JP4303660B2 - 溶着装置及び溶着方法 - Google Patents
溶着装置及び溶着方法 Download PDFInfo
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- JP4303660B2 JP4303660B2 JP2004251497A JP2004251497A JP4303660B2 JP 4303660 B2 JP4303660 B2 JP 4303660B2 JP 2004251497 A JP2004251497 A JP 2004251497A JP 2004251497 A JP2004251497 A JP 2004251497A JP 4303660 B2 JP4303660 B2 JP 4303660B2
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- fluororesin material
- heating
- fluororesin
- welding
- temperature
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- 238000003466 welding Methods 0.000 title claims description 43
- 238000000034 method Methods 0.000 title claims description 11
- 239000000463 material Substances 0.000 claims description 81
- 238000010438 heat treatment Methods 0.000 claims description 44
- 238000002844 melting Methods 0.000 claims description 18
- 230000008018 melting Effects 0.000 claims description 18
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 18
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 18
- 238000005304 joining Methods 0.000 claims description 15
- -1 perfluoroalkyl vinyl ether Chemical compound 0.000 claims description 7
- 229920006026 co-polymeric resin Polymers 0.000 claims description 5
- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical group FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 claims description 5
- 229910052731 fluorine Inorganic materials 0.000 claims description 2
- 239000011737 fluorine Substances 0.000 claims description 2
- 229920005989 resin Polymers 0.000 claims description 2
- 239000011347 resin Substances 0.000 claims description 2
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 claims 1
- 229920002313 fluoropolymer Polymers 0.000 claims 1
- 238000009864 tensile test Methods 0.000 description 4
- 239000000945 filler Substances 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- PXGOKWXKJXAPGV-UHFFFAOYSA-N Fluorine Chemical compound FF PXGOKWXKJXAPGV-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- BXKDSDJJOVIHMX-UHFFFAOYSA-N edrophonium chloride Chemical compound [Cl-].CC[N+](C)(C)C1=CC=CC(O)=C1 BXKDSDJJOVIHMX-UHFFFAOYSA-N 0.000 description 1
- 238000010292 electrical insulation Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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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
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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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- 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
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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
- B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
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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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- 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
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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
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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
