JP5862315B2 - Manufacturing method of resin molded products - Google Patents

Description

The present invention relates to a method for manufacturing a resin molded product, and more specifically, the first resin material and the second resin material can be tightly bonded in a sealed state by preventing the flow of foamed resin that occurs during laser light irradiation. The present invention relates to a method for producing a resin molded product.

  As a conventional resin molded product, for example, as shown in FIG. 9, a plug material 102 made of a laser transmitting resin and a passage forming material 103 made of a laser absorbing resin for forming an oil passage are provided. An oil filter bracket 101 in which a material 102 is mounted so as to close an opening 103c formed in a passage forming material 103 is known. The bracket 101 abuts the flange portion 102 b of the plug material 102 and the passage forming material 103, and forms a welded portion 107 by irradiating laser light L from the plug material 102 toward the passage forming material 103 on the abutting surface side. And obtained by joining the two 102 and 103 together.

  However, in the conventional bracket, as shown in FIG. 10, the flat surface of the flange portion 102b of the plug member 102 and the flat surface of the passage forming member 103 are abutted with each other. There is a case where the foamed resin S generated when being irradiated with the laser light flows out to both outer sides opened to the atmosphere together with the burrs. As a result, when the foamed resin S communicates, oil leakage occurs or the bonding strength decreases.

  In addition, as a conventional resin molded product, one in which a protrusion is provided on the lower surface of a translucent resin is known in order to gradually discharge air on the welding surface during laser welding (see, for example, Patent Document 1). In addition, as another conventional resin molded product, a product formed by irradiating a laser beam with a welded surface fitted in a concavo-convex shape in order to improve the strength of the joint surface is known (for example, a patent) Reference 2). However, these Patent Documents 1 and 2 do not disclose a foamed resin generated at the time of laser light irradiation and a structure for suppressing an adverse effect caused by the foaming. That is, even in Patent Documents 1 and 2, both outer sides of the laser light irradiation part are open to the atmosphere, and the foamed resin flows out during the laser light irradiation.

JP 2011-5705 A Japanese Patent Laid-Open No. 2005-67208

The present invention has been made in view of the above-described present situation, and can prevent the flow of the foamed resin that occurs during the irradiation of the laser light and can firmly bond the first resin material and the second resin material in a sealed state. It aims at providing the manufacturing method of a resin molded product.

In order to solve the above problems, a first aspect of the present invention, a method for producing a formed by joining a resin molded product by laser light irradiation against the first resin material and second resin material, the resin The molded product includes a welded portion formed by irradiation of the laser beam on the abutting surface side of the first resin material and the second resin material, and the abutting surface side of the first resin material and the second resin material. A flow preventing portion provided on both sides of the welded portion and preventing the flow of foamed resin that occurs when the laser beam is irradiated, and one of the first resin material and the second resin material includes A convex portion protruding toward the other resin material, a concave portion into which the convex portion enters is provided in the other resin material, and the flow preventing portion includes a convex side wall surface forming the convex portion, and The concave portion side that contacts the convex side wall and forms the concave portion Each of the convex portion side wall surface and the concave portion side wall surface is inclined with respect to the abutting direction of the first resin material and the second resin material, and on the outer peripheral side of the weld portion. The inclination direction of the convex side wall surface and the concave side wall surface of the flow prevention part provided, and the inclination direction of the convex side wall surface and the concave side wall surface of the flow prevention part provided on the inner peripheral side of the welding part Intersecting the first resin material and the second resin material, and joining the abutted first resin material and the second resin material by irradiation of the laser beam, In the abutting step, the convex portion is fitted into the concave portion, and the convex portion side wall surface comes into contact with the concave portion side wall surface, whereby the first resin material and the second resin material are abutted surfaces. On the both sides of the planned welding part In the bonding step, a prevention portion is formed, and in the bonding step, the weld portion is formed on the butt surface side of the first resin material and the second resin material, and foaming is generated when the laser light is irradiated by the flow prevention portion. The gist is that the flow of the resin is prevented .
The gist of the invention described in claim 2 is that, in claim 1, the convex part and the concave part are formed in a substantially triangular shape in a longitudinal section or a substantially trapezoidal shape in a longitudinal section.
Invention of Claim 3 is Claim 1 or Claim 2, The said 1st resin material is a plug material, The said 2nd resin material is a channel | path formation material which forms the channel | path through which a fluid flows, The plug member has a male screw portion that is screwed into a female screw portion formed in an opening of the passage forming member, and the plug member is attached to the passage forming member by screwing the female screw portion and the male screw portion. The gist is to be mounted so as to close the opening.

