JP6010641B2 - 樹脂部材及び樹脂部材の接合方法 - Google Patents
樹脂部材及び樹脂部材の接合方法 Download PDFInfo
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- JP6010641B2 JP6010641B2 JP2015013989A JP2015013989A JP6010641B2 JP 6010641 B2 JP6010641 B2 JP 6010641B2 JP 2015013989 A JP2015013989 A JP 2015013989A JP 2015013989 A JP2015013989 A JP 2015013989A JP 6010641 B2 JP6010641 B2 JP 6010641B2
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- resin
- resin member
- groove
- melting start
- ultrasonic welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—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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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/3022—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined
- B29C66/30223—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined said melt initiators being rib-like
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- B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
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- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/2457—Parallel ribs and/or grooves
Description
前記二つの樹脂部材の少なくとも一方は、接合領域に、前記超音波溶着の際に面圧が負荷される溶融開始部の周囲に溝部と、前記溶融開始部から外側に向かう方向に対して交差する方向に沿って形成されて、少なくとも部分的に前記溝部を内側部分及び外側部分に区分する少なくとも一つの壁部と、を備えるとともに、前記溝部の底部を基準位置とする前記壁部の頂部の高さが、前記溝部の外周に位置する前記樹脂部材の面の高さよりも低くされ、前記二つの樹脂部材の接合面を当接させて支持する工程と、振動素子により前記溶融開始部に対して面圧を負荷し、前記二つの樹脂部材を接合する工程と、を備える、樹脂部材の接合方法が提供される。
まず、本発明の実施の形態にかかる樹脂部材の構成について説明する。樹脂部材は、接合対象部材に対して超音波溶着によって接合される部材である。超音波溶着は、例えば、図1に示すように、第1の樹脂部材10と第2の樹脂部材20とを、互いの接合面を当接させて支持した状態で、超音波溶着装置のチップ30を第2の樹脂部材20における接合面の反対側の面から押し当てることにより行われる。本実施形態にかかる樹脂部材は、第1の樹脂部材10及び第2の樹脂部材20のうちの少なくとも一方の樹脂部材に適用することができる。
樹脂部材は、超音波溶着に用いられ、熱可塑性樹脂を含む樹脂部材であれば、特に限定されない。例えば、樹脂部材は、自動車車体用部品に使用される繊維強化樹脂製の部材とすることができる。繊維強化樹脂製の部材の場合、使用される強化繊維は、特に限定されるものではなく、例えば、炭素繊維やガラス繊維等のセラミックス繊維、アラミド繊維等の有機繊維、さらにはこれらを組み合わせた強化繊維を使用することができる。中でも、高い機械特性や強度設計の行いやすさ等の観点から、炭素繊維を含むことが好ましい。
図2は、第1の樹脂部材10の接合領域を示す説明図である。図2には、第1の樹脂部材10の接合領域を示す平面図及び断面図が示されている。断面図は、平面図におけるAA断面の矢視図である。かかる第1の樹脂部材10は板状を成しているが、第1の樹脂部材10は板状に限られず、種々の形状とすることができる。
