JP5298311B2 - Tool horn and ultrasonic welding apparatus using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an ultrasonic welding apparatus for fixing a fibrous mat, which surely pressurizes a pressing surface and a V-shaped projection of a tool horn to the center part of a planned welding region and can provide a strong welding strength and an anchor effect by the V-shaped projection, when a fibrous mat such as nonwoven fabric is fixed to the surface of a resin molded article by ultrasonic welding, and to provide the tool horn for fixing the fibrous mat. <P>SOLUTION: A pressing surface at the columnar tip end of the tool horn 4 is formed into a curved face, a plurality of V-shaped projections or V-shaped grooves are formed in an intersected form along the curved face. Then, while the fibrous mat 91 placed on the resin molded article 90 is pressurized by the curved face having the V-shaped projections or the V-shaped grooves and is subjected to ultrasonic vibration, so that the fibrous mat is welded to the resin molded article. Particularly with the V-shaped projections or the V-shaped grooves, the fibrous mat 91 is welded to the surface of the resin molded article 90 in a bitten form, which enhances a welding strength between the two. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a tool horn and an ultrasonic welding apparatus for ultrasonically welding and fixing a sheet member to other plate materials and the like, and particularly for fixing a fibrous mat for fixing a fibrous mat such as a nonwoven fabric to the surface of a resin molded product. The present invention relates to a tool horn and an ultrasonic welding apparatus.

Conventionally, a fiber mat made of a nonwoven fabric, which is a sound absorbing member for a vehicle, is ultrasonically welded to the back surface of a resin molded product for a vehicle such as an automobile (see, for example, Patent Document 1). In order to increase the welding strength between the fibrous mat and the resin molded product, various improvements have been made to the shape of the tool horn.
FIG. 13 shows a conventional tool horn. 13A is a side view of the tool horn 80, and FIG. 13B is a bottom view of the tool horn 80. A V-shaped protrusion whose cross section protrudes into a V-shape on the pressing surface 81 at the tip of the tool horn 80. The state where the part 82 is formed is shown. In FIG. 13 (b), in order to explain the positional relationship between the pressure surface 81 and the V-shaped projection 82, the right pressure surface is denoted by 81a and the left pressure surface is denoted by 81b when viewed from the front. When viewed from the front, the right V-shaped projecting portion is denoted by 82a, the central V-shaped projecting portion 82b, and the left V-shaped projecting portion 82c.

  The tool horn 80 has a flat pressurizing surface 81 at the lower surface of the tip having a reduced diameter, and V-shaped projections 82 are formed in a lattice shape on the surface of the flat pressurizing surface 81. The V-shaped protrusion 82 is formed on the flat pressure surface 81 of the tool horn 80 because the V-shaped protrusion 82 embeds the fibrous mat 91 on the surface of the resin molded product 90, so-called “anchor effect”. Because there is. In addition, since the height of the V-shaped projection part 82 calculated | required by the conventional tool horn 80 fluctuate | varies with welding conditions, it carried out the welding experiment beforehand and calculated | required the preferable height (for example, refer patent document 2).

  FIG. 14 is a cross-sectional view when the fibrous mat 91 is welded to the resin molded product 90 with the conventional tool horn 80. As shown in FIG. 14A, the welding operation is performed by pushing down the tip of the tool horn 80 in a direction perpendicular to the surfaces of the resin molded product 90 and the fiber mat 91 as indicated by an arrow A. When ultrasonic vibration of 15 kHz to 60 kHz is applied to the tool horn 80 by an ultrasonic driving means (not shown) in a state where the pressing surface 81 on which the V-shaped protrusion 82 is formed presses the fibrous mat 91 with uniform pressure, The fibrous mat 91 and the resin molded product 90 are heated and welded by the sonic vibration. In particular, since the V-shaped projecting portion 82 pushes the fibers of the fibrous mat 91 into the surface of the resin molded product 90, the fibers of the fibrous mat 91 are welded in a state of entering the resin molded product 90, and strong welding strength is obtained. You can have it.

  Here, in the conventional tool horn 80 in which the V-shaped protrusion 82 is formed on the flat pressing surface 81, it is necessary to press the flat pressing surface 81 uniformly against the surface of the resin molded product 90 and the fiber mat 91. . In the case of a press-type ultrasonic welding device that raises and lowers the tool horn with air pressure, it is easy to keep the tool horn up and down in a certain direction and press the surface of the fiber mat evenly. In a manual ultrasonic welding device that performs pressing, it is difficult to press the tool horn perpendicularly to the surface of the resin molded product and the fiber mat, and the surface of the fiber mat can be pressed uniformly each time. There wasn't.

