JP3320010B2 - 樹脂部品の超音波溶着固定方法並びにそれに使用する超音波溶着ホーン - Google Patents

樹脂部品の超音波溶着固定方法並びにそれに使用する超音波溶着ホーン

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Publication number
JP3320010B2
JP3320010B2 JP10784698A JP10784698A JP3320010B2 JP 3320010 B2 JP3320010 B2 JP 3320010B2 JP 10784698 A JP10784698 A JP 10784698A JP 10784698 A JP10784698 A JP 10784698A JP 3320010 B2 JP3320010 B2 JP 3320010B2
Authority
JP
Japan
Prior art keywords
ultrasonic welding
resin component
horn
welding horn
curved
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
JP10784698A
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English (en)
Other versions
JPH11300834A (ja
Inventor
修 山末
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kasai Kogyo Co Ltd
Original Assignee
Kasai Kogyo Co Ltd
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Publication date
Application filed by Kasai Kogyo Co Ltd filed Critical Kasai Kogyo Co Ltd
Priority to JP10784698A priority Critical patent/JP3320010B2/ja
Publication of JPH11300834A publication Critical patent/JPH11300834A/ja
Application granted granted Critical
Publication of JP3320010B2 publication Critical patent/JP3320010B2/ja
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/61—Joining from or joining on the inside
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
    • B29C66/81423—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being concave
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2511/00—Use of natural products or their composites, not provided for in groups B29K2401/00 - B29K2509/00, as filler
    • B29K2511/14—Wood, e.g. woodboard or fibreboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3014—Door linings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3041—Trim panels

