JP6718863B2 - 熱可塑性樹脂フィルム積層体、及び熱可塑性樹脂フィルム積層体を含む成形品 - Google Patents
熱可塑性樹脂フィルム積層体、及び熱可塑性樹脂フィルム積層体を含む成形品 Download PDFInfo
- Publication number
- JP6718863B2 JP6718863B2 JP2017508421A JP2017508421A JP6718863B2 JP 6718863 B2 JP6718863 B2 JP 6718863B2 JP 2017508421 A JP2017508421 A JP 2017508421A JP 2017508421 A JP2017508421 A JP 2017508421A JP 6718863 B2 JP6718863 B2 JP 6718863B2
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- Prior art keywords
- thermoplastic resin
- resin film
- molded product
- welding
- resin molded
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- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
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- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
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- 229920000181 Ethylene propylene rubber Polymers 0.000 description 1
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- APOXBWCRUPJDAC-UHFFFAOYSA-N bis(2,6-dimethylphenyl) hydrogen phosphate Chemical compound CC1=CC=CC(C)=C1OP(O)(=O)OC1=C(C)C=CC=C1C APOXBWCRUPJDAC-UHFFFAOYSA-N 0.000 description 1
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Classifications
-
- 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
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/53—Joining single elements to tubular articles, hollow articles or bars
- B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
- B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
-
- 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
-
- 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
- B29C66/114—Single butt joints
-
- 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
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
- B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
-
- 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
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
- B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
-
- 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
- B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
- B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
- B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
- B29C66/2424—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain
- B29C66/24243—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a quadrilateral
- B29C66/24244—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a quadrilateral forming a rectangle