  FIG. 14B shows a cross-sectional view when the tool horn 80 is welded in a state of being inclined with respect to the surfaces of the resin molded product 90 and the fiber mat 91. For example, as indicated by the arrow B, when the tool horn 80 moves up and down at an angle of θ with respect to the arrow A perpendicular to the surface of the resin molded product 90, the end of the pressure surface 81 hits the piece and the resin molded product 90 It does not hit the surface of the fiber mat 91 uniformly. The pressure surface 81a on the front right side of the tool horn 80 strongly hits the surfaces of the resin molded product 90 and the fiber mat 91, and the pressure surface 81b on the left side of the front surface is lifted. The pressing force is maximum at the pressure surface 81a on the front right side in FIG. 14B and gradually decreases toward the pressure surface 81b on the left side of the front surface. Where the pressing force is insufficient, the welding is insufficient and the necessary welding force cannot be obtained.

  Further, the V-shaped protrusions of the V-shaped protrusion 82a on the front right side in FIG. 14B bite into the resin molded product 90, but the V-shaped protrusions 82b at the center of the front and the V-shaped protrusions 82c on the left side of the front are resin. The depth of biting into the molded product 90 becomes shallow. If the bite depth of the V-shaped protrusion 82 into the resin molded product 90 is shallow, the anchor effect for causing the fibrous mat 91 to bite into the resin molded product 90 cannot be sufficiently obtained.

  In the end, the conventional tool horn 80 has a cylindrical tip and a flat pressing surface. Therefore, when tilted slightly, a narrow region at one end of the pressing surface of the tool horn strongly hits the resin molded product 90, and that portion is strongly welded. However, the central portion of the planned welding region, the peripheral portion thereof, and the other end side have insufficient pressing force, resulting in insufficient welding. That is, when the conventional tool horn 80 is tilted, the contact point of the maximum pressing force is shifted by the radius (for example, 8 mm) of the tool horn pressing surface regardless of the tilt angle (θ). . Therefore, in the conventional tool horn 80, if the tool horn 80 is tilted even if it is pressed aiming at the center of the predetermined welding planned area, the narrow area is deviated from the center of the welding planned area by the radius of the tip of the tool horn. By simply welding the tool horn, the tool horn floats at the center of the intended welding region, its peripheral portion, and the other end, resulting in insufficient welding. The anchor effect also has a problem that it is insufficient at the center of the region to be welded and its peripheral portion.

  Further, the surface of the resin molded product and the fiber mat in the planned welding region is not always flat. The surface of the resin molded product may be a surface having a large curve, a surface having a small curve locally, or a slope. In this case, even in a press-type ultrasonic welding apparatus, the pressure surface of the tool horn is inclined with respect to the surface of the resin molded product and the fiber mat, and a narrow region at one end of the pressure surface of the tool horn is between the resin molded product and the fiber mat. At the center of the planned welding area, its peripheral part, and the other end side, the pressure surface of the tool horn is lifted up, resulting in insufficient welding.

Japanese Patent Laid-Open No. 11-5267 JP 2006-142705 A

  In the present invention, when a fibrous mat such as a nonwoven fabric is fixed to the surface of a resin molded product by ultrasonic welding, the pressing surface of the tool horn and the V-shaped protrusion or V-shaped groove are pressed to the central portion of the planned welding area. Thus, an object of the present invention is to provide an ultrasonic welding apparatus and a tool horn for fixing a fibrous mat, which give strong welding strength and an anchor effect by a V-shaped projection or the like to the center and the peripheral portion of a planned welding region.

  Moreover, even when the tool horn is slightly inclined with respect to the surface of the resin molded product and the fiber mat, the present invention provides a pressing surface, a V-shaped protrusion, or a V-shaped groove at the center of the tool horn and the fiber mat. It is an object of the present invention to provide a tool horn and an ultrasonic welding apparatus that can be pressed against the center of a planned welding region on the surface of a resin molded product and its peripheral portion to reliably weld and fix the center of the welding planned region and its peripheral portion.

