WO2010143437A1 - 複合通気膜およびそれを用いた通気構造 - Google Patents

複合通気膜およびそれを用いた通気構造 Download PDF

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Publication number
WO2010143437A1
WO2010143437A1 PCT/JP2010/003873 JP2010003873W WO2010143437A1 WO 2010143437 A1 WO2010143437 A1 WO 2010143437A1 JP 2010003873 W JP2010003873 W JP 2010003873W WO 2010143437 A1 WO2010143437 A1 WO 2010143437A1
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WO
WIPO (PCT)
Prior art keywords
gas permeable
permeable membrane
porous sheet
main body
composite gas
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2010/003873
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English (en)
French (fr)
Inventor
古山了
森山順一
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nitto Denko Corp
Original Assignee
Nitto Denko Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nitto Denko Corp filed Critical Nitto Denko Corp
Priority to EP20100785969 priority Critical patent/EP2441625A4/en
Priority to CN2010800254101A priority patent/CN102803022A/zh
Priority to US13/377,065 priority patent/US20120114902A1/en
Publication of WO2010143437A1 publication Critical patent/WO2010143437A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V31/00—Gas-tight or water-tight arrangements
    • F21V31/03—Gas-tight or water-tight arrangements with provision for venting
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/02—Details
    • H05K5/0213—Venting apertures; Constructional details thereof
    • 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
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
    • B29C65/1616—Near infrared radiation [NIR], e.g. by YAG lasers
    • 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
    • B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
    • 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
    • B29C66/50—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
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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
    • B29C66/71—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
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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
    • B29C66/72—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
    • B29C66/723—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 multi-layered
    • 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
    • B29C66/739—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 material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • 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
    • B29C66/812—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/81266—Optical properties, e.g. transparency, reflectivity
    • B29C66/81267—Transparent to electromagnetic radiation, e.g. to visible light
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B32B27/322—Layered products comprising a layer of synthetic resin comprising polyolefins comprising halogenated polyolefins, e.g. PTFE
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/02—Details
    • H05K5/0213—Venting apertures; Constructional details thereof
    • H05K5/0215—Venting apertures; Constructional details thereof with semi-permeable membranes attached to casings
    • 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
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • 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
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/959—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 characterised by specific values or ranges of said specific variables
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    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S45/00—Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light
    • F21S45/30—Ventilation or drainage of lighting devices
    • 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
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    • 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
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    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers

Definitions

  • the present invention relates to a composite gas permeable membrane and a gas permeable structure using the same.
  • the housing that houses the electrical components of automobiles, such as lamps, sensors, and ECUs (electronic control units), ensures ventilation between the inside and outside of the housing and prevents foreign objects from entering inside the housing.
  • the ventilation member is attached. An example of such a ventilation member is disclosed in Patent Document 1.
  • the ventilation member disclosed in Patent Document 1 includes a support body 103 on which the ventilation film 102 is disposed and a protective portion 104 that covers the ventilation film 102.
  • a ventilation member 101 is fixed to the opening 107 of the housing 106 via the O-ring 105.
  • the protection unit 104 prevents the gas permeable membrane 102 from being damaged by an external force (for example, water jetting at the time of car washing) or the air permeability of the gas permeable membrane 102 from being deteriorated due to accumulation of dust.
  • an object of the present invention is to provide a composite gas permeable membrane that can easily reduce the height of the gas permeable structure and has high strength, and a gas permeable structure using the same.
  • the present invention A main body including a fluororesin film; An ultra-high molecular weight polyethylene porous sheet having a black color and superimposed on the main body, A laser welding part that integrates both by interposing the main body part and the ultra-high molecular weight polyethylene porous sheet; A composite gas permeable membrane is provided.
  • the present invention provides: A resin part having an opening for ventilation; A gas permeable membrane attached to the resin component so as to close the opening, Provided is a gas permeable structure in which the gas permeable membrane is constituted by the composite gas permeable membrane of the present invention.
  • an ultrahigh molecular weight polyethylene porous sheet (hereinafter referred to as UHMWPE porous sheet) is superposed on the main body including the fluororesin membrane.
  • the UHMWPE porous sheet has higher strength than conventional reinforcing materials such as PET nonwoven fabric. Therefore, a high-strength composite gas permeable membrane can be obtained by combining the UHMWPE porous sheet and the main body. Further, the UHMWPE porous sheet is less likely to cause a decrease in air permeability.