-
- 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
- B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
- 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
-
- 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
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/53—Joining single elements to tubular articles, hollow articles or bars
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/558—Impact strength, toughness
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2398/00—Unspecified macromolecular compounds
- B32B2398/20—Thermoplastics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
- B32B2439/40—Closed containers
- B32B2439/62—Boxes, cartons, cases
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
Description
また他に、接着剤や両面テープを介してフィルムと射出成形品を貼り合せる方法などがあるが、いずれの方法によっても、局部的に接着部の厚みが増加するため外観の良いものは得られなかった。
[2]熱可塑性樹脂フィルム(A)と熱可塑性樹脂成形品(B)とが同種の樹脂材料で形成されている[1]に記載の熱可塑性樹脂フィルム積層体。
[3]熱可塑性樹脂フィルム(A)の厚みが0.2mmから0.3mmである、[1]又は[2]のいずれかに記載の熱可塑性樹脂フィルム積層体。
[4]熱可塑性樹脂成形品(B)が、3cm2以上の開口部を少なくとも1つ以上有し、開口部の少なくとも一部を熱可塑性樹脂フィルム(A)が覆っている[1]〜[3]のいずれかに記載の熱可塑性樹脂フィルム樹脂積層体。
[5]上記[1]〜[4]のいずれかに記載の熱可塑性樹脂フィルム積層体を含有する成形品。
本発明の樹脂組成物に含まれる熱可塑性樹脂には、特に制限はなく、従来、成形材料として使用されているものから任意に選択して使用することができる。例えば、スチレン系樹脂、ポリフェニレンエーテル系樹脂、ポリオレフィン系樹脂、ポリ塩化ビニル系樹脂、ポリアミド系樹脂、ポリエステル系樹脂、ポリカーボネート系樹脂及びアクリル系樹脂等が挙げられる。
本発明において、熱可塑性樹脂フィルム(A)の厚みは0.4mm以下である。これは熱可塑性樹脂フィルムにおいて、厚みが0.4mm以下である領域の表面積がフィルム全体の表面積の70%以上であるものをいう。熱可塑性樹脂フィルム(A)の厚みが0.4mmより大きいと、通常、射出成形での成形が容易となり、また充分な厚みを有するためエネルギーダイレクターの押込による外観不良が観察されないことから、本発明の効果が充分に得られない。熱可塑性樹脂フィルム(A)の好ましい厚みは0.01mmから0.4mm以下であり、さらに好ましくは0.1mmから0.4mm、最も好ましくは0.2mmから0.3mmである。熱可塑性樹脂フィルム(A)の厚みが0.01mmより小さいとフィルムが薄すぎるため、超音波溶着後の良好な外観が得られず、また筐体として用いた場合、内部部品の保護が不充分となる問題が生じ得る。なお、本発明の熱可塑性樹脂フィルム(A)は、Tダイを用いた溶融押出法、溶剤キャスト法、ブロー成形法から製造されたフィルムを用いることができる。
本発明において、熱可塑性樹脂成形品(B)は、厚みの平均が0.5mm以上である。また、熱可塑性樹脂成形品(B)の成形方法は、射出成形品、プレス成形品、ブロー成形品、押出成形品、真空成形品、圧空成形品などが挙げられるが、生産性の観点から射出成形品が好ましく用いられる。
溶着代(エネルギーダイレクター)(C)は、熱可塑性樹脂フィルム(A)と熱可塑性樹脂成形品(B)を接合するために、熱可塑性樹脂成形品(B)の溶着面に設置される。接合法としては、超音波溶着が用いられる。超音波溶着においては、熱可塑性樹脂成形品(B)に設置された溶着代(エネルギーダイレクター)に超音波エネルギーが集中し、熱可塑性樹脂成形品(B)の溶着代(C)と熱可塑性樹脂フィルム(A)との摩擦によって生じる発熱によって、溶融した溶着代(エネルギーダイレクター)と熱可塑性樹脂フィルム(A)が接合される。
エネルギーダイレクターは、接合される熱可塑性樹脂フィルム(A)側、すなわち上側に向かって凸の形状であり、フィルム厚み断面の形状が三角形であることが好ましい。この断面の三角形については、頂点の角度が40度から120度のエネルギーダイレクターが用いられ、好ましくは頂点の角度は50〜70度、最も好ましくは60度である。すなわち、断面形状が正三角形であることが特に好ましい。このように、溶着代(エネルギーダイレクター)(C)の断面形状が三角形、特に正三角形であれば、超音波溶着において、超音波エネルギーを上端部、すなわち三角形の頂点に集中させることを可能にしつつ、熱可塑性樹脂成形品(B)側、すなわち三角形の底辺側の溶着代の領域を十分に確保できる。このような観点から、溶着代(エネルギーダイレクター)(C)の断面形状として、四角形を回避すべきであり、円状も回避することが好ましい。溶着代(エネルギーダイレクター)(C)の形状は、射出成形又は熱プレス成形から金型で転写する方法、成形品の機械切削、印刷等による加工によって付与できる。