第1の樹脂部材10は、接合領域に溶融開始部Sを備える。接合領域は、超音波溶着時に第2の樹脂部材20に対向配置されて、第2の樹脂部材20に接合される領域である。溶融開始部Sは、超音波溶着時に、主として面圧が負荷される領域である。図示した溶融開始部Sは、円形に形成されている。かかる溶融開始部Sの外形及び大きさは、超音波溶着装置のチップ30の外形及び大きさに対応している(図1を参照)。
溶融開始部Sの周囲には、溶融樹脂を受容するための溝部12が設けられている。溝部12は、溶融開始部Sの周囲を囲むように形成されている。本実施形態では、溝部12は、全体として環状に形成され、第1の壁部14a及び第2の壁部14bにより、第1の溝部12a、第2の溝部12b及び第3の溝部12cに区分されている。第1の壁部14aは、溝部12を、内側部分の第1の溝部12aと、外側部分の第2の溝部12b及び第3の溝部12cとに区分する。また、第2の壁部14bは、溝部12を、少なくとも部分的に、内側部分の第1の溝部12a及び第2の溝部12bと、外側部分の第3の溝部12cとに区分する。
以上、本実施形態にかかる樹脂部材としての第1の樹脂部材10の構成について説明した。次に、本実施形態にかかる樹脂部材の接合方法として、超音波溶着により、第1の樹脂部材10を第2の樹脂部材20に対して接合する方法の一例について説明する。
図4〜図7は、第1の樹脂部材10が第2の樹脂部材20に接合される様子を示す説明図である。図4〜図6において、上方に、重ね合わせられた第1の樹脂部材10及び第2の樹脂部材20を、第2の樹脂部材20側から見た図が示され、下方に、第1の樹脂部材10及び第2の樹脂部材20の断面図(XX断面、YY断面、ZZ断面の矢視図)が示されている。図7の断面図は、図4〜図6の断面図に対応する。
比較のために、溶融開始部、溝部及び壁部を備えない樹脂部材同士を超音波溶着により接合する対比例について説明する。図8〜図10は、対比例において、第1の樹脂部材110が第2の樹脂部材120に接合される様子を示す説明図である。図8〜図10は、それぞれ本実施形態による接合方法を示す図4〜図6に対応する図である。
以上説明した本実施形態にかかる樹脂部材及び樹脂部材の接合方法では、樹脂部材(第1の樹脂部材10)が、溶融開始部Sと、溝部12と、溝部12を第1の溝部12a、第2の溝部12b及び第3の溝部12cに区分する第1の壁部14a及び第2の壁部14bを備える。これにより、超音波溶着装置によって面圧がかけられる溶融開始位置が特定される。また、溶融開始部Sの周囲を囲むように形成された溝部12が、壁部14a,14bにより区分されていることから、超音波溶着により生じた溶融樹脂Pは、壁部14a,14bにより堰き止められつつ、溶融開始部Sに近い第1の溝部12aから順次流れ込む。
以下、本実施形態にかかる樹脂部材(第1の樹脂部材10)の変形例の幾つかを説明する。
図11は、変形例1にかかる樹脂部材50Aの接合面を示す平面図である。変形例1にかかる樹脂部材50Aは、溝部12内に、溶融開始部Sを中心として想定される円の接線方向に延びる複数の壁部52を備える。それぞれの壁部52は、溶融開始部Sから外側に向かう方向に対して交差するように形成され、それぞれの位置において、溝部12を、溶融開始部Sに近い内側部分と、溶融開始部Sから離れた外側部分とに区分する。壁部52が、溶融開始部Sの周囲を全周に亘って連続していない場合、それぞれの壁部52の長さが、例えば3.0mm以上であることが好ましい。壁部52の長さが短すぎると、溶融樹脂を堰き止める効果を得られない場合があるからである。
図12は、変形例2にかかる樹脂部材50Bの接合面を示す平面図である。変形例2にかかる樹脂部材50Bは、上記の実施形態における第1の樹脂部材10における第1の壁部14a及び第2の壁部14bが不連続にされて、断続的に形成された壁部54a,54bを備えた例である。変形例2においても、それぞれの壁部54a,54bの長さが、例えば3.0mm以上であることが好ましい。変形例2にかかる樹脂部材50Bにおいても、超音波溶着時に発生する溶融樹脂は、壁部54a,54bにより堰き止められつつ、溝部12の内側部分から順次外側部分に流れ込む。したがって、変形例2にかかる樹脂部材50Bにおいても、超音波溶着時に生じた溶融樹脂が確実に接合強度の向上に寄与しつつ、接合領域の界面の厚さの増加が抑制される。
図13は、変形例3にかかる樹脂部材40の接合面を示す平面図である。変形例3にかかる樹脂部材40は、溝部42が、壁部44a,44bによって区分され、それぞれの溝部42a,42b,42cが全体として同心円状をなしている。ただし、上記の実施形態にかかる第1の樹脂部材10の溝部12a,12b,12cとは異なり、溝部42a,42b,42cが、溶融開始部Sの周囲に不連続に配置されている。変形例3にかかる樹脂部材40においても、超音波溶着時に発生する溶融樹脂は、壁部44a,44bにより堰き止められつつ、溝部42の内側部分から順次外側部分に流れ込む。したがって、変形例3にかかる樹脂部材40においても、超音波溶着時に生じた溶融樹脂が確実に接合強度の向上に寄与しつつ、接合領域の界面の厚さの増加が抑制される。
