KR20160147737A - 가스 투과 부재 및 그 제조 방법 - Google Patents

가스 투과 부재 및 그 제조 방법 Download PDF

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Publication number
KR20160147737A
KR20160147737A KR1020167028176A KR20167028176A KR20160147737A KR 20160147737 A KR20160147737 A KR 20160147737A KR 1020167028176 A KR1020167028176 A KR 1020167028176A KR 20167028176 A KR20167028176 A KR 20167028176A KR 20160147737 A KR20160147737 A KR 20160147737A
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South Korea
Prior art keywords
gas permeable
welding
housing
horn
fluororesin
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KR1020167028176A
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English (en)
Inventor
교코 이시이
요우조우 야노
Original Assignee
닛토덴코 가부시키가이샤
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Priority to KR1020227031594A priority Critical patent/KR20220129677A/ko
Publication of KR20160147737A publication Critical patent/KR20160147737A/ko

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    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • 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
    • 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
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • 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
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap 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
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • 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
    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/2422—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 circular, oval or elliptical
    • B29C66/24221—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 circular, oval or elliptical being circular
    • 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
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
    • 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
    • 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
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • 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
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B29C66/712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
    • 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
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • 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
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B29C66/73116—Melting point of different melting point, i.e. the melting point of one of the parts to be joined being different from the melting point of the other part
    • 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
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7318—Permeability to gases or liquids
    • B29C66/73181—Permeability to gases or liquids permeable
    • B29C66/73182—Permeability to gases or liquids permeable to gases
    • 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
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/735—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the extensive physical properties of the parts to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Engineering & Computer Science (AREA)
  • Thermal Sciences (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Fluid Mechanics (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

가공 대상에 접해야 할 작용면(62p)에 볼록부(62t)가 형성된 용착 혼(62)을 사용하여, 불소 수지로 만들어진 가스 투과성의 불소 수지 다공질막(4)을 열가소성 수지로 만들어진 수지 부품(2)에 용착한다. 용착 혼(62)의 작용면(62p)에는, 예를 들어 복수의 볼록부(62t)가 형성되어 있다. 복수의 볼록부(62t)는, 작용면(62p)에 있어서 격자 형상으로 나열되어 있어도 된다.

Description

가스 투과 부재 및 그 제조 방법{GAS PERMEATION MEMBER AND PRODUCTION METHOD THEREFOR}
본 발명은, 통기 부재, 방수 통음 부재 등의 가스 투과 부재 및 그 제조 방법에 관한 것이다.
램프, 센서, ECU(electronic control unit) 등의 자동차의 전기 부품을 수용하기 위한 하우징에는, 하우징의 내부와 외부의 통기를 확보하면서, 하우징의 내부로의 이물의 침입을 저지하기 위한 통기 부재가 설치되어 있다. 예를 들어, 특허문헌 1에는, 차량용 램프 하우징의 개구부에 가스 투과막을 접착 또는 용착하는 것이 기재되어 있다.
가스 투과막을 램프 하우징 등의 수지 부품에 고정하는 방법으로서, 특허문헌 1은, 접착 및 용착을 개시하고 있다. 접착은, 간단한 방법이지만, 생산성이 그다지 좋지 않은 점, 접착 강도가 경시적으로 저하되는 점 등의 문제를 안고 있다. 한편, 용착은, 재료의 상성(相性)의 문제를 안고 있다. 특히, 가스 투과막이 불소 수지로 만들어지고, 수지 부품이 열가소성 수지로 만들어져 있을 때, 가스 투과막을 수지 부품에 용착하는 것은 용이하지 않다. 그로 인해, 종래의 수지 부품의 표면에는, 용착 리브가 형성되어 있다. 수지 부품의 표면의 용착 리브에 가스 투과막을 압박하면서 용착 리브를 용융 및 고화시킴으로써, 수지 부품과 가스 투과막 사이의 용착 강도를 높일 수 있다(특허문헌 2).
일본 특허 공개 제2006-324260호 공보 일본 특허 공개 제2009-078866호 공보
특허문헌 2의 방법에 의하면, 용착 강도의 향상을 기대할 수 있기는 하지만, 수지 부품에 용착 리브가 불가결하게 된다. 용착 리브에 의존하지 않고, 충분한 용착 강도를 달성할 수 있는 기술이 요망되고 있다.
