JP3859321B2 - 繊維強化樹脂成形体の溶着方法 - Google Patents

繊維強化樹脂成形体の溶着方法 Download PDF

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JP3859321B2
JP3859321B2 JP25975597A JP25975597A JP3859321B2 JP 3859321 B2 JP3859321 B2 JP 3859321B2 JP 25975597 A JP25975597 A JP 25975597A JP 25975597 A JP25975597 A JP 25975597A JP 3859321 B2 JP3859321 B2 JP 3859321B2
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Prior art keywords
reinforced resin
fiber reinforced
resin molded
fiber
molded body
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JP25975597A
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JPH1190986A (ja
Inventor
義人 葛原
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Press Kogyo Co Ltd
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Press Kogyo Co Ltd
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    • 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
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1432—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface direct heating of the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1464—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface making use of several radiators
    • B29C65/1467—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/562—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined
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    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
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    • B29C65/7805—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features
    • B29C65/7808—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features in the form of holes or slots
    • B29C65/7811—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features in the form of holes or slots for centring purposes
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3034—Particular design of joint configurations the joint involving an anchoring effect making use of additional elements, e.g. meshes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • 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
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/324—Avoiding burr formation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/326—Shaping the burr, e.g. by the joining tool
    • 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
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1412—Infrared [IR] radiation
    • B29C65/1422—Far-infrared radiation [FIR]
    • 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
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • 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
