JP6968766B2 - 積層体 - Google Patents

積層体 Download PDF

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Publication number
JP6968766B2
JP6968766B2 JP2018152268A JP2018152268A JP6968766B2 JP 6968766 B2 JP6968766 B2 JP 6968766B2 JP 2018152268 A JP2018152268 A JP 2018152268A JP 2018152268 A JP2018152268 A JP 2018152268A JP 6968766 B2 JP6968766 B2 JP 6968766B2
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Prior art keywords
thermal expansion
resin
laminated body
coefficient
ratchet structure
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JP2020026093A (ja
JP2020026093A5 (ja
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拓平 束田
章弘 望月
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Polyplastics Co Ltd
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Polyplastics Co Ltd
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Priority to JP2018152268A priority Critical patent/JP6968766B2/ja
Priority to PCT/JP2019/031636 priority patent/WO2020036141A1/ja
Priority to CN201980043638.4A priority patent/CN112384363B/zh
Priority to US17/262,880 priority patent/US11607868B2/en
Priority to DE112019004113.4T priority patent/DE112019004113T5/de
Publication of JP2020026093A publication Critical patent/JP2020026093A/ja
Publication of JP2020026093A5 publication Critical patent/JP2020026093A5/ja
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    • B32B15/08—Layered products comprising a layer of metal comprising metal 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
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Description

