JP3389837B2 - Method and apparatus for high frequency fusion of thermoplastic resin - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a high frequency welding method and apparatus for thermoplastic resin, in particular, to a method and equipment fusing the raising or fabric member to the thermoplastic resin.

[0002]

2. Description of the Related Art Some automobile interiors, such as door trims, are decorated by attaching a carpet or a fabric to the surface of a core material (molding material) of a thermoplastic resin. Conventionally, the core material and the carpet were joined by an adhesive, a tacker, etc., but the application of the adhesive,
It was necessary to perform crimping and tacking the end parts, which required many steps. For this reason, the applicant of the present invention has disclosed that
In No. 8, a technique for joining a fabric to a thermoplastic resin by high frequency dielectric heating was proposed.

[0003]

[SUMMARY OF THE INVENTION However, even in the technique of using a high frequency <br/> Yuden heating, it is necessary to respectively bond the joint by weld blade, it was not possible to sufficiently reduce the number of steps . Further, since the weld blade is pressed from the fabric side, the fabric surface may be damaged.

The present invention has been made to solve the above-mentioned problems, and its purpose is to make a raised or cloth-like member into a thermoplastic resin in a small number of steps and without damaging the surface . It is to propose a method and a device that can be fused. Another object of the present invention is to propose a method and an apparatus capable of firmly bonding a raised or cloth-like member to a thermoplastic resin. Further, the present invention is to propose a device for fusing a raised or cloth-like member to a thermoplastic resin, which is capable of efficiently cooling the fusing horn .

[0005]

To achieve the above object, according to an aspect of, the high frequency fusing a thermoplastic resin according to claim 1, the first thermoplastic resin ing lining brushed or fabric member
And the second thermoplastic resin are in contact with each other.
So that they are fluffed or cloth-like members.
Facing each other, and multiple high-frequency coils are placed inside with a space.
The placed first pressing die and the second thermoplastic resin side face each other
And, a plurality of cylinder which is arranged to face the plurality of coils
Pinching with a second pressing die that has a fusing horn
And then fusing the each fusion horns heated Ri by the high frequency <br/> wave induction heating by the respective coils, the second thermoplastic resin to <br/> the raising or cloth-like member The technical feature is to make it happen.

In order to achieve the above object, in the high frequency fusion apparatus for thermoplastic resins according to claim 2, the thermoplastic resins are separated from each other.
The back side of the first thermoplastic resin is laminated so that it touches
Brushed or cloth-like member formed by beating, and second thermoplastic resin
For supporting the door, a first press die facing the raising or cloth-like member, at a high-frequency coil spacing within
A first press die in which a plurality arranged Te, and the first press die
In, for the first has been brushed or cloth-like member supported on the press die and a second thermoplastic resin to press nip, opposite the plurality of coils on a surface facing the second thermoplastic resin Distribution
And press the raised or cloth-like member and the second thermoplastic resin.
When clamped, it is heated by high frequency induction by each coil.
And technical; and a second press die having a plurality of cylindrical fusing horn that.

Further, high-frequency fusing device of the thermoplastic resin according to claim 3, in claim 2, the tip portion of the front Symbol fusing horn, center without a chevron protrusion, circles from the center to the periphery A technical feature is that a recess having an arcuate cross section is formed.

Further, high-frequency fusing device of the thermoplastic resin according to claim 4, in claim 3, the tip of the pre-Symbol fusion horns
The technical feature is that the peripheral edge of the portion is formed in a corrugated shape.

Further, high-frequency fusing device of the thermoplastic resin according to claim 5, in claim 2, the tip portion of the front Symbol fusing horn, technical characterized by forming the protrusions of the plurality of small-diameter cylindrical And

Further, high-frequency fusing device of the thermoplastic resin according to claim 6, in claims 2 to 5, before Symbol fusion horns
The tip portion, a tapered shape that is Unishitagai diameter suited to-edge
The technical feature is that it is formed .

Further, high-frequency fusing device of the thermoplastic resin according to claim 7, in claims 2 to 5, before Symbol fusion horns
In the vicinity of the tip, and technical features that were provided with a ring-shaped stopper to prevent the outflow to the outside of the molten thermoplastic resin.

Further, high-frequency fusing device of the thermoplastic resin according to claim 8, in claim 7, the stopper, formed by low flux loss member having heat resistance, to reduce the magnetic flux losses due to the stopper The technical feature is that

Further, high-frequency fusing device of the thermoplastic resin according to claim 9, in claims 2 to 5, before Symbol fusion horns
The hollow form and caused to communicate a pipe hollow portion, and technical features that it has a-passing flow of cooling air into the hollow portion from the pipe.

In order to achieve the above object, the method for high-frequency fusion bonding of thermoplastic resin according to claim 10 provides the method according to claim 1.
Te, the wound electromotive force detecting coil to said fusing horn
The electromotive force of the electromotive force detection coil is monitored, and when a predetermined time has elapsed after the electromotive force suddenly increased, the high frequency coil
The technical feature is that the application of high frequency to the coil is stopped.

[0015] To achieve the above object, the thermoplastic claim 10 in a high frequency welding method of the resin of claim 11, an electromotive force monitoring before Symbol electromotive force detecting coil, and the current of the electromotive force, a predetermined The technical feature is that when the difference from the electromotive force given the time delay becomes large, it is determined that the electromotive force suddenly increases.

Further, in the high-frequency fusion method for thermoplastic resin according to claim 12, in the method according to claim 10 or 11,
As the electromotive force detection coil, a first coil wound around the fusion horn in a first direction and a second coil wound in a direction opposite to the first direction are connected in series. Consist of
The technical feature is that it is used .