  • the UHMWPE porous sheet and the main body are integrated at the laser welding part.
  • the fluororesin film (main body part) and the UHMWPE porous sheet it is difficult to set conditions for heating and pressurization, and bonding may be insufficient. It is not good to apply heat and pressure to the dark clouds between the main body and the UHMWPE porous sheet in order to damage the fluororesin film.
  • the present invention it is not necessary to perform heat lamination between the fluororesin film and the UHMWPE porous sheet, so that such a problem can be eliminated.
  • the UHMWPE porous sheet has a dark color, the local melting of UHMWPE by laser absorption can be easily performed, and the laser welded portion can be formed with high accuracy.
  • FIG. 6A The whole perspective view of a case which has a ventilation structure concerning a 1st embodiment of the present invention.
  • Perspective view of ventilation member (ventilation structure) using composite ventilation membrane 6A is an exploded perspective view of the ventilation member (venting structure) shown in FIG. 6A.
  • FIG. 1 is an overall perspective view of a housing having a ventilation structure according to an embodiment of the present invention.
  • FIG. 2 is a cross-sectional view of the ventilation structure shown in FIG.
  • the housing 200 includes a composite gas permeable membrane 6, a first housing component 11 (upper portion of the housing), and a second housing component 12 (bottom portion of the housing).
  • a ventilation structure 13 is formed by the composite gas permeable membrane 6 and the first casing component 11.
  • the composite gas permeable membrane 6 allows air and water vapor to pass between the inside and outside of the housing 200, while preventing foreign matters such as liquid and dust from entering the housing 200.
  • the atmosphere inside the housing 200 can be made equal to the outside atmosphere without allowing foreign substances to enter.
  • the ventilation structure 13 includes a composite gas permeable membrane 6 and a first housing component 11 to which the composite gas permeable membrane 6 is attached.
  • the first housing component 11 serves as a support that supports the composite gas permeable membrane 6.
  • the first casing component 11 is provided with an opening 11h for venting between the inside and the outside of the casing 200 (FIG. 1).
  • the composite gas permeable membrane 6 is attached to the first housing part 11 so as to close the opening 11h.
  • the outer peripheral portion 6 g of the composite gas permeable membrane 6 is embedded in the first housing component 11. That is, the composite gas permeable membrane 6 and the first housing component 11 are integrated by insert molding. In this way, the composite gas permeable membrane 6 can be firmly joined to the first housing part 11.
  • the composite gas permeable membrane 6 does not protrude from the surface of the gas permeable structure 13. In other words, since the composite gas permeable membrane 6 is located at a position pulled down from the surface of the first housing component 11, it is difficult for external force to reach the composite gas permeable membrane 6.
  • the composite gas permeable membrane 6 has a main body portion 2 including a fluororesin film and a resin porous sheet 3 superimposed on the main body portion 2.
  • the resin porous sheet 3 is provided only on one side of the main body 2.
  • the resin porous sheet 3 is made of an ultra high molecular weight polyethylene (UHMWPE) porous sheet.
  • UHMWPE ultra high molecular weight polyethylene
  • the composite gas permeable membrane 6 is fixed to the first casing component 11 in such a direction that the UHMWPE porous sheet 3 is exposed to the outside of the casing 200.
  • the shape of the composite gas permeable membrane 6 is typically circular, but may be other shapes such as a square as long as the opening 11h can be blocked.
  • a laser weld 4 is formed between the main body 2 and the UHMWPE porous sheet 3, a laser weld 4 is formed.
  • the laser welding part 4 is integrated with the main body part 2 and the UHMWPE porous sheet 3 by being interposed therebetween.
  • the UHMWPE porous sheet 3 is colored black for the purpose of improving laser absorption.
  • the laser welding part 4 is formed in the outer peripheral part 6g of the composite gas permeable membrane 6.
  • the laser welding portion 4 has an annular shape in plan view and is embedded in the first housing component 11. It is preferable that the laser welded portion 4 is formed only on the outer peripheral portion 6g embedded in the first casing component 11 because the laser welded portion 4 does not hinder ventilation. *
  • the main body 2 may have a fluororesin film 2a and a reinforcing material 2b provided on one side of the fluororesin film 2a.
  • a fluororesin film 2a and a reinforcing material 2b provided on one side of the fluororesin film 2a.
