JP5787150B2 - 繊維強化熱可塑性樹脂の接合方法 - Google Patents
繊維強化熱可塑性樹脂の接合方法 Download PDFInfo
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
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- 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
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- B29C65/5014—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being fibre-reinforced
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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
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- B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
- B29C65/5007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like
- B29C65/5021—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being multi-layered
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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
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
- B29C65/5007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like
- B29C65/5028—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being textile in woven or non-woven form
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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
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
- B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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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
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
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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
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
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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
- B29C66/71—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
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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
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
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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
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
- B29C66/72141—Fibres of continuous length
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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
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
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Description
接合しようとするに含まれる強化繊維としては、例えばガラス繊維、炭素繊維、アラミド繊維などが挙げられる。強化繊維の繊維長としては、連続繊維、或いは数平均繊維長10mm以上において、本発明の効果が顕著である。
積層物としては、全ての層において強化繊維の方向が同じ一方向材や、各層で強化繊維の方向が直交した直交積層体が挙げられる。また、各層の強化繊維の方向が任意の角度になるように各層を積層させてもよい。一方、織物としては、平織、綾織、朱子織、三軸織等が例示される。
被接合面に配置する熱可塑性樹脂材料としては、接合される繊維強化熱可塑性樹脂に含まれる強化繊維の数平均繊維長の最小値よりもその数平均繊維長が短い強化繊維を含む材料、或いは、強化繊維を含まない材料を使用する。配置する繊維強化熱可塑性樹脂材料の強化繊維の体積含有率(JIS K 7052あるいは K 7075に準じて測定。)は、0〜60%とすることが好ましい。強化繊維の体積含有率を60%以下とすることで、熱可塑性樹脂材料中の熱可塑性樹脂と接合しようとする繊維強化熱可塑性樹脂中の熱可塑性樹脂が溶融しあって一体化する。
繊維強化熱可塑性樹脂に含まれる強化繊維として、連続繊維である炭素繊維(三菱レイヨン社製、製品名:TR50S、直径約7μm、12000本集束した束状)を使用した。この炭素繊維束を開繊し、熱可塑性樹脂としてポリプロピレン(プライムポリマー社製、製品名:J108M)を含浸させ、強化繊維の体積含有率(JIS K 7075に準拠。)47%、幅12mm、厚み100μmの連続炭素繊維強化熱可塑樹脂テープを製造した。ついで、このテープを積層することで炭素繊維方向を一方向に引き揃えたが縦240mm、横240mm、厚み2mmのサンプルを作成し、そこから、炭素繊維方向が長さ方向になるようにして、長さ120mm、幅25mm、厚み2mmのサンプルを作成した。このサンプルの強化繊維は連続繊維である。
被接合サンプルAと同様にして連続炭素繊維強化熱可塑樹脂テープを製造し、これを20mmの長さ(繊維長)にカットして、一対の平板状の金型中に、面方向にランダム(無方向的)に分散、堆積させ縦240mm、横240mm、厚み2mmのサンプルを作成し、そこから長さ120mm、幅25mm、厚み2mmのサンプルを作成した。このサンプルの強化繊維の数平均繊維長は20mmであった。
熱可塑性樹脂材料Aとして、ポリプロピレン樹脂(プライムポリマー社製、製品名:J108M)をフィルム状にしたポリプロピレンフィルム(長さ20mm、幅25mm、厚み0.1mm)を使用した。
熱可塑性樹脂材料Bとして、被接合サンプルAで使用した連続炭素繊維強化熱可塑樹脂テープを20mmの長さ(繊維長)にカットして、一対の平板状の金型中に、面方向にランダム(無方向的)に分散、堆積させ縦100mm、横100mm、厚み0.3mmのサンプルを作成し、そこから長さ20mm、幅25mm、厚み0.3mmのサンプルを切り出し、熱可塑性樹脂材料Bとした。このサンプルの強化繊維の数平均繊維長は20mmであった。
連続炭素繊維強化熱可塑樹脂テープのカット長を10mmとした以外は、熱可塑性樹脂材料Bと同様にして、長さ20mm、幅25mm、厚み0.3mmのサンプルを切り出し、熱可塑性樹脂材料Cとした。このサンプルの強化繊維の数平均繊維長は10mmであった。
連続炭素繊維強化熱可塑樹脂テープのカット長を30mmとした以外は、熱可塑性樹脂材料Bと同様にして、長さ20mm、幅25mm、厚み0.3mmのサンプルを切り出し、熱可塑性樹脂材料Dとした。このサンプルの強化繊維の数平均繊維長は30mmであった。
被接合サンプル1、被接合サンプル2の両方に被接合サンプルAを用いた。2つの被接合サンプル1の片方の端に、熱可塑性樹脂材料Aを超音波溶着機(ブランソン社製、製品名:2000LP)で接合した後、2つの被接合サンプル1,2を重なりあいの長さ(ラップ長)が20mmとなるようにし、振動溶着機(ブランソン社、製品名:M624、接合圧力6MPa、振幅1.5mm、周波数240Hz)で、ラップ部分の厚みが3.8mmになるまで接合した。重なりあいの面積は25mm×20mm=5.0×10−4m2である。このサンプルをオートグラフ(島津製作所製、製品名:AG−X)を用いて2mm/分で引張り試験をしたところ、最大荷重は4750Nであった。せん断強度は4750N/5.0×10−4m2=9.5MPaであった。
被接合サンプル1、被接合サンプル2の両方に熱可塑性樹脂材料Bを使用した以外は、実施例1と同様な操作を実施した。結果を表1に示す。
熱可塑性樹脂材料を使用しなかった以外は、実施例1と同様な操作を実施した。結果を表1に示す。
被接合サンプル1、被接合サンプル2の両方に被接合サンプルBを用い、ラップ部分の厚みが3.6mmになるまで接合した以外は実施例1と同様な操作を実施した。結果を表1に示す。
熱可塑性樹脂材料として熱可塑性樹脂材料Cを使用した以外は、実施例3と同様な操作を実施した。結果を表1に示す。
熱可塑性樹脂材料を使用しなかった以外は、実施例3と同様な操作を実施した。結果を表1に示す。
熱可塑性樹脂材料Aに替えて熱可塑性樹脂材料Bを使用した以外は、実施例3と同様な操作を実施した。結果を表1に示す。
熱可塑性樹脂材料Aに替えて熱可塑性樹脂材料Dを使用した以外は、実施例3と同様な操作を実施した。結果を表1に示す。
2 繊維強化熱可塑性樹脂
3 熱可塑性樹脂材料
Claims (7)
- 二つの繊維強化熱可塑性樹脂を接合する際に、少なくとも一方の繊維強化熱可塑性樹脂の被接合面に熱可塑性樹脂材料を予め配置させ、超音波溶着機を用いて、熱可塑性樹脂材料を繊維強化熱可塑性樹脂の被接合面に接合し、その後、二つの繊維強化熱可塑性樹脂を接合する繊維強化熱可塑性樹脂の接合方法。
- 少なくとも一方の繊維強化熱可塑性樹脂の被接合面に含まれる強化繊維が連続繊維である請求項1に記載の繊維強化熱可塑性樹脂の接合方法。
- 前記強化繊維が数平均繊維長10mm以上の非連続繊維である請求項1に記載の繊維強化熱可塑性樹脂の接合方法。
- 前記熱可塑性樹脂材料が繊維強化熱可塑性樹脂からなり、熱可塑性樹脂材料に含まれる強化繊維の数平均繊維長が、接合される繊維強化熱可塑性樹脂に含まれる強化繊維の数平均繊維長の最小値よりも短い請求項1〜3のいずれかに記載の繊維強化熱可塑性樹脂の接合方法。
- 前記熱可塑性樹脂材料が強化繊維を含まない熱可塑性樹脂である請求項1〜3のいずれかに記載の繊維強化熱可塑性樹脂の接合方法。
- 前記熱可塑性樹脂材料の厚みが、0.05mm〜1mmである請求項1〜5のいずれかに記載の繊維強化熱可塑性樹脂の接合方法。
- 二つの繊維強化熱可塑性樹脂の接合する際に、振動溶着法を用いる請求項1〜6のいずれかに記載の繊維強化熱可塑性樹脂の接合方法。
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