[0017]

In [Action and Effect] the high frequency welding method according to claim 1 of a thermoplastic resin, a plurality of fusion horns provided in the second press die and <br/> heated, brushed into the second thermoplastic resin Alternatively, since the cloth-like member is fused, the processing steps can be reduced as compared with the case of fusing with one fusing horn. Further , since the fusion horn is pressed from the second thermoplastic resin side, that is, the back surface side ,
The raised surface or the surface of the cloth-like member is not damaged.

In the thermoplastic resin high-frequency fusing device according to the second aspect, a plurality of fusing horns are arranged at intervals in the second pressing die, and the plurality of fusing horns are heated to produce the second fusing horn. Since the napped or cloth-like member is fused to the thermoplastic resin of (1), the number of processing steps can be reduced as compared with the case of fusing with one fusing horn. Also, either the second thermoplastic resin side or back side
Since the fusion-bonding horn is pressed , the raised hair or the surface of the cloth-like member is not damaged.

[0019] In the high-frequency fusing device of the thermoplastic resin according to claim 3, the tip portion of the fusion horns, it the center chevron protrusion
Since the concave portion having the arcuate cross section is formed from the center toward the peripheral edge, the second thermoplastic resin can be firmly fused to the raised or cloth-like member.

[0020] In the high-frequency fusing device of the thermoplastic resin according to claim 4, in claim 3, since the front end portion periphery of the fusion horns is formed in a waveform, brushed a second thermoplastic resin or a cloth member It can be firmly fused.

In the high frequency fusion apparatus for thermoplastic resin of the fifth aspect, since the plurality of small-diameter columnar projections are formed at the tip of the fusion horn, the second thermoplastic resin is raised or clothed. It can be firmly fused to the strip-shaped member.

[0022] In the high-frequency fusing device of the thermoplastic resin according to claim 6, the distal end portion of the fusing horn, Unishitagai diameter suited to-edge
Since it is formed in a taper shape , the molten thermoplastic resin does not leak to the outside, and the second thermoplastic resin can be firmly fused to the raised or cloth-like member.

[0023] In the high-frequency fusing device of the thermoplastic resin according to claim 7, since the vicinity of the distal end portion of the fusing horn, it is arranged a ring-shaped stopper to prevent the outflow to the outside of the molten thermoplastic resin The molten thermoplastic resin does not leak to the outside, and the second thermoplastic resin can be firmly fused to the raised or cloth-like member.

[0024] In the high-frequency fusing device of the thermoplastic resin according to claim 8, the stopper, the low flux loss member having heat resistance
And more formation, to reduce the magnetic flux loss due to the stopper
Because you have urchin, it may work to reduce the magnetic flux losses in the stopper.

[0025] In the high-frequency fusing device of the thermoplastic resin according to claim 9, fused horn is hollow formed by allowed communicating pipe hollow portion, the flow through the cooling air into the hollow portion from the pipe
Since it is possible , the fusion horn can be efficiently cooled, and the processing efficiency can be improved.

[0026] In the high-frequency fusing a thermoplastic resin according to claim 10, monitors the electromotive force of the wound welding horn electromotive force detecting coil, and the second thermoplastic resin is melted fusion bonding horn There approaches the high-frequency coil, when the electromotive <br/> power of the electromotive force detecting coil has passed a predetermined time rapidly increases, i.e., the first thermoplastic resin and second thermoplastic resin Is melted moderately and high frequency occurs at the timing when the anchor effect occurs
The application of high frequency to the coil is stopped. Therefore, the first thermoplastic resin and the second thermoplastic resin can be firmly bonded.

In the thermoplastic resin high-frequency fusion method according to claim 11, the electromotive force rapidly increases when the difference between the current electromotive force and the electromotive force delayed by the predetermined time increases. for determining that, rapid increase in exactly the electromotive force, i.e., the second
Thermoplastic resins can be detected that the melted and fusion bonding horn is close to the high-frequency coil. For this reason, the application of the high frequency to the high frequency coil can be stopped at the timing when the first thermoplastic resin and the second thermoplastic resin are appropriately melted and the anchor effect is generated, so that the first thermoplastic resin and the first thermoplastic resin can be stopped. It is possible to firmly bond the second thermoplastic resin.

The high-frequency welding side of the thermoplastic resin of claim 12
In the method , as the coil for detecting electromotive force,
A first coil wound in the direction of and a second coil wound in the opposite direction to the first direction are connected in series .
There is . Therefore, noise is canceled out by the first coil and the second coil, so that the electromotive force of the electromotive force detection coil can be accurately detected, and high-frequency fusion of the thermoplastic resin can be performed with high accuracy. It will be possible.

[0029]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments embodying the present invention will be described below with reference to the drawings. FIG. 1 shows a structure of a device for fusing a carpet to a door trim according to a first embodiment of the present invention. This fusing device is composed of a first pressing die 30 configured to fit the shape of the door trim and a second pressing die 40 formed to match the shape of the pressing die 30. The second pressing die 40 is provided with a plurality of fusion horns 50 for high frequency fusion. On the other hand, in the first press die 30, high <br/>-frequency coil 32 is arranged so as to correspond to each of the fusion horns 50. The carpet 10 is disposed on the first pressing die 30.
A thermoplastic PP (polypropylene) resin 20 that forms a door trim is laid on top of the above with a non-woven fabric 18 interposed therebetween.