  • the reinforcing material 2b may be provided on both surfaces of the fluororesin film 2a or may be omitted. That is, the main body 2 may be configured only by the fluororesin film 2a.
  • the reinforcing material 2b can be omitted, and the number of parts can be reduced. Further, the main body 2 may be white for the purpose of relatively less absorbing a laser having a predetermined wavelength. When the reinforcing material 2b is provided, the reinforcing material 2b is also preferably white.
  • the fluororesin film 2a is a breathable film, and is typically a porous film.
  • the fluororesin that can be used for the fluororesin film 2a include polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene, tetrafluoroethylene-hexafluoropropylene copolymer, and tetrafluoroethylene-ethylene copolymer.
  • PTFE polytetrafluoroethylene
  • PTFE is preferable because it has a small area and can ensure high air permeability and is excellent in the ability to prevent foreign matter from entering the housing 200.
  • the PTFE porous membrane can be produced by a known molding method such as a stretching method or an extraction method.
  • the fluororesin film 2a may be subjected to oil repellent treatment or water repellent treatment.
  • Reinforcing material 2b is a member made of a resin such as polyester, polyethylene, or aramid. By providing the reinforcing material 2b, handling of the fluororesin film 2a is facilitated.
  • the form of the reinforcing material 2b is not particularly limited as long as the air permeability of the gas permeable membrane 6 can be maintained.
  • the reinforcing material 2b is a woven fabric, a non-woven fabric, a net, or a mesh, and is typically a non-woven fabric.
  • the fluororesin film 2a and the reinforcing material 2b may be bonded together by thermal lamination, or may be bonded using an adhesive.
  • the fluororesin film 2a and the reinforcing material 2b are bonded to each other through welded portions or adhesive portions that are uniformly dispersed in the plane. If the area of the welded portion or the bonded portion is, for example, in the range of 5 to 20% of the total area, water resistance is not sufficient or peeling is unlikely to occur.
  • the thickness of the main body 2 is in the range of 0.02 to 1.0 mm (or 0.05 to 0.2 mm) in consideration of required properties such as strength, air permeability, water resistance, and laser transmittance. There should be.
  • the air permeability of the main body 2 is preferably in the range of 0.1 to 500 sec / 100 cm 3 as a Gurley value obtained by the Gurley tester method specified in JIS P 8117.
  • the water pressure resistance of the main body 2 is preferably 1.0 kPa or more.
  • the conventional ventilation member is provided with a member for protecting the ventilation film. This is to prevent the air-permeable membrane from being damaged by being directly impacted by foreign matter such as water droplets.
  • the composite gas permeable membrane 6 since the main body 2 is protected by the UHMWPE porous sheet 3, even if the composite gas permeable membrane 6 is not covered with other members, the composite gas permeable membrane 6 is damaged. It is hard to receive. By omitting other members for covering the composite gas permeable membrane 6, it is possible to reduce the number of parts and the height of the gas permeable structure.
  • a member that covers the composite gas permeable membrane 6 may be provided in the ventilation structure 13 shown in FIG. 2, a member that covers the composite gas permeable membrane 6 may be provided.
  • the thickness of the UHMWPE porous sheet 3 is not particularly limited, but may be in the range of 0.02 to 3.0 mm (or 0.05 to 1.0 mm). From the viewpoint of sufficiently ensuring the strength of the composite gas permeable membrane 6, it is preferable that the thickness t2 of the UHMWPE porous sheet 3 is larger than the thickness t1 of the main body 2. For example, the thicknesses t1 and t2 can be determined so as to satisfy 2 ⁇ (t2 / t1) ⁇ 50.
  • ultra high molecular weight polyethylene means polyethylene having an average molecular weight of 500,000 or more.
  • the average molecular weight of ultra high molecular weight polyethylene is usually in the range of 2 to 10 million.
  • the average molecular weight can be measured, for example, by a method defined in ASTM D4020 (viscosity method).
  • UHMWPE Ultra High High Molecular Weight Poly-ethylene
  • the UHMWPE porous sheet 3 can be manufactured from a sintered body of UHMWPE powder.
  • the sintered body of UHMWPE powder is obtained by sintering UHMWPE powder (average particle size of 30 to 200 ⁇ m) filled in a mold at a temperature near the melting point of UHMWPE (for example, 130 to 160 ° C.).