なお、溶着代(C)は、熱可塑性樹脂成形品(B)の溶着面において、連なって列状(ライン状)に配置されていることが好ましい。特に、溶着代(C)は、熱可塑性樹脂成形品(B)の溶着面において一列に設けられていることが好ましい。熱可塑性樹脂成形品(B)の溶着面において溶着代(C)の複数の列、例えば、平行な複数の列を設けると、超音波エネルギーが複数の列に分散されるためである。
C(mm)/A(mm)×100(%)の値が、好ましくは72%〜130%であり、
(1−C(mm)/A(mm))×100(%)の値が、好ましくは−28%〜30%である。
なお好ましくは、溶着代24の高さ24Hは、熱可塑性樹脂フィルム(A)10の厚み10Tの75〜125%、より好ましくは80〜120%、特に好ましくは85〜115%である。溶着代(エネルギーダイレクター)の高さ24Hが上限を超える場合は、溶着強度は得られるがエネルギーダイレクターの押込による外観不良が起こりやすいという問題が生じ得る。また溶着代(エネルギーダイレクター)の高さ24Hが下限を満たさない場合は、良好な外観の積層体が得られるが、溶着強度が低下する問題が生じ得る。
図1に示されるように、熱可塑性樹脂フィルム10と熱可塑性樹脂成形品20とを互いに対向させた状態で、矢印の示すように溶着させる超音波溶着により、熱可塑性樹脂フィルム10と熱可塑性樹脂成形品20との積層体が形成される。こうして得られる積層体の熱可塑性樹脂フィルム10と熱可塑性樹脂成形品20との間において、溶着代24は、超音波溶着により溶けて熱可塑性樹脂フィルム10と溶融混合された接合部となる。このため、製造された積層体における熱可塑性樹脂フィルム10と熱可塑性樹脂成形品20との接合領域では、これらの部材の表面はいずれも実質的に平滑になり、外観上の問題は生じない。
本発明における熱可塑性樹脂フィルム(A)と熱可塑性樹脂成形品(B)の熱変形温度は、これらの樹脂が非晶性樹脂の場合はガラス転移温度とし、これらの樹脂が結晶性樹脂の場合は融点とする。熱変形温度はDSC(示差熱走査熱量分析計)によって測定できる。非相溶系のポリマーアロイ材の場合は、マトリックス樹脂の熱変形温度とする。
熱可塑性樹脂フィルム(A)と熱可塑性樹脂成形品(B)の組合せは、好ましくは、熱変形温度の差が20℃以下のものを用いる。より好ましくは、熱変形温度の差は15℃以下であり、特に好ましくは10℃以下である。なかでも熱可塑性樹脂フィルム(A)と熱可塑性樹脂成形品(B)樹脂の種類は相溶性の高いもの、もしくは反応性の高いものが好ましく用いられる。特に、熱可塑性樹脂フィルム(A)と熱可塑性樹脂成形品(B)を、同種の樹脂材料で形成することが好ましい。ここでいう同種の材料とは、段落[0013]以下に示した樹脂の系統が同一のもの、より具体的には同種の化学結合を有する熱可塑性樹脂材料のことをいう。そのため、同種の分子構造を有する樹脂材料であれば、分子量が異なるもの、共重合の種類、共重合組成比、添加剤の配合量が異なっているものであっても、本発明における同種の樹脂材料と定義する。
熱可塑性樹脂フィルム(A)と熱可塑性樹脂成形品(B)の熱変形温度の差が20℃を超える場合、外観を優先にした場合は樹脂溶着強度が不充分となり、その溶着強度を優先した場合はさらに高い超音波エネルギーが必要となるため、得られた熱可塑性樹脂フィルム積層体(成形品)の外観が劣るといった問題が生じ得る。
本発明の熱可塑性樹脂フィルム積層体の製造方法においては、超音波溶着が用いられる。すなわち、熱可塑性樹脂フィルム積層体は、上述の熱可塑性樹脂フィルム(A)と、上述の熱可塑性樹脂成形品(B)の溶着代(C)とを超音波溶着することにより、製造される。例えば、熱可塑性樹脂成形品(B)の開口部の周囲に溶着代(C)を設け、開口部を覆うように熱可塑性樹脂フィルム(A)を接合させることにより、熱可塑性樹脂フィルム積層体が得られる。
こうして製造された筐体である積層体40においては、厚みが熱可塑性樹脂フィルム10よりも大きい熱可塑性樹脂成形品20の壁部材20Wにより全面を形成した場合に比べて、より広い内部空間40Aを確保することができ、例えば電池などの内部部品を収容するスペースが増すこととなる。
熱可塑性樹脂の熱変形温度(Tg)は、示差熱走査熱量分析計セイコー電子工業(株)製のSSC−5200(DSC)で測定した。測定においては、窒素雰囲気下で樹脂成分が溶融する温度(260℃)に20℃/minで昇温し、−30℃まで急冷した後、再度10℃/minで昇温(2nd run)した。得られたDSC曲線から始点法によってガラス転移温度及び融点を求めた。
超音波溶着強度の評価として、フィルム積層体の溶着後の成形品の成形品穴開き部を、成形品側から指で押込み破壊した。
特に良好:溶着部での破壊は見られなかった。
良好:一部、溶着代での破壊が見られた。
不良:溶着していたフィルムが剥離した。
フィルム積層体の超音波溶着後の成形品積層体の外観評価を目視にて行った。目視観察はフィルム側から行った。フィルム表面に溶着代(エネルギーダイレクター)の押込みによる表面傷がほとんどなく特に優れた状態を特に良好、表面傷が少なく良好な状態を良好、表面傷がやや目立つものをやや不良、表面傷が大きく外観に劣る状態を不良とした。