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Description

【発明の詳細な説明】
【０００１】
【発明の属する技術分野】本発明は、樹脂部品を内装部
品等の相手部品に超音波溶着加工により接合固定する樹
脂部品の超音波溶着固定方法並びにそれに使用する超音
波溶着用ホーンに関する。
【０００２】
【従来の技術】通常、自動車室内には、ドアトリム，リ
ヤコーナートリム，各種ピラートリム等の内装基材が車
体パネルに装着されており、通常は、図４に示すよう
に、芯材１ａと表皮材１ｂとからなる内装部品１の裏
面、すなわち、芯材１ａ面に両側にフランジを設けたク
リップブラケット２の両側のフランジ２ａを超音波溶着
加工により固定してなり、特に、内装部品１の芯材１ａ
として複合ＰＰ樹脂系素材を使用し、かつ、クリップブ
ラケット２としてＰＰ樹脂成形体を使用した場合、ＰＰ
樹脂が高周波ウエルダ特性が低いため、通常、超音波溶
着加工により固定が行なわれる。
【０００３】そして、最近の傾向として、内装部品１の
形状が曲面形状に設定されることが多く、通常、クリッ
プブラケット２においてもそのフランジ２ａは内装部品
１の面形状に即した曲面形状に設定され、図５に示すよ
うに、内装部品１の芯材１ａ裏面にクリップブラケット
２のフランジ２ａを密着接合した後、超音波溶着ホーン
３を押し当てて、超音波振動を加えてクリップブラケッ
ト２と内装部品１との接合固定を行なっていた。
【０００４】
【発明が解決しようとする課題】しかしながら、一般に
使用されている超音波溶着ホーン３の先端面３ａがフラ
ット面であるため、図５に示す曲面部位に先端面３ａが
平坦な超音波溶着ホーン３を押し当てた場合、側部の当
接部（図中符号ａで示す）でのみ加工部と超音波溶着ホ
ーン３が接触するため、十分な溶着面積が得られず、ク
リップブラケット２が脱落する等の不具合が生じやす
い。
【０００５】また、超音波溶着ホーン３の先端面３ａを
曲面状に設定した場合でも、溶着部分の曲率と超音波ホ
ーン３の先端面３ａの曲率とが同一でないと上述したよ
うな位置ズレにより十分な溶着強度が得られず、クリッ
プブラケット２の脱落を招くという不具合が抜本的に解
決されるものではない。
【０００６】また、内装部品１に対するクリップブラケ
ット２の取付位置の違いにより、フランジ２ａの形状が
異なるため、その都度超音波溶着ホーン３の先端面３ａ
の曲面形状を対応させなければならず、加工ポイント毎
にことなる超音波溶着ホーン３を容易することは経費の
高騰化を招き、実際的な対策とはなり得ない。
【０００７】この発明は、このような事情に鑑みてなさ
れたもので、樹脂部品を内装基材等の相手部品に超音波
溶着加工により接合固定する樹脂部品の超音波溶着固定
方法並びにそれに使用する超音波溶着ホーンにおいて、
溶着部分がどのような曲面形状に設定されていても、樹
脂部品を十分な接合強度を持って固定することが可能で
あり、かつ、溶着部分の曲率が多少変化しても、同一の
溶着用ホーンを共用できる樹脂部品の超音波溶着固定方
法、並びにそれに使用する超音波溶着ホーンを提供する
ことを目的とする。
【０００８】
【課題を解決するための手段】上記目的を達成するため
に、請求項１記載の発明は、湾曲状に成形された内装部
品の湾曲面に、樹脂部品を超音波溶着加工により溶着固
定する樹脂部品の超音波溶着固定方法において、内装部
品の湾曲部に樹脂部品の溶着部分を密着接合させ、先端
面にその先端が鋭利な突起を複数個設けた超音波溶着ホ
ーンをその上側から押し付け、樹脂部品内にこの突起を
一部食い込ませて超音波溶着加工を施すことを特徴とす
る。
【０００９】更に、請求項２記載の発明は、内装部品の
湾曲部に樹脂部品を超音波溶着接合する超音波溶着ホー
ンにおいて、ホーンの先端面に超音波溶着時、樹脂部品
内部に食い込む先端が鋭利な突起を複数個設けたことを
特徴とする。
【００１０】また、請求項３記載の発明は、超音波溶着
ホーンの先端面が内装基材と樹脂部品との接合曲面に対
応する曲面部として設定されていることを特徴とする。
【００１１】以上の構成から明らかなように、請求項
１，２記載の発明によれば、超音波溶着ホーンの先端面
には、先端が鋭利な突起が複数個設けられているため、
例えば、樹脂部品と相手部品との溶着部が曲面形状を呈
していても、突起が樹脂部品内部に食い込むため、十分
な溶着面積を確保することができ、超音波溶着加工を行
なった際の接合強度を強化することができる。
【００１２】また、請求項３記載の発明によれば、超音
波溶着ホーンの先端面が予め湾曲状に設定されているた
め、樹脂部品と相手部品との間の溶着部分がかなりな曲
率の曲面状に設定されていても、突起の先端が樹脂部品
が有効に食い込み、十分な溶着面積が得られ、樹脂部品
と相手部品との間の溶着部分の接合強度を強化できる。
【００１３】
【発明の実施の形態】以下、本発明に係る樹脂部品の超
音波溶着固定方法並びにそれに使用する超音波溶着ホー
ンの実施形態について、添付図面を参照しながら詳細に
説明する。
【００１４】図１は本発明方法をドアトリムにクリップ
ブラケットを溶着固定する方法に適用した一実施形態を
示す分解斜視図、図２はドアトリムにクリップブラケッ
トを超音波溶着固定する工程を示す断面図、図３は超音
波溶着ホーンの別実施形態を示す要部斜視図である。
【００１５】図１において、自動車用ドアトリム１０の
所定箇所にクリップブラケット２０が超音波溶着ホーン
３０により溶着固定される態様を示すもので、ドアトリ
ム１０は、芯材１１の表面に表皮材１２が貼付された積