本発明は、熱膨張係数の異なる２種の材料の積層体であって、この積層体の積層面の構造がラチェット構造を有する積層体に関する。
熱膨張係数の異なる２種の材料の積層体であって、熱変化を力学的変化に変換するものとしてバイメタルがよく知られている。バイメタルは、温度変化により積層体の曲る程度が変化することを利用するものであり、スイッチング等種々の分野で利用されている。バイメタルでは、温度がもとの温度に戻ることにより、積層体の形状も元に戻り、加熱−冷却による熱変化は力学的変形量として積層体には残らない。
本発明の発明者は、加熱−冷却の繰り返しを力学的な変形量として残すことのできる構造を見出した。
本発明の目的は、下記によって達成された。
１． 熱膨張係数の異なる２種の第１部材および第２部材の積層体であって、積層面がラチェット構造を有している積層体。ただし、第１部材の熱膨張係数は、第２部材の熱膨張係数よりも大きい。
２． 前記ラチェット構造が下記式1〜３を満足する前記１記載の積層体。
１．面方向への移動条件
Figure 0006968766
 ２．厚さ方向への移動条件：
Figure 0006968766
 ３．ロック条件：
Figure 0006968766
 ただし、各記号は、下記を意味する。
Figure 0006968766
Figure 0006968766
Figure 0006968766
Figure 0006968766
Figure 0006968766
 ３．前記第１部材および第２部材が、第１部材が樹脂であり、第２部材が金属である前記１または２記載の積層体。
本発明によれば、加熱−冷却の繰り返しを力学的な変形量として残すことができる。そしてその変形量を、応力という力学量で残すこともできる。
本発明のラチェット機能を有するインサート成形品の断面図である。第２部材を固定している。 本発明のラチェット構造の式進み角、戻り角の定義を示す図である。 本発明のラチェット構造を有する樹脂−金属積層体の動きを示す概念図である。 図３で示した樹脂−金属積層体の動きを示す、実際の写真である。 図４で示した積層体の実際に計測されたラチェット構造の形状である。 射出成形して作製した本発明のラチェット構造の例である。 射出成形して作製した本発明のラチェット構造の例である。
以下、本発明を詳しく説明する。
＜積層体＞
本発明の積層体は、熱膨張係数の異なる２種の第１部材および第２部材の積層体であって、積層面がラチェット構造を有していることを特徴とする。
≪熱膨張係数の異なる２種の材料≫
本発明における熱膨張係数とは、２３〜５５℃においての１Ｋあたりの線膨張率（×１０−６／Ｋ）を言う。
本発明に使用できる材料としては、熱膨張係数が１０以上であるものが好ましく使用でき、２種の材料第１部材および第２部材の熱膨張係数の差は、原理的には異なってさえいれば本発明の効果を得ることができるが、実用的には、５〜２５０（×１０−６／Ｋ）であり、好ましくは、２０〜２００（×１０−６／Ｋ）である。
樹脂としては熱膨張係数が６０〜２５０（×１０−６／Ｋ）のもの、例えば、ポリエチレン、ポリプロピレン、ナイロン６、ＡＢＳ、ポリカーボネート、ポリアセタール、ポリエチレンテレフタレート、ポリブチレンテレフタレー、ポリフェニレンサルファイド、液晶ポリマー、シクロオレフィンポリマー等を挙げることができる。樹脂においては、熱膨張係数の調整のために無機充填材を含有させてもよい。
金属としては、熱膨張係数４〜５０（×１０−６／Ｋ）のもの、例えば、アルミニウム、クロム、チタン、鉄、ニッケル、真鍮、銅、およびステンレスのようなこれらの合金等を挙げることができる。
金属以外の無機物としては、熱膨張係数３〜１５（×１０−６／Ｋ）のもの、例えば、ガラス、セラミック等が挙げられる。
上記以外の材料として、ＣＦＲＰやＧＦＲＰ等の複合材料も挙げる事が出来る。複合材料においても、熱膨張係数の調整のために、繊維量や繊維配向角度を調整させてもよい。
２種の材料としては、樹脂同士、金属同士、樹脂−金属、樹脂−セラミック、樹脂-複合材料等を適宜選択することができるが、樹脂−金属の組み合わせは好ましい。
≪積層面のラチェット構造≫
本発明においてラチェット構造とは、積層体の積層面において２種の材料を第１部材、第２部材とすると、それぞれお互いに、いわゆる歯車と歯止めの役目を果たす構造を有するものである（図１）。鮫肌リブレット、鋸刃、鱗等も含まれる。
本発明のラチェット構造では、図２で示すように下記の式１〜３を満足するものであることが好ましい。
１．厚さ方向への移動条件：
Figure 0006968766
 ２．面方向への移動条件：
Figure 0006968766
 ３．ロック条件：
Figure 0006968766
 ただし、各記号は、下記を意味する。
Figure 0006968766
Figure 0006968766
Figure 0006968766
Figure 0006968766
Figure 0006968766
式１は、厚さ方向に移動するための条件である。式２は、面方向、すなわち面内長手方向に移動するための条件である。式３は、加熱後冷却した際に、もとの状態に戻らないための条件である。
本発明では、弾性変形内での熱膨張および収縮が発生することが条件となる。熱膨張係数が大きい第１部材が全体的に膨張(厚さ方向＋面方向)した際に、積層体の面方向に存在する全ピッチのうち、任意の1箇所でも元々のマイクロラチェット構造箇所とは異なる箇所で噛み合えば、ロックが成立すると考える。
これら式１〜３を満たした積層体である場合、加熱−冷却の繰り返しを積層体の力学的変形量として残すことができる。
図１の積層体を例にすると、それぞれの材料に矢印の方向に加熱−冷却により力を発生する。まず加熱により第１部材、第２部材ともに熱膨張し、その変形量が１ユニット分を超えると、その後冷却して収縮しようとしてもラチェットによりロックがかかり、元の状態に戻ることができなくなる。
マイクロラチェット構造の加工深さｔは第１部材肉厚の０．０５〜２．３％であることが好ましく、０．１〜１．０％であることがより好ましく、０．１５〜０．５％であることがさらに好ましく、０．１８〜０．３％であることが特に好ましい。加工深さｔの実測値としては１〜１６０μｍであることが好ましく、２〜１００μｍであることがより好ましく、３〜５０μｍであることがさらに好ましく、５〜２０μｍであることが特に好ましい。また、第１部材肉厚ｈはが１〜１０ｍｍであることが好ましく、１．５〜８ｍｍであることがより好ましく、２〜６ｍｍにであることがさらに好ましい。
≪積層体の形状≫
本発明の積層体には、特に形状の決まりはなく、２種の材料がともに所望の成形体、シートであってもよいし、一方が円柱であって他方をその円柱に巻き付けるような形状であっても良い。
＜実施態様＞
図３、４において、金属の円柱周りにポリアセタール樹脂を成形するインサート樹脂成形の例を示す。金属よりも樹脂の方が、熱膨張係数は大きい。金属の円柱には図３で示すようなラチェットが形成されている。このラチェット構造の上に樹脂層をインサート成形により形成する。
この積層体は、加熱−冷却を繰り返すことにより、図３Ａ点線で示す位置から、図３Ｂの位置に樹脂の積層部が移動した。図４は、実際に移動したことを示す写真である。図５は、各部材の具体的なサイズを示したものである。
さらには、別の実施態様として図６で示すように、樹脂を流し込むゲートの反対側にはで示すウェルドと呼ばれる樹脂の合流点に使用することができる。このウェルド部分は、別方向から流れてきた樹脂が合流することから、樹脂の均一性に劣り、応力や歪の集中によってウェルドが開くことで割れの起点となりやすいため、加熱−冷却の変形の繰り返しには弱い部分として知られている。
図７では、ウェルドに向かって樹脂が変形する形状のラチェットを金属柱に形成していることを示している。この積層体の場合、加熱−冷却を繰り返すことによりウェルドに向かって樹脂が変形しようとする力が働くことになる。つまり、ウェルドが閉じる方向に向かって樹脂が変形することから、ウェルドでの接合強度が増し、加熱−冷却の変形の繰り返しによるウェルドでの破壊が起こりにくくなる。
このように、本発明においては、加熱−冷却の繰り返しを力学的量に変換することができる。

Claims (1)

  1. 熱膨張係数の異なる２種の第１部材および第２部材の積層体であって、積層面がラチェット構造を有し、
    該ラチェット構造が下記式1〜３を満足する積層体。
    １．厚さ方向への移動条件：
    Figure 0006968766
     ２．面方向への移動条件：
    Figure 0006968766
     ３．ロック条件：
    Figure 0006968766
     ただし、各記号は、下記を意味する。
    Figure 0006968766
    Figure 0006968766
    Figure 0006968766
    Figure 0006968766
    Figure 0006968766
     ただし、第１部材の熱膨張係数は、第２部材の熱膨張係数よりも大きく、該第１部材が樹脂であり、該第２部材が金属である。
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