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • 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
    • B29C66/81415—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 bevelled
    • B29C66/81419—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 bevelled and flat
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、熱可塑性樹脂からなる母材中に強化繊維が埋め込まれた繊維強化樹脂成形体の溶着方法に関するものである。
【０００２】
【従来の技術及び発明が解決しようとする課題】
一般に、熱可塑性樹脂からなる母材中に強化繊維が埋め込まれた繊維強化樹脂複合材料は、成形が容易な上に、軽量で、且つ場合によっては金属以上の優れた機械的強度を発揮することから、乗用車やトラック等のバンパービーム等の材料として用いられている。
【０００３】
ところで、このような繊維強化樹脂複合材料にて形成された成形体ａ，ａ同士を接合するためには、図６に示すようにボルトｂ等による機械的接合の他に、図７に示すように接着剤ｃ等を用いた化学的接合方法が考えられているが、これらの接合方法では以下に示すような欠点がある。
【０００４】
すなわち、ボルトｂ等による機械的接合の場合では、ボルト孔ｄの切削等の機械加工が必要になる上に、点接合のため、充分な接合強度を得ることが困難であった。しかも、ボルトｂ等の接合部材が成型体表面に露出するため、美観上好ましくない。
【０００５】
一方、接着剤等を用いた化学的接合方法の場合では、繊維強化樹脂複合材料で成形された成形体ａが成形時に表面が樹脂リッチ層ｅとなって強化繊維ｆが存在しないことから、強度の低い樹脂リッチ層ｅ同士のみが接合されて繊維強化された部分は接合されない。そのため、接合部の機械的強度が母材ｇの強度より大幅に低下してしまい、場合によっては母材ｇ強度の半分以下の荷重で亀裂が入ったり、剥離してしまうといった問題点がある。
【０００６】
そこで、本発明はこのような課題を有効に解決するために案出されたものであり、その目的は、繊維強化樹脂成形体同士を接合するに際して、その接合部の美観及び機械的強度の低下等を防止することができる新規な繊維強化樹脂成形体の溶着方法を提供するものである。
【０００７】
【課題を解決するための手段】
上記課題を解決するために本発明は、熱可塑性樹脂からなる母材中に強化繊維が埋め込まれた繊維強化樹脂成形体を形成し、これら繊維強化樹脂成形体端部を重ね合わせて接合する繊維強化樹脂成形体の溶着方法において、上記繊維強化樹脂成形体端部の接合側面を、繊維強化樹脂成形体の板厚ｔに対してその３０〜８０％深さまで加熱すると共に、上記熱可塑性樹脂が溶け落ちないように溶融させ、上記強化繊維の一部を溶融部の表面にまで露出させた後、その溶融部同士を向き合った状態に重ね合わせ、その重ね合わせた部分を加圧成形しながら溶着、接合するようにしたものである。
【０００８】
従って、その接合部においては、両繊維強化樹脂成形体中の強化繊維が相互に絡み合って連続した状態で存在することになるため、その接合部の機械的強度が低下することはない。また、溶着による方法であるため、ボルトなどの機械的接合のような美観の低下を招くこともない。
【０００９】
【発明の実施の形態】
次に、本発明を実施する好適一形態を添付図面を参照しながら詳述する。
【００１０】
本発明に係る繊維強化樹脂成形体の溶着方法は、例えば、図１（Ａ）に示すように、予め板状あるいは角材状に成形された繊維強化樹脂成形体１，１端部の接合部分を加熱溶融して溶融部２，２を形成する加熱溶融工程と、図１（Ｂ）に示すように、この溶融部２，２同士を向き合った状態に重ね合わせ、その重ね合わせた部分を圧着して接合成形する加圧接合成形工程とからなっている。
【００１１】
ここで本発明方法の対象となる繊維強化樹脂成形体１は、スチレン系、アクリル系、セルロース系、ポリエチレン系等の熱可塑性樹脂からなる母材３中に炭素繊維やガラス繊維等の強化繊維４を埋め込んで母材３の強度を向上させたいわゆる複合材料であり、その表層部には、美観のために強化繊維４が殆ど存在しない樹脂リッチ層５が形成されている。
【００１２】
そして、本発明は図示するようにこの繊維強化樹脂成形体１の接合部分を板厚ｔに対してその３０〜８０％深さまで加熱することで、表層部の樹脂リッチ層５のみならず、その内部の強化繊維４を含む母材３の部分まで溶融させて内部の強化繊維４をその溶融部２側へは勿論、さらにその溶融部２の表面にまで露出させた状態とした後、図１（Ｂ）に示すように、その溶融部２，２同士を向き合った状態に重ね合わせ、その重ね合わせた部分を圧着させて接合し、その後、この接合部６を冷却して固化することで両繊維強化樹脂成形体１，１を一体的に接合するようにしたものである。
【００１３】
従って、その接合部においては、両繊維強化樹脂成形体１，１中の強化繊維４が相互に絡み合って連続した状態で接合部６中で固形化させるため、その接合部６の機械的性質は、繊維強化樹脂成形体１の本体と同等の強度を発揮することが可能となり、亀裂や剥離が発生することなく良好な接合を行うことができる。
【００１４】
次に、本発明の具体的実施の形態を説明する。
【００１５】
図２及び図３は、本発明の第一工程である加熱溶融工程を行うための加熱溶融装置の実施の一形態を示したものである。
【００１６】