  • the obtained sintered body is usually block-shaped. If the block-like sintered body is formed into a sheet by cutting, a UHMWPE porous sheet can be obtained. According to this production method (powder sintering method), the porosity of the obtained UHMWPE porous sheet is in the range of 20 to 50%.
  • the UHMWPE porous sheet 3 has a black color so that a laser having a predetermined wavelength is more easily absorbed than the main body 2.
  • the UHMWPE porous sheet 3 is colored black.
  • the coloring may be performed only on the portion where the laser welded portion 4 is to be formed, it is easier to perform the entire coloring.
  • UHMWPE powder and a colorant may be mixed to produce a sintered body.
  • carbon black such as Black Pearls L and Black Pearls 1000 available from Cabot Corporation can be suitably used.
  • These coloring agents can be contained in the range of, for example, 1 to 10 parts by weight with respect to 100 parts by weight of the UHMWPE powder.
  • “having black” means that a coloring agent for coloring black is included.
  • the blackness specified in JIS ⁇ Z ⁇ 8721 lightness (achromatic color) is determined as 1 to 4 is “black”, 5 to 8 is “gray”, and 9 or more is “white”.
  • the UHMWPE porous sheet 3 is gray or black (blackness of 8 or less), and is preferably black (blackness of 4 or less) from the viewpoint of laser absorption efficiency.
  • the UHMWPE porous sheet 3 manufactured from a sintered body of UHMWPE powder retains the excellent characteristics of UHMWPE such as chemical resistance, wear resistance, and releasability. Moreover, by making it porous, properties such as air permeability, cushioning properties, and slidability are also obtained.
  • the posture of the composite gas permeable membrane 6 with respect to the first housing component 11 is determined so that the UHMWPE porous sheet 3 is exposed on the surface. Therefore, it is preferable for the ventilation structure 13 of this embodiment that the resin porous sheet 3 is excellent in chemical resistance. Due to the UHMWPE porous sheet 3 having high slidability, foreign matter is less likely to adhere to the composite gas permeable membrane 6.
  • the UHMWPE porous sheet 3 is harder and has higher strength than a polyethylene nonwoven fabric or the like that is a general reinforcing material.
  • the UHMWPE porous sheet 3 having the same strength is compared with the polyethylene nonwoven fabric, the UHMWPE porous sheet 3 is overwhelmingly thin and excellent in air permeability.
  • the composite gas permeable membrane 6 is directly exposed to an external atmosphere (for example, an engine room of an automobile), so that the composite gas permeable membrane 6 itself needs to have sufficient physical strength. .
  • the UHMWPE porous sheet 3 has an advantage that both strength and air permeability can be achieved at a high level.
  • the laser welding method is extremely effective for bonding the main body 2 including the fluororesin film and the UHMWPE porous sheet 3 together. This is because it is difficult to select heating and pressurizing conditions in thermal lamination between the UHMWPE porous sheet and the main body 2.
  • a relatively thick UHMWPE porous sheet is used from the viewpoint of strength, heat is hardly transmitted during thermal lamination, and bonding may be insufficient. Applying heat and pressure to the dark clouds between the main body 2 and the UHMWPE porous sheet 3 is not good because the fluororesin film 2a may be damaged. According to the present embodiment, it is not necessary to perform thermal lamination between the main body 2 and the UHMWPE porous sheet 3, so that such a problem can be eliminated.
  • the first housing part 11 and the second housing part 12 are molded products of thermoplastic resin or elastomer.
  • thermoplastic resins PBT (polybutylene terephthalate), PET (polyethylene terephthalate), PPS (polyphenylene sulfide), PSU (polysulfone), PP (polypropylene), PE (polyethylene), ABS (acrylonitrile / butadiene / styrene copolymer) Is mentioned.
  • the elastomer include rubber compositions containing chloroprene rubber, isoprene rubber, styrene / butadiene rubber, and natural rubber as a main component. Using these resins, the casing parts 11 and 12 can be manufactured by a known molding method such as injection molding.
  • the material of the housing parts 11 and 12 may further include a pigment, a reinforcing filler, and other additives.
  • a pigment is carbon black and titanium white.
  • Specific examples of the reinforcing filler are glass particles and glass fibers.
  • Specific examples of other additives are water repellents and insulating materials.