In the carpet 10, nylon bristles 12 are planted on a base cloth 14, and a PE backing 16 made of a thermoplastic PE (polyethylene) resin is arranged on the back surface side of the base cloth 14, and the nylon bristles 12 are It is preventing it from coming off.

For convenience of illustration, only a part of the first pressing die 30 and the second pressing die 40 is shown, and the two fusion horns 5 are also shown.
Although only 0 is shown, the first pressing die 30 and the second pressing die 40 have a three-dimensional curved surface formed according to the shape of the door trim, and a large number of fusion horns 50 are formed along the curved surface.
The carpets are arranged at intervals, and the joining of the carpet to the door trim is completed in one fusing step.

FIG. 2A shows a fusing horn 50 of the fusing device according to the first embodiment. In the drawing, a side view of the tip of the fusion horn 50 is shown on the upper left side, a bottom view (plan view) of the tip of the fusion horn is shown on the lower left side, and a perspective view of the tip is shown on the right. The columnar fusion horn 50 is made of iron, which is a magnetic material, so that it can generate heat by an eddy current when a high frequency is applied, and as shown in the figure, the tip end portion and the central peak are formed. Rutotomoni that having a shape of a protrusion 50a, or the tip of the protrusion 50a
Recess 50c formed of an arc-shaped cross section towards the Luo periphery 50b is formed. The dimension from the peripheral edge 50b to the deepest part of the recess 50c is 1 mm, and the outer diameter of the fusion horn 50 is 6 mm. As shown in FIG. 1 (A), the width S of the nylon bristles 12 of the carpet 10 planted is about 13 mm. This is because the entanglement and the fusion of the PP resin 20 and the carpet 10 are made strong.

Here, referring to FIG. 1 again, the fusing by the fusing device will be described. First, a high frequency is applied to the coil 32 of the first pressing die 30 shown in FIG. 1 (A) to heat the fusion horn 50. Then, as shown in FIG. 1B, the second pressing die 40 is pressed to the first pressing die 30 side, and the PP resin 20 is applied to the carpet 10 at the tip of the fusion horn 50.
The fusion horn 50 is pressed against the back side of the
The PE backing 16 of the resin 20 and the carpet 10 and dissolved <br/> melt, the carpet 10 to the PP resin (trim) 20
Fuse together. After that, the application of high frequency to the coil 32 is stopped, the fusion horn 50 is cooled, and then the first pressing die 40 is pulled up to complete the processing.

The door trim (PP
A cross section of the resin 20) is shown in FIG. 4, and a portion surrounded by a frame H in the drawing is enlarged and shown in FIG. Note that this enlarged view 5 is a sketch of an end face obtained by cutting an actual fused door trim. As shown in FIG. 4, during fusion, a small amount of the melted PP resin 20 overflows around the opening 20b of the hole 20a formed by the fusion horn 50 to form a ring portion 20c. Here, by using the fusion horn 50 in which the recess 50c is formed, the overflow amount of the PP resin 20 is suppressed and most of the melted PP resin 20 is directed to the carpet 10 side. Here, the PP resin forming the door trim 20 and the PE resin forming the PE backing 16 are not mixed with each other, but the fusion horn 5 having the shape described above with reference to FIG.
By using 0, as shown in FIG.
0 and the PE backing 16 are complicatedly interlocked at the joint, and a so-called anchor effect is generated. Therefore, the carpet 10 can be firmly fused to the door trim 20.

The structure of the fusion horn 60 according to a modification of the first embodiment will be described with reference to FIG. The fusion horn 60 according to this modification is the same as the fusion horn 50 shown in FIG. 2A except that the peripheral edge 60b at the tip is formed in a corrugated shape.

FIG. 6 shows a cross section of the door trim (PP resin 20) which has been fusion-bonded with the fusion horn 60 of the modified example, and the portion surrounded by a frame I in the drawing is enlarged and shown in FIG. . Note that this enlarged view 7 is a sketch of an end face obtained by cutting an actual fused door trim. As shown in FIG. 6, during fusion, a small amount of the melted PP resin 20 overflows around the opening 20b of the hole 20a formed by the fusion horn 60 to form a ring portion 20c. Here, by using the fusion horn 60 having the above-described shape, the overflow amount of the PP resin 20 is suppressed, and most of the melted PP resin 20 is directed to the carpet 10 side. By using the fusion horn 60 having the shape described above with reference to FIG. 2B, the PP resin 2 as shown in FIG.
0 and the PE backing 16 are complicatedly interlocked at the joint to generate an anchor effect. Therefore, the carpet 10 can be firmly fused to the door trim 20.

The construction of the fusion horn 60 according to another modification of the first embodiment will be described with reference to FIG. The fusion horn 70 according to this another modification has four small-diameter columnar projections 70e at the tip 70d.

FIG. 8 shows a cross section of the door trim (PP resin 20) which has been fusion-bonded with the fusion horn 70 of the modified example, and the portion surrounded by a frame J in the figure is enlarged and shown in FIG. . It should be noted that this enlarged view 9 is a sketch of an end face obtained by cutting an actual fused door trim. The fusion horn 7 having the shape described above with reference to FIG.
By using 0, as shown in FIG.
The PE backing 16 and the PE backing 16 are interlocked at the joint to generate an anchor effect. Therefore, the carpet 10 can be firmly fused to the door trim 20.