According to the method for manufacturing a resin molded product of the present invention, since the flow prevention unit is provided on both sides of the welded portion on the abutting surface side of the first resin material and the second resin material, the flow prevention unit generates a laser beam. The foamed resin is prevented from flowing to both sides of the laser light irradiation site. As a result, the first resin material and the second resin material can be firmly joined in a sealed state.
Also, one of the first resin material and the second resin material is provided with a convex portion, the other resin material is provided with a concave portion, and the flow preventing portion is provided with a convex side wall surface and a concave side wall surface. Therefore, the flow of the foamed resin is prevented by the contact of the convex side wall surface and the concave side wall surface.
Further, each of the convex side wall surface and the concave side wall surface is inclined with respect to the abutting direction of the first resin material and the second resin material. Firmly contacted.

  According to the method for producing a resin molded product of the present invention, the first resin material and the second resin material are abutted, and the abutted first resin material and the second resin material are joined by irradiation with laser light. In the abutting step, the flow preventing portions are formed on both sides of the planned welding portion on the abutting surface side of the first resin material and the second resin material, and in the joining step, the first resin material and the second resin material are abutted. A welded portion is formed on the surface side, and the flow of the foamed resin that occurs when the laser beam is irradiated is prevented by the flow preventing portion. As a result, the first resin material and the second resin material can be firmly joined in a sealed state.

The present invention will be further described in the following detailed description with reference to the drawings referred to, with reference to non-limiting examples of exemplary embodiments according to the present invention. Similar parts are shown throughout the several figures.
It is a longitudinal cross-sectional view which shows the use condition of the oil filter bracket which concerns on an Example. It is a principal part enlarged view of FIG. FIG. 3 is a fragmentary cutaway view taken along arrow III in FIG. 2. It is an enlarged view of the IV arrow part of FIG. It is explanatory drawing for demonstrating the manufacturing method of the said oil filter bracket. It is explanatory drawing for demonstrating the manufacturing method of the said oil filter bracket, (a) shows the state which matched the plug material and the channel | path formation material, (b) shows the state after irradiation of a laser beam. It is explanatory drawing for demonstrating the resin molded product of another form, (a) shows the form by which a flow prevention part is comprised with the outer wall surface of an uneven | corrugated | grooved part, (b) is an uneven | corrugated | grooved part of a longitudinal cross-section substantially trapezoid shape (C) shows an uneven part having a substantially semicircular longitudinal section. It is explanatory drawing for demonstrating the resin molded product of another form, (a) shows the form which provides an uneven | corrugated part upside down, (b) shows the form which provides a convex part only in one resin material. . It is a principal part longitudinal cross-sectional view of the conventional oil filter bracket. It is an enlarged view of the X arrow part of FIG.

  The items shown here are exemplary and illustrative of the embodiments of the present invention, and are the most effective and easy-to-understand explanations of the principles and conceptual features of the present invention. It is stated for the purpose of providing what seems to be. In this respect, it is not intended to illustrate the structural details of the present invention beyond what is necessary for a fundamental understanding of the present invention. It will be clear to those skilled in the art how it is actually implemented.

1. Resin molded product Embodiment 1 The resin molded product according to 1 is a resin molded product (1) formed by abutting the first resin material (2) and the second resin material (3) and joining them by laser light irradiation. 2 It is provided on both sides of the welded portion (7) formed by laser light irradiation on the butting surface side of the resin material and the welding portion on the butting surface side of the first resin material and the second resin material, and at the time of laser light irradiation And a flow prevention unit (8) for preventing the flow of the foamed resin to be generated (see, for example, FIG. 2). The said flow prevention part is normally spaced apart from the irradiation part of a laser beam. The “both sides” means both sides in a direction substantially orthogonal to the abutting direction of the first resin material and the second resin material. In addition, the above “flow” intends a flow from the laser beam irradiation portion toward both sides thereof.