  • FIG. 4A the main-body part 2 containing a fluororesin film
  • the main body 2 and the UHMWPE porous sheet 3 are, for example, circular having the same diameter.
  • a translucent jig 9 is placed on the laminate of the main body 2 and the UHMWPE porous sheet 3. Appropriate pressure is applied to the translucent jig 9 to bring the main body 2 and the UHMWPE porous sheet 3 into close contact.
  • the translucent jig 9 is for maintaining the positional relationship between the main body 2 and the UHMWPE porous sheet 3 and has an opening 9h for heat dissipation.
  • the translucent jig 9 is typically made of a transparent glass plate that transmits laser. By using such a translucent jig 9, it is possible to prevent the main body 2 from being damaged.
  • the laser LB is irradiated to the interface between the main body 2 and the UHMWPE porous sheet 3 through the light transmitting jig 9.
  • the laser LB incident from the main body 2 side mainly melts the surface layer of the UHMWPE porous sheet 3 in the vicinity of the interface between the main body 2 and the UHMWPE porous sheet 3. Thereby, the laser welding part 4 (FIG. 2) is formed.
  • Laser welding conditions may be adjusted in consideration of damage to the main body 2 and the UHMWPE porous sheet 3.
  • the laser output is in the range of 20 to 300 W (or 20 to 50 W)
  • the laser wavelength is in the range of 800 to 1100 nm (or 800 to 950 nm)
  • the welding time is 0.05 to 5.0 seconds (or 0.1 to 1). .5 seconds).
  • the type of laser is not particularly limited, and a gas laser such as a CO 2 laser or an excimer laser may be used, or a solid laser such as a YAG laser may be used.
  • a large number of composite gas permeable membranes 6 can be manufactured in a lump from a laminate of the main body 2 and the UHMWPE porous sheet 3. Specifically, as shown in FIG. 5, a large-area laminate W is prepared, and a plurality of scheduled cutting lines CL corresponding to the shape of the composite gas permeable membrane 6 to be manufactured are determined. The laser irradiation process is sequentially performed on each region so that the laser welding portion 4 is formed in the region inside the planned cutting line CL. After the formation of the laser welded portion 4, the laminate W is punched along the planned cutting line CL. In this way, a large number of composite gas permeable membranes 6 can be efficiently manufactured from one laminate W. Productivity is also improved because the number of times small parts are handled is reduced.
  • the composite gas permeable membrane 6 is set in a mold for molding the first housing part 11.
  • An injection molding process for forming the first casing component 11 is performed so that the outer peripheral portion 6g of the composite gas permeable membrane 6 is wrapped with the resin injected into the mold. Since the high strength UHMWPE porous membrane 3 is combined with the main body 2, the composite gas permeable membrane 6 is not easily damaged when the composite gas permeable membrane 6 is set in the mold. Moreover, since the main-body part 2 and the UHMWPE porous sheet 3 are laser-welded beforehand, it is easy to handle. Therefore, automation of the manufacturing process of the ventilation structure 13 is easy.
  • the ventilation structure 23 shown in FIGS. 6A and 6B includes a support body 21 having an opening 21h for ventilation, and a composite ventilation film 6 attached to the support body 21. That is, the ventilation structure 23 is configured as a ventilation member (vent plug).
  • the composite gas permeable membrane 6 has been described with reference to FIG. 2, and is fixed to the support 21 with an adhesive or an adhesive tape.
  • the composite gas permeable membrane 6 and the support 21 may be integrated by insert molding.
  • the support 21 may be the casing itself.
  • a housing 201 illustrated in FIG. 7 includes a first housing component 11, a second housing component 12, and a ventilation member 33 (a ventilation structure) attached to the opening 11 h of the first housing component 11. Attachment of the ventilation member 33 to the opening 11h of the first housing component 11 may be performed using an adhesive or an adhesive tape, or may be performed by thermal welding. In the ventilation member 33, the composite gas permeable membrane 6 and the support 31 are integrated by insert molding. According to Modification 1 and Modification 2, there is an advantage that a nondestructive test (for example, a water resistance test or visual observation) can be performed at the time when the ventilation members 23 and 33 are manufactured. In addition, it is easy to cope with a design change of a housing that should be provided with a ventilation structure. Moreover, the method for attaching the ventilation members 23 and 33 to the housing can be selected from various methods such as the use of an adhesive or an adhesive tape, welding, and heat caulking.