본 발명의 목적은, 수지 부품과 수지막 사이의 용착 강도를 높이는 것에 있다.
즉, 본 개시는,
가공 대상에 접해야 할 작용면에 볼록부가 형성된 용착 혼을 사용하여, 불소 수지로 만들어진 가스 투과성의 불소 수지 다공질막을 열가소성 수지로 만들어진 수지 부품에 용착하는 공정을 포함하는, 가스 투과 부재의 제조 방법을 제공한다.
다른 측면에 있어서, 본 개시는,
열가소성 수지로 만들어진 수지 부품과,
상기 수지 부품에 설치되고, 불소 수지로 만들어진 가스 투과성의 불소 수지 다공질막을 구비하고,
상기 불소 수지 다공질막은, 가공 대상에 접해야 할 작용면에 볼록부가 형성된 용착 혼을 사용해서 상기 수지 부품에 용착되어 있는, 가스 투과 부재를 제공한다.
상기 기술에서는, 수지 부품에 가스 투과성의 불소 수지 다공질막이 용착된다. 용착 혼의 작용면에는 볼록부가 형성되어 있다. 그로 인해, 불소 수지 다공질막과 수지 부품과의 계면에 용착 혼으로부터의 하중을 집중시키기 쉽다. 그 결과, 수지 부품과 불소 수지 다공질막 사이의 용착 강도를 용이하게 높일 수 있다.
도 1은 본 발명의 제1 실시 형태에 따른 통기 부재의 종단면도
도 2는 도 1에 도시하는 통기 부재의 제조에 사용되는 초음파 용착 장치의 구성도
도 3은 용착 혼의 작용면의 평면도
도 4는 다른 용착 혼의 단면도 및 평면도
도 5a는 본 발명의 제2 실시 형태에 따른 통기 부재(가스 투과막이 형성된 덮개 부분)를 구비한 하우징의 사시도
도 5b는 도 5a에 도시하는 하우징의 부분 단면도
이하, 본 발명의 실시 형태에 대해서, 도면을 참조하면서 설명한다. 본 발명은, 이하의 실시 형태에 한정되지 않는다.
(제1 실시 형태)
도 1에 도시하는 바와 같이, 본 실시 형태에 따른 통기 부재(10)는, 지지체(2), 가스 투과막(4), 커버(6) 및 시일 링(8)을 구비하고 있다. 통기 부재(10)는, 예를 들어 하우징(20)(상세하게는, 하우징의 덮개 부분)의 개구부(20h)에 설치되어 있다. 통기 부재(10) 및 하우징(20)에 의해 통기 구조(100)가 형성되어 있다.
하우징(20)은, 전기 부품 및/또는 기계 부품을 수용하기 위해 사용되는 하우징이다. 하우징(20)은, 전형적으로는 램프, 모터, 센서, 스위치, ECU, 기어박스 등의 자동차 부품의 하우징이다. 하우징(20)은, 전광 게시판, 도로 표지 등의 자동차 부품 이외의 부품을 수용하기 위한 하우징으로서도 사용될 수 있다. 통기 부재(10)는, 액체 및 고체의 침입을 방지하면서, 하우징(20) 내부의 환기를 행하기 위한 부재이다. 가스 투과막(4)은, 하우징(20)의 내부 공간(22)과 외부 공간(24) 사이의 기체의 유통을 허용하는 한편, 액체 및 고체가 내부 공간(22)에 침입하는 것을 방지한다.
본 실시 형태에 있어서, 지지체(2)는, 열가소성 수지로 만들어진 수지 부품이다. 가스 투과막(4)은, 불소 수지로 만들어진 가스 투과성의 불소 수지 다공질막이다. 본 실시 형태에 있어서, 가스 투과막(4)은, 보강재 등을 갖지 않고, 불소 수지 다공질막만으로 구성되어 있다. 열가소성 수지는 상대적으로 낮은 융점을 갖고, 불소 수지는 상대적으로 높은 융점을 갖는다. 지지체(2)는, 통기 경로로서의 관통 구멍(2h)을 갖는다. 관통 구멍(2h)을 막도록, 지지체(2)의 상면에 가스 투과막(4)이 용착되어 있다. 지지체(2)와 가스 투과막(4)의 사이에는, 지지체(2)를 구성하는 열가소성 수지가 용융 및 고화함으로써 형성된 용착부(14)가 형성되어 있다. 용착부(14)는, 예를 들어 평면에서 보아 환형상이다.