Here, the fusion horn 5 shown in FIG.
0, the fusion horn 60 shown in FIG. 2 (B), and the fusion horn 70 shown in FIG. 2 (C) were tested for differences in fusion strength, and the results will be described with reference to FIG. In the figure (A)
Indicates the fusion force of the fusion horn 50. Here, one fusing horn 50 provided a fusing force of 2.5 Kgf. Further, (B) in the figure shows the fusion force (2 Kgf) by the fusion horn 60. (C) in the figure is a fusion horn 7.
The fusion force (1.7 Kgf) due to 0 is shown. From this test result, it was found that the highest fusion force can be obtained with the fusion horn 50 having the shape shown in FIG.

Next, a second embodiment of the present invention will be described with reference to FIGS. Figure 11
As shown in (A), in the fusion apparatus of the first embodiment, when the fusion horn 50 is inserted into the PP resin 20 side, the melted PP resin 20 overflows and the ring portion 20c
Are formed. Therefore, in the second embodiment, by providing a taper at the tip of the fusion horn,
The amount of PP resin 20 overflowing is reduced, and the molten PP resin 20 is directed toward the carpet 10.

The shape of the fusing horn 150 of the fusing device of the second embodiment will be described with reference to FIG. The structure of the fusion horn 150 of the second embodiment is almost the same as the structure of the first embodiment described above with reference to FIG. However, the fusion horn 15 of the second embodiment
0, the diameter of the tip portion 150d is 6 mm as in the fusion horn 50 of the first embodiment, while the diameter of the body portion 150d is 150 mm.
The diameter of f (8 mm) is formed thick, and a taper 150 g is provided from the body portion 150 f to the tip portion 150 d.

Next, a modified example of the fusion bonding horn of the second embodiment will be described with reference to FIG. The structure of the fusion horn 160 of the modification of the second embodiment is almost the same as the structure of the modification (fusion horn 60) of the first embodiment described above with reference to FIG. However, in the fusion horn 160 of the second embodiment, the body portion 16 is
160g taper from 0f toward the tip 160d
Is provided.

Further, another modified example of the fusion bonding horn of the second embodiment will be described with reference to FIG. The structure of the fusion horn 170 of the modified example of the second embodiment is shown in FIG.
The configuration is almost the same as that of another modified example (fusion horn 70) of the first embodiment described above with reference to (C). However, in the fusing horn 170 of the second embodiment, the body portion 17 is
170g taper from 0f toward the tip 170d
Is provided.

Next, the fusion by the fusion device of the second embodiment will be described. First, the first shown in FIG.
A high frequency is applied to the coil 32 of the pressing die 30 to heat the fusion horn 150. Then, as shown in FIG. 11C, a second pressing die (not shown) is pressed against the first pressing die 30 side, and the PP resin 20 is applied to the back surface side of the carpet 10 at the tip of the fusion horn 150. Fusing horn 15 pressed against and heated
0 melts the PP resin 20 and the PE backing 16 of the carpet 10 to fuse the carpet 10 to the PP resin (door trim) 20. At this time, since the fusing horn is provided with the taper 150 g, the melted PP resin 20 does not leak outside, and the carpet 10 can be firmly fused to the door trim 20.

Next, a third embodiment of the present invention will be described with reference to FIGS. The fusing horn 50 of the fusing device of the third embodiment has a structure shown in FIG.
As shown in FIG.
A ring-shaped stopper 80 that prevents the resin 20 from flowing out is attached. The stopper 80 is iron or
The ring-shaped recess 80b is formed from a metal member such as aluminum and extends from the lower end peripheral edge 80a to the lower end central portion 80c, and the melted PP resin can be received in the recess 80b. Here, in FIG.
FIG. 12B shows a structure in which a stopper 80 is attached to the fusion horn 60 shown in FIG.
It shows a configuration in which a stopper 80 is attached to the fusion horn 70 shown in FIG.

Next, the fusion by the fusion device of the third embodiment will be described with reference to FIG. First, FIG.
A high frequency is applied to the coil 32 of the first pressing die 30 shown in (A) to heat the fusion horn 50. And in FIG.
As shown in (B), a second pressing die (not shown) is pressed toward the first pressing die 30 side, and the PP is made to move at the tip of the fusion horn 50.
The resin 20 is pressed against the back surface side of the carpet 10, and the PP resin 20 and the carpet 10 are heated by the heated fusion horn 50.
The PE backing 16 is melted and the carpet 10 is fused to the PP resin (door trim) 20. At this time,
Since the stopper 80 is provided, the melted PP resin 2
0, only without leaking slightly as shown in FIG. 13 (C),
Since most of them are directed to the carpet 10 side, the carpet 10 can be firmly fused to the door trim 20. Further, in this embodiment, since the stopper 80 is provided, the insertion amount (insertion length) of the fusion horn can be regulated, and the fusion horn can be prevented from penetrating the surface of the carpet 10. Furthermore, the melted PP resin 20 is
Since the ring portion 20c is solidified in a shape along the concave portion 80b, the ring portion 20c looks good. Therefore, the carpet 10 can be suitably used when the carpet 10 is fused to the door pocket portion of the door trim of the automobile, that is, the portion where the passenger can reach the back surface.

Next, a fourth embodiment of the present invention will be described with reference to FIG. As shown in FIG. 14 (A), the fusing horn 250 of the fusing device of the fourth embodiment is stepped by making the vicinity of the tip end 250d smaller than the diameter of the body 250f. A ring-shaped stopper 180 is fitted on the outer periphery of the stepped tip portion 250d. Here, the stopper 180 is heat-resistant
By using epoxy resin, which is a low magnetic flux loss member,
Reduction of the magnetic flux losses in the stopper 180 is FIG. In this example, the stopper 180 is made of epoxy resin, but it can be made of various materials such as glass and porcelain, which are heat resistant low magnetic flux loss members. Here, FIG.
4 (B) shows a configuration in which a stopper 180 is applied to the fusion horn 60 shown in FIG. 2 (B) of the first embodiment, and FIG. 14 (C) shows it in FIG. 2 (C). Fusion horn 7
The configuration in which the stopper 180 is applied to 0 is shown.