  • Example 1 The ventilation structure shown in FIG. 2 was manufactured.
  • the fluororesin film 2a Nito Denko's Temish (registered trademark) NTF810A, thickness 0.3 mm, ⁇ 13 mm, no nonwoven fabric
  • UHMWPE porous sheet 3 Nito Denko's sunmap (registered) (Trademark) LC-T, thickness 1.0 mm, ⁇ 13 mm
  • the UHMWPE porous sheet 3 was previously colored black.
  • the composite gas permeable membrane 6 and the first housing part 11 were integrated by an insert injection molding method to obtain a gas permeable structure 13 shown in FIG.
  • Polybutylene terephthalate was used as the material of the first housing part 11.
  • Example 2 Using the composite gas permeable membrane 6 obtained in Sample 1, a vent plug (vent structure 23) shown in FIG. 6A was produced. This vent plug was fixed to the opening 11 h of the first housing part 11 with an adhesive.
  • Example 3 A conventional gas permeable membrane (Temish (registered trademark) NTF2131A-S06, manufactured by Nitto Denko Corporation, thickness 0.17 mm, ⁇ 13 mm, with nonwoven fabric on one side) was directly laser-welded to the first housing part 11.
  • Temish registered trademark
  • NTF2131A-S06 manufactured by Nitto Denko Corporation, thickness 0.17 mm, ⁇ 13 mm, with nonwoven fabric on one side
  • High pressure car wash test was performed on the ventilation structures of Samples 1 to 3.
  • the high-pressure car wash test is a method of injecting water from nozzles 80 arranged at 0 °, 30 °, 60 ° and 90 ° to the ventilation structure, This is a test to check for intrusion.
  • a water feeling paste for detecting water was applied to the inside of the casing. When the paste changed color from green to red, it was determined that water entered the casing.
  • the conditions for jetting water from the nozzle 80 were as follows. Injection pressure: 8MPa Water temperature: 80 ° C Time (each angle): 30 seconds Flow rate: 14 liters / minute
  • the present invention can be applied to automobile parts such as lamps, motors, sensors, switches, ECUs, and gear boxes.
  • automobile parts such as lamps, motors, sensors, switches, ECUs, and gear boxes.