The tool horn of the present invention has a columnar shape with a thick base and a thin tip at the tip, and is held by the operator's hand and pressed against the fibrous mat placed on the resin molded product with the pressing surface of the tip . A tool horn for ultrasonically welding the fibrous mat to the resin molded product, wherein the pressing surface is a curved surface having one apex, and a plurality of concentric cross-sections V-shaped around the apex of the curved surface of the pressing surface. A plurality of radial cross-section V-shaped projections or cross-section V-shaped grooves centering on the apex of the curved surface of the pressing surface and the V-shaped cross section of the pressing surface, the concentric cross-section V-shaped projection Alternatively, the cross-sectional V-shaped groove and the radial cross-sectional V-shaped protrusion or the cross-sectional V-shaped groove are arranged so as to intersect each other, and when the pressing surface presses the tool horn against the surface of the fiber mat, Concentric and radial cross-section near the apex of the pressing surface It is configured to impart an anchoring effect by raising or a V-shaped groove.
And, in any case where the tool horn is pressed from the vertical or near vertical angle with respect to the surface of the fibrous mat, the welding object is formed by the cross-sectional V-shaped protrusion or the cross-sectional V-shaped groove of the tool horn. The fiber mat is welded by applying an anchor effect to the central portion and the peripheral portion of the planned welding region.
By adopting this configuration, even if the tool horn is pressed at an angle inclined with respect to the object to be welded, the center of the planned welding area and its peripheral part are formed on the pressing surface of the tool horn and the V-shaped protrusion or the V-shaped section. Press with a groove . Then, the center of the planned welding region and its peripheral portion are welded.

In the tool horn of the present invention, the curved surface of the pressing surface is a hemispherical surface. By adopting this configuration, the object to be welded is pressed by pressing the hemispherical surface.

Moreover, the tool horn of the present invention is a fiber mat in which an object to be welded is placed on a resin molded product.
By adopting this configuration, even if the tool horn is pressed at an inclined angle with respect to the surface of the resin molded product and the fiber mat placed thereon, the center of the area to be welded and its peripheral portion are connected to the tool horn. It presses with a pressing surface and a cross-sectional V-shaped protrusion or a cross-sectional V-shaped groove . Then, the center of the planned welding region and its peripheral portion are welded.

The ultrasonic welding apparatus of the present invention further includes ultrasonic vibration generating means connected to the tool horn and applying ultrasonic vibration to the tool horn. By adopting this configuration, ultrasonic welding is performed on the object to be welded using the tool horn, so that the center and peripheral portions of the planned welding area can be removed even if the object to be welded is pressed in an inclined state. It is possible to weld the center of the planned welding area and its peripheral portion by pressing with the pressing surface of the horn and the V-shaped protrusion or the V-shaped groove .

  Furthermore, in the ultrasonic welding apparatus of the present invention, the tool horn can be manually operated. By adopting this configuration, even the tool horn that is difficult to be always pressed vertically can be welded to the center of the planned welding region and its peripheral portion.

According to the present invention, when the tool horn is pressed aiming at the center of the welding area of the surface of the plate member and the sheet member placed thereon, the pressing direction of the tool horn is inclined with respect to the surface of the plate member and the sheet member. and even though, that the pressing surface of the tool horn forms a curved surface, since no uneven contact can push without a pressing force is biased, central and pressing surface of the peripheral portion the tool horn region to be fused and a cross-sectional V-shaped collision Okoshima other is pressed by the V-shaped cross section grooves, it is possible to weld the central and peripheral portions thereof of the region to be fused.

According to the present invention, the pressing surface and a V-shaped butt Okoshima other tool horn cross section V-shaped groove, at an oblique angle relative to resin moldings and fibrous mat surface placed thereon be pressed, the center and its pressing surface peripheral portion and a V-shaped butt Okoshima other region to be fused is pressed by a V-shaped groove, it is reliable and stable welding operation.
According to the present invention, when a plate member such as a resin molded article and a sheet member such as a fibrous mat represented by a nonwoven fabric are fixed by ultrasonic welding, the center of the planned welding area and its peripheral portion are pressed by the tool horn. face and a V-shaped butt Okoshima other can be pressed by a V-shaped groove, obtain the anchor effect due to a strong welding strength and the V-shaped projection.

  Also, by using such a tool horn for the ultrasonic welding device, the efficiency of the welding work can be improved, especially the accuracy of the manual ultrasonic welding device that is operated by holding the tool horn by hand. Can be made.