層構造体が採用され、芯材１１としては、木粉等のフィ
ラーを混入したＰＰ樹脂板を加熱軟化処理後、所要形状
に冷間プレス成形して形成され、表皮材１２は、塩ビシ
ート裏面に、ポリエチレンフォームが裏打ちされた積層
シート材料が使用されている。
【００１６】そして、クリップブラケット２０は、ポリ
プロピレン樹脂の射出成形体からなり、肉厚が２ｍｍ
で、周囲に取付用フランジ２１が設定され、中央に樹脂
クリップの収納スペースを確保するとともに、ドアパネ
ルとのクリアランスを考慮したクリップ着座部２２が取
付用フランジ２１よりもパネル側に突出する位置に設定
されており、クリップ着座部２２は、クリップを係止す
るクリップ係止孔２３が設けられている。尚、クリップ
ブラケット２０は、図１に示す周囲に取付用フランジ２
１を周設した構成の他にも、両側にフランジを設定した
ハット型のブラケット等でも良い。
【００１７】更に、上記ドアトリム１０は、立体感を強
調したり、また、所望の曲面形状を確保するために、所
定箇所に曲面部分が設定されており、例えば、クリップ
ブラケット２０の取付フランジ２１がドアトリム１０の
芯材１１側に接合固定されるが、この取付用フランジ２
１の設定箇所のドアトリム１０が曲面状であれば、取付
用ブラケット２１も同様の曲率を備えた曲面状に成形さ
れる。
【００１８】そして、ドアトリム１０の曲面部１３にク
リップブラケット２０の曲面状の取付用フランジ２１を
合わせて、この部分を強固に超音波溶着固定するため
に、本発明方法においては、超音波溶着ホーン３０の先
端面３１に先端が鋭利な複数の突起３２を形成したこと
が特徴である。この突起３２としては、突出寸法が５ｍ
ｍ程度で突起幅が７〜８ｍｍ程度に設定されている。
【００１９】従って、クリップブラケット２０をドアト
リム１０の裏面所定箇所にこの超音波溶着ホーン３０を
使用して超音波溶着固定するには、図２に示すように、
ドアトリム１０の曲面部１３にクリップブラケット２０
の取付用フランジ２１を載置し、その上側から超音波溶
着ホーン３０を押し当てて、適宜圧を加えれば、超音波
溶着ホーン３０に設けた複数の突起３２はブラケット２
０の厚みの７０〜８０％間でクリップブラケット２０の
取付用フランジ２１内に突起３２が食い込み、従来のよ
うに端末部分のみで超音波溶着が行なわれるのに対し
て、突起３２設定箇所でクリップブラケット２０が溶融
軟化して、ドアトリム１０に対してクリップブラケット
２０を強固に超音波溶着固定することが可能となる。
【００２０】また、超音波溶着ホーン３０は、図３に示
すように、超音波溶着ホーン３０の先端面３０を図示す
るように曲面部３３として設定しても良く、このよう
に、超音波溶着ホーン３０の先端面３１に曲面部３３を
設定すれば、クリップブラケット２０等の樹脂部品とド
アトリム１０等の相手部品との間の溶着部分がかなり複
雑な曲面状に設定されていても十分に溶着面積を確保し
て、強固な溶着強度を得ることができる。
【００２１】
【発明の効果】以上説明した通り、本発明は、以下に記
載する格別の作用効果を有する。
【００２２】（１）請求項１記載の樹脂部品の超音波溶
着固定方法並びに請求項２記載の超音波溶着ホーンによ
れば、超音波溶着ホーンの先端面に先端が鋭利な突起を
複数個設定して、この突起を樹脂部品に食い込ませて溶
着面積を確保するというものであるから、樹脂部品と相
手部品との間の溶着部位が曲面状に設定されていても、
従来の超音波溶着ホーンの溶着面では溶着面積が確保で
きず、溶着強度が不足したが、複数の突起が樹脂部品内
部に食い込み、突起に相当する数だけ溶着ポイントを確
保でき、湾曲部における樹脂部品の超音波溶着固定時に
おける接合強度を高め、超音波溶着加工における信頼性
を高めることができるという効果を有する。
【００２３】（２）請求項１記載の樹脂部品の超音波溶
着固定方法、並びに請求項２記載の超音波溶着ホーンに
よれば、超音波溶着ホーンの先端面に先端が鋭利な突起
を複数個設定して、この突起を樹脂部品に食い込ませて
溶着面積を確保するというものであるから、樹脂部品と
相手部品との接合部分の曲率が変化しても、各突起の樹
脂部品に対する食込み量が変化するだけで、各突起に対
応する溶着ポイントを確保できることから、溶着部分の
形状変更や仕様変更に対して同一の超音波溶着ホーンを
共用化することができ、造形自由度を高めることができ
るとともに、ホーンの加工工数を大幅に低減できるとい
う効果を有する。
【００２４】（３）請求項３記載の超音波溶着ホーンに
よれば、超音波溶着ホーンの先端面を予め曲面形状に設
定するというものであるから、樹脂部品と相手部品との
溶着部分の曲率が大きく設定されても、超音波溶着ホー
ン先端面の突起が十分に樹脂部品内に食い込むことが可
能であるため、曲面部の度合いが大きくても十分な強度
でもって樹脂部品を溶着固定することができるという効
果を有する。
【図面の簡単な説明】
【図１】本発明方法をドアトリムに対するクリップブラ
ケットの接合固定に適用した一実施形態を示す説明図。
【図２】図１に示すドアトリムにクリップブラケットを
超音波溶着固定する工程を示す断面図。
【図３】本発明に係る超音波溶着ホーンの別実施形態を
示す要部斜視図。
【図４】従来の樹脂部品の超音波溶着固定を示す説明
図。
【図５】従来の超音波溶着ホーンを使用した曲面部分の
超音波溶着加工を示す説明図。
【符号の説明】
１０ 自動車用ドアトリム １１ 芯材 １２ 表皮材 ２０ クリップブラケット ２１ 取付用フランジ ２２ クリップ着座部 ２３ クリップ係止孔 ３０ 超音波溶着ホーン ３１ 先端面 ３２ 突起 ３３ 曲面部