  Embodiment 1 As the resin molded product according to the present invention, for example, one of the first resin material (2) and the second resin material (3) has a convex portion (10) protruding toward the other resin material. The other resin material is provided with a concave portion (11) into which the convex portion enters, and the flow prevention portion (8) is provided on the convex side wall surface (10a) forming the convex portion and the convex side wall surface. The form (for example, refer FIG. 4 etc.) comprised by the recessed part side wall surface (11a) which contact | abuts and forms a recessed part can be mentioned.

  In the above-mentioned form, for example, each of the convex side wall surface (10a) and the concave side wall surface (11a) is in the abutting direction (P) of the first resin material (2) and the second resin material (3). It can be inclined (see, for example, FIG. 4). Examples of the inclination angle (θ1) with respect to the abutting direction of the convex side wall surface (10a) and the concave side wall surface (11a) include 5 to 85 degrees (preferably 30 to 60 degrees). In this case, for example, the inclination angle with respect to the abutting direction of the concave portion side wall surface can be set to a value equal to or larger than the inclination angle with respect to the convex side wall surface abutting direction. Thereby, a convex part side wall surface and a recessed part side wall surface are contact | abutted still more strongly.

  Embodiment 1 For example, one of the first resin material and the second resin material is the plug material (2), and the other resin material forms a fluid flow path. It is a passage forming material (3), and the plug material is mounted so as to close the opening (3c) formed in the passage forming material, and the plug material is a screw portion formed in the opening of the passage forming material. (3d) having screw parts (2a) screwed together, and the plug material is pressed in the abutting direction (P) against the passage forming material by the screwing of these screw portions, and the plug material and the passage forming material are Further, it is possible to mention a mode of joining by irradiation of laser light in the pressurized state (see, for example, FIGS. 1 and 2). Thereby, a plug material and a channel | path formation material can be simply joined, without using the exclusive jig for pressurization.

  One resin material of the first resin material and the second resin material has a laser transmission property that transmits laser light, and the other resin material has a laser absorption property that absorbs laser light. Examples of the resin material include amorphous resins such as polystyrene (PS), low density polyethylene (LDPE), and polycarbonate (PC), polypropylene (PP), polybutylene terephthalate (PBT), and polyethylene terephthalate (PET). , Polyamide (PA), polyacetal (POM) and the like. Moreover, this resin material can contain dye and / or a pigment, for example. Examples of the type of laser light include semiconductor, gas, solid, and liquid laser light.

2. Manufacturing method of resin molded product Embodiment 2 The method for manufacturing a resin molded product according to the first embodiment is the same as in the first embodiment. The method of manufacturing a resin molded product according to the present invention includes a step of abutting the first resin material (2) and the second resin material (3), and a laser beam (L In the abutting step, the flow prevention portion (8) is formed on both sides of the planned welding portion on the abutting surface side of the first resin material and the second resin material, and joined. In the process, the welded portion is formed on the abutting surface side of the first resin material and the second resin material, and the flow preventing portion prevents the flow of the foamed resin (S) generated when the laser beam is irradiated. (See, for example, FIG. 6). In the joining step, usually, the laser beam is not irradiated to the flow preventing portion.

  Hereinafter, the present invention will be specifically described with reference to the drawings. In this embodiment, an oil filter bracket for connecting an oil filter and an engine is illustrated as a “resin molded product” according to the present invention.

(1) Configuration of Oil Filter Bracket As shown in FIG. 1, an oil filter bracket 1 according to this embodiment includes a plug material 2 (a “first resin according to the present invention” made of a laser-transmitting resin (for example, nylon). And a passage forming material 3 (illustrated as “second resin material” according to the present invention) made of a laser-absorbing resin (for example, nylon or the like).

  The plug member 2 has a male screw portion 2a and a flange portion 2b connected to one end side in the axial direction of the male screw portion 2a. One end of the passage forming member 3 is attached to the engine 25 and the other end is attached to the case 5 of the oil filter 4. This passage forming member 3 has a return passage 3a for returning the oil filtered by the oil filter 4 to the engine 25, and a feed passage 3b for sending the oil from the engine 25 to the oil filter 4 as a whole. It is formed in a bent tubular shape. In addition, an opening 3 c that opens to the outside is formed at the bent portion of the passage forming member 3. A female screw portion 3d (see FIG. 2) into which the male screw portion 2a of the plug member 2 is screwed is provided on the inner peripheral side of the opening 3c. The oil filter 4 is configured by housing a filter element 6 having a filter medium in a case 5.

