JP4046281B2 - Ultrasonic bonding method for resin parts - Google Patents

Ultrasonic bonding method for resin parts Download PDF

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Publication number
JP4046281B2
JP4046281B2 JP2003053555A JP2003053555A JP4046281B2 JP 4046281 B2 JP4046281 B2 JP 4046281B2 JP 2003053555 A JP2003053555 A JP 2003053555A JP 2003053555 A JP2003053555 A JP 2003053555A JP 4046281 B2 JP4046281 B2 JP 4046281B2
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Japan
Prior art keywords
resin
door trim
ultrasonic
welding
ultrasonic welding
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Expired - Fee Related
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JP2003053555A
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JP2004262041A (en
Inventor
昌彦 菅野
亨 篠原
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Kasai Kogyo Co Ltd
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Kasai 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • 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
    • B29C65/60—Riveting or staking
    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • 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
    • B29C65/60—Riveting or staking
    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • B29C65/607—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking the integral rivets being hollow
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • 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
    • B29C66/81413—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 non-symmetrical
    • 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
    • B29C66/81427—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 ridge, e.g. for making a weakening line; comprising a single tooth
    • B29C66/81429—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 ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
    • 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
    • B29C66/83—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
    • 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
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • 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
    • B29C66/73—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
    • 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

Description

【０００１】
【発明の属する技術分野】
この発明は、複数のトリムメンバーを超音波溶着方法により接合する樹脂部品の超音波接合方法に係り、特に、超音波接合時に生じる余剰樹脂を製品裏面側に強制的に誘導することで、良好な外観性能が得られ、かつ他部品との干渉も未然に防止できる樹脂部品の超音波接合方法に関する。
【０００２】
【従来の技術】
図１１は、上下二分割構成の自動車用ドアトリム１を示す分解図であり、図１２は、自動車用ドアトリムにおける超音波加工時の状態を示す断面図である。図面において、自動車用ドアトリム１はドアトリムアッパー２とドアトリムロア３とから構成されている。そして、ドアトリムアッパー２は樹脂芯材２ａの表面に表皮２ｂを貼着した積層構造体からなり、モールドプレス成形工法、あるいはコールドプレス成形工法により、所望の曲面形状に成形されているとともに、ドアトリムロア３は合成樹脂の射出成形体から構成されている。