  • the present invention can be applied to electric products such as mobile communication devices, cameras, electric razors, electric toothbrushes, and washing machines (for example, humidity sensors for washing machines).

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Abstract

　通気構造１３は、通気用の開口部１１ｈを有する樹脂部品１１と、開口部１１ｈを塞ぐように樹脂部品１１に取り付けられた複合通気膜６とを備えている。複合通気膜６は、フッ素樹脂膜を含む本体部２と、本体部２に重ね合わされた超高分子量ポリエチレン多孔質シート３とを備えている。超高分子量ポリエチレン多孔質シート３は、黒色を有する。本体部２と超高分子量ポリエチレン多孔質シート３との間には、両者を一体化しているレーザー溶着部４が形成されている。

Description

複合通気膜およびそれを用いた通気構造
　本発明は、複合通気膜およびそれを用いた通気構造に関する。
　ランプ、センサ、ＥＣＵ（electronic control unit）等の自動車の電装部品を収容する筐体には、筐体の内部と外部との通気を確保するとともに、筐体内部への異物の侵入を阻止するための通気部材が取り付けられている。そのような通気部材の一例が特許文献１に開示されている。
　特許文献１に開示されている通気部材は、図９に示すように、通気膜１０２が配置された支持体１０３と、通気膜１０２を覆う保護部１０４とを備えている。このような通気部材１０１を、Ｏリング１０５を介して筐体１０６の開口部１０７に固定する。通気膜１０２を気体が透過することにより、筐体１０６の通気を確保できる。保護部１０４は、外力（例えば洗車時の水噴射）によって通気膜１０２がダメージを受けたり、塵芥の堆積によって通気膜１０２の通気性が低下したりするのを防止する。
特開２００４－４７４２５号公報
　近年、各種製品の小型化の流れを受けて、通気部材の高さの低減が要求されている。図９に示す従来の通気部材１０１の高さの低減は、保護部１０４を省略することによって実現できるが、通気膜１０２の耐久性の面で問題がある。
　また、通気部材の高さを低減する試みとして、通気膜と支持体とをインサート成形で一体化する試みもある。しかし、インサート成形時に位置決めピン等により通気膜がダメージを受け、耐水不良等の不具合が発生しやすくなる点が問題視されている。
　こうした事情に鑑み、本発明は、通気構造の高さの低減が容易かつ高強度を有する複合通気膜およびそれを用いた通気構造を提供することを目的とする。
　すなわち、本発明は、
　フッ素樹脂膜を含む本体部と、
　黒色を有し、前記本体部に重ね合わされた超高分子量ポリエチレン多孔質シートと、
　前記本体部と前記超高分子量ポリエチレン多孔質シートとに介在することによって両者を一体化しているレーザー溶着部と、
　を備えた、複合通気膜を提供する。
　他の側面において、本発明は、
　通気用の開口部を有する樹脂部品と、
　前記開口部を塞ぐように前記樹脂部品に取り付けられた通気膜とを備え、
　前記通気膜が、上記本発明の複合通気膜によって構成されている、通気構造を提供する。
　上記本発明の複合通気膜によると、超高分子量ポリエチレン多孔質シート（以下、ＵＨＭＷＰＥ多孔質シートと称する）がフッ素樹脂膜を含む本体部に重ね合わされている。ＵＨＭＷＰＥ多孔質シートは、ＰＥＴ不織布等の従来の補強材に比べ、高強度を有する。そのため、ＵＨＭＷＰＥ多孔質シートと本体部とを組み合わせることによって、高強度の複合通気膜が得られる。また、ＵＨＭＷＰＥ多孔質シートは、通気性低下の原因にもなりにくい。
　さらに、ＵＨＭＷＰＥ多孔質シートと本体部とがレーザー溶着部で一体化されている。フッ素樹脂膜（本体部）とＵＨＭＷＰＥ多孔質シートとの熱ラミネーションは、加熱および加圧の条件設定が難しく、貼り合わせが不十分となる場合がある。本体部とＵＨＭＷＰＥ多孔質シートとの貼り合わせを行うために両者の間に熱および圧力を闇雲にかけるのも、フッ素樹脂膜がダメージを受けるおそれがあるのでよくない。これに対し、本発明によれば、フッ素樹脂膜とＵＨＭＷＰＥ多孔質シートとの熱ラミネーションをせずに済むので、そうした問題を排除できる。また、ＵＨＭＷＰＥ多孔質シートが暗色を有するので、レーザーの吸収によるＵＨＭＷＰＥの局所的な溶融を簡単に行え、レーザー溶着部を精度よく形成できる。
本発明の第１実施形態にかかる通気構造を有する、筐体の全体斜視図 図１に示す筐体の通気構造（および複合通気膜）の断面図 複合通気膜の本体部の断面図 複合通気膜の製造工程図 図４Ａに続く製造工程図 多数個の複合通気膜を効率的に製造する方法の説明図 複合通気膜を用いた通気部材（通気構造）の斜視図 図６Ａに示す通気部材（通気構造）の分解斜視図 図６Ａに示す通気部材を用いた筐体の断面図 耐水試験方法の説明図 従来の通気部材の断面図
