a plurality of filaments at least in part.
[8]. The ultrasonic welding member is a mesh of a substantially lattice-like woven or knitted fabric at least in part, and the ultrasonic welding member is held between the welding target surface of the first member and the welding target surface of the second member. Forming a joint between the ultrasonic welding member and the welding target surface of the first member and a joint between the ultrasonic welding member and the welding target surface of the second member. The ultrasonic welding method according to the above [7], characterized in that
[9]. The ultrasonic wave according to any one of the above items [6] to [8], wherein the ultrasonic welding member is in the form of a plurality of dots arranged at substantially equal intervals at least in part. Welding method.
[10]. The thermoplastic resin contained in the member for ultrasonic welding is characterized in that it is selected from the group consisting of PP, PA6, PA66, PC, PS, PVC, polyester, ABS, PPS, PEEK, and PEKK. The ultrasonic welding method as described in any one of 6]-[9] terms.
The target of the present invention (items [1] to [5] above) related to the ultrasonic welding member is the member itself. The first member and the second member are not included in the scope of the present invention related to a member for ultrasonic welding.
本発明の超音波溶着用部材は、溶着対象部材である第１の部材および第２の部材とは独立して取り扱われるものであるため、溶着のためのリブ状の突起を予め設ける必要性がない。
そして、この超音波溶着用部材は、２つの溶着対象部材間の方向における厚みの設計制約が少なく（特にメッシュを採用した場合）、また、超音波溶着用部材の体積を小さくすることができるため、製造効率が高く、製造時間・コストを抑制することが可能である。
さらに、この超音波溶着用部材は、超音波溶着用部材と溶着対象表面との接合箇所（溶着の起点）が少なくとも一部において非連続的に存在するようにし、非接合箇所が空気通路を確保するように外部に開放されており、かつ、接合箇所と非接合箇所の面積比を所定範囲内に調整することによって、溶着部にボイドが残りにくく、接合部の高い気密性が得られるため、十分な溶着強度を確保することが可能となる。
これらの効果は、上記超音波溶着方法を用いた場合にも、同様に得られる。
Since the ultrasonic welding member of the present invention is handled independently of the first and second members to be welded, it is necessary to provide in advance a rib-like projection for welding. Absent.
And since this ultrasonic welding member has few design restrictions of the thickness in the direction between two welding object members (especially when a mesh is adopted), and the volume of the ultrasonic welding member can be made small. The manufacturing efficiency is high, and the manufacturing time and cost can be suppressed.
Furthermore, in this ultrasonic welding member, the joining portion (starting point of welding) between the ultrasonic welding member and the surface to be welded is discontinuously present at least in part, and the non-joining portion secures an air passage It is opened to the outside so that the area ratio of the bonded portion and the non-bonded portion is adjusted within a predetermined range, voids are less likely to remain in the welded portion, and high airtightness of the bonded portion can be obtained. It becomes possible to secure sufficient welding strength.
These effects are similarly obtained when the above ultrasonic welding method is used.
図２を参照して、本発明の一実施形態に係る超音波溶着用部材を説明する。
図２（ａ）中、５は、扁平な略直方体形状の輪郭を有し、熱可塑性樹脂から形成された超音波溶着用部材である。６は、超音波溶着用部材５の一表面上にて、断面が略半円状になるように複数列にわたって略平行に穿たれた凹部である。７は、当該表面における超音波溶着用部材の各凹部間の表面である。８は、超音波溶着用部材５の略平面状である他方の表面である。凹部６の各々は、略等間隔に、かつ部材厚みの略半分以上の深さを有するように、当該表面の一方の端から他方の端に至るまで形成されている。
ここで、凹部間表面７の合計面積は、当該表面輪郭上の凹部６による差渡し面積（ある凹部間表面７及び隣接する凹部間表面７の間の差渡し面積）の合計よりも小さくなることが好ましい。そうすることによって、超音波溶着用部材５の当該表面が溶着対象部材と接したときに、非接合箇所の合計面積を接合箇所の合計面積よりも大きくすることが容易になり、その結果、溶着強度を確保しつつも省資源的・省コストな溶着が可能になる。
An ultrasonic welding member according to an embodiment of the present invention will be described with reference to FIG.
In FIG. 2A, reference numeral 5 denotes a member for ultrasonic welding which has a flat and substantially rectangular outline and is made of a thermoplastic resin. Reference numeral 6 denotes a concave portion which is formed substantially in parallel over a plurality of rows so that the cross section becomes substantially semicircular on one surface of the ultrasonic welding member 5. Reference numeral 7 denotes a surface between the recesses of the ultrasonic welding member on the surface. Reference numeral 8 denotes the other surface of the ultrasonic welding member 5 which is substantially planar. Each of the recesses 6 is formed from one end to the other end of the surface so as to have approximately equal intervals and a depth of approximately half or more of the member thickness.
Here, the total area of the inter-concave surface 7 is smaller than the sum of the cross-sectional area of the inter-concave surface 6 (the inter-concave surface 7 and the adjacent inter-concave surface 7). Is preferred. By doing so, when the surface of the ultrasonic welding member 5 contacts the welding object member, it becomes easy to make the total area of the non-joining places larger than the total area of the joining places, as a result, welding Resource-saving, cost-saving welding is possible while securing strength.
図２（ｂ）に示すように、熱可塑性樹脂から形成された第１部材３の溶着対象表面３ｓと熱可塑性樹脂から形成された第２部材４の溶着対象表面４ｓと間に、超音波溶着用部材５を挟持させ、この状態にて超音波溶着用ホーン（図示せず）から超音波振動を与えることによって溶着を行うことができる。一般に、溶着対象である両部材は互いに略平行あるいは嵌合する形状を有することから、本図では、溶着対象表面３ｓと溶着対象表面４ｓとが互いに略平行である場合を示す。このように溶着対象表面３ｓと溶着対象表面４ｓと間に超音波溶着用部材５を挟持させた状態では、凹部６は溶着対象表面３ｓに接することなく非接合箇所６’を構成する。また、凹部間表面７は溶着対象表面３ｓに接して接合箇所７を構成する（溶着対象表面３ｓと溶着対象表面４ｓとが平行でありかつ超音波溶着用部材５が直方体の輪郭を有する限りにおいて、凹部間表面７は接合箇所７に近似される）。それに対して、超音波溶着用部材５の他方の表面８は、全体的に溶着対象表面４ｓに接して接合箇所（接合面）８を構成する。 As shown in FIG. 2B, ultrasonic welding is performed between the welding target surface 3s of the first member 3 formed of a thermoplastic resin and the welding target surface 4s of the second member 4 formed of a thermoplastic resin. Welding can be performed by sandwiching the forging member 5 and applying ultrasonic vibration from an ultrasonic welding horn (not shown) in this state. In general, since both members to be welded have substantially parallel or fitted shapes with each other, the case where the welding target surface 3s and the welding target surface 4s are substantially parallel to each other is shown in this figure. As described above, in a state in which the ultrasonic welding member 5 is held between the welding target surface 3s and the welding target surface 4s, the recess 6 forms a non-joining portion 6 'without being in contact with the welding target surface 3s. Further, the inter-recessed surface 7 is in contact with the welding target surface 3s to form a joint portion 7 (as long as the welding target surface 3s and the welding target surface 4s are parallel and the ultrasonic welding member 5 has a rectangular parallelepiped contour. The inter-recess surface 7 is approximated to the bonding point 7). On the other hand, the other surface 8 of the ultrasonic welding member 5 is entirely in contact with the surface 4s to be welded to form a bonding point (bonding surface) 8.
超音波溶着用部材５の素材である熱可塑性樹脂は、第１部材３の熱可塑性樹脂および／または第２部材４の熱可塑性樹脂と同一であることが好ましい。あるいは、超音波溶着用部材５の素材である熱可塑性樹脂は、第１部材３の熱可塑性樹脂および／または第２部材４の熱可塑性樹脂よりも低い融点を有するものであることが好ましい。このような熱可塑性樹脂の具体例としては、特に限定されるわけではないが、ＰＰ、ＰＡ６、ＰＡ６６、ＰＣ、ＰＳ、ＰＶＣ、ポリエステル、ＡＢＳ、ＰＰＳ、ＰＥＥＫ、ＰＥＫＫ等を挙げることができる。超音波溶着用部材５は、溶着対象表面の起伏変化への対応の観点から、全体として所定の柔軟性を有することが好ましい。 The thermoplastic resin that is the material of the ultrasonic welding member 5 is preferably the same as the thermoplastic resin of the first member 3 and / or the thermoplastic resin of the second member 4. Alternatively, it is preferable that the thermoplastic resin that is the material of the ultrasonic welding member 5 have a melting point lower than that of the thermoplastic resin of the first member 3 and / or the thermoplastic resin of the second member 4. Specific examples of such thermoplastic resins include, but are not limited to, PP, PA6, PA66, PC, PS, PVC, polyester, ABS, PPS, PEEK, PEKK, and the like. It is preferable that the member 5 for ultrasonic welding has predetermined | prescribed softness | flexibility as a whole from a viewpoint of the response to the ups and downs change of the welding object surface.