Since the stopper 180 is provided also in the fusing apparatus of the fourth embodiment, the P melted during the fusing is performed.
P resin 20 is slightly only without leakage, most of carpet 1
Since it goes to the 0 side, the carpet 10 can be firmly fused to the door trim 20. Also, the stopper 18
0 by configuring it low flux loss member to obtain Ri FIG reduction of magnetic flux loss at the time of fusing. Further, in the fourth embodiment, since the stopper 180 is fitted to the fusion horn with a step, the stopper can be formed easily from various materials such as porcelain which are difficult to process and form. . Further, in this embodiment, since the stopper is provided, the insertion amount (insertion length) of the fusion horn can be regulated, and the fusion horn can be prevented from penetrating the surface of the carpet 10.

Next, a fifth embodiment of the present invention will be described with reference to FIG. In the above-described first to fourth embodiments, after fusion is completed, air is blown from the nozzle (not shown) to the fusion horn to cool it, so that when the fusion horn is pulled out, the PP resin is It was attached to the fusing horn side to prevent it from becoming a stringing state. On the other hand, in the fifth embodiment, a ventilation mechanism is provided inside the fusion horn so that the fusion horn can be efficiently cooled.

As shown in FIG. 15 (A), the fusing horn 350 of the fusing device of the fifth embodiment is provided with a hollow cylindrical portion 350d at its tip, and the cylindrical portion 350d is provided with the cylindrical portion 350d. A pipe 350i for supporting is connected. Then, the cooling air sent through the pipe 350i is configured to be discharged from the through hole 350h formed in the cylindrical portion 350d. This hollow cylindrical part 3
At the lower end of 50d, that is, the tip of the fusion horn 350, a protrusion 350a and a recess 350c are formed, as in the fusion horn 50 of the first embodiment described above with reference to FIG. . Here, FIG. 15 (B) shows an example in which the configuration of the fifth embodiment is applied to the fusion horn 60 shown in FIG. 2 (B) of the first embodiment, and FIG. 15 (C) shows , Fig. 2
The example which applied the structure of 5th Embodiment to the fusion horn 70 shown to (C) is shown.

In the conventional fusion horn, the tip of the fusion horn, which has the highest temperature, was inserted into the PP resin side and could not be directly cooled by blowing air from the nozzle. On the other hand, in the fusing device of the fifth embodiment, the cooling air is caused to flow from the pipe 350i into the cylindrical portion 350d and is cooled from the inside, so that the portion of the fusing horn 350 which is inserted into the PP resin side. The efficient,
That is, it is possible to cool in a short period of time, and it is possible to improve processing efficiency.

Next, a fusion bonding apparatus according to the sixth embodiment of the present invention will be described with reference to FIGS. In the conventional fusion bonding apparatus, it was not possible to properly manage the heat management of the fusion horn, that is, at which point the high frequency application should be stopped and the cooling of the fusion horn should be started. For this reason, the heating is stopped when the temperature of the fusion horn is low or after it becomes too high, and the fusion force varies. Further, the appearance of the fusion-bonded portion deteriorates due to the variation in temperature, and in particular, when the temperature is too high, the resin may flow out to the surface side of the carpet 10.

On the other hand, in the sixth embodiment, as shown in FIG.
As shown in FIG.
By winding 0 and monitoring the electromotive force of the detection coil 80 , the temperature of the fusion horn 50 is controlled, and the temperature of the fusion horn is controlled so as to exert the highest fusion force, and the fusion force is controlled. It is uniform.

The operation of the fusing apparatus according to the sixth embodiment will be described with reference to the graph of FIG. 17A showing the electromotive force generated by the detection coil 80. First, at time C1, the high frequency is applied to the high-frequency coil 32 shown in FIG. 16, to start heating of the fusing horn 50. By applying a high frequency, the temperature of the fusion horn 50 rises, and the detection coil 8
The electromotive force of 0 gradually increases (at times C1 to C
2), fused horn 50 begin melting PP resin 20 is an electromotive force approaches to slightly <br/> high-frequency coil 32 side further increases (time C2～A). Here, when the PP resin 20 is completely melted, fused horn 50 is rapidly approaching the electromotive force increases rapidly to a high-frequency coil 32 (time to D). At a time point (time B) after a lapse of a predetermined time from time A when the electromotive force suddenly rises, the high frequency application is stopped, that is, the time between time A and time B is controlled to control the temperature of the fusion horn 50. Then, the temperature of the fusion horn is controlled so as to exert the highest fusion force.

[0055] PP resin 20 described above is completely melted, fused horn 50 is rapidly approaching electromotive force is described with reference to the flowchart of FIG. 18 for the detection of the timing of spikes to a high-frequency coil 32. In FIG. 17A, the solid line shows the waveform of the electromotive force in real time, and the chain line shows the waveform with a delay of DT. In addition, FIG.
FIG. 18 is an explanatory view showing an enlarged part of cycle F in FIG. 17 (A). In the sixth embodiment, it is determined whether or not the electromotive force has sharply increased based on the magnitude of the difference between the real-time electromotive force value shown by the solid line and the delayed electromotive force value shown by the chain line. That is, when the electromotive force is gradually increasing as instructed at the timing G in FIG. 17B,
The difference between the real-time electromotive force value and the delayed electromotive force value is small. On the other hand, when the electromotive force suddenly rises, the difference between the real-time electromotive force value and the delayed electromotive force value increases as instructed at the timing H.