【０００３】
次いで、ドアトリムアッパー２とドアトリムロア３との接合構造は、ドアトリムロア３の接合縁部に沿って、溶着用ボス４が適宜ピッチ間隔で立設され、この溶着用ボス４をドアトリムアッパー２に対応して開設されている取付孔５内に挿入した後、図１２に示すように、溶着用ボス４の先端部分に超音波溶着用ホーン６によりカシメ加工を施すことで両者を接合している（例えば、特許文献１参照。）。
【０００４】
【特許文献１】
特開２００１−１９８９３６号公報 （第４頁、図８、図９）
【０００５】
【発明が解決しようとする課題】
このように、一方側がドアトリムロア３のように樹脂部品である場合、複数のトリムメンバー２，３を接合する方法としては、樹脂部品であるドアトリムロア３に溶着用ボス４を立設して、ドアトリムアッパー２の取付孔５内に溶着用ボス４を挿入し、溶着用ボス４の先端部分に超音波溶着カシメ加工を施す方式が多用されているのが実情である。
【０００６】
しかしながら、上述した従来の超音波接合方法においては、溶着用ボス４先端部分の溶融樹脂量が超音波溶着用ホーン６の容量６ａを越えた場合、余剰樹脂が生じ、この余剰樹脂は図１３に示すように、製品表面側にバリａとなって流れ出すか、あるいは裏面側にバリｂとして流れ出してしまう。
【０００７】
従って、製品表面側にバリａが流出した場合は、ドアトリム１の製品外観を大幅に損なうという不具合があり、また、ドアトリムアッパー２の裏面側にバリｂが流出した場合には、ドアパネル等、隣接部品との干渉問題が生じ、パネルへの取付作業に支障を来たしたり、あるいは、走行中の振動により、バリｂがパネルとぶつかり、打音が発生し、静粛な走行が期待できないという問題点があった。
【０００８】
更に、超音波溶着用ホーン６の下降ストローク量や超音波振動等の条件面での細かな調整を必要とするなど、煩雑な条件出しを強いられ、このことが生産性を低下させる大きな要因となっている。
【０００９】
この発明は、このような事情に鑑みてなされたもので、一方側が樹脂部品である複数のトリムメンバーを超音波溶着加工方法により相互に接合する樹脂部品の超音波接合方法であって、製品表面への余剰樹脂の流れ出しがなく、良好な外観性能が得られるとともに、パネル等の隣接部品に対する干渉といった問題もなく、しかも、ラフな条件設定でも充分な溶着強度が得られる樹脂部品の超音波接合方法を提供することを目的とする。
【００１０】
【課題を解決するための手段】
上記目的を達成するために、本発明は、複数のトリムメンバーにおける一方側の樹脂部品の裏面に溶着用突部が立設され、他方側のトリムメンバーに上記溶着用突部に対応して取付孔が開設され、この取付孔内に溶着用突部を挿入し、該溶着用突部の先端部分を超音波溶着用ホーンによりカシメ加工することで、複数のトリムメンバーを接合一体化する樹脂部品の超音波接合方法において、前記超音波溶着用ホーンの先端部分に切欠きが形成されるとともに、超音波溶着時に生じる溶着用突部先端部分の余剰樹脂を上記切欠きを通して超音波溶着用ホーン対向側のトリムメンバーの裏面に誘導することにより、余剰樹脂が製品表面側にバリとなって流出することを回避するようにしたことを特徴とする。
【００１１】
ここで、複数のトリムメンバーとしては、例えば、ドアトリムアッパーとドアトリムロアとからなる上下二分割構成のドアトリムや、アッパーメンバーとロアメンバーとからなるリヤサイドトリム、ラゲージサイドトリム、又は、ドアトリムとその背面側に取り付けられるポケットバックカバーなどに適用でき、相互に隣接する部品であり、一方側が溶着用突部を突設した樹脂部品であれば用途は問わない。
【００１２】
従って、本発明によれば、樹脂部品の裏面に立設した超音波用突部を相手部品の取付孔内に挿入した後、この超音波用突部の先端部分に超音波溶着用ホーンにより溶着加工を施す際、超音波溶着用ホーンの容量以上の溶融樹脂が生じた際、超音波溶着用ホーンの先端部分に設けた切欠きを通してこの余剰樹脂が超音波溶着用ホーン対向側、すなわち製品裏面側に誘導されるため、余剰樹脂は接合面側から製品表面側に流れ出すことがない。
【００１３】
更に、超音波溶着用ホーンの容量以上の余剰樹脂を積極的に相手部品の裏面側に誘導するというものであるから、超音波溶着用ホーンの下降ストローク量や加工条件等の管理を比較的容易に行なえる。
【００１４】
また、本発明の別の実施態様は、前記超音波溶着用ホーンにより溶着用突部の先端部分をカシメ加工する際、超音波溶着用ホーンに設けられている切欠きの設定位置を調整することで、超音波溶着時に生じる余剰樹脂の誘導方向を制御するようにしたことを特徴とする。
【００１５】
従って、超音波溶着用ホーンの容量以上の余剰樹脂は、相手部品の裏面側に誘導されるとともに、誘導方向については切欠きの設定位置を任意に調整することで隣接部品との間のクリアランス等を考慮して選択できるため、車体パネル等、隣接部品との間の干渉や、走行中の振動によるパネルとの打音という問題は有効に解決される。
【００１６】
【発明の実施の形態】
以下、本発明に係る樹脂部品の超音波接合方法の好適な実施の形態について、上下二分割構成のドアトリムに適用した場合について、添付図面を参照しながら詳細に説明する。
【００１７】
図１は本発明方法によりドアトリムアッパーとドアトリムロアとを超音波接合して製作した自動車用ドアトリムを示す正面図、図２は同自動車用ドアトリムの構成を示す断面図、図３は同自動車用ドアトリムにおけるドアトリムアッパーとドアトリムロアとの超音波接合部分を示す拡大断面図、図４は本発明方法に使用する超音波溶着用ホーンの先端部分の形状を示す斜視図、図５は同自動車用ドアトリムにおけるドアトリムアッパーとドアトリムロアとの超音波接合前の状態を示す説明図、図６は同自動車用ドアトリムにおけるドアトリムアッパーとドアトリムロアとの超音波接合時の状態を示す説明図、図７は超音波接合時における超音波溶着用ホーンの切欠きの位置関係を示す説明図、図８は超音波接合後の状態を示す断面図、図９，図１０は複数の切欠きを設けた超音波溶着用ホーンによる超音波接合時の状態を示す平面図並びに断面図である。