ここでは、超音波溶着用部材５と溶着対象表面３ｓとの接合箇所７の各々が、非接合箇所６’の各々に隔てられる形で、非連続に形成されることになる（以下では「非連続形成要件」という）。
超音波溶着用部材５と溶着対象表面３ｓとの非接合箇所６’の全ては、凹部６の各々が超音波溶着用部材５の表面の一方の端から他方の端に至るまで形成されていることに起因して、超音波溶着用部材５の外部に対して開放されている（以下では「外部開放要件」という）。
超音波溶着用部材５と溶着対象表面３ｓとの非接合箇所６’の合計面積Ａに対する、超音波溶着用部材５と溶着対象表面３ｓとの接合箇所７の合計面積Ｂの比率は、１未満、好ましくは０．８未満、さらに好ましくは０．５未満になるように形成されている（以下では「接合箇所低減要件」という）。なお、近似的に、合計面積Ｂは、凹部間表面７の面積の合計として計算され、合計面積Ａは、超音波溶着用部材５において凹部６を穿つ以前の当該面の面積から合計面積Ｂを減じた値として計算される。
Here, each of the joining points 7 between the ultrasonic welding member 5 and the welding target surface 3s is discontinuously formed in such a manner as to be separated from each of the non-joining points 6 '(in the following "Continuous formation requirements").
All of the non-joining points 6 'between the ultrasonic welding member 5 and the welding target surface 3s are formed from one end of the surface of the ultrasonic welding member 5 to the other end of each of the concave portions 6 It is open | released with respect to the exterior of the member 5 for ultrasonic welding (It is called "external open | release requirements" hereafter).
The ratio of the total area B of the joint 7 between the ultrasonic welding member 5 and the welding target surface 3s to the total area A of the non-joint 6 'between the ultrasonic welding member 5 and the welding target surface 3s is less than 1 Preferably, it is formed to be less than 0.8, and more preferably less than 0.5 (hereinafter referred to as “joint reduction requirement”). Incidentally, approximately, the total area B is calculated as the sum of the areas of the inter-recess surface 7, and the total area A is the total area B from the area of the surface before the recess 6 is formed in the ultrasonic welding member 5. Calculated as the reduced value.
換言すれば、この構造は、非連続形成要件、外部開放要件および接合箇所低減要件を満たす限りにおいて、超音波溶着用部材の体積を小さくすることができるため、設計上の大きなフレキシビリティを有し、製造効率が高く、製造時間・コストを抑制することが可能である。さらに、この超音波溶着用部材は、超音波溶着用部材と溶着対象表面との接合箇所（溶着の起点）が非連続的に存在するようにし、非接合箇所が空気通路を確保するように外部に開放されている。そのうえ、この超音波溶着用部材は、接合箇所と非接合箇所の面積比を、１未満、好ましくは０．８未満、さらに好ましくは０．５未満になるように調整することによって、溶着部にボイドが残りにくく（溶着層内部に空気溜まりが形成され難く）、接合部の高い気密性が得られるため、十分な溶着強度を確保することが可能となる。 In other words, this structure has a large design flexibility because it can reduce the volume of the ultrasonic welding member as long as it satisfies the discontinuous formation requirement, the external opening requirement, and the joint reduction requirement. The manufacturing efficiency is high, and the manufacturing time and cost can be suppressed. Furthermore, in the ultrasonic welding member, the junction (the welding start point) between the ultrasonic welding member and the surface to be welded is discontinuously present, and the non-junction is outside the air passage. It is open to you. Moreover, the member for ultrasonic welding has a welded area by adjusting the area ratio of the bonded area to the non-bonded area to be less than 1, preferably less than 0.8, and more preferably less than 0.5. Since voids do not easily remain (air buildup is not easily formed inside the welding layer) and high airtightness of the joint is obtained, it is possible to secure sufficient welding strength.
なお、超音波溶着用部材５は、平坦な略直方体形状の輪郭である必要はなく、溶着対象部材の形状に合わせて任意の形状に変更することができる。凹部６の断面形状は、略半円状とする替わりに、略矩形にしてもよいし、略三角形にしてもよい。また、凹部６の各々の間隔、その深さは、上記３要件を満たす限りにおいて、特に限定されない。材料コストの低減、省資源の観点から、所望の溶着強度が確保される限りにおいて、凹部６の各々の間隔は小さいほうがより好ましく、その深さは大きいほうがより好ましい。例えば、凹部６の各々の平均的な深さは、超音波溶着用部材５の厚みに対して３分の２以上であることがより好ましい。
また，代替的な実施形態として、超音波溶着用部材５の一表面上に、凹部６に加えて、これと略垂直に交差させる形で、断面が略半円状になるように複数列にわたって略平行に穿たれた凹部を更に設けてもよい。この場合の新たに設けられた交差列の凹部およびその凹部間表面の形状・配列に関する設計範囲は、上述と同様に設定することができる。
また、更なる代替的な実施形態として、超音波溶着用部材５の他方の表面８にも、凹部および凹部間表面を同様に形成してもよい。
これらの構造によって、材料コストの低減、製造の効率化を更に進めることができる。
The ultrasonic welding member 5 does not have to have a flat substantially rectangular parallelepiped outline, and can be changed into any shape according to the shape of the welding target member. The cross-sectional shape of the concave portion 6 may be substantially rectangular or substantially triangular instead of substantially semicircular. Further, the distance between the recesses 6 and the depth thereof are not particularly limited as long as the above three requirements are satisfied. From the viewpoint of material cost reduction and resource saving, as long as the desired welding strength is ensured, the distance between the recesses 6 is preferably smaller and the depth more preferably. For example, the average depth of each of the recesses 6 is more preferably two thirds or more of the thickness of the ultrasonic welding member 5.
Further, as an alternative embodiment, in addition to the recess 6 on one surface of the ultrasonic welding member 5, the cross-section is formed in a substantially semi-circular shape so as to intersect substantially perpendicularly with it. A substantially parallel recess may be further provided. In this case, the design range regarding the shape and arrangement of the newly provided cross rows of recesses and the surface between the recesses can be set in the same manner as described above.
Further, as a further alternative embodiment, the other surface 8 of the ultrasonic welding member 5 may be similarly formed with the recess and the inter-recess surface.
These structures can further reduce the cost of materials and improve the efficiency of manufacturing.
次に、図３を参照して、本発明の他の一実施形態に係る超音波溶着用部材を説明する。
図３（ａ）中、１２は、断面略矩形の、ある一方向に延伸された、扁平な直方体である超音波溶着用部材片であり、熱可塑性樹脂から形成されている。１３は、超音波溶着用部材片１２の一方の表面であり、１４は、超音波溶着用部材片１２の他方の表面である。超音波溶着用部材１１は、実質的に同一形状を有する複数の超音波溶着用部材片１２が、同一平面上に、略等間隔にて略平行に配置された集合体である。
ここで、超音波溶着用部材片１２の表面１３（または表面１４）の合計面積は、隣接する表面１３（または表面１４）間の差渡し面積の合計よりも小さくなることが好ましい。そうすることによって、超音波溶着用部材片１２（すなわち超音波溶着用部材１１）の表面１３（または表面１４）が溶着対象部材と接したときに、非接合箇所の合計面積を接合箇所の合計面積よりも大きくすることが容易になり、その結果、溶着強度を確保しつつも省資源的・省コストな溶着が可能になる。
Next, a member for ultrasonic welding according to another embodiment of the present invention will be described with reference to FIG.
In FIG. 3A, reference numeral 12 denotes a flat rectangular parallelepiped ultrasonic welding member piece having a substantially rectangular cross section and stretched in one direction, and is made of a thermoplastic resin. Reference numeral 13 denotes one surface of the ultrasonic welding member piece 12, and 14 denotes the other surface of the ultrasonic welding member piece 12. The ultrasonic welding member 11 is an assembly in which a plurality of ultrasonic welding member pieces 12 having substantially the same shape are disposed substantially in parallel at substantially equal intervals on the same plane.
Here, it is preferable that the total area of the surface 13 (or the surface 14) of the ultrasonic welding member piece 12 be smaller than the total of the cross-sectional area between the adjacent surfaces 13 (or the surface 14). By doing so, when the surface 13 (or the surface 14) of the ultrasonic welding member piece 12 (that is, the ultrasonic welding member 11) is in contact with the welding object member, the total area of the non-joining points is the total of the joining points It becomes easy to make it larger than the area, and as a result, resource-saving and cost-saving welding is possible while securing welding strength.