図3に示すように、2つの開口部を有し、図1及び2に示された成形品とは形状の異なる平板状の成形品にフィルム積層体を溶着させた後に、成形品積層のたわみの度合いを目視にて確認した。たわみがほとんどない状態を良好、たわみが大きい状態を不良とした。
<熱可塑性樹脂>
ポリカーボネート樹脂は表1の配合でコンパウンド化を実施、ポリブチレンテレフタレートは市販のものを用いた。
(a−1)三菱エンジニアリングプラスチックス(株)製「ユーピロン(登録商標)S−3000F」、ビスフェノールA型芳香族ポリカーボネート樹脂、熱変形温度(ガラス転移温度)145℃
(a−2)三菱エンジニアリングプラスチックス(株)製「ノバデュラン(登録商標)5020」、ポリブチレンテレフタレート樹脂、熱変形温度(融点)224℃
(a−3)三菱エンジニアリングプラスチックス(株)製「ノバデュラン(登録商標)5510S」、ポリブチレンテレフタレート樹脂、熱変形温度(融点)219℃
<難燃剤>
(b−1)大八化学工業(株)製 「PX−200」、芳香族縮合リン酸エステル系難燃剤、1,3−フェニレンビス(ジ−2,6−キシレニルホスフェート)
<樹脂ペレットの製造>
ポリカーボネート樹脂組成物のコンパウンド化には、1ベントを備えた日本製鋼所社製二軸押出機TEX30α(C18ブロック)を用いた。そして、スクリュー回転数200rpm、吐出量20kg/時間、バレル温度270℃の条件で各成分を混練し、ストランド状に押出した溶融樹脂を水槽にて急冷し、ペレタイザーを用いてペレット化してポリカーボネート樹脂組成物のコンパウンドを得た。
バレル直径32mm、スクリューのL/D=35の二軸押出機からなるTダイ溶融押出機を用い、吐出量20kg/h、スクリュー回転数200rpmで幅400mmのシートを成形した。シリンダー・ダイヘッド温度の設定は、ポリカーボネートは260℃、ポリブチレンテレフタレートは235℃で行った。フィルムの表面は、一方が鏡面、もう一方には表面粗さRa=1.5μmのマット形状が転写されたものを用いた。フィルム厚みは表1に示したものを用いた。超音波溶着試験に用いたフィルムの大きさは、図3に示した熱可塑性樹脂成形品(B)を覆うため150mm×40mmにカットしたものを用いた。
表1に記載した組成品の150mm×100mm×1.2mm厚平板の樹脂プレートを射出成形で成形した。得られた射出成形品を切削加工することによって、図3に示す寸法、及び図1に概略的に示した形状の溶着代(ED、エネルギータイレクター)(C)24を有する熱可塑性樹脂成形品(B)20を製造した。なお、図3及び4中の符号とは異なる数値は、各部材の寸法(mm)を示す。これらの数値は、各部材の寸法の一例であり、各部材の寸法を限定するものではない。
上述の熱可塑性樹脂成形品(B)20と、熱可塑性樹脂フィルム(A)10とが一体となった溶着代一体型熱可塑性樹脂成形品を作製した。溶着代(ED、エネルギータイレクター)(C)の高さは、表1に示す0.1〜0.4mmの値とした。そして図3に示す形状を有する熱可塑性樹脂成形品(B)20を用いて、熱可塑性樹脂フィルムが2つの開口部20Hを完全に覆うように、熱可塑性樹脂フィルム10と熱可塑性樹脂成形品20とを溶着させた。熱可塑性樹脂成形品(B)20の厚さは1.0mm、縦及び横の長さはそれぞれ4.0cm及び15.0cmであり、各開口部20Hの縦及び横の長さはそれぞれ1.0cm及び12.5cmであり、各開口部20Hの面積は12.5cm2であった(図3参照)。そして、熱可塑性樹脂成形品(B)20の溶着面20S上に、開口部20Hの周囲を囲むように、溶着代(C)24を破線で示された位置に設けた。図4において、図3に示す溶着面20Sの領域I及びIIを拡大して示す。
このように、開口部20Hの実質的に全周を囲むように溶着代(C)24を設けて超音波溶着を行うことにより、熱可塑性樹脂フィルム(A)10を、熱可塑性樹脂成形品(B)20に対して強固に固定することができる。なお、溶着面20Sの領域Iにおいて、溶着代(C)24の途切れている領域20Dを設けることにより(図4参照)、溶着代を設ける加工が容易になる。
成形品開口部を覆うフィルムのたわみ状態について、超音波溶着品とインモールドフィルムによる射出成形品との比較を行うため、インモールドフィルムによる射出成形品を成形した。あらかじめ超音波溶着用成形品と同寸法(150×40mm)のポリカーボネート樹脂フィルムを金型内に設置、超音波溶着用金型の溶着代(C)の彫込がない金型にてポリカーボネート樹脂の射出成形を行った。以下の成形条件、すなわち、シリンダー温度320℃、金型温度95℃の条件で成形した。インモールドフィルム成形で得られた結果を比較例4に示す。
超音波溶着は、日本エマソン社製のBranson 2000Xdt(20kHz 2200W)を用い、成形品形状に合ったチタン合金製の溶着ホーンを使用した。溶着試験は熱可塑性樹脂フィルム(A)の鏡面側と熱可塑性樹脂成形品(B)の溶着代が形成されている面とで行い、熱可塑性樹脂成形品(B)を上部ホーン側、熱可塑性樹脂フィルム(A)を下部ホーン受け台に固定し溶着試験を行った。熱可塑性樹脂フィルム(A)のマット柄の保護のため、フィルムに厚さ0.03mmのポリエチレン製の保護フィルムを接触させて試験を行った。超音波溶着試験におけるパラメータの設定は以下の通りである。すなわち、照射時間0.3sec(ポリブチレンテレフタレート樹脂では0.45sec)、ホールド時間0.3sec、エアーシリンダ圧力200kPa、トリガーフォース250N、及び振幅100%の条件で超音波溶着試験を実施した。
