JP4439290B2 - 熱可塑性樹脂製部の製造方法 - Google Patents
熱可塑性樹脂製部の製造方法 Download PDFInfo
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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
- B29C65/02—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
- B29C65/16—Laser beams
- B29C65/1629—Laser beams characterised by the way of heating the interface
- B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission 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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- 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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- 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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- 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
- B29C66/40—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
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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
- B29C66/70—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
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- 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
- 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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- B29C65/1606—Ultraviolet [UV] radiation, e.g. by ultraviolet excimer lasers
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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
- B29C65/02—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
- B29C65/16—Laser beams
- B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
- B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
- B29C65/1616—Near infrared radiation [NIR], e.g. by YAG lasers
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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
- B29C65/02—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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- B29C65/1619—Mid infrared radiation [MIR], e.g. by CO or CO2 lasers
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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
- B29C65/02—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
- B29C65/16—Laser beams
- B29C65/1629—Laser beams characterised by the way of heating the interface
- B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one 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
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
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- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
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- B29C66/1244—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
- B29C66/12441—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue being a single wall
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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
- B29C66/70—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
- 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
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Description
(1)レーザ光は第1部材を透過する。
(2)第1部材を透過したレーザ光は、第2部材の表面近傍で吸収されて熱に変換される。
といった2点を挙げることができる。第1部材を透過したレーザ光が、第2部材の表面近傍で吸収されて熱に変換されることによって、第1部材及び第2部材の接合面が溶融して、第1部材と第2部材とを一体化させることができる。
第2部材と対面する第1部材の表面の部分には、凹部が設けられており、
凹部の底部に接触するように、且つ、凹部と対向する第2部材の表面の部分に接触するように、レーザ光吸収部材を凹部内に配置したとき、レーザ光吸収部材は、凹部周辺において第1部材と第2部材との間に隙間(SP)が存在するような高さ(H)を有し、
(A)凹部の底部に接触するように、且つ、凹部と対向する第2部材の表面の部分に接触するように、レーザ光吸収部材を凹部内に配置し、そして、第2部材に対して第1部材を押圧した状態にて第1部材と第2部材とを配置した後、
(B)第2部材に対して第1部材を押圧した状態で第1部材及び/又は第2部材を介してレーザ光をレーザ光吸収部材に照射してレーザ光吸収部材を溶融させて、凹部周辺において第1部材と第2部材とを接触させ、次いで、レーザ光のレーザ光吸収部材への照射を中止し、レーザ光吸収部材を冷却することで、第1部材に対してレーザ光吸収部材を融着させ、且つ、第2部材に対してレーザ光吸収部材を融着させて、第1部材と第2部材とを一体化する、
工程を具備することを特徴とする。
0.8≦S2/S1≦1.2、
望ましくは、
0.9≦S2/S1≦1.0、
を満足することが好ましい。S2/S1の値が上記の範囲から逸脱しても熱可塑性樹脂製部材の製造は十分に可能であるが、S2/S1の値が0.8未満では、冷却後のレーザ光吸収部材と凹部との間に大きな空隙が生じる虞がある。一方、S2/S1の値が1.2を越える場合、第2部材と対面しない第1部材の表面(外面)や、第1部材と対面しない第2部材の表面(外面)に膨れが生じる虞がある。尚、S2/S1の値が1.0を越えた場合、場合によっては、溶融したレーザ光吸収部材が凹部から溢れることがあるが、実質的に、何ら問題は生じない。また、この場合、第2部材に対して第1部材を押圧した状態で第1部材及び/又は第2部材を介してレーザ光をレーザ光吸収部材に照射してレーザ光吸収部材を溶融させて、凹部周辺において第1部材と第2部材とを接触させるとき、凹部周辺において第1部材と第2部材とがレーザ光吸収部材を介して接触する場合もあり得るが、このような状態も、凹部周辺において第1部材と第2部材とが接触する形態に包含される。
第2部材と対面する第1部材の表面の部分には、凹部が設けられており、
凹部周辺において第1部材と第2部材とは接触しており、
接合部材は凹部内に配されており、
第1部材に対して接合部材が融着し、且つ、第2部材に対して接合部材が融着していることを特徴とする。
0.8≦S’2/S1≦1.0、
望ましくは、
0.9≦S’2/S1≦1.0、
を満足することが好ましい。
(1)第2部材に対して第1部材を押圧すること
(2)第1部材に対して第2部材を押圧すること
(3)第2部材に対して第1部材を押圧し、且つ、第1部材に対して第2部材を押圧すること
の3つの形態は全て等価である。第2部材に対して第1部材を押圧した状態における押圧力として、1×104Pa乃至1×106Paを例示することができる。
比較例1として、図9の(A)及び(B)に模式的な断面図を示すように、実施例1と同じ材料から製造された第1部材110と第2部材120とレーザ光吸収部材130とを準備した。第1部材110及び第2部材120の形状、寸法を、実施例1における第1部材10及び第2部材20と同じとした。但し、実施例1と異なり、第2部材120と対面する第1部材110の表面(接合面)の部分には凹部が設けられておらず、平坦である。また、レーザ光吸収部材130の形状は、幅30mm×厚さ1mm×長さ100mmである。
Claims (5)
- レーザ光を実質的に吸収しない熱可塑性樹脂からそれぞれが成る第1部材と第2部材とを、レーザ光吸収部材及びレーザ光を用いて一体化する熱可塑性樹脂製部材の製造方法であって、
第2部材と対面する第1部材の表面の部分には、凹部が設けられており、
凹部の底部に接触するように、且つ、凹部と対向する第2部材の表面の部分に接触するように、レーザ光吸収部材を凹部内に配置したとき、レーザ光吸収部材は、凹部周辺において第1部材と第2部材との間に隙間(SP)が存在するような高さ(H)を有し、
(A)凹部の底部に面接触するように、且つ、凹部と対向する第2部材の表面の部分に面接触するように、レーザ光吸収部材を凹部内に配置し、そして、第2部材に対して第1部材を押圧した状態にて第1部材と第2部材とを配置した後、
(B)第2部材に対して第1部材を押圧した状態で第1部材及び/又は第2部材を介してレーザ光をレーザ光吸収部材に照射してレーザ光吸収部材を溶融させて、凹部周辺において第1部材と第2部材とを接触させ、次いで、レーザ光のレーザ光吸収部材への照射を中止し、レーザ光吸収部材を冷却することで、第1部材に対してレーザ光吸収部材を融着させ、且つ、第2部材に対してレーザ光吸収部材を融着させて、第1部材と第2部材とを一体化する、
工程を具備し、
凹部の軸線方向と垂直な仮想平面で凹部を切断したときの断面形状、及び、レーザ光吸収部材の軸線方向と垂直な仮想平面でレーザ光吸収部材を切断したときの断面形状は矩形であり、
凹部の軸線方向と垂直な仮想平面で凹部を切断したときの凹部断面積をS 1 、レーザ光吸収部材の軸線方向と垂直な仮想平面でレーザ光吸収部材を切断したときのレーザ光吸収部材断面積をS 2 としたとき、
0.9≦S 2 /S 1 ≦1.0
を満足し、且つ、
0.1≦SP/H≦0.6
を満足することを特徴とする熱可塑性樹脂製部材の製造方法。 - レーザ光の波長は、0.7μm乃至1.2μmであることを特徴とする請求項1に記載の熱可塑性樹脂製部材の製造方法。
- レーザ光吸収部材は、熱可塑性樹脂及びカーボンブラックから成ることを特徴とする請求項1に記載の熱可塑性樹脂製部材の製造方法。
- 第1部材を構成する熱可塑性樹脂と、第2部材を構成する熱可塑性樹脂と、レーザ光吸収部材を構成する熱可塑性樹脂とは、同じ熱可塑性樹脂であることを特徴とする請求項3に記載の熱可塑性樹脂製部材の製造方法。
- 熱可塑性樹脂はポリカーボネート樹脂であることを特徴とする請求項4に記載の熱可塑性樹脂製部材の製造方法。
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