JPWO2016027775A1 - 接合構造体および接合構造体の製造方法 - Google Patents
接合構造体および接合構造体の製造方法 Download PDFInfo
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- JPWO2016027775A1 JPWO2016027775A1 JP2016544197A JP2016544197A JPWO2016027775A1 JP WO2016027775 A1 JPWO2016027775 A1 JP WO2016027775A1 JP 2016544197 A JP2016544197 A JP 2016544197A JP 2016544197 A JP2016544197 A JP 2016544197A JP WO2016027775 A1 JPWO2016027775 A1 JP WO2016027775A1
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- perforated
- laser
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- joined
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Classifications
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- Electromagnetism (AREA)
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Abstract
Description
まず、図1を参照して、本発明の第1実施形態による接合構造体100について説明する。
次に、図1および図2を参照して、第1実施形態による接合構造体100の製造方法について説明する。
次に、図3〜図6を参照して、第1部材10の変形例について説明する。
次に、図7および図8を参照して、上記した第1実施形態の効果を確認するために行った実験例1および2について説明する。
この実験例1では、第1実施形態に対応する実施例1による接合構造体500(図8参照)と、比較例1による接合構造体とを作製し、それぞれについての接合評価を行った。なお、接合評価としては、熱衝撃試験を行っていないものについて接合強度を測定するとともに、熱衝撃試験後のものについて接合強度を測定し、その測定結果に基づいて合否判定を行った。その結果を表1に示す。
レーザ:ファイバレーザ(波長1062nm)
周波数:10kHz
出力:3.0W
走査速度:650mm/sec
走査回数:20回
照射間隔:65μm
サブパルス数:20
なお、周波数は、複数(この例では20)のサブパルスによって構成されるパルスの周波数である。つまり、この照射条件では、1秒間に650mm移動しながら65μmの間隔で1万回レーザ(パルス)を照射し、そのパルスが20のサブパルスによって構成されている。なお、走査回数は、レーザが同じ箇所に繰り返し照射される回数である。
予備乾燥:120℃×5時間
金型温度:120℃
シリンダ温度:270℃
保圧:100MPa
このようにして、実施例1の接合構造体500を作製した。なお、第2部材502は、板状に形成されており、長さが100mmであり、幅が25mmであり、厚みが3mmである。
不合格(×):「熱衝撃試験後の接合強度」/「熱衝撃試験前の接合強度」<90%
上記した表1に示すように、熱衝撃試験前では、実施例1の接合構造体500は、比較例1の接合構造体に比べて、せん断方向および剥離方向の接合強度が高くなっていた。これにより、実施例1の接合構造体500のように、穿孔部の内周面に突出部を形成することにより、接合強度が向上することが判明した。なお、熱衝撃試験後においても、実施例1の接合構造体500は、比較例1の接合構造体に比べて、せん断方向および剥離方向の接合強度が高くなっていた。
この実験例2では、第1実施形態に対応する実施例2による接合構造体と、比較例2による接合構造体とを作製し、それぞれについての接合評価を行った。なお、接合評価は実験例1と同様に行った。その結果を表2に示す。
レーザ:ファイバレーザ(波長1062nm)
周波数:10kHz
出力:1.1W
走査速度:650mm/sec
走査回数:3回
照射間隔:65μm
サブパルス数:3
上記した表2に示すように、熱衝撃試験前では、実施例2の接合構造体は、比較例2の接合構造体に比べて、せん断方向および剥離方向の接合強度が高くなっていた。さらに、実施例2の接合構造体では、熱衝撃試験前の接合強度を熱衝撃試験後においても90%以上維持できることが判明した。すなわち、実験例2では、実験例1と同様の結果が得られることが判明した。つまり、第1部材の材料として、樹脂であるPPSを用いた場合であっても、突出部を有する穿孔部を形成することにより、接合強度の向上を図るとともに、熱サイクル環境下における耐久性の向上を図ることができた。