【００１８】
図１乃至図３において、本発明を適用して製作した自動車用ドアトリム１０の構成について説明する。この自動車用ドアトリム１０は、ドアトリムアッパー２０とドアトリムロア３０との上下二分割体から構成されている。そして、ドアトリムアッパー２０には、ドアロック機構のロック状態を解除するインサイドハンドルの縁飾り部材としてのインサイドハンドルエスカッション１１が取り付けられており、更に、アームレスト部には、プルハンドル１２及びパワーウインドウスイッチフィニッシャー１３が設けられている。また、ドアトリムロア３０には、備品を収容できるドアポケット開口１４が開設され、そのフロント側には、スピーカグリル１５が一体あるいは別体に設けられいる。
【００１９】
更に詳しくは、ドアトリムアッパー２０とドアトリムロア３０との具体的な構成について、図２を基に説明すると、ドアトリムアッパー２０は、保形性と図示しないドアパネルへの取付剛性を備えた所望の曲面形状に成形された樹脂芯材２１の表面に手触り感並びに外観性能を良好に保つ表皮２２が一体貼着された積層構造体から構成されている。上記樹脂芯材２１としては、汎用の熱可塑性樹脂が使用でき、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、アイオノマー系樹脂、アクリロニトリル／ブタジエン／スチレン（ＡＢＳ）樹脂等が使用できる。
【００２０】
また、この熱可塑性樹脂中に適宜フィラー、例えばガラス繊維、カーボン繊維等の無機繊維や、タルク、クレイ、シリカ、炭酸カルシウム等の無機粒子等の充填剤が混入されていても良い。そして、樹脂芯材２１は、モールドプレス成形、射出成形等により所望の曲面形状に成形される。
【００２１】
一方、表皮２２は、織布シートや不織布シート、又は合成樹脂シート等のシート材料が使用でき、所望ならばこれらシート材料の裏面にポリエチレンフォーム等のクッション層を裏打ちした積層シート材料を使用することもできる。そして、樹脂芯材２１の表面に表皮２２を貼付する方法としては、樹脂芯材２１の成形時に一体成形しても良く、また、バキューム成形等により別途表皮２２を貼付しても良い。
【００２２】
次いで、ドアトリムロア３０は、これも素材としては、ドアトリムアッパー２０における樹脂芯材２１の素材である熱可塑性樹脂と同一のものが使用できる。例えば、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、アイオノマー系樹脂、アクリロニトリル／ブタジエン／スチレン（ＡＢＳ）樹脂等が使用できる。また、このドアトリムロア３０は、特にポケット開口１４の開口縁部の剛性を強化するために、中空部がドアポケット回りに形成されていても良い。
【００２３】
次に、ドアトリムアッパー２０とドアトリムロア３０の接合構造については、ドアトリムアッパー２０の下縁に沿って適宜ピッチ間隔で取付孔２３が開設されているとともに、ドアトリムロア３０の接合縁の裏面には、上記取付孔２３のピッチ間隔に対応して溶着用ボス３１が立設されている。そして、溶着用ボス３１を取付孔２３内に挿入した後、溶着用ボス３１の先端を超音波溶着によりカシメ加工することで、ドアトリムアッパー２０とドアトリムロア３０とが強固に接合一体化されている。尚、溶着用ボス３１に替えて、溶着用リブや爪を使用することもできる。
【００２４】
ところで、本発明方法の特徴は、ドアトリムアッパー２０とドアトリムロア３０とを溶着用ボス３１の超音波溶着加工により両者を接合する際、溶着強度を充分確保できることは勿論のこと、ドアトリム１０の表面に余剰樹脂がバリとして流出することがなく、ドアトリム１０における外観意匠性を良好に保つことが特徴の一つである。
【００２５】
すなわち、図３に示すように、ドアトリムロア３０の裏面に突設形成した溶着用ボス３１は、ドアトリムアッパー２０の取付孔２３を通してその裏面側に突出され、溶着用ボス３１の先端部分は、超音波溶着加工によりカシメ部３２が形成されるとともに、超音波溶着用ホーンの容量以上の溶融樹脂は、余剰樹脂３３としてドアパネル４０と比較的クリアランスを大きく設定されたエリアに強制的に誘導されている。
【００２６】
そして、余剰樹脂３３を裏面側に強制的に誘導することにより、取付孔２３を通じてドアトリムロア３０側に余剰樹脂が流れ出すことがないため、ドアトリム１０表面にバリが形成されることがなく、良好な外観意匠性を維持することができる。更に、ドアトリムアッパー２０の裏面側に誘導される余剰樹脂３３は、ドアパネル４０との間のクリアランスが大きい部位に設定すれば、ドアパネル４０との干渉等の不具合も生じることがない。
【００２７】
次いで、溶着用ボス３１の超音波溶着加工方法において、図４乃至図７に基づいて説明する。まず、本発明方法に使用する超音波溶着用ホーン５０は、図４に示すように、先端面は図３に示すカシメ部３２の形状を付与できるように、中央部がやや突出した椀状の加工面５１が設定され、この加工面５１の湾曲形状によりホーン容量が決定される。そして、本発明に使用する超音波溶着用ホーン５０は、先端周縁の一部に切欠き５２が形成されている。
【００２８】
従って、図５に示すように、治具テーブル６０上にドアトリムロア３０を載置し、ドアトリムロア３０の溶着用ボス３１がドアトリムアッパー２０の取付孔２３内に嵌まり込むようにドアトリムアッパー２０をセットした状態で溶着用ボス３１の先端に図４に示す超音波溶着用ホーン５０を位置決めして、所定圧でプレスしながら所定の振動を加えれば、図６に示すように、溶着用ボス３１の先端部分は超音波溶着用ホーン５０の加工面５１に即した形状のカシメ部３２が形成されるとともに、ホーン容量以上の余剰樹脂３３は、超音波溶着用ホーン５０に設けた切欠き５２から外部に導入され、ドアトリムアッパー２０の裏面側に流出する。
【００２９】
このとき、ドアパネル４０とのクリアランス等を考慮して、余剰樹脂３３が流れ出しても、別段ドアパネル４０との干渉問題が生じない、図７中斜線で示す部位に余剰樹脂３３を誘導しようとすれば、超音波溶着用ホーン５０の切欠き５２を図中θの範囲内に位置決めすることで、バリとなる余剰樹脂３３を適切方向に誘導することができる。また、切欠き５２を大きく設定すれば、図８に示すように、一箇所から大量の余剰樹脂３３を流出させることができ、他部品との干渉という問題を有効に解決できる。