BRIEF DESCRIPTION OF THE DRAWINGS The external view which showed the tool horn concerning Embodiment 1 of this invention, the ultrasonic welding apparatus using the same, the sheet | seat member (fiber mat | matte) and board | plate material (resin molded product) which are welding objects. 1 is an external perspective view of a tool horn according to a first embodiment of the present invention. (A) Sectional drawing which shows the welding operation | work using the tool horn concerning Embodiment 1 of this invention (b) Sectional drawing which shows the welding operation | work using the tool horn concerning Embodiment 1 of this invention. The schematic diagram which shows the deviation | shift amount when the tool horn concerning Embodiment 1 of this invention inclines. Sectional drawing which shows the welding operation | work using the tool horn concerning Embodiment 1 of this invention. (A) Sectional drawing of the tool horn tip concerning Embodiment 2 of this invention (b) The side view of the tool horn tip concerning Embodiment 2 of this invention. (A) Sectional drawing of the tool horn tip concerning Embodiment 3 of this invention (b) The side view of the tool horn tip concerning Embodiment 3 of this invention. The external appearance perspective view of the tool horn concerning the reference example 1. FIG. (A) cross-sectional view showing a welding operation using a tool horn according to a cross-sectional view (b) Example 1 shows the welding operation using a tool horn according to the reference example 1. (A) cross-sectional view showing a welding operation using a tool horn according to a cross-sectional view (b) Reference Example 2 showing the welding operation using a tool horn according to Reference Example 2. The external appearance perspective view of the front-end | tip part of the tool horn concerning the reference example 3. FIG. The external appearance perspective view which gave the shadow of the front-end | tip part of the tool horn concerning the reference example 4. FIG. (A) Side view of a conventional tool horn (b) Bottom view showing a pressing surface of a conventional tool horn. (A) Sectional drawing which shows the welding operation | work using the conventional tool horn (b) Sectional drawing which shows the welding operation | work using the conventional tool horn.

  An embodiment for carrying out the present invention will be described with reference to the drawings. FIG. 1 is an external view showing a schematic configuration of a tool horn according to a first embodiment of the present invention and an ultrasonic welding apparatus using the same. Reference numeral 1 denotes a main body portion of the ultrasonic welding apparatus, which incorporates electronic control means for creating ultrasonic vibrations such as an ultrasonic power source unit, an energy control unit, and an overall control unit (not shown). The main body unit 1 is provided with an input / output unit 14 as a man-machine interface for setting welding conditions and the like, and a notification unit 15 indicating the progress of welding work. An ultrasonic signal is sent from the main body 1 through the cable 2, the ultrasonic signal is converted into mechanical ultrasonic vibration by the converter 3 connected to the cable 2, and the tool horn 4 connected to the converter 3 is ultrasonically vibrated. It is composed. In addition, although the booster etc. which adjust an amplitude are integrated between the converter 3 and the tool horn 4, description is abbreviate | omitted here.

  The tool horn 4 shown in FIG. 1 has a cylindrical shape with a step, with the base side being thick and the tip side being thin. The pressing surface forming the tip surface of the tool horn 4 is a curved surface, and a plurality of V-shaped protrusions or V-shaped grooves are formed along the curved surface. Reference numeral 90 denotes a resin molded product (plate material) on which a fibrous mat 91 (sheet member) is placed. The operator grasps the thick cylindrical portion with the converter 3 of the tool horn 4 by hand and is perpendicular to the surface of the resin molded product 90 and the fiber mat 91 placed thereon (as indicated by the arrow A). ), Pressing the pressing surface. Then, the tool horn 4 is moved from the main body 1 in a state where the curved surface formed with the V-shaped projections or V-shaped grooves is pressed vertically as indicated by the arrow A from above the fiber mat 91 placed on the resin molded product 90. The fiber mat 91 is welded to the resin molded product 90 by applying ultrasonic vibration of 15 kHz to 60 kHz through

  FIG. 2 is an external perspective view of the tool horn 4 according to the first embodiment of the present invention. In FIG. 2, the tip side of the tool horn 4 is faced up so that the shape of the pressing surface can be seen well. As shown in FIG. 1, the tool horn 4 has a substantially cylindrical shape with a thick base 4b and a thin tip 4a, and the two are connected by a smoothly curved intermediate portion 4c. The pressing surface 4d is a hemispherical surface, and has a plurality of concentric V-shaped grooves 5 centered on the apex and irregularities formed by intersecting a plurality of radial V-shaped grooves 6 centered on the apex. Yes. The tool horn 4 is used by pressing the center and the peripheral part of the planned welding area of the fibrous mat 91 placed on the resin molded product 90 with the pressing surface 4d having unevenness.