First, the elapsed time is set to T and the voltage at time T is set to V (S10). Next, data processing variables are defined (S12). Here, the delay time DT
For example, 0.2 seconds is set as the determination invalid time Cut Tim.
Set a predetermined time in e. Here, the judgment invalid time is
As shown in FIG. 17A, the power is turned on (time C
From 1), a predetermined time before the rise of the electromotive force (time A) occurs, and during this period, the electromotive force does not suddenly increase, so the voltage measurement is stopped. Further, for example, 1V is set as the power-on detection threshold value Slant1.
This value is the slope of the electromotive force when the power is turned on from time C1 to time C2 in FIG. 17A, and it is detected that the power is turned on based on this slope. Further, the resin crossing start detection voltage skew value Volt is set. This value is shown in FIG.
This is for detecting a rapid increase in electromotive force at the time points A to D. Furthermore, the peak generated voltage error DV is set. This is because the electromotive force value detected through the coil is
Since the noise component is included, it is a value for canceling the noise. Further, the resin crossing promotion time JT is set. This JT is from time D to time B shown in FIG.
Until then, by continuing high-frequency heating to the fusion horn 50, the resin is crossed and a high fusion force is exerted.

Subsequently, the data initial value is set (S1
4). Here, the maximum voltage PeakVolt is set to 0, the maximum voltage generation time PeakTime is set to 0, and the elapsed time T
Is reset to 0. Then, the energization of the high frequency oscillator is started, the high frequency is applied from the coil 32 shown in FIG. 16, and the heating of the dielectric horn 50 is started (S16). Next, the timer T is started (S18), and the start time is set to T (S20). After that, the electromotive force value V (T-DT) obtained by delaying the current electromotive force value V (T)
It is determined whether or not the value obtained by subtracting is less than the power rise detection threshold value Slantl set in step 12 described above (S22). Until the subtracted value is less than Slant 1, that is, until it is confirmed that the power is turned on (Yes in S22), the process returns to step 20 and the start time is reset to T. On the other hand,
If the subtracted value exceeds Slant1 and it is confirmed that the power is turned on (No in S22), the above-described determination invalid time Cut T
It waits until "ime" has elapsed (S24).

Here, when the determination invalid time Cut Time has elapsed (S24 returns Yes). Detection of a sudden rise in electromotive force shown in FIG. 17A is started. First, an electromotive force value V (T-DT) obtained by delaying the current electromotive force value V (T).
Is the measured maximum electromotive force value Peak V
It is determined whether it exceeds olt (S26). Here, when the subtracted value exceeds the maximum electromotive force value (Yes in S26),
The subtracted value is set as the maximum electromotive force value (S28). That is, the largest value among the differences between the current electromotive force value V (T) and the electromotive force value V (T-DT) given the delay time is set as the maximum electromotive force value PeakVolt.

Subsequently, a value obtained by subtracting the electromotive force value V (T-DT), which is a delay time from the current electromotive force value V (T), and the peak generated voltage error DV for canceling the above-mentioned noise is obtained. , It is determined whether or not the maximum electromotive force value Peak Volt is exceeded (S30). Here, when the subtraction value exceeds the maximum electromotive force value (Yes in S30), the current time T is set as the time Peak Time at which the maximum electromotive force is generated (S32). That is, the maximum electromotive force generation time Peak Time is set so as not to be affected by an error due to noise.

Then, the maximum measured electromotive force value Peek
It is determined whether Volt is less than the resin crossing start detection voltage skew value Volt set in step 12 described above in order to detect a rapid increase in electromotive force at time A-D in FIG. 17A (S34). Here, the detected maximum electromotive force value P
eek Volt is the resin crossing start detection voltage skew value Vo
When it is less than lt, that is, before the electromotive force suddenly rises (No in S34), the process returns to step 26, and the detection of the maximum electromotive force value Peak Volt is continued. On the other hand, when the maximum electromotive force value Peak Volt is equal to or higher than the resin crossing start detection voltage skew value Volt, that is, when the electromotive force suddenly increases (S34 is Yes), the maximum electromotive force generation time Peak Time is changed from the current time. It is determined whether the subtracted value is less than the resin intersection promotion time JT set in step 12 described above (S36). Here, the resin intersection promotion time JT
17), that is, from time D to time B shown in FIG. 17A, when the high frequency heating of the fusion horn 50 is continued (S3
6 is Yes), the energization of the high frequency oscillator is terminated (S3
8), all processing is completed.

In the sixth embodiment, since it is determined whether the electromotive force suddenly rises or not based on the difference between the real-time electromotive force value and the delayed electromotive force value, it is possible to accurately change the electromotive force. It can be detected and the temperature of the fusion horn can be controlled to exert the highest fusion force. In the sixth embodiment, the delay time is set by software, but it is also possible to obtain the delayed electromotive force value by using the delay circuit.

Next, the seventh embodiment of the present invention will be described. In the high-frequency welding device of the sixth embodiment described above, when attempting to fuse the carpet 10 to the curved portion of the door trim 20 as shown in FIG. 19, the first pressing die 30 has a curved structure, Since the distance from the coil 32 to the detection coil 90 is increased and the magnetic field strength from the coil 32 to the detection coil 90 is reduced, it is relatively susceptible to noise. That is, while the intensity of noise from the outside is constant, the magnetic field intensity is inversely proportional to the square of the distance from the coil 32 to the detection coil 90.
It becomes difficult to accurately detect the sudden rise in electromotive force described above with reference to (A).