図３（ｂ）に示すように、熱可塑性樹脂から形成された第１部材９の溶着対象表面９ｓと熱可塑性樹脂から形成された第２部材１０の溶着対象表面１０ｓと間に、超音波溶着用部材１１（超音波溶着用部材片１２の集合体）を挟持させ、この状態にて超音波溶着用ホーン（図示せず）から超音波振動を与えることによって溶着を行うことができる。実際、溶着対象である両部材は互いに略平行あるいは嵌合する形状を有することから、本図では、溶着対象表面９ｓと溶着対象表面１０ｓとが互いに略平行である場合を示す。このように溶着対象表面９ｓと溶着対象表面１０ｓと間に超音波溶着用部材１１を挟持させた状態では、超音波溶着用部材片１２が存在しない箇所では非接合箇所１３’および非接合箇所１４’ を構成する。また、表面１３および表面１４は、それぞれ、溶着対象表面９ｓおよび溶着対象表面１０ｓに接して接合箇所１３および接合箇所１４になる（溶着対象表面９ｓと溶着対象表面１０ｓとが平行でありかつ超音波溶着用部材片１２の各々が等しい厚みを有する限りにおいて、表面１３および表面１４は、それぞれ、接合箇所１３および接合箇所１４に近似される）。 As shown in FIG. 3B, ultrasonic welding is performed between the welding target surface 9s of the first member 9 formed of a thermoplastic resin and the welding target surface 10s of the second member 10 formed of a thermoplastic resin. The welding can be performed by sandwiching the forging member 11 (the aggregate of the ultrasonic welding member pieces 12) and applying ultrasonic vibration from the ultrasonic welding horn (not shown) in this state. In fact, since both members to be welded have substantially parallel or fitted shapes with each other, the case where the welding target surface 9s and the welding target surface 10s are substantially parallel to each other is shown in this figure. As described above, in the state where the ultrasonic welding member 11 is held between the welding target surface 9s and the welding target surface 10s, the non-joining portion 13 'and the non-joining portion 14 are not present at the portion where the ultrasonic welding member piece 12 does not exist. Configure '. Further, the surface 13 and the surface 14 are in contact with the welding target surface 9s and the welding target surface 10s, respectively, to be the bonding portion 13 and the bonding portion 14 (the welding target surface 9s and the welding target surface 10s are parallel and ultrasonic waves As long as each of the welding member pieces 12 has the same thickness, the surface 13 and the surface 14 are respectively approximated to the joint 13 and the joint 14).
上記実施形態と同様に、超音波溶着用部材１１の素材である熱可塑性樹脂は、第１部材９の熱可塑性樹脂および／または第２部材１０の熱可塑性樹脂と同一であることが好ましい。あるいは、超音波溶着用部材１１の素材である熱可塑性樹脂は、第１部材９の熱可塑性樹脂および／または第２部材１０の熱可塑性樹脂よりも低い融点を有するものであることが好ましい。このような熱可塑性樹脂の具体例としては、特に限定されず、上述の実施形態と同様のものを用いることができる。超音波溶着用部材片１２は、溶着対象表面の起伏変化への対応の観点から、全体として所定の柔軟性を有することが好ましい。 It is preferable that the thermoplastic resin which is a raw material of the member 11 for ultrasonic welding is the same as the thermoplastic resin of the 1st member 9 and / or the thermoplastic resin of the 2nd member 10 similarly to the said embodiment. Alternatively, it is preferable that the thermoplastic resin that is the material of the ultrasonic welding member 11 has a melting point lower than that of the thermoplastic resin of the first member 9 and / or the thermoplastic resin of the second member 10. It does not specifically limit as a specific example of such a thermoplastic resin, The thing similar to the above-mentioned embodiment can be used. The ultrasonic welding member piece 12 preferably has a predetermined flexibility as a whole from the viewpoint of coping with the change in surface roughness of the welding target surface.
ここでは、超音波溶着用部材片１２と溶着対象表面９ｓとの接合箇所１３の各々が、非接合箇所１３’の各々に隔てられる形で、非連続に形成されることになる（「非連続形成要件」が満たされている）。さらに、超音波溶着用部材片１２と溶着対象表面１０ｓとの接合箇所１４の各々が、非接合箇所１４’の各々に隔てられる形で、非連続に形成されることになる（ここでも「非連続形成要件」が満たされている）。
超音波溶着用部材片１２と溶着対象表面９ｓとの非接合箇所１３’の全ては、超音波溶着用部材片１２の各々の間で一方の端から他方の端に至るまで形成されていることに起因して、超音波溶着用部材１１の外部に対して開放されている（「外部開放要件」が満たされている）。超音波溶着用部材片１２と溶着対象表面１０ｓとの非接合箇所１４’の全ては、超音波溶着用部材片１２の各々の間で一方の端から他方の端に至るまで形成されていることに起因して、超音波溶着用部材１１の外部に対して開放されている（ここでも「外部開放要件」が満たされている）。
超音波溶着用部材片１２と溶着対象表面９ｓとの非接合箇所１３’の合計面積Ａに対する、超音波溶着用部材片１２と溶着対象表面９ｓとの接合箇所１３の合計面積Ｂの比率は、１未満、好ましくは０．８未満、さらに好ましくは０．５未満になるように形成されている（「接合箇所低減要件」が満たされている）。
また、超音波溶着用部材片１２と溶着対象表面１０ｓとの非接合箇所１４’の合計面積Ａ’に対する、超音波溶着用部材片１２と溶着対象表面１０ｓとの接合箇所１４の合計面積Ｂ’の比率は、１未満、好ましくは０．８未満、さらに好ましくは０．５未満になるように形成されている（「接合箇所低減要件」が満たされている）。
なお、近似的に、合計面積Ｂ（またはＢ’）は、表面１３（または表面１４）の面積の合計として計算され、合計面積Ａ（またはＡ’）は、超音波溶着用部材片１２の全体について直線的に形成される最外輪郭（集合体としての超音波溶着用部材１１の輪郭）の表面１３相当面の面積または表面１４相当面の面積から合計面積Ｂ（またはＢ’）を減じた値として計算される。
Here, each of the bonding points 13 between the ultrasonic welding member piece 12 and the welding target surface 9s is discontinuously formed so as to be separated from each of the non-bonding points 13 '("discontinuous" Requirements for formation are satisfied). Furthermore, each of the bonding points 14 between the ultrasonic welding member piece 12 and the welding target surface 10s is discontinuously formed in such a manner as to be separated from each of the non-bonding points 14 '"Continuous formation requirements" are satisfied).
All non-joining points 13 'between the ultrasonic welding member piece 12 and the welding target surface 9s are formed between one end and the other end between the ultrasonic welding member pieces 12 , Open to the outside of the ultrasonic welding member 11 (the "outside opening requirement" is satisfied). All of the non-joining points 14 'between the ultrasonic welding member piece 12 and the welding target surface 10s are formed from one end to the other end between each of the ultrasonic welding member pieces 12 Because of this, it is open to the outside of the ultrasonic welding member 11 (again, the "outside open requirement" is satisfied).
The ratio of the total area B of the joining portion 13 between the ultrasonic welding member piece 12 and the welding target surface 9s to the total area A of the non welding portion 13 'between the ultrasonic welding member piece 12 and the welding target surface 9s is It is formed to be less than 1, preferably less than 0.8, and more preferably less than 0.5 ("joint reduction requirement" is satisfied).
In addition, the total area B 'of the joining portion 14 between the ultrasonic welding member piece 12 and the welding target surface 10s relative to the total area A' of the non-joining portion 14 'between the ultrasonic welding member piece 12 and the welding target surface 10s. Is set to be less than 1, preferably less than 0.8, and more preferably less than 0.5 ("joint reduction requirements" are satisfied).
Approximately, the total area B (or B ') is calculated as the sum of the areas of the surface 13 (or the surface 14), and the total area A (or A') is the entire ultrasonic welding member piece 12 The total area B (or B ') is reduced from the area of the surface 13 equivalent surface or the area of the surface 14 equivalent surface of the outermost contour (contour of the ultrasonic welding member 11 as an assembly) formed linearly for Calculated as a value.