【００３０】
更に、超音波溶着用ホーン５０の先端部分に複数の切欠き５２を設定した場合、例えば、図９に示すように、４方位に４つの切欠き５２を設ければ、超音波接合時には、各切欠き５２から４方位に余剰樹脂３３は流出するものの、図１０に示すように、余剰樹脂３３の高さを低く抑えることができる。
【００３１】
このように、本発明による超音波接合方法によれば、樹脂バリが製品表面側に現われることがなく、外観性能を良好に維持できるとともに、特に、余剰樹脂３３の流出方向を超音波溶着用ホーン５０の切欠き５２の向きを調整することで簡単に制御でき、また、超音波溶着用ホーン５０に設ける切欠き５２の大きさや数を変更することで、余剰樹脂３３の流出量や形状等を調整できることから、製品表面側への樹脂の漏出を確実に防止できるとともに、隣接する車体パネルや隣接する部品との干渉という不具合も有効に解決できる。
【００３２】
加えて、余剰樹脂３３を有効に制御できることから、超音波溶着用ホーン５０の下降ストローク量や加工時間等、条件面を従来に比べて比較的ラフに設定することもでき、超音波溶着加工における工程管理を容易に行なえ、しかも、トライアル工数も低減できるという利点がある。
【００３３】
尚、以上説明した実施形態は、ドアトリムアッパー２０とドアトリムロア３０との上下二分割体からなるドアトリム１０に本発明方法を適用したものであるが、ドアトリムの背面にポケットバックカバーを超音波溶着固定する場合や、アッパーメンバーとロアメンバーとからなるリヤサイドトリム，ラゲージサイドトリム等に有効に適用することができる。その他、電気製品等、樹脂部品の突部を溶着する構造のもの全般に利用できる。また、取付孔を有する部品は必ずしも樹脂部品である必要はないが、双方を同一系統の樹脂材料で統一すれば、相互の相溶性により、接合強度が強固なものとなるため、有利である。
【００３４】
【発明の効果】
以上説明した通り、本発明に係る樹脂部品の超音波接合方法は、超音波溶着用ホーンの先端部分に余剰樹脂を強制的に外部に流出させる切欠きを設定し、超音波溶着用ホーンの容量以上の余剰樹脂を相手部品の裏面側に積極的に誘導するというものであるから、製品表面側に余剰樹脂がバリとなって流出することがなく、超音波溶着固定部付近の表面外観を良好に維持できるという効果を有する。
【００３５】
更に、本発明に係る樹脂部品の超音波接合方法によれば、相手部品の裏面側に誘導される余剰樹脂は、超音波溶着用ホーンの先端部に設けた切欠きの向きを任意に調整することにより、余剰樹脂の流出方向を適宜制御できるため、隣接部品との間の干渉等が生じることがなく、合わせ精度を良好に維持できるという効果を有する。
【００３６】
また、本発明に係る樹脂部品の超音波接合方法によれば、余剰樹脂を切欠きを通じて相手部品の裏面側に強制的に誘導することで、超音波溶着加工時における加工条件を比較的ラフに設定でき、トライアル工数や管理工数を低減できるという効果を有する。
【図面の簡単な説明】
【図１】本発明に係る樹脂部品の超音波接合方法を適用してドアトリムアッパーとドアトリムロアとを接合して製作した自動車用ドアトリムを示す正面図である。
【図２】図１中II−II線断面図である。
【図３】図１に示す自動車用ドアトリムにおけるドアトリムアッパーとドアトリムロアとの超音波接合部を示す拡大図である。
【図４】本発明方法に使用する超音波溶着用ホーンの先端部分の形状を示す斜視図である。
【図５】図１に示す自動車用ドアトリムにおけるドアトリムアッパーとドアトリムロアとの超音波溶着加工前の状態を示す説明図である。
【図６】図１に示す自動車用ドアトリムにおけるドアトリムアッパーとドアトリムロアとの超音波接合時の状態を示す説明図である。
【図７】図１に示す自動車用ドアトリムにおけるドアトリムアッパーとドアトリムロアの超音波接合時における超音波溶着用ホーンの切欠きの位置関係を示す説明図である。
【図８】図１に示す自動車用ドアトリムにおけるドアトリムアッパーとドアトリムロアの超音波接合後の状態を示す断面図である。
【図９】複数の切欠きを設けた超音波溶着用ホーンによる超音波接合時の状態を示す平面図である。
【図１０】複数の切欠きを設けた超音波溶着用ホーンによる超音波接合時の状態を示す断面図である。
【図１１】従来の上下二分割構造の自動車用ドアトリムを示す分解図である。
【図１２】従来の自動車用ドアトリムにおけるドアトリムアッパーとドアトリムロアとの超音波接合要領を示す説明図である。
【図１３】従来の自動車用ドアトリムにおけるドアトリムアッパーとドアトリムロアの超音波接合時の不具合を示す説明図である。
【符号の説明】
１０ 自動車用ドアトリム
２０ ドアトリムアッパー
２１ 樹脂芯材
２２ 表皮
２３ 取付孔
３０ ドアトリムロア（樹脂部品）
３１ 溶着用ボス
３２ カシメ部
３３ 余剰樹脂（バリ）
４０ ドアパネル
５０ 超音波溶着用ホーン
５１ 加工面
５２ 切欠き
６０ 治具テーブル[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an ultrasonic bonding method for resin parts in which a plurality of trim members are bonded by an ultrasonic welding method, and in particular, by surplus resin generated at the time of ultrasonic bonding is forcibly guided to the product back side, The present invention relates to an ultrasonic bonding method for resin parts that can achieve appearance performance and can prevent interference with other parts.