Therefore, in the high frequency fusion bonding apparatus of the seventh embodiment, a structure capable of canceling the noise is adopted. In this high-frequency fusion bonding device, as shown in FIG. 20, the detection coil 190 wound around the outer periphery of the stopper 80 is wound counterclockwise with the first coil portion 190a wound clockwise in the drawing. And a second coil portion 190a, and the first coil portion 190a and the second coil portion 190a are connected in series.

The operation of the high frequency fusion apparatus of the seventh embodiment will be described. The electromotive force due to external noise is
The first coil portion 190a and the second coil portion 190a are uniformly induced and are mutually canceled. On the other hand, a high electromotive force is generated by the magnetic field from the coil 32 in the second coil portion 190b arranged close to the high frequency induction coil 32 (see FIG. 19). Further, the first coil portion 190a separated from the high frequency induction coil 32 (see FIG. 19).
Generates a low electromotive force. The second coil portion 190b
Is canceled by the electromotive force generated in the first coil portion 190a, but since the influence of noise is canceled as described above, the electromotive force suddenly increases as described with reference to FIG. Can be accurately detected.

The voltage change rate when the electromotive force sharply rises by the high frequency fusion apparatus of the sixth embodiment shown in FIG. 19 and the voltage change when the electromotive force sharply rises by the high frequency fusion apparatus of the seventh embodiment shown in FIG. FIG. 21 shows a comparison with the rate. Since the influence of noise is canceled in the configuration of the seventh embodiment, it is theoretically expected to improve the rate of change by 18% as compared with the configuration of the sixth embodiment. Therefore, in the high frequency fusion bonding apparatus of the seventh embodiment, the carpet 1 is attached to the curved surface portion of the door trim 20.
Even when fusing 0, the temperature of the fusing horn 50 can be accurately controlled, and the temperature of the fusing horn can be controlled to exert the highest fusing force.

In the first to seventh embodiments described above, examples were given in which the carpet was fused to the PP resin, but in the present invention, various napped members made of thermoplastic resin or cloth-like members such as fabrics are used. It can be widely applied when fusing.

[Brief description of drawings]

FIG. 1A and FIG. 1B are process diagrams showing a fusion process by a fusion device according to a first embodiment of the present invention.

2A is a side view, a bottom view, and a perspective view of the fusion horn according to the first embodiment, and FIG.
A side view, a bottom view, and a fusion horn according to a modified example of the embodiment.
FIG. 2C shows a perspective view, and FIG. 2C shows a side view, a bottom view, and a perspective view of a fusion bonding horn according to another modification of the first embodiment.

FIG. 3 is a graph showing the fusion force by the fusion horn shown in FIGS. 2 (A), 2 (B), and 2 (C).

FIG. 4 is a cross-sectional view showing a connection portion between the PP resin and the carpet fused by the fusion horn according to the first embodiment.

FIG. 5 is an enlarged cross-sectional view showing a connection portion between the PP resin and the carpet shown in FIG.

FIG. 6 is a cross-sectional view showing a connecting portion between a PP resin and a carpet fused by a fusion horn according to a modified example of the first embodiment.

7 is an enlarged cross-sectional view showing a connection portion between the PP resin and the carpet shown in FIG.

FIG. 8 is a cross-sectional view showing a connecting portion between a PP resin and a carpet fused by a fusion horn according to another modification of the first embodiment.

9 is an enlarged sectional view showing a connecting portion between the PP resin and the carpet shown in FIG.

FIG. 10 (A) shows a side view, a bottom view, and a perspective view of a fusion bonding horn according to the second embodiment, and FIG.
Is a side view of a fusion bonding horn according to a modified example of the second embodiment,
FIG. 10C shows a bottom view and a perspective view, and FIG. 10C shows a side view, a bottom view, and a perspective view of a fusion bonding horn according to another modification of the second embodiment.

FIG. 11 (A) is a process drawing showing a fusing step by the fusing device according to the first embodiment of the present invention.
11 (B) and FIG. 11 (C) are process drawings showing a fusion bonding process by the fusion bonding apparatus according to the second embodiment of the present invention.

FIG. 12 (A) is a side view of a fusion horn according to a third embodiment, and FIG. 12 (B) is a side view of a fusion horn according to a modification of the third embodiment. , FIG. 12 (C)
[Fig. 6] is a side view of a fusion bonding horn according to another modification of the third embodiment.

13A, 13B, and 13C.
[Fig. 8] is a process drawing showing a fusing step by a fusing device according to a third embodiment of the present invention.

FIG. 14 (A) is a side view of a fusion horn according to a fourth embodiment, and FIG. 14 (B) is a side view of a fusion horn according to a modification of the fourth embodiment. , FIG. 14 (C)
[Fig. 8] is a side view of a fusion bonding horn according to another modification of the fourth embodiment.

FIG. 15 (A) is a sectional view of a fusion horn according to a fifth embodiment, and FIG. 15 (B) is a sectional view of a fusion horn according to a modification of the fifth embodiment. , FIG. 15 (C)
[Fig. 8] is a cross-sectional view of a fusion bonding horn according to another modification of the fifth embodiment.

FIG. 16 is an explanatory diagram showing a configuration of a fusion bonding device according to a sixth embodiment of the present invention.

17 (A) is a graph of electromotive force detected by the fusion bonding apparatus according to the sixth embodiment of the present invention, and FIG. 17 (B) is a cycle F in FIG. 17 (A). It is explanatory drawing which expands and shows a part.

FIG. 18 is a flowchart of a high frequency fusion bonding method according to a sixth embodiment.