上述の実施形態と同様に、この構造は、非連続形成要件、外部開放要件および接合箇所低減要件を満たす限りにおいて、超音波溶着用部材の体積を小さくすることができるため、設計上の大きなフレキシビリティを有し、製造効率が高く、製造時間・コストを抑制することが可能である。さらに、この超音波溶着用部材は、超音波溶着用部材と溶着対象表面との接合箇所（溶着の起点）が非連続的に存在するようにし、非接合箇所が空気通路を確保するように外部に開放されている。そのうえ、この超音波溶着用部材は、接合箇所と非接合箇所の面積比を、１未満、好ましくは０．８未満、さらに好ましくは０．５未満になるように調整することによって、溶着部にボイドが残りにくく（溶着部材内部に空気溜まりが形成され難く）、接合部の高い気密性が得られるため、十分な溶着強度を確保することが可能となる。 Similar to the above-described embodiment, this structure can reduce the volume of the ultrasonic welding member as long as it satisfies the discontinuous formation requirement, the external opening requirement, and the joint reduction requirement, so that a large design flexibility can be achieved. It is possible to have high efficiency, high production efficiency, and low production time and cost. Furthermore, in the ultrasonic welding member, the junction (the welding start point) between the ultrasonic welding member and the surface to be welded is discontinuously present, and the non-junction is outside the air passage. It is open to you. Moreover, the member for ultrasonic welding has a welded area by adjusting the area ratio of the bonded area to the non-bonded area to be less than 1, preferably less than 0.8, and more preferably less than 0.5. Since a void does not easily remain (an air accumulation is not easily formed inside the welding member) and high airtightness of the joint is obtained, it is possible to secure sufficient welding strength.
なお、超音波溶着用部材片１２は、断面略矩形の扁平な直方体である必要はなく、溶着対象部材の形状に合わせて任意の形状に変更することができる。また、超音波溶着用部材片１２の各配列および間隔は、上記３要件を満たす限りにおいて、特に限定されない。
また，代替的な実施形態として、溶着対象の一部において、上記のように略平行に超音波溶着用部材片１２を配置し、溶着対象の他の一部においては、これと異なる方向にて略平行に超音波溶着用部材片１２を配置してもよい。また、図２に係る実施形態と図３に係る実施形態を組み合わせてもよい。これによって、溶着対象部材の複雑な立体形状に合わせる形で、よりフレキシブルな溶着設計が可能になり、加えて、材料コストの低減、製造の効率化を更に進めることができる。
The ultrasonic welding member piece 12 does not have to be a flat rectangular parallelepiped having a substantially rectangular cross section, and can be changed to any shape in accordance with the shape of the welding target member. Moreover, each arrangement | positioning and the space | interval of the ultrasonic welding member piece 12 are not specifically limited as long as the said 3 requirements are satisfy | filled.
As an alternative embodiment, the ultrasonic welding member piece 12 is disposed substantially parallel as described above in a part of the welding object, and in another direction in another part of the welding object. The ultrasonic welding member pieces 12 may be disposed substantially in parallel. Also, the embodiment according to FIG. 2 and the embodiment according to FIG. 3 may be combined. As a result, a more flexible welding design can be made in accordance with the complex three-dimensional shape of the welding target member, and in addition, the material cost can be reduced and the manufacturing efficiency can be further advanced.
次に、図４を参照して、本発明の更なる他の一実施形態に係る超音波溶着用部材を説明する。
図４中、１６は、断面略矩形の扁平な直方体である超音波溶着用部材片であり、熱可塑性樹脂から形成されている。１７は、超音波溶着用部材片１６の一方の表面であり、１８は、超音波溶着用部材片１６の他方の表面である。超音波溶着用部材１５は、実質的に同一形状を有する複数の超音波溶着用部材片１６が、略等間隔にて、交差する複数列を構成するように、同一平面上に配置された集合体である。ここで、超音波溶着用部材片１６の表面１７（または表面１８）の合計面積Ａは、表面１７（または表面１８）全体の外側輪郭によって形成される面積Ｂから合計面積Ａを引いた面積よりも小さくなることが好ましい。そうすることによって、超音波溶着用部材片１６（すなわち超音波溶着用部材１５）の表面１７（または表面１８）が溶着対象部材と接したときに、非接合箇所の合計面積を接合箇所の合計面積よりも大きくすることが容易になり、その結果、溶着強度を確保しつつも省資源的・省コストな溶着が可能になる。
Next, a member for ultrasonic welding according to still another embodiment of the present invention will be described with reference to FIG.
In FIG. 4, reference numeral 16 denotes a member for ultrasonic welding, which is a flat rectangular parallelepiped having a substantially rectangular cross section, and is formed of a thermoplastic resin. Reference numeral 17 denotes one surface of the ultrasonic welding member piece 16, and reference numeral 18 denotes the other surface of the ultrasonic welding member piece 16. The ultrasonic welding member 15 is a group in which a plurality of ultrasonic welding member pieces 16 having substantially the same shape are arranged on the same plane so as to form a plurality of intersecting lines at substantially equal intervals. It is a body. Here, the total area A of the surface 17 (or surface 18) of the ultrasonic welding member piece 16 is the area obtained by subtracting the total area A from the area B formed by the outer contour of the entire surface 17 (or surface 18). It is preferable that the By doing so, when the surface 17 (or the surface 18) of the ultrasonic welding member piece 16 (that is, the ultrasonic welding member 15) is in contact with the welding object member, the total area of the non-joining points is the sum of the joining points It becomes easy to make it larger than the area, and as a result, resource-saving and cost-saving welding is possible while securing welding strength.
図示していないが、熱可塑性樹脂から形成された第１部材の溶着対象表面と熱可塑性樹脂から形成された第２部材の溶着対象表面と間に、超音波溶着用部材１５（超音波溶着用部材片１６の集合体）を挟持させ、この状態にて超音波溶着用ホーンから超音波振動を与えることによって溶着を行うことができる。このように２つの溶着対象表面と間に超音波溶着用部材１５を挟持させた状態では、超音波溶着用部材片１６が存在しない箇所では非接合箇所を構成する。また、表面１７および表面１８は、それぞれ溶着対象表面に接して接合箇所になる。（２つの溶着対象表面が平行でありかつ超音波溶着用部材片１６の各々が等しい厚みを有する限りにおいて、表面１７および表面１８は、それぞれ、接合箇所に近似される）。 Although not shown, a member for ultrasonic welding 15 (for ultrasonic welding) is formed between a welding target surface of a first member formed of a thermoplastic resin and a welding target surface of a second member formed of a thermoplastic resin. Welding can be performed by holding the assembly of the member pieces 16 and applying ultrasonic vibration from the ultrasonic welding horn in this state. As described above, in a state in which the ultrasonic welding member 15 is held between the two welding target surfaces, a non-joining place is configured at a place where the ultrasonic welding member piece 16 does not exist. In addition, the surface 17 and the surface 18 are in contact with the surface to be welded and become bonding points. (The surface 17 and the surface 18 are respectively approximated to the joint as long as the two surfaces to be welded are parallel and each of the ultrasonic welding member pieces 16 has the same thickness).
上記実施形態と同様に、超音波溶着用部材１５の素材である熱可塑性樹脂は、溶着対象である第１部材の熱可塑性樹脂および／または第２部材の熱可塑性樹脂と同一であることが好ましい。あるいは、超音波溶着用部材１５の素材である熱可塑性樹脂は、第１部材の熱可塑性樹脂および／または第２部材の熱可塑性樹脂よりも低い融点を有するものであることが好ましい。このような熱可塑性樹脂の具体例としては、特に限定されず、これまで述べた実施形態と同様のものを用いることができる。 Similar to the above embodiment, the thermoplastic resin which is the material of the ultrasonic welding member 15 is preferably identical to the thermoplastic resin of the first member to be welded and / or the thermoplastic resin of the second member. . Alternatively, it is preferable that the thermoplastic resin which is a material of the ultrasonic welding member 15 has a melting point lower than that of the thermoplastic resin of the first member and / or the thermoplastic resin of the second member. It does not specifically limit as a specific example of such a thermoplastic resin, The thing similar to embodiment described so far can be used.
ここでは、溶着対象である第１部材および第２部材の各々について、超音波溶着用部材片１６と溶着対象表面との接合箇所の各々が、非接合箇所の各々に隔てられる形で、非連続に形成されることになる（「非連続形成要件」が満たされている）。
溶着対象である第１部材および第２部材の各々について、超音波溶着用部材片１６と溶着対象表面との非接合箇所の全ては、超音波溶着用部材１５の外部に対して開放されている（「外部開放要件」が満たされている）。
溶着対象である第１部材および第２部材の各々について、超音波溶着用部材片１６と溶着対象表面との非接合箇所の合計面積Ａに対する、超音波溶着用部材片１６と溶着対象表面との接合箇所の合計面積Ｂの比率は、１未満、好ましくは０．８未満、より好ましくは０．５未満、さらに好ましくは０．４未満、最も好ましくは０．３未満になるように形成されている（「接合箇所低減要件」が満たされている）。なお、近似的に、合計面積Ｂは、表面１７（または表面１８）の面積の合計として計算され、合計面積Ａは、超音波溶着用部材片１６の全体について直線的に形成される最外輪郭（集合体としての超音波溶着用部材１５の輪郭）の表面１７相当面の面積または表面１８相当面の面積から合計面積Ｂを減じた値として計算される。
Here, for each of the first member and the second member to be welded, each of the joining points between the ultrasonic welding member piece 16 and the surface to be welded is separated from each other at each non-joining point. (The “non-continuous formation requirement” is satisfied).