- B29C66/50—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
- B29C66/52—Joining tubular articles, bars or profiled elements
- B29C66/526—Joining bars
- B29C66/5261—Joining bars for forming coaxial connections, i.e. the bars to be joined forming a zero angle relative to each other
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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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
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- 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
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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
- B29C66/90—Measuring or controlling the joining process
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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
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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
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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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- B29C65/82—Testing the joint
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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
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- B29C65/82—Testing the joint
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Description
本発明は、難溶着性のフッ素樹脂材料の接合面を溶着するための溶着装置及び溶着方法の改良に関する。
従来より、ポリテトラフルオロエチレン（ＰＴＦＥ）等のフッ素樹脂は、その卓越した熱的、化学的安定性及び電気絶縁性等のために、各種用途に多用されている。このＰＴＦＥは、原料粉をそのまま、または所定の充填材とともに金型に充填して圧縮し、３５０〜４００℃の温度で所定時間加熱して成形する。このような成形後のＰＴＦＥは、融点以上に加熱しても溶着させることが困難な難溶着性のフッ素樹脂材料である。このため、大型の部材を製作するにはＰＴＦＥ材料同士を所定の熱融着性フッ素樹脂材料等を介して溶着し、接合する必要がある。
例えば、下記特許文献１には、ポリテトラフルオロエチレンよりなる成形体を加熱圧着して接合する方法が開示されている。
特公昭６０−５６６１１号公報
しかし、上記従来の技術においては、ＰＴＦＥ材料同士を加熱圧着した後冷却すると、接合部近傍領域で材料の収縮変形が発生するという問題があった。
本発明は、上記従来の課題に鑑みなされたものであり、その目的は、加熱圧着した後材料の収縮変形が発生しない溶着装置及び溶着方法を提供することにある。
上記目的を達成するために、本発明は、難溶着性のフッ素樹脂材料の接合面を溶着するための溶着装置であって、複数の前記フッ素樹脂材料の接合面が対向するように前記フッ素樹脂材料を固定する固定手段と、前記フッ素樹脂材料の前記接合面及びその近傍を、前記フッ素樹脂材料の溶融温度以上の温度に加熱する加熱手段と、前記加熱手段の両端側に配置され、前記溶融温度より低い温度で前記フッ素樹脂材料を余熱する余熱手段と、を備えることを特徴とする。この場合、上記フッ素樹脂材料の接合面の間には、テトラフルオロエチレン・パーフルオロアルキルビニルエーテル共重合樹脂（ＰＦＡ）または変性ＰＴＦＥ等の熱融着性フッ素樹脂材料が配置され、前記加熱手段により前記熱融着性フッ素樹脂材料が加熱されて前記接合面を融着するのが好適である。
また、上記加熱手段の加熱温度は、３３５〜４００℃であり、前記余熱手段の余熱温度が２００〜３００℃であるのが好適である。また、上記加熱手段の加熱領域の長さは１０〜１００ｍｍであるのが好適である。さらに、上記余熱手段の余熱領域の長さは１０〜１００ｍｍであるのが好適である。
また、本発明は、難溶着性のフッ素樹脂材料の接合面を溶着するための溶着方法であって、複数の前記フッ素樹脂材料の接合面が対向するように前記フッ素樹脂材料を固定し、前記フッ素樹脂材料の接合面の間に熱融着性フッ素樹脂材料を介在させ、前記フッ素樹脂材料の前記接合面及びその近傍を、前記フッ素樹脂材料の溶融温度以上の温度に加熱し、前記接合面及びその近傍を、前記フッ素樹脂材料の溶融温度以上の温度に加熱する際に、前記フッ素樹脂材料の加熱部位の外側を前記溶融温度より低い温度で予熱することを特徴とする。この場合、上記熱融着性フッ素樹脂材料は、テトラフルオロエチレン・パーフルオロアルキルビニルエーテル共重合樹脂（ＰＦＡ）または変性ＰＴＦＥであるのが好適である。
本発明によれば、フッ素樹脂材料を溶融温度以上の温度に加熱している間、余熱手段により溶融温度より低い温度でフッ素樹脂材料の加熱部位の外側を余熱するので、接合面近傍領域の収縮変形を抑制できる。
以下、本発明を実施するための最良の形態（以下、実施形態という）を、図面に従って説明する。
図１には、本発明にかかる溶着装置の構成の断面図が示される。図１において、ＰＴＦＥ等の難溶着性のフッ素樹脂材料１０は、互いにその接合面１２が対向するように配置され、固定手段１４で支持、固定されている。このフッ素樹脂材料１０としては、ガラスファイバーなどのフィラーを配合したＰＴＦＥ等も使用できる。フッ素樹脂材料１０の接合面１２の周囲には、接合面１２及びその近傍を、フッ素樹脂材料１０の溶融温度以上の温度に加熱する加熱手段１６が配置されている。また、加熱手段１６の両端側には、余熱手段１８が配置されており、フッ素樹脂材料１０の加熱手段１６で加熱される領域である加熱部位の外側を、フッ素樹脂材料１０の溶融温度より低い温度で余熱するように構成されている。