次に、図9を参照して、本発明の第2実施形態による接合構造体200について説明する。
次に、図9および図10を参照して、第2実施形態による接合構造体200の製造方法について説明する。
次に、図11〜図14を参照して、第1部材30の変形例について説明する。
次に、上記した第2実施形態の効果を確認するために行った実験例3について説明する。
レーザ:ファイバレーザ(波長1062nm)
周波数:10kHz
出力:3.8W
走査速度:650mm/sec
走査回数:20回
照射間隔:65μm
サブパルス数:20
実施例3の接合構造体では、1パルスが複数のサブパルスで構成されるレーザを照射することにより、第1部材の表面には穿孔部が形成されるとともに、その穿孔部の表面から入り込んだ位置に突出部が形成される。すなわち、表3に示すように、開口径R4(図9参照)が、表面の開口径R3(図9参照)および開口径R5(図9参照)よりも小さくなっている。なお、比較例3の第1部材には、すり鉢状(円錐状)の穿孔部が形成されており、実施例3の開口径R4およびR5に対応する形状が形成されていない。
次に、隣接する穿孔部の間隔(中心間距離)の好ましい範囲を確認するために行った実験例3−1について説明する。
レーザ:ファイバレーザ(波長1062nm)
周波数:10kHz
出力:3.8W
走査回数:20回
サブパルス数:20
上記した表4に示すように、実施例3−1〜3−3の接合構造体では、熱衝撃試験前の接合強度を熱衝撃試験後においても90%以上維持することができた。これに対して、参考例3−1および3−2では、熱衝撃試験後の接合強度保持率が90%より低かった。したがって、隣接する穿孔部の間隔は、重畳して潰れない距離であって、200μm以下であることが好ましい。なお、実施例3−3の接合構造体では、実施例3−1および3−2に比べて、穿孔部の数が少ないため、接合強度自体が低くなっているが、熱サイクル環境下における耐久性は確保することができている。
次に、穿孔部の表面の開口径R3の好ましい範囲を確認するために行った実験例3−2について説明する。
レーザ:ファイバレーザ(波長1062nm)
周波数:10kHz
出力:3.8W
走査速度:1200mm/sec
照射間隔:120μm
上記した表5に示すように、実施例3−4〜3−6の接合構造体では、熱衝撃試験前の接合強度を熱衝撃試験後においても90%以上維持することができた。これに対して、参考例3−3および3−4では、熱衝撃試験後の接合強度保持率が90%より低かった。したがって、穿孔部の表面の開口径R3は、30μm〜100μmであることが好ましい。なお、実施例3−4〜3−6の接合構造体では、上記した実施例3−1および3−2に比べて、穿孔部の数が少ないため、接合強度自体が低くなっているが、熱サイクル環境下における耐久性は確保することができている。
次に、穿孔部の深さの好ましい範囲を確認するために行った実験例3−3について説明する。
レーザ:ファイバレーザ(波長1062nm)
周波数:10kHz
出力:3.8W
走査速度:650mm/sec
照射間隔:65μm
上記した表6に示すように、実施例3−7〜3−9の接合構造体では、熱衝撃試験前の接合強度を熱衝撃試験後においても90%以上維持することができた。これに対して、参考例3−5および3−6では、熱衝撃試験後の接合強度保持率が90%より低かった。したがって、穿孔部11の深さは、30μm〜300μmであることが好ましい。
次に、本発明の第3実施形態による接合構造体について説明する。この第3実施形態では、穿孔部を形成する際と、第1部材および第2部材を接合する際との少なくともいずれか一方を行うときに、不活性ガス雰囲気または減圧雰囲気にしている。
次に、図15〜図18を参照して、第3実施形態による接合構造体の製造方法について説明する。
次に、上記した第3実施形態の効果を確認するために行った実験例4について説明する。
レーザ:ファイバレーザ(波長1062nm)
周波数:10kHz
出力:3.8W
走査速度:650mm/sec
走査回数:40回
照射間隔:65μm
サブパルス数:20
このように、1パルスが複数のサブパルスで構成されるレーザを照射することにより、第1部材の表面の所定領域には穿孔部が形成されるとともに、その穿孔部の内周面に突出部が形成される。
レーザ:半導体レーザ(波長808nm)
発振モード:連続発振
出力:30W
焦点径:4mm
走査速度:1mm/sec
密着圧力:0.6MPa
このレーザの照射により、第1部材を加熱し、その熱により第2部材を溶融する。そして、溶融された第2部材が穿孔部に充填された後に、第2部材が固化される。これにより、第1部材と第2部材とが接合される。