[0002]
[Prior art]
FIG. 11 is an exploded view showing the automobile door trim 1 having a vertically divided configuration, and FIG. 12 is a cross-sectional view showing a state of the automobile door trim during ultrasonic processing. In the drawing, an automobile door trim 1 is composed of a door trim upper 2 and a door trim lower 3. The door trim upper 2 is formed of a laminated structure in which a skin 2b is adhered to the surface of the resin core material 2a. The door trim upper 2 is molded into a desired curved shape by a mold press molding method or a cold press molding method. 3 is comprised from the injection molding of a synthetic resin.
[0003]
Next, in the joining structure of the door trim upper 2 and the door trim lower 3, the welding bosses 4 are provided at appropriate pitch intervals along the joint edge of the door trim lower 3, and the welding bosses 4 correspond to the door trim upper 2. Then, as shown in FIG. 12, after being inserted into the mounting hole 5 established, the tip portion of the welding boss 4 is caulked with an ultrasonic welding horn 6 to join them together ( For example, see Patent Document 1.)
[0004]
[Patent Document 1]
JP 2001-198936 A (page 4, FIG. 8, FIG. 9)
[0005]
[Problems to be solved by the invention]
Thus, when one side is a resin part like the door trim lower 3, as a method of joining the plurality of trim members 2 and 3, the welding boss 4 is erected on the door trim lower 3 which is a resin part, The actual situation is that a method of inserting the welding boss 4 into the mounting hole 5 of the door trim upper 2 and subjecting the tip portion of the welding boss 4 to ultrasonic welding and caulking is frequently used.
[0006]
However, in the conventional ultrasonic bonding method described above, when the amount of the molten resin at the tip of the welding boss 4 exceeds the capacity 6a of the ultrasonic welding horn 6, surplus resin is generated, and this surplus resin is shown in FIG. As shown, it flows out as a burr a on the product surface side or flows out as a burr b on the back surface side.
[0007]
Therefore, when the burr a flows out to the product surface side, there is a problem that the product appearance of the door trim 1 is greatly impaired. When the burr b flows out to the back side of the door trim upper 2, the door panel or the like is adjacent. There is a problem that interference with parts may cause problems in mounting to the panel, or burr b may collide with the panel due to vibration during traveling, and noise may be generated, and silent driving cannot be expected. there were.
[0008]
Furthermore, complicated conditions such as the need for fine adjustment in terms of conditions such as the descending stroke amount and ultrasonic vibration of the ultrasonic welding horn 6 are forced, and this is a major factor that lowers productivity. It has become.
[0009]
The present invention has been made in view of such circumstances, and is an ultrasonic bonding method for resin parts in which a plurality of trim members, one side of which is a resin part, are bonded to each other by an ultrasonic welding method. Ultrasonic bonding of resin parts that does not cause excess resin to flow out, has good appearance performance, has no problem of interference with adjacent parts such as panels, and provides sufficient welding strength even under rough conditions It aims to provide a method.
[0010]
[Means for Solving the Problems]
In order to achieve the above object, according to the present invention , a welding protrusion is erected on the back surface of a resin part on one side of a plurality of trim members, and is attached to the trim member on the other side corresponding to the welding protrusion. A resin part that joins and integrates multiple trim members by inserting a welding projection into this mounting hole and crimping the tip of the welding projection with an ultrasonic welding horn. In the ultrasonic bonding method, a notch is formed in the tip portion of the ultrasonic welding horn, and the surplus resin at the tip portion of the welding projection generated during the ultrasonic welding is opposed to the ultrasonic welding horn through the notch. By guiding to the back surface of the trim member on the side , excess resin is prevented from flowing out as a burr on the product surface side .
[0011]
Here, as the plurality of trim members, for example, a door trim having a vertically divided structure including a door trim upper and a door trim lower, a rear side trim consisting of an upper member and a lower member, a luggage side trim, or a door trim and its rear side It can be applied to a pocket back cover or the like that is attached to, and is a component adjacent to each other.
[0012]
Therefore, according to the present invention, after inserting the ultrasonic projection standing on the back surface of the resin component into the mounting hole of the counterpart component, the ultrasonic projection is welded to the tip of the ultrasonic projection by an ultrasonic welding horn. When molten resin exceeding the capacity of the ultrasonic welding horn is produced during processing, this excess resin passes through the notch provided at the tip of the ultrasonic welding horn, and this surplus resin is opposite the ultrasonic welding horn, that is, the back of the product. Therefore, the surplus resin does not flow from the bonding surface side to the product surface side.
[0013]
Furthermore, since the surplus resin that exceeds the capacity of the ultrasonic welding horn is actively guided to the back side of the mating part, it is relatively easy to manage the amount of stroke and processing conditions of the ultrasonic welding horn. It can be done.
[0014]
Another embodiment of the present invention is to adjust a setting position of a notch provided in the ultrasonic welding horn when crimping a tip portion of the welding protrusion with the ultrasonic welding horn. Thus, the guiding direction of the surplus resin generated during ultrasonic welding is controlled.