12 溝部
12a 第1の溝部
12b 第2の溝部
12c 第3の溝部
14a 第1の壁部
14b 第2の壁部
20 第2の樹脂部材(接合対象)
30 チップ
50A,50B 樹脂部材
52 壁部
54a,54b 壁部
110 第1の樹脂部材
120 第2の樹脂部材
S 溶融開始部
Claims (7)
- 熱可塑性樹脂を含み、超音波溶着により互いに接合される樹脂部材であって、
前記超音波溶着の際に面圧が負荷される溶融開始部と、
前記溶融開始部の周囲を囲むように形成された溝部と、
前記溶融開始部から外側に向かう方向に対して交差するように形成され、少なくとも部分的に前記溝部を内側部分及び外側部分に区分する少なくとも一つの壁部と、
を備え、
前記溝部の底部を基準位置とする前記壁部の頂部の高さが、前記溝部の外周に位置する前記樹脂部材の面の高さよりも低い、樹脂部材。 - 熱可塑性樹脂を含み、超音波溶着により互いに接合される樹脂部材であって、
前記超音波溶着の際に面圧が負荷される溶融開始部と、
前記溶融開始部の周囲を囲むように形成された溝部と、
前記溶融開始部から外側に向かう方向に対して交差するように形成され、少なくとも部分的に前記溝部を内側部分及び外側部分に区分する複数の壁部と、
を備え、
前記溝部の底部を基準位置とする前記複数の壁部の頂部の高さが、前記溶融開始部の高さよりも低く、前記溶融開始部から離れるにしたがって前記壁部の頂部の高さが低くなる、樹脂部材。 - 前記樹脂部材の表面を基準位置とする前記溝部の深さが1.0mm以下である、請求項1又は2に記載の樹脂部材。
- 前記壁部により区分された前記溝部の前記内側部分及び前記外側部分は、同心円状に配置される、請求項1〜3のいずれか1項に記載の樹脂部材。
- 前記溶融開始部の大きさは、前記超音波溶着に用いられる超音波溶着装置のチップの大きさに対応する、請求項1〜4のいずれか1項に記載の樹脂部材。
- 熱可塑性樹脂を含む二つの樹脂部材を超音波溶着により接合する接合方法であって、
前記二つの樹脂部材の少なくとも一方は、接合領域に、前記超音波溶着の際に面圧が負荷される溶融開始部の周囲に溝部と、前記溶融開始部から外側に向かう方向に対して交差する方向に沿って形成されて、少なくとも部分的に前記溝部を内側部分及び外側部分に区分する少なくとも一つの壁部と、を備えるとともに、前記溝部の底部を基準位置とする前記壁部の頂部の高さが、前記溝部の外周に位置する前記樹脂部材の面の高さよりも低くされ、
前記二つの樹脂部材の接合面を当接させて支持する工程と、
振動素子により前記溶融開始部に対して面圧を負荷し、前記二つの樹脂部材を接合する工程と、
を備える、樹脂部材の接合方法。 - 熱可塑性樹脂を含む二つの樹脂部材を超音波溶着により接合する接合方法であって、
前記二つの樹脂部材の少なくとも一方は、接合領域に、前記超音波溶着の際に面圧が負荷される溶融開始部の周囲に溝部と、前記溶融開始部から外側に向かう方向に対して交差する方向に沿って形成されて、少なくとも部分的に前記溝部を内側部分及び外側部分に区分する複数の壁部と、を備えるとともに、前記溝部の底部を基準位置とする前記複数の壁部の頂部の高さが、前記溶融開始部の高さよりも低くされ、かつ、前記溶融開始部から離れるにしたがって前記壁部の頂部の高さが低くされ、
前記二つの樹脂部材の接合面を当接させて支持する工程と、
振動素子により前記溶融開始部に対して面圧を負荷し、前記二つの樹脂部材を接合する工程と、
を備える、樹脂部材の接合方法。
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US9770863B2 (en) * | 2014-12-12 | 2017-09-26 | GM Global Technology Operations LLC | Systems and methods to reduce air pocket formation during welding |
US9878489B2 (en) * | 2014-12-18 | 2018-01-30 | GM Global Technology Operations LLC | Spin-welding of polymeric components having large surface area or non-complementary weld interfaces |
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JP6565403B2 (ja) * | 2015-07-15 | 2019-08-28 | 浜名湖電装株式会社 | 樹脂成形品の製造方法 |
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