For each of the first member and the second member to be welded, all non-joining points between the ultrasonic welding member piece 16 and the welding target surface are open to the outside of the ultrasonic welding member 15 ("External access requirement" is satisfied).
With respect to each of the first member and the second member to be welded, the ultrasonic welding member piece 16 and the welding target surface with respect to the total area A of the non-joining portion between the ultrasonic welding member piece 16 and the welding target surface The ratio of the total area B of the bonding points is formed to be less than 1, preferably less than 0.8, more preferably less than 0.5, still more preferably less than 0.4, most preferably less than 0.3 (The “joint reduction requirements” are satisfied). Note that approximately, the total area B is calculated as the sum of the areas of the surface 17 (or the surface 18), and the total area A is the outermost contour formed linearly for the entire ultrasonic welding member piece 16 It is calculated as a value obtained by subtracting the total area B from the area of the surface 17 equivalent surface or the area of the surface 18 equivalent surface (the outline of the ultrasonic welding member 15 as an assembly).
これまで述べた実施形態と同様に、この構造は、非連続形成要件、外部開放要件および接合箇所低減要件を満たす限りにおいて、超音波溶着用部材の体積を小さくすることができるため、設計上の大きなフレキシビリティを有し、製造効率が高く、製造時間・コストを抑制することが可能である。さらに、この超音波溶着用部材は、超音波溶着用部材と溶着対象表面との接合箇所（溶着の起点）が非連続的に存在するようにし、非接合箇所が空気通路を確保するように外部に開放されている。そのうえ、この超音波溶着用部材は、接合箇所と非接合箇所の面積比を、１未満、好ましくは０．８未満、より好ましくは０．５未満、さらに好ましくは０．４未満、最も好ましくは０．３未満になるように調整することによって、溶着部にボイドが残りにくく（溶着部材内部に空気溜まりが形成され難く）、接合部の高い気密性が得られるため、十分な溶着強度を確保することが可能となる。 As in the embodiments described above, this structure can reduce the volume of the ultrasonic welding member as long as it satisfies the discontinuous formation requirement, the external opening requirement, and the joint reduction requirement. It has great flexibility, high manufacturing efficiency, and can reduce manufacturing time and cost. Furthermore, in the ultrasonic welding member, the junction (the welding start point) between the ultrasonic welding member and the surface to be welded is discontinuously present, and the non-junction is outside the air passage. It is open to you. Moreover, this ultrasonic welding member has an area ratio of the bonding site to the non-bonding site of less than 1, preferably less than 0.8, more preferably less than 0.5, still more preferably less than 0.4, and most preferably By adjusting so as to be less than 0.3, voids are less likely to remain in the welded portion (air buildup is less likely to be formed in the inside of the welded member), and high airtightness of the bonded portion is obtained. It is possible to
なお、超音波溶着用部材片１６は、断面略矩形の扁平な直方体である必要はなく、溶着対象部材の形状に合わせて任意の形状に変更することができる。例えば、超音波溶着用部材片１６は、扁平な略円柱状でもあってよい。また、超音波溶着用部材片１６の各配列および間隔は、上記３要件を満たす限りにおいて、特に限定されない。例えば、超音波溶着用部材片１６は、不規則に配列されていてもよい。
また，代替的な実施形態として、図４に係る実施形態を、図２に係る実施形態および／または図３に係る実施形態と組み合わせてもよい。これによって、溶着対象部材の複雑な立体形状に合わせる形で、よりフレキシブルな溶着設計が可能になり、加えて、材料コストの低減、製造の効率化を更に進めることができる。
The ultrasonic welding member piece 16 does not have to be a flat rectangular parallelepiped having a substantially rectangular cross section, and can be changed into any shape according to the shape of the welding target member. For example, the ultrasonic welding member piece 16 may be flat and substantially cylindrical. Moreover, each arrangement | positioning and the space | interval of the ultrasonic welding member piece 16 are not specifically limited as long as the said 3 requirements are satisfy | filled. For example, the ultrasonic welding member pieces 16 may be arranged irregularly.
Also, as an alternative embodiment, the embodiment according to FIG. 4 may be combined with the embodiment according to FIG. 2 and / or the embodiment according to FIG. As a result, a more flexible welding design can be made in accordance with the complex three-dimensional shape of the welding target member, and in addition, the material cost can be reduced and the manufacturing efficiency can be further advanced.
次に、図５および図６を参照して、本発明の一実施形態に係るメッシュ様式の超音波溶着用部材を説明する（織物を例示する）。
図５は、超音波溶着用メッシュの平面図および一部拡大断面である。図中、１９は超音波溶着用メッシュを示し、２０は超音波溶着用メッシュ１９の織物を構成する略直角に交差するように織られた糸（断面略円形の縦糸および横糸）であり、２１は糸の外径であり、２２は織物を構成する隣接糸条の間隔：メッシュのいわゆる「開き」である。糸２０の外径２１は、特に限定されないが、例えば０．１〜１ｍｍ程度であってよく、より好ましくは０．１５〜０．６ｍｍの範囲である。メッシュの開き２２は、特に限定されないが、例えば０．１〜２ｍｍ程度であってよく、より好ましくは０．２〜１.２ｍｍの範囲である。
Next, with reference to FIGS. 5 and 6, a mesh-type ultrasonic welding member according to an embodiment of the present invention will be described (exemplary woven fabric).
FIG. 5 is a plan view and a partially enlarged cross section of the ultrasonic welding mesh. In the figure, reference numeral 19 denotes a mesh for ultrasonic welding, and 20 is a yarn (longitudinal and transverse yarns having a substantially circular cross section) which are woven so as to intersect substantially orthogonally and which constitute a woven fabric of the ultrasonic welding mesh 19. Is the outer diameter of the yarn, and 22 is the spacing between adjacent yarns that make up the fabric: the so-called "opening" of the mesh. The outer diameter 21 of the yarn 20 is not particularly limited, but may be, for example, about 0.1 to 1 mm, and more preferably in the range of 0.15 to 0.6 mm. The mesh opening 22 is not particularly limited, but may be, for example, about 0.1 to 2 mm, and more preferably 0.2 to 1.2 mm.
図５の一部拡大断面から把握されるように、超音波溶着用メッシュ１９の織物は、実質的に一平面上で、縦糸および横糸が略直角に交差するように織られていることによって、縦糸および横糸の各々が、それぞれ隣接する交差点の間で波打つような状態になる。この縦糸および横糸からなる織物構造を総合的に観察すれば、各交差点にて凸部を形成し、各交差点の合間では凹部を形成することになる。このような立体的な構造を有することによって、超音波溶着用メッシュ１９の一方の面あるいはその裏面が溶着対象部材と接したときに、非接合箇所の合計面積を接合箇所の合計面積よりもかなり大きくすることが容易になり、その結果、溶着強度を確保しつつも省資源的・省コストな溶着が可能になる。 As can be understood from the partially enlarged cross section of FIG. 5, the woven fabric of the ultrasonic welding mesh 19 is woven such that the warp yarns and weft yarns intersect at substantially right angles substantially on one plane, Each of the warp yarns and weft yarns is in an undulating state between adjacent intersections. By comprehensively observing the woven fabric structure consisting of the warp and the weft, a convex portion is formed at each intersection, and a concave portion is formed between each intersection. By having such a three-dimensional structure, when one surface or the back surface of the ultrasonic welding mesh 19 is in contact with the member to be welded, the total area of the non-joining points is considerably larger than the total area of the joining points It becomes easy to enlarge, and as a result, resource-saving and cost-saving welding can be performed while securing welding strength.
図６に示すように、熱可塑性樹脂から形成された第１部材２３の溶着対象表面２３ｓと熱可塑性樹脂から形成された第２部材２４の溶着対象表面２４ｓと間に、超音波溶着用メッシュ１９を挟持させ、この状態にて超音波溶着用ホーン（図示せず）から超音波振動を与えることによって溶着を行うことができる。実際、溶着対象である両部材は互いに略平行あるいは嵌合する形状を有することから、本図では、溶着対象表面２３ｓと溶着対象表面２４ｓとが互いに略平行である場合を示す。このように溶着対象表面２３ｓと溶着対象表面２４ｓと間に超音波溶着用メッシュ１９を挟持させた状態では、超音波溶着用メッシュ１９の糸２０が存在しない箇所では非接合箇所２５’および非接合箇所２６’ を構成する。また、超音波溶着用メッシュ１９の糸２０は、溶着対象表面２３ｓおよび溶着対象表面２４ｓに接して接合箇所２５および接合箇所２６になる。 As shown in FIG. 6, the ultrasonic welding mesh 19 is formed between the welding target surface 23s of the first member 23 formed of a thermoplastic resin and the welding target surface 24s of the second member 24 formed of a thermoplastic resin. Welding can be performed by applying ultrasonic vibration from an ultrasonic welding horn (not shown) in this state. In fact, since both members to be welded have substantially parallel or fitted shapes with each other, the case where the welding target surface 23s and the welding target surface 24s are substantially parallel to each other is shown in this figure. As described above, in a state in which the ultrasonic welding mesh 19 is held between the welding target surface 23s and the welding target surface 24s, the non-joining portion 25 'and the non-joining are not performed in the portion where the thread 20 of the ultrasonic welding mesh 19 does not exist. Configure point 26 '. In addition, the thread 20 of the ultrasonic welding mesh 19 is in contact with the surface 23 s to be welded and the surface 24 s to be welded, to be a joint 25 and a joint 26.