지지체(2)를 구성하는 열가소성 수지로서는, 폴리프로필렌, 폴리부틸렌테레프탈레이트, 아크릴로니트릴-부타디엔-스티렌 공중합체, 폴리카르보네이트 등을 들 수 있다. 이들 열가소성 수지의 융점은, 대략 100 내지 200℃이다. 지지체(2)를 구성하는 열가소성 수지에는, 유리 파이버 등의 첨가제가 포함되어 있어도 된다. 가스 투과막(4)을 구성하는 불소 수지로서는, 폴리테트라플루오로에틸렌(PTFE), 폴리클로로트리플루오로에틸렌, 테트라플루오로에틸렌-헥사플루오로프로필렌 공중합체, 테트라플루오로에틸렌-에틸렌 공중합체 등을 들 수 있다. 이들 불소 수지의 융점은, 대략 250 내지 350℃이다. 가스 투과막(4)의 두께는 특별히 한정되지 않고, 예를 들어, 0.1 내지 0.5㎜이다. 제2 실시 형태와 같이, 가스 투과막(4)이 커버 등으로 보호되어 있지 않은 경우, 가스 투과막(4)이 비교적 두꺼울 것(예를 들어, 0.2 내지 0.4㎜)이 권장된다. 얇은 불소 수지막 또는 얇은 불소 수지막과 보강재로 구성된 막과 같은 얇은 가스 투과막(4)은, 열 및 진동을 전달하기 쉬우므로, 용착되기 쉽다. 한편, 두꺼운 가스 투과막(4)은, 열 및 진동을 전달하기 어려워, 용착되기 어려우므로, 본 명세서에 기재된 기술을 적용할 것이 특히 권장된다.
커버(6)는, 가스 투과막(4)을 보호하도록 지지체(2)에 설치되어 있다. 커버(6)는, 지지체(2)와 동일한 재료로 만들어져 있어도 되고, 지지체(2)와는 다른 재료로 만들어져 있어도 된다.
지지체(2)는, 복수의 다리부(12)를 갖는다. 통기 구조(100)에 있어서, 지지체(2)의 다리부(12)는, 하우징(20)의 개구부(20h)에 끼워져 있다. 다리부(12)는, 하우징(20)의 내면에 걸림 결합되어 있다. 이에 의해, 통기 부재(10)가 하우징(20)에 고정되어 있다. 시일 링(8)은, 지지체(2)의 하면과 하우징(20)의 외면 사이에 배치되어 있다. 시일 링(8)에 의해, 지지체(2)와 하우징(20) 사이의 간극이 봉해져 있다. 시일 링(8)은, 예를 들어 니트릴 고무, 에틸렌-프로필렌 고무, 실리콘 고무, 불소 고무, 아크릴 고무, 수소화 니트릴 고무 등의 엘라스토머로 만들어져 있다.
하우징(20)은 복수의 부분, 예를 들어 덮개 부분과 저부분으로 구성되어 있다. 통기 부재(10)를 설치하기 위한 개구부(20h)는, 어느 부분에 형성되어 있어도 된다. 하우징(20)은, 예를 들어 수지로 만들어져 있다. 단, 본 실시 형태에 있어서, 하우징(20)의 재료는 한정되지 않는다. 하우징(20)은 금속으로 만들어져 있어도 된다.
이어서, 도 1에 도시하는 통기 부재(10)의 제조 방법을 설명한다.