  Fig.3 (a) is sectional drawing which shows the welding operation | work by the tool horn 4 concerning Embodiment 1 of this invention. The tip portion 4a of the tool horn is pressed perpendicularly to the surface of the resin molded product 90 placed horizontally and the fiber mat 91 placed thereon as indicated by the arrow A. In particular, the edge portion of the V-shaped groove formed on the pressing surface 4 d of the tool horn presses the fibrous mat 91 against the surface of the resin molded product 90. The tool horn 4 vibrates ultrasonically with an amplitude of several microns in the axial direction, so that the fibrous mat 91 and the resin molded product 90 generate heat, and the fibrous mat 91 bites into the surface of the resin molded product 90. When the ultrasonic vibration of the tool horn 4 stops, the heat generation stops, and the welding is completed in a form in which the fiber mat 91 cools and bites into the surface of the resin molded product 90.

  FIG.3 (b) is sectional drawing which shows the welding operation | work by the tool horn 4 concerning Embodiment 1 of this invention similarly to Fig.3 (a). However, in FIG.3 (b), the tool horn 4 is pressing in the B arrow direction inclined (theta) degree from the A arrow which is an original up-and-down moving direction. The pressing surface 4d of the tool horn of the present invention is formed by intersecting a plurality of V-shaped grooves on a hemispherical surface, and the contact position of the hemispherical surface corresponds to the inclination even when pressed from an obliquely inclined direction. Then, the surface of the resin molded product 90 and the fiber mat 91 placed thereon is pushed at a position slightly deviated from the center of the planned welding region.

Here, how much the contact point of the tool horn 4 deviates from the center of the planned welding area when the tool horn 4 is pressed from a direction inclined by an angle θ from the normal to the surface of the object to be welded is shown in FIG. I will explain.
FIG. 4 is a schematic diagram showing a deviation amount when the tool horn 4 according to the first embodiment of the present invention is tilted. FIG. 4 shows a planned welding region on the surface H of the object to be welded by sliding the tool horn 4 having a hemispherical surface with a radius R in the direction of arrow B inclined by an angle θ from the normal to the surface H of the object to be welded. The state when it is going to press the point (O1) which is the center of is shown. The hemispherical surface at the tip of the tool horn 4 advances toward the point (O1) on the surface H of the object to be welded, but before that, the lowermost part of the hemispherical surface contacts the surface H of the object to be welded. End up. The position at which the lowermost part of the hemispherical surface is in contact with the surface H of the object to be welded is a point (O2) shifted by a distance ΔL from the point (O1) on the surface H of the object to be welded, as shown in FIG. And the tool horn 4 presses centering on the point (O2) instead of the point (O1) of the surface H of the welding object.

  The distance (ΔL) deviated from the center of the planned welding region is a value (ΔL = R · tan θ) obtained by multiplying the radius (R) of the hemispherical surface of the tool horn tip by the inclination angle (θ). For example, when the radius (R) of the hemisphere is 8 mm, the shifted distance (ΔL) is about 0.7 mm if the inclination angle (θ) is 5 degrees, and about 1.4 mm even if it is 10 degrees. Compared with the fact that the center of the pressing force is shifted by about the radial dimension (8 mm) of the tip portion in the conventional tool horn already described, the center of the planned welding region is within the error range aimed at the center of the planned welding region. The periphery can be welded.

  As described above, according to the tool horn 4 of the present invention, even if the tool horn 4 is slightly inclined, the center and the peripheral portion of the planned welding region can be pressed and welded by ultrasonic vibration. Further, at the edge portion of the V-shaped groove provided on the pressing surface 4d of the tool horn, the fiber mat 91 in the center and the peripheral portion of the planned welding region is welded in a state where the fiber mat 91 is bitten into the resin molded product 90, and an anchor effect is obtained. Give rise to As a result, it is possible to stably weld the fiber mat and the resin molded product in the center of the planned welding region and the peripheral portion thereof with a strong welding force.