なお、今回開示した実施形態は、すべての点で例示であって、限定的な解釈の根拠となるものではない。したがって、本発明の技術的範囲は、上記した実施形態のみによって解釈されるものではなく、特許請求の範囲の記載に基づいて画定される。また、本発明の技術的範囲には、特許請求の範囲と均等の意味および範囲内でのすべての変更が含まれる。
11、11b、11c、11d 穿孔部
12、12b、121c、122c、12d 突出部
13 表面
14 隆起部
20、41 第2部材
30、30a、30b、30c、30d 第1部材
31、31b、31c、31d 穿孔部
32、32b、321c、322c、32d 突出部
33 表面
34 隆起部
100 接合構造体
111 拡径部
112 縮径部(第1縮径部)
113 底部
200 接合構造体
311 縮径部(第2縮径部)
312 拡径部
313 縮径部(第1縮径部)
314 底部
Claims (13)
- 第1部材と第2部材とが接合された接合構造体であって、
前記第1部材の表面には開口を有する穿孔部が形成されるとともに、前記第1部材の穿孔部には前記第2部材が充填されており、
前記穿孔部は、深さ方向において表面側から底部に向けて開口径が大きくなる拡径部と、深さ方向において表面側から底部に向けて開口径が小さくなる第1縮径部とを有し、
前記拡径部が表面側に形成され、前記第1縮径部が底部側に形成されていることを特徴とする接合構造体。 - 請求項1に記載の接合構造体において、
前記穿孔部は、深さ方向において表面側から底部に向けて開口径が小さくなる第2縮径部を有し、
前記第2縮径部が前記拡径部よりも表面側に形成されていることを特徴とする接合構造体。 - 請求項1または2に記載の接合構造体において、
前記穿孔部は、前記第1部材の表面に複数形成されており、
隣接する穿孔部の間隔が200μm以下であることを特徴とする接合構造体。 - 請求項1〜3のいずれか1つに記載の接合構造体において、
前記穿孔部の表面の開口径は、30μm〜100μmであることを特徴とする接合構造体。 - 請求項1〜4のいずれか1つに記載の接合構造体において、
前記穿孔部の深さは、30μm〜300μmであることを特徴とする接合構造体。 - 請求項1〜5のいずれか1つに記載の接合構造体において、
前記第1部材は、金属、熱可塑性樹脂、または、熱硬化性樹脂であることを特徴とする接合構造体。 - 請求項1〜6のいずれか1つに記載の接合構造体において、
前記第2部材は、熱可塑性樹脂、または、熱硬化性樹脂であることを特徴とする接合構造体。 - 請求項1〜7のいずれか1つに記載の接合構造体において、
前記穿孔部の開口の周囲には、表面から上方に隆起する隆起部が設けられていることを特徴とする接合構造体。 - 請求項1〜8のいずれか1つに記載の接合構造体において、
前記穿孔部は、軸心が表面に対して傾斜するように形成されていることを特徴とする接合構造体。 - 請求項1〜9のいずれか1つに記載の接合構造体において、
前記拡径部および前記第1縮径部は、連なるように形成され、深さ方向に複数組形成されていることを特徴とする接合構造体。 - 第1部材と第2部材とが接合された接合構造体の製造方法であって、
前記第1部材の表面に開口を有する穿孔部を形成する工程と、
前記第1部材の穿孔部に前記第2部材を充填して固化させる工程とを備え、
前記穿孔部は、深さ方向において表面側から底部に向けて開口径が大きくなる拡径部と、深さ方向において表面側から底部に向けて開口径が小さくなる第1縮径部とを有し、
前記拡径部が表面側に形成され、前記第1縮径部が底部側に形成されることを特徴とする接合構造体の製造方法。 - 請求項11に記載の接合構造体の製造方法において、
前記第1部材は金属であり、
不活性ガス雰囲気下または減圧雰囲気下で前記第1部材の表面にレーザを照射することにより、前記穿孔部を形成することを特徴とする接合構造体の製造方法。 - 請求項11または12に記載の接合構造体の製造方法において、
前記第1部材は金属であり、前記第2部材は熱可塑性樹脂または熱硬化性樹脂であり、
不活性ガス雰囲気下または減圧雰囲気下で前記第1部材の穿孔部に前記第2部材を充填して固化させることを特徴とする接合構造体の製造方法。
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EP3184295B1 (en) | 2019-06-12 |
US20170259468A1 (en) | 2017-09-14 |
CN106715108A (zh) | 2017-05-24 |
TWI708650B (zh) | 2020-11-01 |
WO2016027775A1 (ja) | 2016-02-25 |
US10449698B2 (en) | 2019-10-22 |
EP3184295A4 (en) | 2017-08-30 |
KR20170029559A (ko) | 2017-03-15 |
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