上記実施形態と同様に、超音波溶着用メッシュ１９の素材である熱可塑性樹脂は、溶着対象である第１部材２３の熱可塑性樹脂および／または第２部材２４の熱可塑性樹脂と同一であることが好ましい。あるいは、超音波溶着用メッシュ１９の素材である熱可塑性樹脂は、第１部材２３の熱可塑性樹脂および／または第２部材２４の熱可塑性樹脂よりも低い融点を有するものであることが好ましい。このような熱可塑性樹脂の具体例としては、特に限定されず、これまで述べた実施形態と同様のものを用いることができる。超音波溶着用メッシュ１９は、溶着対象表面の起伏変化への対応の観点から、全体として所定の柔軟性を有することが好ましい。 As in the above embodiment, the thermoplastic resin that is the material of the ultrasonic welding mesh 19 is the same as the thermoplastic resin of the first member 23 to be welded and / or the thermoplastic resin of the second member 24. Is preferred. Alternatively, it is preferable that the thermoplastic resin that is the material of the ultrasonic welding mesh 19 has a melting point lower than that of the thermoplastic resin of the first member 23 and / or the thermoplastic resin of the second member 24. It does not specifically limit as a specific example of such a thermoplastic resin, The thing similar to embodiment described so far can be used. It is preferable that the ultrasonic welding mesh 19 have a predetermined flexibility as a whole from the viewpoint of coping with the change in roughness of the surface to be welded.
ここでは、超音波溶着用メッシュ１９の糸２０と溶着対象表面２３ｓとの接合箇所２５の各々が、非接合箇所２５’の各々に隔てられる形で、非連続に形成されることになる（「非連続形成要件」が満たされている）。さらに、超音波溶着用メッシュ１９の糸２０と溶着対象表面２４ｓとの接合箇所２６の各々が、非接合箇所２６’の各々に隔てられる形で、非連続に形成されることになる（ここでも「非連続形成要件」が満たされている）。
超音波溶着用メッシュ１９の糸２０と溶着対象表面２３ｓとの非接合箇所２５’の全ては、超音波溶着用メッシュ１９が立体的なメッシュ構造であることに起因し、超音波溶着用メッシュ１９の外部に対して開放されている（「外部開放要件」が満たされている）。超音波溶着用メッシュ１９の糸２０と溶着対象表面２４ｓとの非接合箇所２６’の全ては、超音波溶着用メッシュ１９が立体的なメッシュ構造であることに起因し、超音波溶着用メッシュ１９の外部に対して開放されている（ここでも「外部開放要件」が満たされている）。
超音波溶着用メッシュ１９の糸２０と溶着対象表面２３ｓとの非接合箇所２５’の合計面積に対する、超音波溶着用メッシュ１９の糸２０と溶着対象表面２３ｓとの接合箇所２５の合計面積の比率は、糸２０が略円形断面を有することから、計算・測定を要することなく一見して１を大きく下回る値となる（理論上は糸２０が織られた各交点でのみ溶着対象表面と接するため「接合箇所低減要件」が満たされている）。
Here, each of the bonding points 25 between the thread 20 of the ultrasonic welding mesh 19 and the welding target surface 23s is discontinuously formed so as to be separated from each of the non-bonding points 25 '(" Discontinuous formation requirements are met). Furthermore, each of the bonding points 26 between the thread 20 of the ultrasonic welding mesh 19 and the welding target surface 24s is discontinuously formed so as to be separated from each of the non-bonding points 26 '(also here “Non-continuous formation requirements” are satisfied).
The ultrasonic welding mesh 19 has a three-dimensional mesh structure because all of the non-joining points 25 ′ between the thread 20 of the ultrasonic welding mesh 19 and the welding target surface 23 s are the ultrasonic welding mesh 19. Open to the outside (the "outside open requirement" is satisfied). The ultrasonic welding mesh 19 has a three-dimensional mesh structure because all of the non-joining points 26 'between the thread 20 of the ultrasonic welding mesh 19 and the welding target surface 24s are ultrasonic welding mesh 19 Open to the outside (again the "open access requirements" are satisfied).
Ratio of the total area of the bonding points 25 between the thread 20 for ultrasonic welding mesh 19 and the welding target surface 23s to the total area of the non-bonding parts 25 'between the yarn 20 for ultrasonic welding mesh 19 and the welding target surface 23s Since the yarn 20 has a substantially circular cross-section, the value at first glance is considerably lower than 1 without requiring calculation and measurement (theoretically, the yarn 20 is in contact with the surface to be welded only at each intersection point where the yarn 20 is woven) “Joint reduction requirements” are satisfied).
上述の実施形態と同様に、この構造は、非連続形成要件、外部開放要件および接合箇所低減要件を満たす限りにおいて、超音波溶着用部材の体積を小さくすることができるため、設計上の大きなフレキシビリティを有し、製造効率が高く、製造時間・コストを抑制することが可能である。さらに、この超音波溶着用部材は、超音波溶着用部材と溶着対象表面との接合箇所（溶着の起点）が非連続的に存在するようにし、非接合箇所が空気通路を確保するように外部に開放されている。そのうえ、この超音波溶着用部材は、接合箇所と非接合箇所の面積比が１を大きく下回ることによって、溶着部にボイドが残りにくく（溶着部材内部に空気溜まりが形成され難く）、接合部の高い気密性が得られるため、十分な溶着強度を確保することが可能となる。 Similar to the above-described embodiment, this structure can reduce the volume of the ultrasonic welding member as long as it satisfies the discontinuous formation requirement, the external opening requirement, and the joint reduction requirement, so that a large design flexibility can be achieved. It is possible to have high efficiency, high production efficiency, and low production time and cost. Furthermore, in the ultrasonic welding member, the junction (the welding start point) between the ultrasonic welding member and the surface to be welded is discontinuously present, and the non-junction is outside the air passage. It is open to you. In addition, in the ultrasonic welding member, when the area ratio of the bonding portion to the non-bonding portion is much less than 1, voids are hardly left in the welded portion (air stagnation is hardly formed in the welded member), and Since high airtightness is obtained, it is possible to secure sufficient welding strength.
なお、超音波溶着用メッシュ１９の糸２０の織り方は、上記３要件を満たす限りにおいて、図示した平織に限定されず、例えば、綾織（斜文織）や繻子織であってもよい。織物に替えて、編物を用いてもよい。また、超音波溶着用メッシュ１９の縦糸２０の糸条間の間隔と横糸２０の糸条間の間隔とが同じである必要はない（すなわち、一方向のメッシュの開きとそれと交差する方向のメッシュの開きが同じである必要はない）。溶着対象面内で均一な溶着を行う観点から、超音波溶着用メッシュ１９の縦糸２０の糸条間の間隔と横糸２０の糸条間の間隔とが、それぞれ一定かつ同一である平織が、最も好ましい。縦糸の素材と横糸の素材は、同じであっても異なっていてもよいが、製造効率の面から通常同じものが用いられる。
また代替的な実施形態として、図５、６に係る実施形態を、図２に係る実施形態および／または図３に係る実施形態および／または図４に係る実施形態と組み合わせてもよい。これによって、溶着対象部材の複雑な立体形状に合わせる形で、よりフレキシブルな溶着設計が可能になり、加えて材料コストの低減、製造の効率化を更に進めることができる。
The method of weaving the yarns 20 of the ultrasonic welding mesh 19 is not limited to the illustrated plain weave as long as the above three requirements are satisfied, and may be twill weave or twill weave, for example. Instead of the woven fabric, a knitted fabric may be used. Moreover, the spacing between the threads of the warp 20 of the ultrasonic welding mesh 19 and the spacing between the threads of the weft 20 do not have to be the same (ie, the opening of the mesh in one direction and the mesh in the direction intersecting it) The opening does not have to be the same). From the viewpoint of performing uniform welding within the welding target surface, the plain weave in which the spacing between the warp yarns 20 of the ultrasonic welding mesh 19 and the spacing between the weft yarns 20 are respectively the same and identical preferable. The material of the warp and the material of the weft may be the same or different, but the same material is generally used from the viewpoint of production efficiency.