  This is the same when the surface of the welding planned area is a curved surface or a slope. FIG. 5 is a cross-sectional view of the tool horn 4 according to the first exemplary embodiment of the present invention when the fibrous mat 91 is welded to a resin molded product 90a having a planned welding region having an inclined surface and both ends being horizontal. In this case, the pressing surface 4d of the tool horn goes up and down in the direction of arrow A perpendicular to the horizontal surfaces on both ends of the resin molded product 90a, but the resin molded product 90a and the fiber mat 91 placed thereon are arranged. The surface is inclined at θ degrees. The tool horn 4 presses the surface of the welding planned area obliquely, which is substantially the same as the state of FIG. FIG. 5 shows that the center of the planned welding area and its peripheral part can be welded even if the planned welding area is inclined with respect to the tool horn 4.

(Embodiment 2)
Next, a second embodiment of the present invention will be described. In Embodiment 2 of the present invention, the curvature radius of the curved surface on the pressing surface of the tool horn 41 is increased, and a plurality of V-shaped grooves are formed to intersect the curved surface. Fig.6 (a) is sectional drawing of the front-end | tip part of the tool horn 41 concerning Embodiment 2 of this invention. In the tool horn 41, concentric V-shaped grooves 41c and 41d having different diameters such as φD2 and φD3 are engraved, and V-shaped grooves are engraved radially around the apex 41b so as to intersect with the V-shaped grooves 41c and 41d.

  FIG.6 (b) is a side view which shows the external appearance of the front-end | tip part of the tool horn 41 concerning Embodiment 2 of this invention. As described above, in the tool horn 41, the radius of the curved surface of the pressing surface is increased and the deep concentric V-shaped groove is provided. The surface of the fibrous mat 91 placed thereon is pushed. Therefore, the area | region which presses the fiber mat 91 to the resin molded product 90 increases rather than the tool horn 4 of Embodiment 1. FIG. As a result, the area to be welded is increased, and the amount of the fiber mat 91 biting into the resin molded product 90 by the V-shaped groove is increased so that the welding can be performed with a stronger welding force than the tool horn 4 of the first embodiment.

(Embodiment 3)
Next, a third embodiment of the present invention will be described. In the third embodiment of the present invention, the pressing surface of the tool horn 42 is a hemispherical surface, but the number of deep concentric V-shaped grooves having different diameters such as φD1, φD2, and φD3 is increased and intersected therewith. In this manner, the number of edges is increased by carving a V-shaped groove radially around the vertex 42b. Fig.7 (a) is sectional drawing of the front-end | tip part of the tool horn 42 concerning Embodiment 3 of this invention. FIG.7 (b) is a side view of the front-end | tip part of the tool horn 42 concerning Embodiment 3 of this invention.

Thus, in the tool horn 42 of Embodiment 3 of this invention, the deep concentric V-shaped groove | channel is increased, the number of the edges which produce an anchor effect is increased, and the welding force is enlarged.
( Reference Example 1 )
Next, Reference Example 1 will be described. In Reference Example 1 , the pressing surface of the tool horn 43 is a hemispherical surface, but a V-shaped protrusion (convex portion) is provided instead of the V-shaped groove (concave portion). FIG. 8 is an external perspective view of the tool horn 43 according to the first reference example . In Reference Example 1 of the present invention, the V-shaped protrusions 53 and 63 are formed in a lattice shape.

FIG. 9A is a cross-sectional view showing a welding operation by the tool horn 43 according to the first reference example . The tip of the tool horn 43 is pressed vertically against the surfaces of the resin molded product 90 placed horizontally and the fiber mat 91 placed thereon. The V-shaped projections 53 and 63 formed on the pressing surface 43 d of the tool horn 43 press the fibrous mat 91 against the surface of the resin molded product 90. FIG. 9A shows a state in which the V-shaped protrusions 53a, 53b, and 53c bite the fibrous mat 91 into the resin molded product 90.

  Then, when the tool horn 43 is ultrasonically vibrated with an amplitude of several microns in the axial direction, the fiber mat 91 and the resin molded product 90 generate heat, the resin molded product 90 is melted, and the fiber mat 91 is converted into the resin molded product 90. Bite into the surface. When the ultrasonic vibration of the tool horn 43 stops, the heat generation stops and the welding is completed in the form that the fiber mat 91 is cooled and bites into the surface of the resin molded product 90. This is the same as the other embodiments of the present invention already described.