먼저, 지지체(2), 가스 투과막(4) 및 커버(6)를 준비한다. 지지체(2) 및 커버(6)는, 사출 성형법 등의 공지된 수지 성형 방법에 의해 제작될 수 있다. 가스 투과막(4)으로서의 불소 수지막은, 연신법, 추출법 등의 공지된 불소 수지 성형 방법에 의해 제작될 수 있다. 가스 투과막(4)으로서 적합한 PTFE 다공질막은, 예를 들어 닛토덴코사로부터 입수할 수 있다.
이어서, 가스 투과막(4)을 지지체(2)에 용착한다. 이 공정에서는, 도 2에 도시하는 용착 장치(300)를 사용할 수 있다. 본 실시 형태에 있어서, 용착 장치(300)는 초음파 용착 장치이며, 고정대(60), 용착 혼(62), 초음파 진동자(64), 실린더(65), 공기 압축기(66), 초음파 발진기(67) 및 제어기(68)를 구비하고 있다. 즉, 용착 혼(62)은, 초음파 용착용 용착 혼일 수 있다. 초음파 용착은, 고강도의 용착을 높은 생산성으로 달성할 수 있다. 용착 장치(300)의 구성은, 용착 혼(62)을 제외하고, 시판되고 있는 초음파 용착 장치와 같다.
고정대(60)에는, 가스 투과막(4)이 용착되어야 할 지지체(2)(수지 부품)가 배치되어 있다. 실린더(65)는, 공기 압축기(66)로 생성된 압축 공기를 이용하여, 용착 혼(62) 및 초음파 진동자(64)를 가스 투과막(4)에 접근시킴과 함께, 용착 혼(62)으로부터 가스 투과막(4)에 인가되는 압력을 조절한다. 제어기(68)는, 초음파 발진기(67)를 제어하고, 초음파 진동자(64)를 통하여 용착 혼(62)에 인가되어야 할 초음파 진동의 주파수를 조절한다.
본 실시 형태에 있어서, 용착 혼(62)은, 가공 대상인 가스 투과막(4)에 접해야 할 작용면(62p)에 볼록부(62t)가 형성된 용착 혼이다. 그로 인해, 가스 투과막(4)과 지지체(2)의 계면에 용착 혼(62)으로부터의 하중을 집중시키기 쉽다. 그 결과, 지지체(2)와 가스 투과막(4) 사이의 용착 강도를 용이하게 높일 수 있다. 용착 혼(62)은, 예를 들어 알루미늄 합금, 티타늄 합금 등의 금속으로 만들어져 있다.
도 3에 도시하는 바와 같이, 용착 혼(62)의 작용면(62p)은, 평면에서 보아 환상이다. 작용면(62p)에는, 복수의 볼록부(62t)가 형성되어 있다. 복수의 볼록부(62t)는, 작용면(62p)에 있어서 격자형(크로스 해칭형)으로 나열되어 있다. 하나하나의 볼록부(62t)는, 사각추 형상을 갖고 있다. 환언하면, 볼록부(62t)는, 평면에서 보아 정사각형의 형상을 갖고 있다. 이러한 볼록부(62t)가 작용면(62p)에 간극 없이(가장 밀하게) 배열되어 있다. 이와 같은 구성에 의하면, 가스 투과막(4)과 지지체(2)의 계면에 용착 혼(62)으로부터의 하중을 집중시키기 쉽다. 또한, 지지체(2)와 가스 투과막(4) 사이의 용착 강도를 용이하게 높일 수 있다.
도 3에 도시하는 용착 혼(62)을 대신하여, 도 4에 도시하는 용착 혼(72)도 사용할 수 있다. 용착 혼(72)의 작용면(72p)은, 평면에서 보아 환상(원환상)이다. 작용면(72p)에는 2개의 볼록부(72t)가 형성되어 있다. 각 볼록부(72t)는, 평면에서 보아, 작용면(72p)과 동심형의 환상이다. 이러한 볼록부(72t)에 의해서도, 가스 투과막(4)과 지지체(2)의 계면에 용착 혼(72)으로부터의 하중을 집중시키기 쉽다. 볼록부(72t)의 수는 2개로 한정되지 않는다. 볼록부(72t)가 작용면(72p)에 하나만 형성되어 있어도 되고, 3개 이상 형성되어 있어도 된다.