10T 熱可塑性樹フィルムの厚み
20 熱可塑性樹脂成形品
20H 開口部
20S 溶着面
24 溶着代
24H 溶着代の高さ
Claims (8)
- 厚みが0.01mmから0.4mm以下の熱可塑性樹脂フィルム(A)と、溶着代(C)を有する厚み0.5mm以上の熱可塑性樹脂成形品(B)の前記溶着代(C)とを超音波溶着して得られる熱可塑性樹脂積層体であって、
該溶着代(C)の高さが該熱可塑性樹脂フィルム(A)の厚みの72〜130%であり、
前記熱可塑性樹脂フィルム(A)と前記熱可塑性樹脂成形品(B)の熱変形温度の差が20℃以下であり、
前記熱可塑性樹脂成形品(B)が、開口部を少なくとも1つ以上有し、前記開口部の少なくとも一部を前記熱可塑性樹脂フィルム(A)が覆っていて、
前記熱可塑性樹脂成形品(B)が、3cm 2 以上の開口部を少なくとも1つ以上有する熱可塑性樹脂フィルム積層体。 - 前記熱可塑性樹脂フィルム(A)と前記熱可塑性樹脂成形品(B)とが同種の樹脂材料で形成されている請求項1に記載の熱可塑性樹脂フィルム積層体。
- 前記熱可塑性樹脂フィルム(A)の厚みが0.2mm〜0.3mmである、請求項1又は2のいずれかに記載の熱可塑性樹脂フィルム積層体。
- 前記熱可塑性樹脂成形品(B)において、前記開口部の周囲を囲むように前記溶着代(C)が設けられている、請求項1〜3のいずれか一項に記載の熱可塑性樹脂フィルム積層体。
- 前記溶着代(C)が、前記熱可塑性樹脂成形品(B)の溶着面において列状に配置されている、請求項1〜4のいずれか一項に記載の熱可塑性樹脂フィルム積層体。
- 前記溶着代(C)の高さが、前記熱可塑性樹脂成形品(B)の溶着面から前記溶着代(C)の頂点までの長さである、請求項1〜5のいずれか一項に記載の熱可塑性樹脂フィルム積層体。
- 前記熱変形温度が、前記熱可塑性樹脂フィルム(A)と前記熱可塑性樹脂成形品(B)が非晶性樹脂であるときにはガラス転移温度であり、前記熱可塑性樹脂フィルム(A)と前記熱可塑性樹脂成形品(B)が結晶性樹脂であるときには融点である、請求項1〜6のいずれか一項に記載の熱可塑性樹脂フィルム積層体。
- 請求項1〜7のいずれか一項に記載の熱可塑性樹脂フィルム積層体を含有する成形品。
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JPS52141880A (en) * | 1976-05-19 | 1977-11-26 | Ici Ltd | Laminated structure and method for its production |
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JPS58160125A (ja) * | 1982-03-17 | 1983-09-22 | Hitachi Ltd | 成形体とその製造方法 |
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JPS6254757A (ja) | 1985-05-23 | 1987-03-10 | Toray Ind Inc | ポリフエニレンスルフイド樹脂組成物 |
US4865217A (en) * | 1987-08-31 | 1989-09-12 | Sumitomo Bakelite Company, Limited | Easily openable sealed container |
US4909434A (en) * | 1988-05-20 | 1990-03-20 | The Procter & Gamble Company | Moisture impervious carton having one-piece pouring spout sealed to innermost and outermost surfaces |
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US5912084A (en) * | 1994-08-10 | 1999-06-15 | E. I. Du Pont De Nemours And Company | Packaging seal layer |
JP2000043915A (ja) * | 1998-07-29 | 2000-02-15 | Toppan Printing Co Ltd | 耐圧性蓋体 |
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JP2000326413A (ja) * | 1999-05-20 | 2000-11-28 | Meiwa Ind Co Ltd | 超音波溶着方法 |
US7655457B2 (en) * | 2003-11-17 | 2010-02-02 | Hitachi, Ltd. | Cell culture vessel and cultured cell |
JP4558374B2 (ja) | 2004-05-11 | 2010-10-06 | 上野製薬株式会社 | 液晶ポリエステル樹脂組成物の接合方法および液晶ポリエステル樹脂組成物接合体 |
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