As an alternative embodiment, the embodiment according to FIGS. 5, 6 may be combined with the embodiment according to FIG. 2 and / or the embodiment according to FIG. 3 and / or the embodiment according to FIG. As a result, a more flexible welding design can be made in accordance with the complex three-dimensional shape of the welding target member, and in addition, the material cost can be reduced and the manufacturing efficiency can be further advanced.
超音波溶着用ホーンおよび超音波溶着の条件としては、特に限定されず、用いる溶着対象部材や本発明に係る超音波溶着用部材の形状・素材に応じて、公知のものから選択することができる。
本発明に係る超音波溶着用部材は、溶着層におけるボイドの残存を回避しつつ十分な溶着強度を得ることができるため、特に、炭素繊維等の繊維および薄い樹脂の複層構造を有する複合材料や、複雑な形状の外面を有する溶着対象部材の超音波溶着のためにも好適に用いることができる。
The conditions for the ultrasonic welding horn and the ultrasonic welding are not particularly limited, and can be selected from known ones depending on the welding target member to be used and the shape and material of the ultrasonic welding member according to the present invention. .
The ultrasonic welding member according to the present invention can obtain sufficient welding strength while avoiding the remaining of voids in the welding layer, and in particular, a composite material having a multilayer structure of fibers such as carbon fibers and a thin resin Also, it can be suitably used for ultrasonic welding of a member to be welded having an outer surface of complicated shape.
以下では、本発明に係る超音波溶着用部材の典型例として、図５〜６に示す実施形態の超音波溶着用メッシュについて、実際に溶着を行い、引張剪断強度の測定および溶着部の断面観察を行った。
本発明は、添付の特許請求の範囲によって特定されるあらゆる実施形態を包含するものであって、以下の実施例によって限定的に解釈されるべきではない。
In the following, as a typical example of the member for ultrasonic welding according to the present invention, welding is actually performed for the mesh for ultrasonic welding of the embodiments shown in FIGS. 5 to 6, and measurement of tensile shear strength and cross-sectional observation of the welded portion Did.
The present invention covers all the embodiments specified by the appended claims, and should not be interpreted restrictively by the following examples.
溶着対象部材である一対の熱可塑性樹脂板の間に、超音波溶着用メッシュを挟持し、これらの溶着対象部材の超音波溶着を行った。２０ｍｍ×２５０ｍｍのフラットな面のホーンを有し、出力３０００Ｗの超音波溶着機を用いた。溶着面積は、２５ｍｍ×１２．７ｍｍとした。 The ultrasonic welding mesh was sandwiched between a pair of thermoplastic resin plates as welding target members, and ultrasonic welding of these welding target members was performed. An ultrasonic welder with a power of 3000 W was used with a 20 mm × 250 mm flat surface horn. The welding area was 25 mm × 12.7 mm.
［実施例１］
溶着対象部材である一対の熱可塑性樹脂板として、ＰＥＥＫ樹脂製の平板を用いた。
超音波溶着用メッシュとして、同じくＰＥＥＫ樹脂製の、開きが全体として均一な平織メッシュであって、糸外径が０．２ｍｍ、開きが０．３ｍｍのものを用いた。
これらの材料を用いて超音波溶着を行い、溶着部の断面観察を行った。
Example 1
The flat plate made of PEEK resin was used as a pair of thermoplastic resin boards which are welding object members.
As a mesh for ultrasonic welding, a plain weave mesh made of PEEK resin and having a uniform spread as a whole, and having an outer diameter of 0.2 mm and a spread of 0.3 mm was used.
The ultrasonic welding was performed using these materials, and the cross-sectional observation of the welding part was performed.
［実施例２］
糸外径０．４ｍｍ、開き０．４５ｍｍの超音波溶着用メッシュを用いた以外は、実施例１と同様に超音波溶着を行い、溶着部の断面観察を行った。
Example 2
Ultrasonic welding was performed in the same manner as in Example 1 except that an ultrasonic welding mesh having an outer diameter of 0.4 mm and an opening of 0.45 mm was used, and cross-sectional observation of the welded portion was performed.
［実施例３］
糸外径０．５ｍｍ、開き１．０ｍｍの超音波溶着用メッシュを用いた以外は、実施例１と同様に超音波溶着を行い、溶着部の断面観察を行った。
[Example 3]
Ultrasonic welding was performed in the same manner as in Example 1 except that an ultrasonic welding mesh having an outer diameter of 0.5 mm and an opening of 1.0 mm was used, and cross-sectional observation of the welded portion was performed.
［実施例４］
溶着対象部材である一対の熱可塑性樹脂板として、ＰＰ樹脂製の平板を用いた。
超音波溶着用メッシュとして、同じくＰＰ樹脂製の、開きが全体として均一な平織メッシュであって、糸外径が０．２１５ｍｍ、開きが０．２９７ｍｍのものを用いた。
これらの材料を用いて超音波溶着を行い、溶着部の断面観察を行った。
Example 4
A flat plate made of PP resin was used as a pair of thermoplastic resin plates which are welding target members.
As a mesh for ultrasonic welding, a plain weave mesh made of PP resin and having a uniform spread as a whole and having an outer diameter of 0.215 mm and a spread of 0.297 mm was used.
The ultrasonic welding was performed using these materials, and the cross-sectional observation of the welding part was performed.
［比較例１］
超音波溶着用メッシュの代わりに、ＰＥＥＫ樹脂製の均一厚みを有するフィルム（厚み０．１ｍｍ）を用いた以外は、実施例１と同様に超音波溶着を行い、溶着部の断面観察を行った。
Comparative Example 1
Ultrasonic welding was performed in the same manner as in Example 1 except that a film (0.1 mm in thickness) having a uniform thickness made of PEEK resin was used instead of the ultrasonic welding mesh, and the cross section of the welded portion was observed. .
［比較例２］
超音波溶着用メッシュの代わりに、ＰＥＥＫ樹脂製の均一厚みを有するシート（厚み０．２ｍｍ）に対して打ち抜き加工を施し、特許文献１（特開平８−１５０６６９号公報（特許第３５３６３８５号））のネット形状を模したシートを用いた以外は、実施例１と同様に超音波溶着を行い、溶着部の断面観察を行った。
Comparative Example 2
Patent Document 1 (Japanese Patent Application Laid-Open No. 8-150669 (Japanese Patent No. 3536385)) is subjected to punching on a sheet (0.2 mm in thickness) having a uniform thickness made of PEEK resin instead of the mesh for ultrasonic welding. Ultrasonic welding was performed in the same manner as in Example 1 except that a sheet simulating the net shape of was used, and cross-sectional observation of the welded portion was performed.
上記の各実施例および比較例について、一方の溶着対象面に関する接合箇所の合計面積／非接合箇所の合計面積の比率、及び溶着断面の外観評価の結果を、以下の表１に示す。
ここで、溶着断面は、ボイド（溶着時に混入した気泡）が観察されなかった場合を「○」、ボイドが観察された場合を「×」として評価した。
About each above-mentioned example and comparative example, a ratio of a total area / total area of a non-joining place about a welding object side and a result of appearance evaluation of a welding section are shown in the following table 1.
Here, the cross section of the welding was evaluated as "o" when no void (air bubbles mixed in during welding) was observed, and as "x" when void was observed.
表１から分かるように、上述の非連続形成要件、外部開放要件および接合箇所低減要件の全てを満たす、本発明に係る実施例１〜４の超音波溶着用部材を用いた場合には、ボイドが観られなかった。
それとは対照的に、非連続形成要件、外部開放要件および接合箇所低減要件のいずれも満たさない比較例１のフィルムを用いた場合、ならびに、外部開放要件および接合箇所低減要件を満たさない比較例２のシートを用いた場合には、溶着時に混入した気泡に起因するボイドが観察された。
As can be seen from Table 1, when the ultrasonic welding members of Examples 1 to 4 according to the present invention which satisfy all of the above-mentioned discontinuous formation requirements, external openness requirements and joint location reduction requirements are used, void Was not seen.
In contrast, when using the film of Comparative Example 1 which does not satisfy any of the discontinuous formation requirement, the external openness requirement and the joint reduction requirement, and the comparative example 2 which does not satisfy the external openness requirement and the joint reduction requirement. In the case of using the sheet of the above, voids resulting from air bubbles mixed in at the time of welding were observed.
［実施例５］
溶着対象部材である一対の熱可塑性樹脂板として、ＰＥＥＫ樹脂をマトリックスとする炭素繊維複合材を用いた。超音波溶着用メッシュとして、ＰＥＥＫ樹脂製の、開きが全体として均一な平織メッシュであって、糸外径が０．５ｍｍ、開きが１．０ｍｍのものを用いた。これらの材料を用いて超音波溶着を行い、引張剪断強度の測定を行った。
[Example 5]
A carbon fiber composite material using PEEK resin as a matrix was used as a pair of thermoplastic resin plates which are welding target members. As a mesh for ultrasonic welding, a plain weave mesh made of PEEK resin and having a uniform spread as a whole, and having an outer diameter of 0.5 mm and a spread of 1.0 mm was used. Ultrasonic welding was performed using these materials, and measurement of tensile shear strength was performed.