[0015]
Therefore, surplus resin more than the capacity of the ultrasonic welding horn is guided to the back side of the mating part, and the clearance between adjacent parts can be adjusted by arbitrarily adjusting the setting position of the notch in the guiding direction. Therefore, it is possible to effectively solve the problems of interference with adjacent parts such as a vehicle body panel, and sound hitting the panel due to vibration during traveling.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a preferred embodiment of an ultrasonic bonding method for resin parts according to the present invention will be described in detail with reference to the accompanying drawings when applied to a door trim having a vertically divided structure.
[0017]
FIG. 1 is a front view showing an automobile door trim manufactured by ultrasonically joining a door trim upper and a door trim lower according to the method of the present invention, FIG. 2 is a sectional view showing the configuration of the automobile door trim, and FIG. 3 is a door trim for the automobile. FIG. 4 is a perspective view showing the shape of the tip of the ultrasonic welding horn used in the method of the present invention, and FIG. FIG. 6 is an explanatory view showing a state before ultrasonic bonding between the door trim upper and the door trim lower, FIG. 6 is an explanatory view showing a state at the time of ultrasonic bonding between the door trim upper and the door trim lower, and FIG. 7 is ultrasonic bonding. FIG. 8 is a sectional view showing a state after ultrasonic bonding, FIG. 10 is a plan view and cross-sectional view showing a state during ultrasonic bonding by ultrasonic welding horn having a plurality of notches.
[0018]
1 to 3, the configuration of an automobile door trim 10 manufactured by applying the present invention will be described. The automobile door trim 10 is composed of an upper and lower divided body of a door trim upper 20 and a door trim lower 30. The door trim upper 20 is attached with an inside handle escutcheon 11 as an edge decoration member of the inside handle for releasing the locked state of the door lock mechanism. Further, the pull handle 12 and the power window switch finisher are mounted on the armrest portion. 13 is provided. Further, the door trim lower 30 is provided with a door pocket opening 14 capable of accommodating equipment, and a speaker grill 15 is provided integrally or separately on the front side thereof.
[0019]
More specifically, a specific configuration of the door trim upper 20 and the door trim lower 30 will be described with reference to FIG. 2. The door trim upper 20 has a desired curved surface shape having shape retention and mounting rigidity to a door panel (not shown). It is composed of a laminated structure in which a skin 22 that keeps a good touch feeling and appearance performance is integrally attached to the surface of the resin core material 21 that is molded into a single layer. As the resin core material 21, a general-purpose thermoplastic resin can be used. Polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, acrylonitrile / Butadiene / styrene (ABS) resin or the like can be used.
[0020]
In addition, fillers such as inorganic fibers such as glass fibers and carbon fibers, and inorganic particles such as talc, clay, silica, and calcium carbonate may be appropriately mixed in the thermoplastic resin. The resin core material 21 is molded into a desired curved surface shape by mold press molding, injection molding, or the like.
[0021]
On the other hand, as the outer skin 22, a sheet material such as a woven fabric sheet, a nonwoven fabric sheet, or a synthetic resin sheet can be used. If desired, a laminated sheet material in which a cushion layer such as polyethylene foam is lined on the back surface of these sheet materials should be used. You can also. And as a method of sticking the skin 22 on the surface of the resin core material 21, it may be integrally formed when the resin core material 21 is molded, or the skin 22 may be separately attached by vacuum molding or the like.
[0022]
Next, as the material of the door trim lower 30, the same material as the thermoplastic resin that is the material of the resin core material 21 in the door trim upper 20 can be used. For example, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, and the like can be used. Further, the door trim lower 30 may have a hollow portion formed around the door pocket in order to enhance the rigidity of the opening edge portion of the pocket opening 14 in particular.
[0023]
Next, regarding the joint structure of the door trim upper 20 and the door trim lower 30, the mounting holes 23 are formed at appropriate pitch intervals along the lower edge of the door trim upper 20, and the back surface of the joint edge of the door trim lower 30 is A welding boss 31 is erected corresponding to the pitch interval of the mounting holes 23. Then, after inserting the welding boss 31 into the mounting hole 23, the door trim upper 20 and the door trim lower 30 are firmly joined and integrated by crimping the tip of the welding boss 31 by ultrasonic welding. . Instead of the welding boss 31, a welding rib or a claw can be used.
[0024]
By the way, the method of the present invention is characterized in that when the door trim upper 20 and the door trim lower 30 are joined together by ultrasonic welding of the welding boss 31, the welding strength can be sufficiently secured, and the surface of the door trim 10 can be secured. One of the features is that the surplus resin does not flow out as burrs and the appearance design of the door trim 10 is kept good.
[0025]
That is, as shown in FIG. 3, the welding boss 31 protrudingly formed on the back surface of the door trim lower 30 is projected to the back surface side through the mounting hole 23 of the door trim upper 20, and the tip end portion of the welding boss 31 is super The caulking portion 32 is formed by the sonic welding process, and the molten resin more than the capacity of the ultrasonic welding horn is forcibly guided as an excess resin 33 to the door panel 40 and an area having a relatively large clearance. .