  As shown in FIGS. 2 to 3, there is a laser between the flange portion 2 b of the plug member 2 and the surface side of the opening 3 c of the passage forming member 3, that is, on the abutting surface side of the plug member 2 and the passage forming member 3. An annular weld 7 is formed by light irradiation. In addition, annular flow prevention portions 8 for preventing the flow of the foamed resin generated when the laser beam is irradiated are provided on the inner peripheral side and the outer peripheral side of the weld portion 7 on the abutting surface side of the plug member 2 and the passage forming member 3. ing.

  On the surface of the flange portion 2 b of the plug member 2, as shown in FIG. 4, annular inner and outer convex portions 10 projecting toward the passage forming member 3 are formed. Each of these convex portions 10 is formed in a substantially triangular shape in longitudinal section, and has an inner wall surface 10a (illustrated as a “convex sidewall surface” according to the present invention) and an outer wall surface 10b. In addition, on the surface side of the opening 3c of the passage forming member 3, annular inner and outer concave portions 11 into which the convex portions 10 are fitted are formed. Each of these recesses 11 is formed in a substantially triangular shape in longitudinal section, and has an inner wall surface 11a (illustrated as “a recess sidewall surface” according to the present invention) and an outer wall surface 11b. And the inner wall surface 10a of the convex part 10 and the inner wall surface 11a of the recessed part 11 are contact | abutting partially or completely, and each said flow prevention part 8 of the inner wall surface 10a of the convex part 10 and recessed part 11 which mutually contact | abut. It is comprised by the inner wall surface 11a.

  The inclination angle θ1 with respect to the abutting direction P of the inner wall surfaces 10a and 11a is about 30 degrees. The inclination angle of the inner wall surface 11a is set to a value equal to or larger than the inclination angle of the inner wall surface 10a due to the angular dimension tolerance. The inclination angle θ2 of the outer wall surface 10b and the outer wall surface 11b with respect to the butting direction P is about 30 degrees.

(2) Manufacturing method of oil filter bracket Next, the manufacturing method of the oil filter bracket 1 of the said structure is demonstrated. As shown in FIG. 5, the male threaded portion 2a of the plug member 2 is screwed into the female threaded portion 3d of the passage forming member 3, and the plug member 2 is attached to the passage forming member 3 so as to close the opening 3c. Then, the flange portion 2b of the plug member 2 and the surface side of the passage forming member 3 are brought into contact with each other with a predetermined pressure (for example, about 1 MPa). Further, as shown in FIG. 6A, each convex portion 10 is fitted in each concave portion 11, and the inner wall surface 10 a of each convex portion 10 abuts on the inner wall surface 11 a of each concave portion 11, thereby preventing the flow prevention portion. 8 is formed. In addition, the outer wall surface 10b of each convex part 10 and the outer wall surface 11b of each recessed part 11 are facing each other with a gap.

  Here, when the plug portion 2 and the passage forming member 3 are abutted, it is desirable that the abutting surfaces are in close contact with each other. However, due to the influence of molding accuracy and the like, there may be a part where the butted surfaces are not completely adhered but separated. Even in this case, the portion 9 (see FIG. 6A) surrounded by the flow prevention unit 8 is sealed.

  Next, a laser beam L (indicated by a broken line in FIG. 6A) is irradiated on the abutting surface side of the plug material 2 and the passage forming material 3 in the direction from the plug material 2 toward the passage forming material 3. The laser beam L is scanned around the opening 3c of the passage forming member 3. Then, as shown in FIG. 6 (b), a welding portion 7 is formed on the abutting surface side of the plug material 2 and the passage forming material 3 by melting the plug material 2 and the passage forming material 3, and the flow preventing portion 8. This prevents the foamed resin S generated when the laser beam L is irradiated from flowing to both sides of the laser beam L irradiation site. As a result, the plug material 2 is joined to the passage forming material 3 to obtain the oil filter bracket 1.