도 3 및 도 4의 예로부터 이해할 수 있듯이, 가스 투과막(4)의 두께, 지지체(2)의 수지의 종류 등에 따라, 용착 혼의 작용면에 있어서의 볼록부의 형상을 적절히 변경할 수 있다.
또한, 가스 투과막(4)을 지지체(2)에 용착하기 위해, 초음파 용착 장치(300)를 대신하여, 열 용착 장치를 사용해도 된다. 일반적으로, 초음파 용착 장치에 있어서, 수지 부품(지지체(2))의 일부는, 마찰열에 의해 녹는다. 열 용착 장치에 있어서, 수지 부품의 일부는, 용착 혼이 가지고 있는 열에 의해 녹는다. 초음파 진동자(64)가 히터로 치환되고, 초음파 발진기(67) 및 제어기(68)가 온도 조절기로 치환되면, 도 2는 열 용착 장치의 구성을 도시한다. 용착 혼(62)은, 열 용착용 용착 혼일 수 있다.
이어서, 제2 실시 형태에 따른 가스 투과 부재를 설명한다. 제1 실시 형태와 제2 실시 형태로 공통되는 요소에는 동일한 참조 부호를 붙이고, 그것들의 설명을 생략하는 경우가 있다. 즉, 각 실시 형태에 따른 설명은, 기술적으로 모순되지 않는 한, 서로 적용될 수 있다. 또한, 기술적으로 모순되지 않는 한, 각 실시 형태는 서로 조합되어도 된다.
(제2 실시 형태)
도 5a 및 도 5b에 도시하는 바와 같이, 가스 투과막(4)은, 하우징(200)에 형성되어 있어도 된다. 하우징(200)은, 제1 부분(20) 및 제2 부분(26)을 포함하는 복수의 부분으로 구성되어 있다. 예를 들어, 제1 부분(20)이 덮개 부분이며, 제2 부분(26)이 바닥 부분이다. 제1 부분(20) 및 제2 부분(26)은, 제1 실시 형태의 통기 부재(10)에 있어서의 지지체(2)와 마찬가지로, 열가소성 수지로 만들어져 있다. 본 실시 형태에서는, 제1 부분(20)에 통기용 개구부(20h)가 형성되어 있다. 개구부(20h)를 막도록, 제1 부분(20)에 가스 투과막(4)이 용착되어 있다. 통기용 개구부(20h)는, 제2 부분(26)에 형성되어 있어도 되고, 제1 부분(20) 및 제2 부분(26)의 양쪽에 형성되어 있어도 된다. 하우징(200)의 제1 부분(20) 및 가스 투과막(4)은, 액체 및 고체의 투과를 방지하면서 환기를 행하기 위한 통기 부재(30)(가스 투과 부재)를 형성하고 있다.
도 5b에 도시하는 바와 같이, 가스 투과막(4)과 하우징(200)의 제1 부분(20) 사이에는, 용착부(14)가 형성되어 있다. 용착부(14)는 평면에서 보아 환상이다. 본 실시 형태에 있어서도, 가스 투과막(4)은, 도 3 또는 도 4를 참조하여 설명한 용착 혼(62 또는 72)을 사용하여, 하우징(200)의 제1 부분(20)에 용착되어 있다.
(기타)
각 실시 형태에 있어서, 가스 투과막(4)이 용착되기 전의 수지 부품(지지체(2) 또는 하우징의 제1 부분(20))의 상면에는, 용착 강도를 높이기 위한 리브가 형성되어 있지 않다. 단, 수지 부품의 상면에 그러한 리브가 형성되어 있어도 된다.
또한, 각 실시 형태에 있어서, 가스 투과막(4)은, 하우징의 환기 및 내압 조정의 역할을 담당하고 있다. 즉, 가스 투과막(4)은 통기막이다. 그러나, 가스 투과막(4)은 통기막에 한정되지 않는다. 본 명세서에 개시된 방법에 의해 제조되어야 할 가스 투과 부재는, 물의 투과를 방지하면서 음성을 투과시키기 위한 방수 통음 부재여도 된다. 가스 투과막(4)을 포함하는 방수 통음 부재는, 예를 들어 휴대 전화 등의 통신 기기의 수화구 및 송화구에 설치된다.