[0026]
Further, by forcibly guiding the surplus resin 33 to the back surface side, the surplus resin does not flow out to the door trim lower 30 side through the mounting hole 23, so that no burrs are formed on the surface of the door trim 10, which is good. Appearance designability can be maintained. Furthermore, if the excess resin 33 guided to the rear surface side of the door trim upper 20 is set at a portion where the clearance with the door panel 40 is large, problems such as interference with the door panel 40 do not occur.
[0027]
Next, an ultrasonic welding method for the welding boss 31 will be described with reference to FIGS. First, as shown in FIG. 4, the ultrasonic welding horn 50 used in the method of the present invention has a bowl-like shape with a slightly protruding central portion so that the tip surface can have the shape of the caulking portion 32 shown in FIG. A machining surface 51 is set, and the horn capacity is determined by the curved shape of the machining surface 51. And as for the ultrasonic welding horn 50 used for this invention, the notch 52 is formed in a part of front-end | tip periphery.
[0028]
Accordingly, as shown in FIG. 5, the door trim lower 30 is placed on the jig table 60, and the door trim upper 20 is placed so that the welding boss 31 of the door trim lower 30 fits into the mounting hole 23 of the door trim upper 20. When the ultrasonic welding horn 50 shown in FIG. 4 is positioned at the tip of the welding boss 31 in the set state and a predetermined vibration is applied while pressing at a predetermined pressure, the welding boss 31 is shown in FIG. A crimping portion 32 having a shape conforming to the processing surface 51 of the ultrasonic welding horn 50 is formed at the tip portion thereof, and excess resin 33 exceeding the horn capacity is obtained from a notch 52 provided in the ultrasonic welding horn 50. It is introduced outside and flows out to the back side of the door trim upper 20.
[0029]
At this time, in consideration of the clearance with the door panel 40 and the like, even if the excess resin 33 flows out, there is no problem of interference with the separate door panel 40. By positioning the notch 52 of the ultrasonic welding horn 50 within the range of θ in the figure, the surplus resin 33 that becomes a burr can be guided in an appropriate direction. Moreover, if the notch 52 is set large, as shown in FIG. 8, a large amount of surplus resin 33 can flow out from one place, and the problem of interference with other parts can be effectively solved.
[0030]
Furthermore, when a plurality of cutouts 52 are set at the tip of the ultrasonic welding horn 50, for example, as shown in FIG. 9, if four cutouts 52 are provided in four directions, Although the excess resin 33 flows out from the notch 52 in four directions, as shown in FIG. 10, the height of the excess resin 33 can be kept low.
[0031]
As described above, according to the ultrasonic bonding method of the present invention, the resin burr does not appear on the product surface side, the appearance performance can be maintained satisfactorily, and the outflow direction of the surplus resin 33 is particularly set in the ultrasonic welding horn. 50 can be easily controlled by adjusting the direction of the notches 52, and the amount and shape of the excess resin 33 can be controlled by changing the size and number of the notches 52 provided in the ultrasonic welding horn 50. Since it can be adjusted, leakage of the resin to the product surface side can be surely prevented, and the problem of interference with the adjacent vehicle body panel and adjacent parts can be effectively solved.
[0032]
In addition, since the surplus resin 33 can be effectively controlled, it is possible to set conditions such as a descending stroke amount and processing time of the ultrasonic welding horn 50 relatively rough as compared with the conventional case, and in ultrasonic welding processing. There is an advantage that process management can be easily performed and the number of trial steps can be reduced.
[0033]
In the embodiment described above, the method of the present invention is applied to the door trim 10 that is composed of the upper and lower divided parts of the door trim upper 20 and the door trim lower 30. However, the pocket back cover is ultrasonically fixed to the back surface of the door trim. In this case, the present invention can be effectively applied to a rear side trim, a luggage side trim, and the like composed of an upper member and a lower member. In addition, it can be used for all types of structures such as electrical products where the protrusions of resin parts are welded. In addition, the part having the mounting hole is not necessarily a resin part, but it is advantageous if both are made of the same type of resin material because the bonding strength becomes strong due to the mutual compatibility.
[0034]
【The invention's effect】
As described above, the ultrasonic bonding method for resin parts according to the present invention sets the notch for forcibly discharging the excess resin to the outside at the tip portion of the ultrasonic welding horn, and the capacity of the ultrasonic welding horn. Since the above surplus resin is actively guided to the back side of the mating part, the surplus resin does not flow out as burrs on the product surface side, and the surface appearance near the ultrasonic weld fixing part is good. It has the effect that it can be maintained.
[0035]
Furthermore, according to the ultrasonic bonding method for resin parts according to the present invention, the surplus resin guided to the back side of the mating part arbitrarily adjusts the direction of the notch provided at the tip of the ultrasonic welding horn. As a result, the outflow direction of the surplus resin can be controlled as appropriate, so that there is no interference between adjacent parts and the alignment accuracy can be maintained satisfactorily.
[0036]
Also, according to the ultrasonic bonding method for resin parts according to the present invention, the excessive resin is forcibly guided to the back side of the mating part through the notch, so that the processing conditions during ultrasonic welding are relatively rough. It can be set and has the effect of reducing the trial man-hours and management man-hours.
[Brief description of the drawings]
FIG. 1 is a front view showing an automobile door trim manufactured by joining a door trim upper and a door trim lower by applying an ultrasonic joining method of resin parts according to the present invention.