(4) Effect of Example As described above, according to the oil filter bracket 1 of the present example, since the flow prevention part 8 provided on both sides of the weld part 7 on the abutting surface side of the plug material 2 and the passage forming material 3 is provided, The flow prevention unit 8 prevents the foamed resin S generated when the laser beam L is irradiated from flowing to both sides of the laser beam irradiation site. As a result, the plug member 2 and the passage forming member 3 can be firmly joined in a sealed state.

  Further, in the present embodiment, the convex portion 10 is provided on the flange portion 2 b of the plug member 2, the concave portion 11 is provided on the passage forming material 3, and the flow prevention portion 8 is disposed on the inner wall surface 10 a of the convex portion 10 and the inner side of the concave portion 11. Since it is comprised by the wall surface 11a, the flow of the foamed resin S is prevented by contact | abutting of these inner wall surfaces 10a and 11a.

  Furthermore, in this embodiment, each of the inner wall surface 10a of the convex portion 10 and the inner wall surface 11a of the concave portion 11 is inclined with respect to the abutting direction P of the plug material 2 and the passage forming material 3, so that these inner wall surfaces 10a. , 11a abut against each other more firmly. In particular, in the present embodiment, the inclination angle of the inner wall surface 11a of the concave portion 11 is set to a value equal to or larger than the inclination angle of the inner wall surface 10a of the convex portion 10 due to the angular dimensional tolerance. Abutted.

  Furthermore, in the present embodiment, the plug member 2 has a screw portion 2a that is screwed into a screw portion 3d formed in the opening 3c of the passage forming member 3, and the plug member 2d is screwed by the screw portions 3d and 2a. The material 2 is pressed against the passage forming material 3 in the abutting direction P, and the plug material 2 and the passage forming material 3 are joined by irradiation with the laser light L in the pressurized state. The plug material 2 and the passage forming material 3 can be easily joined without using a dedicated jig.

  In the present invention, the present invention is not limited to the above embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application. That is, in the said Example, although the flow prevention part 8 comprised by the inner wall face 10a of the convex part 10 and the inner wall face 11a of the recessed part 11 which contact | abutted mutually was illustrated, it is not limited to this, For example, Fig.7 (a) As shown in FIG. 6, the flow preventing portion 8 ′ may be configured by the outer wall surface 10b of the convex portion 10 and the outer wall surface 11b of the concave portion 11 that are in contact with each other.

Moreover, in the said Example, although the vertical cross-section substantially triangular-shaped convex part 10 and the recessed part 11 were illustrated, it is not limited to this, For example, as shown to FIG. 16 and the recess 17 may be adopted . As a reference example, as shown in FIG. 7C, a convex part 18 and a concave part 19 having a substantially semicircular longitudinal section can be mentioned . Furthermore, in the said Example, although the vertical cross-sectional shape was substantially the same shape, although the convex part 10 and the recessed part 11 which mutually fit were illustrated, it is not limited to this, For example, the convex part and recessed part of a shape from which a longitudinal cross-sectional shape differs May be adopted.

Moreover, in the said Example, although the convex part 10 was provided in the plug material 2 and the recessed part 11 which the convex part 10 penetrates in the channel | path formation material 3 was illustrated, it is not limited to this, For example, Fig.8 (a) As shown in FIG. 3, the path forming member 3 may be provided with a convex portion 20 and the plug member 2 may be provided with a concave portion 21 into which the convex portion 20 enters. As a reference example , for example, as shown in FIG. 8 (b), only the plug material 2 (or the passage forming material 3) is in contact with the flat surface 23 of the passage forming material 3 (or the plug material 2). the provided include a mode of forming the flow preventing portion by the convex portion 22 and the flat surface 23 in contact with each other.

  Moreover, in the said Example, although the cyclic | annular (namely, endless shape) weld part 7 and the flow prevention part 8 were illustrated, it is not limited to this, For example, as a linear weld part and a flow prevention part which both ends side separated Also good.

  Moreover, in the said Example, although the inclination angle of the inner side wall surface 11a of the recessed part 11 was made into the value more than the inclination angle of the inner side wall surface 10a of the convex part 10 by angle dimension tolerance, it is not limited to this, For example, the recessed part 11 The inclination angle of the inner wall surface 11 a may be set to a value larger than the inclination angle of the inner wall surface 10 a of the convex portion 10.