[실시예]
(실시예)
30질량％의 유리 파이버 및 70질량％의 폴리부틸렌테레프탈레이트를 포함하는 수지 재료로 만들어진 하우징 부품(ECU 하우징의 덮개 부분: 도 5a 참조)을 준비하였다. 하우징 부품에 직경 5㎜의 개구부를 형성한 후, 초음파 용착 장치(세이덴샤사 제조, 소형 정밀 프레스 시리즈)를 사용하여, 개구부를 막도록, PTFE 다공질막(닛토덴코사 제조, NTF810A, 두께 0.3㎜, 직경 10㎜)을 하우징 부품에 용착하였다. 초음파의 주파수는 28.5kHz, 용착 시간은 0.16초, 용착 압력(에어 압)은 0.15㎫였다. 용착 혼으로서, 도 2 및 도 3을 참조하여 설명한 구조를 갖는 것을 사용하였다. 이와 같이 하여, PTFE 다공질막 및 하우징 부품에 의해 구성된 실시예의 통기 부재를 얻었다.
(비교예)
작용면이 평탄한 용착 혼을 사용한 것을 제외하고, 실시예와 동일한 조건에서 하우징 부품의 개구부에 PTFE 다공질막을 용착하는 것을 시도하였다. 그러나, PTFE 다공질막은, 하우징 부품에 용착되지 않고, 하우징 부품으로부터 간단하게 박리되어 떨어졌다.
[내수 시험]
일본 공업 규격 JIS L 1092(B법, 고수압법)에 기초하여, 실시예의 통기 부재의 내수압을 조사하였다. 구체적으로는, 누수가 발생하는 수압(내수압)을 측정하였다. 결과를 표 1에 나타낸다. 표 1에 나타내는 바와 같이, 실시예의 통기 부재는, 충분한 내수압을 달성하였다. 또한, 실시예와 같이 PTFE 다공질막을 하우징 부품에 문제없이 용착할 수 있는 경우, 용착 결과를 「좋음」이라고 판단하였다. 비교예와 같이 PTFE 다공질막을 하우징 부품에 용착하지 못한 경우, 용착 결과를 「나쁨」이라고 판단하였다.
Figure pct00001
본 명세서에 개시된 기술은, 통기 부재, 방수 통음 부재 등의 가스 투과 부재의 제조에 적용할 수 있다.

Claims (6)

  1. 가공 대상에 접해야 할 작용면에 볼록부가 형성된 용착 혼을 사용하여, 불소 수지로 만들어진 가스 투과성의 불소 수지 다공질막을 열가소성 수지로 만들어진 수지 부품에 용착하는 공정을 포함하는, 가스 투과 부재의 제조 방법.
  2. 제1항에 있어서,
    상기 용착 혼의 상기 작용면에는, 복수의 상기 볼록부가 형성되고,
    상기 복수의 볼록부는, 상기 작용면에 있어서 격자 형상으로 나열되어 있는, 가스 투과 부재의 제조 방법.
  3. 제1항에 있어서,
    상기 작용면은, 평면에서 보아 환상이며,
    상기 볼록부는, 평면에서 보아, 상기 작용면과 동심형의 환상인, 가스 투과 부재의 제조 방법.
  4. 제1항에 있어서,
    상기 용착 혼은, 초음파 용착용 용착 혼인, 가스 투과 부재의 제조 방법.
  5. 제1항에 있어서,
    상기 가스 투과 부재는, (a) 액체 및 고체의 투과를 방지하면서 환기를 행하기 위한 통기 부재이거나, (b) 물의 투과를 방지하면서 음성을 투과시키기 위한 방수 통음 부재인, 가스 투과 부재의 제조 방법.
  6. 열가소성 수지로 만들어진 수지 부품과,
    상기 수지 부품에 설치되고, 불소 수지로 만들어진 가스 투과성의 불소 수지 다공질막을 구비하고,
    상기 불소 수지 다공질막은, 가공 대상에 접해야 할 작용면에 볼록부가 형성된 용착 혼을 사용해서 상기 수지 부품에 용착되어 있는, 가스 투과 부재.
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