FIG. 9B is a cross-sectional view showing the welding operation by the tool horn 43 according to the reference example 1 as in FIG. 9A. However, in FIG.9 (b), the tool horn 43 inclines in the B arrow direction only (theta) degree from the A arrow direction. Therefore, the pressing surface 43d of the tool horn presses the tool horn 43 from an oblique direction against the surface of the resin molded product 90 and the fiber mat 91 placed thereon.

Pressing surface 43d of the engineering tool horn 43 is formed in a shape crossing a plurality of V-shaped projections 53, 63 on the hemisphere. Therefore, even if the surface of the resin molded product 90 and the fiber mat 91 placed thereon is pressed from the oblique direction of the arrow B, the contact position of the hemispherical surface is slightly from the center of the planned welding region according to the inclination. The surface of the resin molded product 90 and the fiber mat 91 placed on the resin molded product 90 is pushed at a position shifted to the position. The fact that the distance (ΔL) deviated from the center of the planned welding area is small has already been described in the first embodiment.

Eventually, engineering tools horn 43 presses the center and its periphery of the region to be fused, welded ultrasonically vibrating. Further, the V-shaped protrusions 53 and 63 provided on the pressing surface 43d of the tool horn 43 cause an anchor effect in which the fibrous mat 91 is welded in a state of being bitten into the resin molded product 90, and the fibrous mat 91 is made of resin. The welding force of the molded product 90 is increased. In particular, the V-shaped protrusions 53 and 63 have the advantage that the fibrous mat 91 can be sharply bited into the resin molded product 90 rather than the edge of the V-shaped groove, and a large welding force can be obtained.

( Reference Example 2 )
Next, Reference Example 2 will be described. In Reference Example 2 of the present invention, a plurality of V-shaped protrusions are formed so as to intersect with a curved surface having a larger radius of the curved surface of the tool horn 44, and the radius of the curved surface at the peripheral portion of the pressed surface is reduced. The corners of the edges are rounded. Although the external view of the tool horn 44 is omitted, the welding operation by the tool horn 44 according to Reference Example 2 is shown as a cross-sectional view in FIGS. FIG. 10A shows a state where the resin molded product 90 and the fiber mat 91 are placed horizontally and the tool horn 44 is pressed vertically as indicated by the arrow A. FIG. 10B shows a state in which the tool horn 44 is pressed in the B arrow direction inclined by θ degrees from the A arrow direction.

Pressing surface of the engineering tool horn 44, as in FIG. 10 (a), similarly to the case of pressing vertically, as shown in FIG. 10 (b), the even and pressed from an oblique direction not from vertical direction, the tool horn 44 The surface of the resin molded product 90 and the fiber mat 91 placed thereon is pushed at a position slightly shifted from the center of the planned welding region according to the inclination. In addition, since the corners of the edge portion on the periphery of the pressing surface are rounded, even if the tool horn 44 is tilted, the corners of the edge portion on the periphery of the pressing surface do not hit each other. In the tool horn 44 of the reference example 2 , it is possible to perform welding with a strong welding force by ultrasonic vibration in a state where the center of the welding scheduled region and its peripheral portion are pressed in a wide range.

( Reference Example 3 )
Next, Reference Example 3 will be described with reference to FIG. In Reference Example 3 of the present invention, the pressing surface of the tool horn 45 is formed as a special curved surface using two different large and small intersecting radii, and a plurality of V-shaped protrusions are formed on the curved surface. doing. In FIG. 11, the external appearance perspective view of the tool horn 45 of the reference example 3 is shown. In this way, by selecting a value suitable for the welding operation for the radius of curvature of the pressing surface of the tool horn 45, the shape of the tool horn 45 is matched to the various shapes of the planned welding area of the resin molded product, and the fibrous mat is strengthened. Weld with welding strength.

( Reference Example 4 )
Next, Reference Example 4 will be described with reference to FIG. In Reference Example 4 , the pressing surface of the tool horn 46 is a curved surface, and a plurality of holes (concave portions) 46e are formed close to each other on the curved surface, and a surface (convex portion) between the plurality of holes and the holes is formed. By 46d, the pressing surface which forms the curved surface of the tool horn 46 is formed uneven. The shape of the plurality of holes (recesses) 46e is a hole having a V-shaped cross section having an inverted conical shape by so-called dish fir processing. The V-shaped hole 46e can be referred to as a conical V-shaped groove. A structure having a large number of V-shaped holes 46e as shown in FIG. 12 has a large number of short V-shaped grooves. The same anchor effect as when placed can be expected. By pressing the fibrous mat against the resin molded product with the projections and edges of the unevenness and applying ultrasonic vibration, it is possible to weld with a strong welding force.