先ず、図２に示す加熱溶融装置は、繊維強化樹脂成形体１を載置する架台１０と、繊維強化樹脂成形体１の接合部を加熱溶融すべく複数の赤外線ヒータ１１，１１，１１，１１を備えた加熱炉１２とから構成されたものである。そして、図示するように、この架台１０上に予め板状あるいは角材状に成形された繊維強化樹脂成形体１，１を、一定の間隔をおいて突き合わせるように載置した後、その突き合わせ端部の接合面の上方に、加熱炉１２を位置させ、赤外線ヒータ１１より照射される遠赤外線あるいは近赤外線によりその接合面を母材３の融点、例えば、ＰＰ系ＧＦ４０％ｆの場合で２１０℃に加熱して母材３を溶融させる。このとき、加熱範囲及び溶融深さは個々の製品要求スペックに基づき決定されるが、溶融深さとしては上述したように例えば板厚ｔの３０〜８０％の範囲で行えば、母材３中に閉じ込められていた強化繊維４部分が母材３の溶融と共に溶融部２までに移動してきてその一部が溶融部表面まで露出した状態となることが確認されている。また、加熱範囲は、加熱炉１２の開口縁部に設けられた調整フェンス１３の大きさ等を調整することによって行うことができる。
【００１７】
一方、図３に示す加熱溶融装置は、繊維強化樹脂成形体１を載置する架台１０の端部に、その溶融部を囲繞するように加熱炉１２を設けたものである。そして、同じくこの架台１０上に予め板状あるいは角材状に成形された繊維強化樹脂成形体１を設置すると共に、その端部を覆うようにヒーター１１を位置させることで、接合部上面のみならず端部まで纏めて加熱溶融することができる。尚、図３に示すように、加熱範囲が大きくてその溶融部が一気に溶け落ちてしまうおそれがある場合には、予めこの溶融部の肉厚を厚くしておいても良い。
【００１８】
次に、このような加熱溶融工程を経た繊維強化樹脂成形体１，１をその溶融部が固化する前に加圧接合成形工程によって接合することになるが、この加圧接合成形工程としては、例えば、図４及び図５に示すような加圧接合成形装置を用いて行うことができる。
【００１９】
図４に示す加圧接合成形装置は、図２に示す加熱溶融工程を経た繊維強化樹脂成形体１，１を載置する下型１４と、この下型１４上の繊維強化樹脂成形体１，１を加圧接合成形する上型１５とから構成されている。
【００２０】
この下型１４にはコイルスプリング１６などで昇降する昇降台１７が設けられており、この昇降台１７上に一方の繊維強化樹脂成形体１が昇降自在に載置されると共に、他方の繊維強化樹脂成形体１がこの下型１４上に直接載置されるようになっている。一方、上型１５には、繊維強化樹脂成形体１，１をそれぞれ押さえ付ける先行シールブロック１８，１８と、後行シールブロック１９が同じくコイルスプリング１６などによって上型１５に対して昇降自在に設けられている。
【００２１】
従って、図４（Ａ）に示すように、下型１４上に繊維強化樹脂成形体１，１をその溶融部が向き合った状態に載置した後、上型１５を押し下げると、図４（Ｂ）に示すように、先ず先行シールブロック１８，１８が両繊維強化樹脂成形体１，１を下型１４上に押さえ付けることによって両溶融部２，２が接触した後、さらに後行シールブロック１９と上型本体が降りてくることによってその溶融部２，２が圧着されて接合と成形が同時に行われることになる。尚、この接合部６が充分溶着して固化したならば上型１５を上昇させた後、成形体を離型することになるが、この際、昇降台１７がコイルスプリング１６によって上昇するように付勢されているため、上型１５の上昇と同時に成形体が持ち上げられて下型１４から離型が容易に行われることになる。
【００２２】
また、図３に示す加熱溶融工程を経た繊維強化樹脂成形体１，１を溶着する場合には図５に示すような加圧接合成形装置を用いることになる。
【００２３】
この加熱接合成形装置は下型２０及び上型２１にそれぞれ先行シールブロック２２，２３をコイルスプリング１６，１６等によってそれぞれ昇降自在に備えたものであり、図５（Ａ）に示すように、この下型２０と上型２１との間に図３に示す加熱溶融工程を経た繊維強化樹脂成形体１，１の溶融部２，２を上下に位置させた後、図５（Ｂ）に示すように上型２１を降下させて溶融部２，２をシールしながら挟み込むようにしたものである。これによって、上記と同様その接合部が圧着されて溶融部２，２同士の接合と成形が同時に行われることになる。尚、図中２４は繊維強化樹脂成形体１，１のずれなどを防止するための位置決めロッドである。
【００２４】
【発明の効果】
以上要するに本発明によれば、繊維強化樹脂成形体の接合部を、繊維強化樹脂成形体の板厚ｔに対してその３０〜８０％深さまで加熱溶融させて強化繊維部分まで溶着するようにしたため、接合部の機械的性質を低下させることなく接合することができる。従って、その接合部の美観を低下させることなく機械的強度が高くなるため、亀裂や剥離が発生することなく信頼性の高い複合樹脂成形体の接合を行うことができる等といった優れた効果を発揮することができる。
【図面の簡単な説明】
【図１】本発明方法の実施の一形態を示す説明図である。
【図２】本発明に係る加熱溶融工程及びその装置の一例を示す説明図である。
【図３】本発明に係る加熱溶融工程及びその装置の一例を示す説明図である。
【図４】本発明に係る加圧接合成形工程及びその装置の一例を示す説明図である。
【図５】本発明に係る加圧接合成形工程及びその装置の一例を示す説明図である。
【図６】ボルトによる機械的接合状態を示す断面図である。
【図７】接着剤による化学的接合状態を示す断面図である。
【符号の説明】
１ 繊維強化樹脂成形体
２ 溶融部
３ 母材
４ 強化繊維
５ 樹脂リッチ層
６ 接合部

Claims (1)

  1. 熱可塑性樹脂からなる母材中に強化繊維が埋め込まれた繊維強化樹脂成形体を形成し、これら繊維強化樹脂成形体端部を重ね合わせて接合する繊維強化樹脂成形体の溶着方法において、上記繊維強化樹脂成形体端部の接合側面を、繊維強化樹脂成形体の板厚ｔに対してその３０〜８０％深さまで加熱すると共に、上記熱可塑性樹脂が溶け落ちないように溶融させ、上記強化繊維の一部を溶融部の表面にまで露出させた後、その溶融部同士を向き合った状態に重ね合わせ、その重ね合わせた部分を加圧成形しながら溶着、接合するようにしたことを特徴とする繊維強化樹脂成形体の溶着方法。
JP25975597A 1997-09-25 1997-09-25 繊維強化樹脂成形体の溶着方法 Expired - Fee Related JP3859321B2 (ja)

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