2 is a cross-sectional view taken along line II-II in FIG.
3 is an enlarged view showing an ultrasonic bonding portion between a door trim upper and a door trim lower in the automobile door trim shown in FIG. 1. FIG.
FIG. 4 is a perspective view showing the shape of a tip portion of an ultrasonic welding horn used in the method of the present invention.
FIG. 5 is an explanatory view showing a state before ultrasonic welding of the door trim upper and the door trim lower in the automobile door trim shown in FIG. 1;
6 is an explanatory view showing a state at the time of ultrasonic bonding between a door trim upper and a door trim lower in the automobile door trim shown in FIG. 1; FIG.
7 is an explanatory view showing a positional relationship between notches of an ultrasonic welding horn at the time of ultrasonic bonding of a door trim upper and a door trim lower in the automobile door trim shown in FIG. 1. FIG.
8 is a cross-sectional view showing a state after ultrasonic bonding of a door trim upper and a door trim lower in the automobile door trim shown in FIG. 1; FIG.
FIG. 9 is a plan view showing a state at the time of ultrasonic bonding by an ultrasonic welding horn provided with a plurality of notches.
FIG. 10 is a cross-sectional view showing a state at the time of ultrasonic bonding by an ultrasonic welding horn provided with a plurality of notches.
FIG. 11 is an exploded view showing a conventional automotive door trim having a vertically divided structure.
FIG. 12 is an explanatory view showing an ultrasonic joining procedure between a door trim upper and a door trim lower in a conventional automobile door trim.
FIG. 13 is an explanatory view showing a problem in ultrasonic joining of a door trim upper and a door trim lower in a conventional automobile door trim.
[Explanation of symbols]
10 Automotive Door Trim 20 Door Trim Upper 21 Resin Core Material 22 Skin 23 Mounting Hole 30 Door Trim Lower (Resin Parts)
31 welding boss 32 caulking part 33 surplus resin (burr)
40 Door panel 50 Ultrasonic welding horn 51 Machined surface 52 Notch 60 Jig table

Claims (2)

複数のトリムメンバー（２０，３０）における一方側の樹脂部品（３０）の裏面に溶着用突部（３１）が立設され、他方側のトリムメンバー（２０）に上記溶着用突部（３１）に対応して取付孔（２３）が開設され、この取付孔（２３）内に溶着用突部（３１）を挿入し、該溶着用突部（３１）の先端部分を超音波溶着用ホーン（５０）によりカシメ加工することで、複数のトリムメンバー（２０，３０）を接合一体化する樹脂部品の超音波接合方法において、
前記超音波溶着用ホーン（５０）の先端部分に切欠き（５２）が形成されるとともに、超音波溶着時に生じる溶着用突部（３１）先端部分の余剰樹脂（３３）を上記切欠き（５２）を通して超音波溶着用ホーン（５０）対向側のトリムメンバー（２０）の裏面に誘導することにより、余剰樹脂（３３）が製品表面側にバリとなって流出することを回避するようにしたことを特徴とする樹脂部品の超音波接合方法。A welding protrusion (31) is erected on the back surface of the resin part (30) on one side of the plurality of trim members (20, 30), and the welding protrusion (31) is provided on the trim member (20) on the other side. A mounting hole (23) is established corresponding to the above, and a welding projection (31) is inserted into the mounting hole (23), and the tip of the welding projection (31) is connected to an ultrasonic welding horn ( 50) In the ultrasonic joining method for resin parts in which a plurality of trim members (20, 30) are joined and integrated by caulking,
A notch (52) is formed at the tip of the ultrasonic welding horn (50), and the excess resin (33) at the tip of the welding projection (31) generated during ultrasonic welding is removed from the notch (52). ) Through the ultrasonic welding horn (50) to the back surface of the trim member (20) on the opposite side, thereby preventing the excess resin (33) from flowing out to the product surface side as burrs. An ultrasonic bonding method for resin parts characterized by the above. 前記超音波溶着用ホーン（５０）により溶着用突部（３１）の先端部分をカシメ加工する際、超音波溶着用ホーン（５０）に設けられている切欠き（５２）の設定位置を調整することで、超音波溶着時に生じる余剰樹脂（３３）の誘導方向を制御するようにしたことを特徴とする請求項１に記載の樹脂部品の超音波接合方法。  When the tip of the welding projection (31) is crimped by the ultrasonic welding horn (50), the setting position of the notch (52) provided in the ultrasonic welding horn (50) is adjusted. The method for ultrasonic bonding of resin parts according to claim 1, wherein the guiding direction of the surplus resin (33) generated during ultrasonic welding is controlled.
JP2003053555A 2003-02-28 2003-02-28 Ultrasonic bonding method for resin parts Expired - Fee Related JP4046281B2 (en)

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JP4683917B2 (en) * 2004-12-28 2011-05-18 日本プラスト株式会社 Positioning welding structure of resin parts
JP6421529B2 (en) * 2014-10-06 2018-11-14 株式会社デンソー Joined member and accelerator device using the same
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JP2023527970A (en) * 2020-06-03 2023-07-03 クリック アンド ソッファ インダストリーズ、インク． Ultrasonic Welding Systems, Methods of Their Use, and Associated Workpieces Containing Welded Conductive Pins

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