Claims (3)

    (57)【特許請求の範囲】
  1. 【請求項１】 湾曲状に成形された内装部品（１０）の
    湾曲面（１３）に、樹脂部品（２０）を超音波溶着加工
    により溶着固定する樹脂部品の超音波溶着固定方法にお
    いて、 内装部品（１０）の湾曲面（１３）に樹脂部品（２０）
    の溶着部分（２１）を密着接合させ、先端が鋭利な突起
    （３２）を先端面（３１）に複数個設けた超音波溶着ホ
    ーン（３０）をその上側から押し付け、樹脂部品（２
    ０）内にこの突起（３２）を一部食い込ませて超音波溶
    着加工を施すことを特徴とする樹脂部品の超音波溶着固
    定方法。
  2. 【請求項２】 内装部品（１０）の湾曲面（１３）に樹
    脂部品（２０）を超音波溶着接合する超音波溶着ホーン
    において、 先端面（３１）に超音波溶着時、樹脂部品（２０）内部
    に食い込む先端が鋭利な突起（３２）を複数個設けたこ
    とを特徴とする超音波溶着ホーン。
  3. 【請求項３】 前記超音波溶着ホーン（３０）の先端面
    （３１）は、内装部品（１０）と樹脂部品（２０）との
    接合曲面に対応する曲面部（３３）として設定されてい
    ることを特徴とする請求項２記載の超音波溶着ホーン。
JP10784698A 1998-04-17 1998-04-17 樹脂部品の超音波溶着固定方法並びにそれに使用する超音波溶着ホーン Expired - Fee Related JP3320010B2 (ja)

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JP4274885B2 (ja) * 2003-09-19 2009-06-10 三菱電機株式会社 超音波接合装置および超音波接合方法
JP2006142705A (ja) * 2004-11-22 2006-06-08 Kasai Kogyo Co Ltd 繊維質マットの固定構造
JP5298311B2 (ja) * 2009-11-27 2013-09-25 精電舎電子工業株式会社 工具ホーンおよびこれを用いた超音波溶着装置

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