［比較例３］
超音波溶着用メッシュの代わりに、ＰＥＥＫ樹脂製の均一厚みを有するフィルム（厚み０．１ｍｍ）を用いた以外は、実施例５と同様に超音波溶着を行い、引張剪断強度の測定を行った。
Comparative Example 3
The ultrasonic welding was performed in the same manner as in Example 5 except that a film (0.1 mm in thickness) having a uniform thickness made of PEEK resin was used instead of the ultrasonic welding mesh, and the tensile shear strength was measured. .
［比較例４］
超音波溶着用メッシュの代わりに、ＰＥＥＫ樹脂製の均一厚みを有するシート（厚み０．２ｍｍ）に対して打ち抜き加工を施し、特許文献１（特開平８−１５０６６９号公報（特許第３５３６３８５号））のネット形状を模したシートを用いた以外は、実施例５と同様に超音波溶着を行い、引張剪断強度の測定を行った。
Comparative Example 4
Patent Document 1 (Japanese Patent Application Laid-Open No. 8-150669 (Japanese Patent No. 3536385)) is subjected to punching on a sheet (0.2 mm in thickness) having a uniform thickness made of PEEK resin instead of the mesh for ultrasonic welding. The ultrasonic welding was performed in the same manner as in Example 5 except that a sheet imitating the net shape of was used, and the tensile shear strength was measured.
上記の実施例５ならびに比較例３及び４について、一方の溶着対象面に関する接合箇所の合計面積／非接合箇所の合計面積の比率、及び引張剪断強度の測定結果を、以下の表２に示す。
表２から分かるように、上述の非連続形成要件、外部開放要件および接合箇所低減要件の全てを満たす、本発明に係る実施例５の超音波溶着用部材を用いた場合には、十分実用的な剪断強度を有していた。それとは対照的に、非連続形成要件、外部開放要件および接合箇所低減要件のいずれも満たさない比較例３のフィルムを用いた場合、ならびに、外部開放要件および接合箇所低減要件を満たさない比較例４のシートを用いた場合には、低い水準の剪断強度を示すかまたは接合しなかった。
As can be seen from Table 2, when using the ultrasonic welding member of Example 5 according to the present invention, which satisfies all the discontinuous formation requirements, external openness requirements and joint location reduction requirements described above, it is sufficiently practical. Shear strength. In contrast, when using the film of Comparative Example 3 which does not satisfy any of the discontinuous formation requirement, the external openness requirement and the joint reduction requirement, and the comparative example 4 which does not satisfy the external openness requirement and the joint reduction requirement. In the case of using the sheet of (1), it showed a low level of shear strength or did not bond.
Claims (6)
この超音波溶着用部材は、熱可塑性樹脂を含んでなり、
超音波溶着用部材は、第１部材の溶着対象表面および第２部材の溶着対象表面の間に挟持させたときに、超音波溶着用部材と第１部材の溶着対象表面との接合箇所および／または超音波溶着用部材と第２部材の溶着対象表面との接合箇所が、少なくとも一部において非連続的に存在するように形成されてなり、
かつ、超音波溶着用部材は、第１部材の溶着対象表面および第２部材の溶着対象表面の間に挟持させたときに、超音波溶着用部材と第１部材の溶着対象表面との非接合箇所および／または超音波溶着用部材と第２部材の溶着対象表面との非接合箇所の全てが、超音波溶着用部材の外部に対して開放されるように形成されてなり、
かつ、超音波溶着用部材を第１部材の溶着対象表面および第２部材の溶着対象表面の間に挟持させたとき、超音波溶着用部材と第１部材の溶着対象表面との非接合箇所の合計面積に対する、超音波溶着用部材と第１部材の溶着対象表面との接合箇所の合計面積の比率が１未満になり、および／または、超音波溶着用部材と第２部材の溶着対象表面との非接合箇所の合計面積に対する、超音波溶着用部材と第２部材の溶着対象表面との接合箇所の合計面積の比率が１未満になり、
超音波溶着用部材が、少なくとも一部において、略等間隔にまたは不規則的に配された複数のドット状であることを特徴とする、
上記超音波溶着用部材。 Prior to ultrasonic welding of the surface to be welded of the first member comprising a thermoplastic resin, and the surface to be welded of a second member comprising a thermoplastic resin having a shape parallel to or fitted to the first member An ultrasonic welding member independent of the first member and the second member, for sandwiching the surfaces to be welded;
The ultrasonic welding member comprises a thermoplastic resin,
When the ultrasonic welding member is held between the welding target surface of the first member and the welding target surface of the second member, the ultrasonic welding member and the welding point of the welding target surface of the first member and / or Or the joint between the ultrasonic welding member and the welding target surface of the second member is formed so as to be discontinuous at least in part,
And when the ultrasonic welding member is held between the welding target surface of the first member and the welding target surface of the second member, the ultrasonic welding member and the welding target surface of the first member are not joined. All of the portions and / or the non-joining points between the ultrasonic welding member and the welding target surface of the second member are formed to be open to the outside of the ultrasonic welding member,
And when the ultrasonic welding member is held between the welding target surface of the first member and the welding target surface of the second member, the non-joining portion of the ultrasonic welding member and the welding target surface of the first member The ratio of the total area of the bonding points between the ultrasonic welding member and the welding target surface of the first member to the total area is less than 1 and / or the welding target surface of the ultrasonic welding member and the second member The ratio of the total area of the bonding points between the ultrasonic welding member and the surface of the second member to be welded is less than 1 with respect to the total area of the non-bonding points of
The ultrasonic welding member is characterized in that at least a portion thereof is in the form of a plurality of dots arranged substantially at equal intervals or irregularly.
The above ultrasonic welding member.
超音波溶着用部材に超音波振動を与えて、第１部材および第２部材を溶着させる工程を含む超音波溶着方法であって、
この超音波溶着用部材は、熱可塑性樹脂を含んでなり、
第１部材の溶着対象表面と第２部材の溶着対象表面との間に超音波溶着用部材を挟持させる工程において、
超音波溶着用部材と第１部材の溶着対象表面との接合箇所および／または超音波溶着用部材と第２部材の溶着対象表面との接合箇所が、少なくとも一部において非連続的に存在するように、超音波溶着用部材を配置し、
かつ、超音波溶着用部材と第１部材の溶着対象表面との非接合箇所および／または超音波溶着用部材と第２部材の溶着対象表面との非接合箇所の全てが、超音波溶着用部材の外部に対して開放されるように、超音波溶着用部材を配置し、
かつ、超音波溶着用部材と第１部材の溶着対象表面との非接合箇所の合計面積に対する、超音波溶着用部材と第１部材の溶着対象表面との接合箇所の合計面積の比率が１未満になり、および／または、超音波溶着用部材と第２部材の溶着対象表面との非接合箇所の合計面積に対する、超音波溶着用部材と第２部材の溶着対象表面との接合箇所の合計面積の比率が１未満になるように、超音波溶着用部材を配置し、
超音波溶着用部材が、少なくとも一部において、略等間隔に配された複数のドット状であることを特徴とする、
上記超音波溶着方法。 A first member between a welding target surface of a first member comprising a thermoplastic resin and a welding target surface of a second member comprising a thermoplastic resin having a shape parallel to or fitted to the first member And a step of holding the ultrasonic welding member independent of the second member and the second member;
An ultrasonic welding method comprising the steps of: applying ultrasonic vibration to a member for ultrasonic welding to weld a first member and a second member,
The ultrasonic welding member comprises a thermoplastic resin,
In the step of holding the ultrasonic welding member between the welding target surface of the first member and the welding target surface of the second member,
The joint between the ultrasonic welding member and the welding target surface of the first member and / or the joint between the ultrasonic welding member and the welding target surface of the second member are present discontinuously at least in part Place the ultrasonic welding member at
In addition, all the non-joining points between the ultrasonic welding member and the welding target surface of the first member and / or all the non-joining points between the ultrasonic welding member and the welding target surface of the second member are ultrasonic welding members Position the ultrasonic welding member so that it is open to the outside of the
In addition, the ratio of the total area of the bonding portion between the ultrasonic welding member and the welding target surface of the first member to the total area of the non-bonding portion between the ultrasonic welding member and the welding target surface of the first member is less than 1 And / or the total area of the joint between the ultrasonic welding member and the welding target surface of the second member relative to the total area of the non-joining area of the ultrasonic welding member and the welding target surface of the second member. Position the ultrasonic welding member so that the ratio of
The ultrasonic welding member is characterized in that it has a plurality of dots arranged at substantially equal intervals at least in part.
The above ultrasonic welding method.
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