FIG. 19 is an explanatory view showing a cross section of the fusion bonding apparatus according to the sixth embodiment.

FIG. 20 is a perspective view of the fusion bonding horn of the seventh embodiment.

FIG. 21 is a graph comparing an electromotive force detected by the high frequency fusion device of the seventh embodiment with an electromotive force detected by the high frequency fusion device of the sixth embodiment.

[Explanation of symbols]

10 carpet 16 PE backing 20 PP resin (door trim) 30 First pressing type 32 coils 40 Second pressing type 50 fusion horn 50a protrusion 50b tip periphery 50c recess 50f taper 60, 70 Fusion horn 70e protrusion 80 stopper 90 detection coil 190 detection coil 190a 1st coil part 190b Second coil section

─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Toshihiko Inagaki 100 Kanayama, Ichiriyama-cho, Kariya city, Aichi Toyota Auto Body Co., Ltd. (72) Inventor Masahiro Taki 100 Kanayama, Ichiriyama-cho, Kariya city, Aichi Toyota Auto Body Incorporated (72) Inventor Shogo Obata 100 Kanayama, Ichiriyama-cho, Kariya city, Aichi Toyota Auto Body Co., Ltd. (72) Inhito Uematsu 100 Kanayama, Ichiriyama-cho, Kariya city, Aichi Toyota Auto Body Co., Ltd. ( 56) References JP-A-6-125423 (JP, A) JP-A-60-159035 (JP, A) Patent 2544240 (JP, B2) JP-B 4-29535 (JP, B2) JP-B 3-31850 (JP, Y2) Jikhohei 6-1804 (JP, Y2) (58) Fields investigated (Int.Cl. ⁷ , DB name) B29C 65/00-65/82

Claims (12)

(57) [Claims] 1. A and raising or fabric member ing lines the first thermoplastic resin and a second thermoplastic resin, thermoplastic
After stacking so that the resins come into contact with each other , face them with the raised or cloth-like member side and
A first pressing die having a plurality of coils arranged at intervals,
It faces the second thermoplastic resin side and faces the plurality of coils.
Having a plurality of cylindrical fusion-bonding horns arranged facing each other
Pressing clamped between two pressing type, then the heated Ri by the high frequency induction heating by the respective fusion horns each coil, that allowed to fuse the raising or fabric member to the second thermoplastic resin A high-frequency fusion method for a thermoplastic resin, comprising: 2. Laminating so that the thermoplastic resins are in contact with each other.
It has been, brushed also formed by lining the first thermoplastic resin
For supporting the cloth-like member and the second thermoplastic resin
Of a first press die facing the raising or cloth-like member, a plurality arranged <br/> first press die at a high-frequency coil spacing inside, the first With the pressing die, the raised hair supported on the first pressing die
Or cloth-like member and for pressing nip and a second thermoplastic resin, wherein the plurality of co to the surface facing the second thermoplastic resin
And a brush-like member and a second heat, which are disposed opposite to each other.
When clamped with a plastic resin, it is
RF welding device of a thermoplastic resin anda <br/> second press die having a plurality of cylindrical fusing horn is frequency induction heating. To 3. A tip of the front Symbol fusing horn, center without a chevron protrusion, an arcuate cross-section from the center to the periphery
RF welding device of the thermoplastic resin according to claim 2, characterized by forming the recess to serve. 4. Before SL RF fuser thermoplastic resin according to claim 3, wherein the tip portion periphery of the fused horn formed in the waveform. 5. A distal end portion of the front Symbol fusing horn, high frequency welding apparatus of a thermoplastic resin according to claim 2, characterized by forming a plurality of small diameter cylindrical protrusion. 6. The distal end portion of the front Symbol fusing horn suited to-edge
The high frequency fusion device for thermoplastic resin according to any one of claims 2 to 5, wherein the high frequency fusion device is formed in a tapered shape having a smaller diameter according to the above. 7. The vicinity of the distal end portion of the front Symbol fusing horn of claims 2 to 5, characterized in that arranged a ring-shaped stopper to prevent the outflow to the outside of the molten thermoplastic resin A high-frequency fusion bonding apparatus for thermoplastic resin according to any one of claims. The method according to claim 8, wherein the stopper is formed by a low magnetic flux loss member having heat resistance, the magnetic flux losses due to the stopper
RF welding device of the thermoplastic resin according to claim 7, characterized in that so as to reduce. 9. The pre-Symbol fusion horns and hollow form, and allowed to communicate a pipe hollow <br/> unit, and characterized in that a-passing flow of cooling air into the hollow portion from the pipe The high frequency fusion device for thermoplastic resin according to any one of claims 2 to 5. 10. A coil for detecting an electromotive force in the fusion horn
The wound monitors the electromotive force of the electromotive force detecting coil, when the electromotive force has exceeded the predetermined time rapidly increases,
The high frequency fusion method for a thermoplastic resin according to claim 1, wherein the high frequency application to the high frequency coil is stopped. 11. A pre-Symbol electromotive force monitoring the electromotive force detecting coil, when the difference between the current of the electromotive force, the electromotive force giving a delay of a predetermined time is increased, the electromotive force abruptly The method for high-frequency fusion bonding of a thermoplastic resin according to claim 10, wherein it is determined that the number has increased. 12. The electromotive force detection coil includes a first coil wound around the fusion horn in a first direction and a second coil wound in a direction opposite to the first direction. claim, characterized in that used as formed by connecting in series 10
Alternatively, the method for high frequency fusion of a thermoplastic resin according to claim 11 .