As described above, in the ultrasonic welding apparatus and the tool horn of the present invention, the tip of the tool horn and a curved surface, a plurality of V-shaped Mizoma other on the curved surface forms a V-shaped collision force. As a result, the fiber mat placed on the resin molded product is welded so as to obtain a strong welding force by applying ultrasonic vibration in a state where the fiber mat is pressed with a tool horn. Therefore, even if the tool horn is pressed from an angle inclined from the vertical direction with respect to each surface of the fiber mat placed on the resin molded product, the center portion of the planned welding region and its peripheral portion are pressed strongly. It can be welded with welding power. Further, by forming a plurality of V-shaped grooves or V-shaped projections provided on the pressing surface forming the curved surface of the tool horn so as to intersect with each other, the fibers of the fiber mat are formed at the center portion of the planned welding region and its peripheral portion. It is possible to perform welding with a so-called anchor effect, in which the resin is welded in the form of being bitten into the resin molded product.

A plurality of V-shaped grooves or V-shaped collision force provided on the curved surface of the pressing surface of the tool horn of the present invention, since functions to bite into the sheet member other than the fibrous mat into the surface of the resin molded product The object is not limited to this, and can be applied when a sheet member other than the fiber mat is welded to the surface of the resin molded product. Furthermore, the ultrasonic welding apparatus and tool horn of the present invention can also be applied to the case where a thin metal foil for electrodes, which is a sheet member, is ultrasonically bonded to another plate material or the like.

The cross section V-shaped butt Okoshimata the pressing surface of the tool horn in the first to third embodiments has a groove, but is preferably V-shaped cross section to obtain the anchor effect, necessarily cross The shape is not limited to a sharp V shape, and may be a trapezoidal cross section, a shape close to a U shape, or a cross sectional shape with rounded edges.

The present invention includes, for example, a case where a soundproof mat is welded to the back surface of a resin molded product inside an in-vehicle door, a housing for an electric product made of a resin molded product, a fiber mat as a heat insulating material, and a building material for housing. It can be applied to a wide range of uses, such as when welding to.
Further, V-shaped grooves or V-shaped collision force provided on the pressing surface plane of the tool horn of the present invention, since the bite into the surface of the resin molded article also a sheet member other than the fibrous mat, fibrous mat It is applicable also when welding other sheet members within the surface of the resin molded product.

  Furthermore, the ultrasonic welding apparatus and tool horn of the present invention can also be applied to the case where a thin metal foil for electrodes, which is a sheet member, is ultrasonically bonded to another plate material or the like.

4 Tool horn 5, 6 V-shaped groove 46e V-shaped hole 53, 63 V-shaped projection 90 Resin molded product 91 Fiber mat

Claims (3)

It has a columnar shape with a thick base and a thin step at the tip, is gripped by an operator's hand and presses the pressing surface of the tip against a fiber mat placed on the resin molded product, and the fiber is applied to the resin molded product. A tool horn for ultrasonically welding a quality mat ,
The pressing surface of the tool horn is a curved surface having one vertex ,
A plurality of concentric V-shaped projections or a V-shaped groove and a plurality of radial V-shaped protrusion around the apex of the curved surface of the pressing surface around the apex of the curved surface of the front Symbol pressing surface Alternatively, a cross-sectional V-shaped groove is formed, and the concentric cross-sectional V-shaped protrusion or cross-sectional V-shaped groove and the radial cross-sectional V-shaped protrusion or cross-sectional V-shaped groove are arranged to intersect each other.
When the tool horn is pressed against the surface of the fibrous mat, the pressing surface is formed by the concentric circular shape and the radial cross-sectional V-shaped protrusion or the cross-sectional V-shaped groove near the top of the pressing surface. A tool horn characterized by being welded with an anchor effect . The tool horn according to claim 1, wherein the curved surface of the pressing surface is a hemispherical surface. The tool horn according to claim 1 or 2 ,
Ultrasonic vibration generating means connected to the tool horn and applying ultrasonic vibration to the tool horn;
An ultrasonic welding apparatus comprising:

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