本発明者らは、上記加熱手段１６により加熱を行っている間、上述した加熱部位の外側を余熱手段１８によりフッ素樹脂材料１０の溶融温度より低い温度で予熱することにより、加熱圧着後のフッ素樹脂材料１０の収縮変形を抑制できることを見い出した。この余熱は、加熱手段１６による加熱と同じタイミングで開始及び終了してもよいし、加熱が終了した後所定時間経過するまで継続してもよい。
なお、上記固定手段１４は、フッ素樹脂材料１０を支持、固定できるものであれば限定されないが、例えば油圧式のクランプ等を使用することができる。また、上記加熱手段１６及び余熱手段１８の、フッ素樹脂材料１０の長さ方向における長さは、フッ素樹脂材料１０の径に応じて適宜決定するが、例えば５０ｍｍ×５０ｍｍのフッ素樹脂の角材同士を接合する場合、加熱手段１６及び余熱手段１８の長さを１０〜１００ｍｍの範囲とするのが好適である。
図１に示された溶着装置により２つのフッ素樹脂材料１０の溶着を行うには、フッ素樹脂材料１０を固定手段１４で支持、固定し、接合面１２を対向させてその間にテトラフルオロエチレン・パーフルオロアルキルビニルエーテル共重合樹脂（ＰＦＡ）または変性ＰＴＦＥのような熱融着性フッ素樹脂を介在させ、余熱手段１８により余熱しつつ、加熱手段１６により所定温度まで加熱する。上記変性ＰＴＦＥとしては、例えば三井デュポンフロロケミカル社製７０Ｊ、ダイキン工業社製Ｍ１１２等がある。
ＰＴＦＥ材料を溶着する場合、余熱温度は２００〜３００℃であり、加熱温度は３３５〜４００℃である。このように、加熱手段１６により接合面１２及びその近傍を、フッ素樹脂材料１０の溶融温度以上の温度で加熱することにより、接合面１２の近傍のフッ素樹脂及び接合面１２の間に介在されたＰＦＡまたは変性ＰＴＦＥが溶融され、接合面１２を互いに融着する。この際、フッ素樹脂材料１０は熱膨張によりその長さ方向に伸びようとするが、固定手段１４によりフッ素樹脂材料１０の上記接合面１２から離隔した部分が支持、固定されているので、対向した接合面１２同士が互いに押圧し合い、その結果接合面１２に２００×１０４Ｎ／ｍ２程度の高い圧力が発生する。このように、接合面１２の近傍の難溶着性フッ素樹脂及び熱融着性フッ素樹脂が溶融した状態で所定時間、例えば２．５時間程度圧力を作用させ、その後冷却することにより、熱融着性フッ素樹脂を介して難溶着性フッ素樹脂材料１０同士を接合面１２において接合することができる。
図２には、上記加熱手段１６及び余熱手段１８の構成例が示される。図２において、加熱手段１６及び余熱手段１８は、ジャケット２０の内部にヒータ２２が挿通されて構成されている。このヒータ２２の形状は、棒状、板状等ジャケット２０に挿通できる形状であれば限定されない。また、ジャケット２０の長さＬは、上述したように、フッ素樹脂材料１０の径に応じて決定される。なお、ジャケット２０は、その中心部に貫通孔２４が形成され、分割線２６により上下又は左右２つに分割可能に構成されている。これにより、分割線２６でジャケット２０を分割して貫通孔２４にフッ素樹脂材料１０を貫通させることができる。
以上に述べた溶着装置により溶着して接合したフッ素樹脂材料１０の接合部の引張試験を実施した。引張試験は、材料を図３に示される形状のマイクロダンベル（ＪＩＳＫ７１３７−２）に加工し、引張試験装置により引張強度を測定した。引張試験装置は、オリオンテック社製テンシロンＵＴＭ−１０Ｔを使用した。なお、上記ダンベルは、溶着装置により接合した接合部２８を含むように加工されている。
なお、比較例として、図４に示されるような深さ３５ｍｍの開先部（溶接用の溝）３０を形成し、この開先部３０に溶融したＰＦＡ３２を満たして接合する従来の溶接方法で溶接したフッ素樹脂材料の、溶接部の引張強度も同様に測定した。
以上の測定結果が、フッ素樹脂材料（母材）の引張強度とともに表１に示される。なお、母材としては、ガラス繊維を１５％含むＰＴＦＥを使用した。
表１に示されるように、母材の引張強度が２３．０ＭＰａであるのに対し、本発明にかかる溶着装置により溶着した場合（本発明品強度）は１８．６ＭＰａとなり、母材の約８０％の強度を維持できた。これに対して、従来の溶接方法（従来品強度）では、引張強度が１２．４ＭＰａまで低下してしまう。この結果から、本発明にかかる溶着装置による溶着方法が優れていることがわかる。
１０ フッ素樹脂材料、１２ 接合面、１４ 固定手段、１６ 加熱手段、１８ 余熱手段、２０ ジャケット、２２ ヒータ、２４ 貫通孔、２６ 分割線、２８ 接合部、３０ 開先部、３２ ＰＦＡ。
Claims (8)
- 難溶着性のフッ素樹脂材料の接合面を溶着するための溶着装置であって、
複数の前記フッ素樹脂材料の接合面が対向するように前記フッ素樹脂材料を固定する固定手段と、
前記フッ素樹脂材料の前記接合面及びその近傍を、前記フッ素樹脂材料の溶融温度以上の温度に加熱する加熱手段と、
前記加熱手段の両端側に配置され、前記溶融温度より低い温度で前記フッ素樹脂材料を加熱する手段と、
を備えることを特徴とする溶着装置。 - 請求項１記載の溶着装置において、前記フッ素樹脂材料の接合面の間には、熱融着性フッ素樹脂材料が配置され、前記加熱手段により前記熱融着性フッ素樹脂材料が加熱されて前記接合面を融着することを特徴とする溶着装置。
- 請求項２記載の溶着装置において、前記熱融着性フッ素樹脂材料は、テトラフルオロエチレン・パーフルオロアルキルビニルエーテル共重合樹脂（ＰＦＡ）または変性ＰＴＦＥであることを特徴とする溶着装置。
- 請求項１から請求項３のいずれか一項記載の溶着装置において、前記加熱手段の加熱温度は、３３５〜４００℃であり、前記溶融温度より低い温度で前記フッ素樹脂材料を加熱する前記手段の加熱温度が２００〜３００℃であることを特徴とする溶着装置。
- 請求項１から請求項４のいずれか一項記載の溶着装置において、前記加熱手段の加熱領域の長さが１０〜１００ｍｍであることを特徴とする溶着装置。
- 請求項１から請求項５のいずれか一項記載の溶着装置において、前記溶融温度より低い温度で前記フッ素樹脂材料を加熱する前記手段の加熱領域の長さが１０〜１００ｍｍであることを特徴とする溶着装置。
- 難溶着性のフッ素樹脂材料の接合面を溶着するための溶着方法であって、
複数の前記フッ素樹脂材料の接合面が対向するように前記フッ素樹脂材料を固定し、
前記フッ素樹脂材料の接合面の間に熱融着性フッ素樹脂材料を介在させ、
前記フッ素樹脂材料の前記接合面及びその近傍を、加熱手段により前記フッ素樹脂材料の溶融温度以上の温度に加熱し、
前記接合面及びその近傍を、前記フッ素樹脂材料の溶融温度以上の温度に加熱する際に、前記加熱手段の両端側に配置された前記フッ素樹脂材料を加熱する手段により、前記フッ素樹脂材料を前記溶融温度より低い温度で加熱する
ことを特徴とする溶着方法。 - 請求項７記載の溶着方法において、前記熱融着性フッ素樹脂材料は、テトラフルオロエチレン・パーフルオロアルキルビニルエーテル共重合樹脂（ＰＦＡ）または変性ＰＴＦＥであることを特徴とする溶着方法。
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