  Moreover, in the said Example, although the plug material 2 and the channel | path formation material 3 were irradiated with the laser beam L in the pressurization state by screwing of the screw parts 3d and 2a, it is not limited to this, This screwing Alternatively or in addition, the plug material 2 and the passage forming material 3 may be irradiated with the laser light L in a pressurized state with a dedicated jig.

  Furthermore, in the said Example, although the oil filter bracket 1 provided with the plug material 2 and the channel | path formation material 3 was illustrated as a resin molded product, it is not limited to this, For example, the 1st case which is faced | matched and forms a filtration chamber And it is good also as a filter case provided with the 2nd case.

  The foregoing examples are for illustrative purposes only and are not to be construed as limiting the invention. Although the invention has been described with reference to exemplary embodiments, it is to be understood that the language used in the description and illustration of the invention is illustrative and exemplary rather than limiting. As detailed herein, changes may be made in its form within the scope of the appended claims without departing from the scope or spirit of the invention. Although specific structures, materials, and examples have been referred to in the detailed description of the invention herein, it is not intended to limit the invention to the disclosure herein, but rather, the invention is claimed. It covers all functionally equivalent structures, methods and uses within the scope of

  The present invention is not limited to the embodiments described in detail above, and various modifications or changes can be made within the scope of the claims of the present invention.

  This technique is widely used as a technique in which the first resin material and the second resin material are brought into contact with each other by being irradiated with laser light. In particular, it is suitably used as a resin molded product through which a fluid such as lubricating oil of an internal combustion engine flows.

  DESCRIPTION OF SYMBOLS 1; Oil filter bracket, 2; Plug material, 3; Passage formation material, 7; Welding part, 8, 8 '; Flow prevention part, 10, 16, 18, 20, 22; Protrusion part, 11, 13, 17, 19, 21; concave portion, L: laser beam, P: butt direction.

Claims (3)

A method of manufacturing a resin molded product obtained by abutting a first resin material and a second resin material and joining them by laser light irradiation,
The resin molded product is
A welded portion formed by irradiating the laser beam on the butting surface side of the first resin material and the second resin material;
A flow preventing portion provided on both sides of the welded portion on the butt surface side of the first resin material and the second resin material, and preventing a flow of foamed resin that occurs during irradiation of the laser beam,
One resin material of the first resin material and the second resin material is provided with a convex portion protruding toward the other resin material, and the other resin material is provided with a concave portion into which the convex portion enters. And
The flow prevention portion is configured by a convex side wall surface that forms the convex portion, and a concave side wall surface that contacts the convex side wall surface and forms the concave portion,
Each of the convex side wall surface and the concave side wall surface is inclined with respect to the butting direction of the first resin material and the second resin material,
Inclination directions of the convex side wall surface and the concave side wall surface of the flow preventing part provided on the outer peripheral side of the welded part, the convex side wall surface of the flow preventing part provided on the inner peripheral side of the welded part, and The inclined direction of the side wall surface of the recess intersects ,
A step of matching the first resin material and the second resin material;
Bonding the first resin material and the second resin material that are butted together by irradiation with the laser beam, and
In the abutting step, the convex portion is fitted into the concave portion, and the convex side wall surface comes into contact with the concave side wall surface, so that the first resin material and the second resin material are welded on the abutting surface side. The flow prevention part is formed on both sides of the planned part,
In the joining step, the weld portion is formed on the abutting surface side of the first resin material and the second resin material, and the flow preventing portion prevents the flow of the foamed resin when the laser light is irradiated. method for producing a resin molded article, characterized in that that. The method for producing a resin molded product according to claim 1, wherein the convex portion and the concave portion are formed in a substantially triangular shape or a substantially trapezoidal shape in a longitudinal section. The first resin material is a plug material, the second resin material is a passage forming material that forms a passage through which a fluid flows, and the plug material is a female screw formed in an opening of the passage forming material. 3. The apparatus according to claim 1, further comprising: a male threaded portion that is screwed to the portion, and being mounted so as to close the opening with respect to the passage forming member by screwing the female threaded portion and the male threaded portion. The manufacturing method of the resin molded product of description.

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