　図１は、本発明の一実施形態にかかる通気構造を有する、筐体の全体斜視図である。図２は、図１に示す通気構造の断面図である。図１に示すように、筐体２００は、複合通気膜６、第１筐体部品１１（筐体の上部）および第２筐体部品１２（筐体の底部）を備えている。複合通気膜６および第１筐体部品１１によって通気構造１３が形成されている。複合通気膜６は、空気や水蒸気が筐体２００の内部と外部との間を行き来するのを許容する一方で、液体や塵芥等の異物が筐体２００の内部に侵入するのを防ぐ。複合通気膜６のこのような働きによって、異物の侵入を許すことなく、筐体２００の内部の雰囲気と外部の雰囲気とを等しくできる。
　図２に示すように、通気構造１３は、複合通気膜６と、複合通気膜６が取り付けられた第１筐体部品１１とを有する。第１筐体部品１１は、複合通気膜６を支持する支持体の役割を担う。第１筐体部品１１には、筐体２００（図１）の内部と外部との間で通気を行うための開口部１１ｈが設けられている。この開口部１１ｈを塞ぐように複合通気膜６が第１筐体部品１１に取り付けられている。具体的には、複合通気膜６の外周部６ｇが第１筐体部品１１に埋め込まれている。すなわち、インサート成形によって、複合通気膜６と第１筐体部品１１とが一体化されている。このようにすれば、複合通気膜６を第１筐体部品１１に強固に接合できる。また、複合通気膜６が通気構造１３の表面に突出していない。言い換えれば、第１筐体部品１１の表面から引き下がった位置に複合通気膜６があるので、複合通気膜６に外力が及びにくい。
　複合通気膜６は、フッ素樹脂膜を含む本体部２と、本体部２に重ね合わされた樹脂多孔質シート３とを有する。本実施形態では、本体部２の片面にのみ樹脂多孔質シート３が設けられている。樹脂多孔質シート３は、超高分子量ポリエチレン（ＵＨＭＷＰＥ）多孔質シートでできている。筐体２００の外部にＵＨＭＷＰＥ多孔質シート３が露出する向きで、複合通気膜６が第１筐体部品１１に固定されている。複合通気膜６の形状は典型的には円形であるが、開口部１１ｈを塞ぐことができる限りにおいて、方形等の他の形状であってもよい。
　本体部２とＵＨＭＷＰＥ多孔質シート３との間には、レーザー溶着部４が形成されている。レーザー溶着部４は、本体部２とＵＨＭＷＰＥ多孔質シート３とに介在することによって両者を一体化している。ＵＨＭＷＰＥ多孔質シート３は、レーザーの吸収をよくする目的で、黒色に着色されている。本実施形態では、複合通気膜６の外周部６ｇにレーザー溶着部４が形成されている。レーザー溶着部４は、平面視で環形状を有しており、第１筐体部品１１に埋まっている。第１筐体部品１１に埋め込まれた外周部６ｇにのみレーザー溶着部４が形成されていると、レーザー溶着部４が通気の妨げにならないので好ましい。　
　図３に示すように、本体部２は、フッ素樹脂膜２ａと、フッ素樹脂膜２ａの片面に設けられた補強材２ｂとを有していてもよい。例えば、ＵＨＭＷＰＥ多孔質シート３、フッ素樹脂膜２ａおよび補強材２ｂの順番でこれらが重ね合わされていると、フッ素樹脂膜２ａを両面から保護できる利点がある。また、補強材２ｂは、フッ素樹脂膜２ａの両面に設けられていてもよいし、省略されてもよい。すなわち、本体部２がフッ素樹脂膜２ａだけで構成されていてもよい。本体部２がＵＨＭＷＰＥ多孔質シート３で支持されるので、補強材２ｂを省略でき、部品点数を削減できる。また、所定波長のレーザーを相対的に吸収しにくくする目的で、本体部２は白色でありうる。補強材２ｂを設ける場合には、補強材２ｂも白色であることが好ましい。
　フッ素樹脂膜２ａは、通気性を有する膜であり、典型的には多孔質膜である。フッ素樹脂膜２ａに使用できるフッ素樹脂として、ポリテトラフルオロエチレン（ＰＴＦＥ）、ポリクロロトリフルオロエチレン、テトラフルオロエチレン－ヘキサフルオロプロピレン共重合体、テトラフルオロエチレン－エチレン共重合体が挙げられる。中でも、小面積で高い通気性が確保でき、筐体２００の内部への異物の侵入を阻止する能力にも優れているＰＴＦＥが好ましい。ＰＴＦＥ多孔質膜は、延伸法や抽出法等の公知の成形方法によって製造できる。フッ素樹脂膜２ａには、撥油処理や撥水処理が施されていてもよい。
　補強材２ｂは、ポリエステル、ポリエチレン、アラミド等の樹脂で作られた部材である。補強材２ｂを設けることによって、フッ素樹脂膜２ａのハンドリングが容易になる。補強材２ｂの形態は、通気膜６の通気性を維持できるものであれば特に限定されず、例えば、織布、不織布、ネットまたはメッシュであり、典型的には不織布である。
　フッ素樹脂膜２ａと補強材２ｂとは、熱ラミネーションによって貼り合わされていてもよいし、接着剤を用いて貼り合わされていてもよい。好ましくは、面内に均一に分散した溶着部または接着部を介して、フッ素樹脂膜２ａと補強材２ｂとが貼り合わされていることである。溶着部または接着部の面積が、例えば全面積の５～２０％の範囲にあると、耐水性が不十分になったり剥がれが生じたりしにくい。
　本体部２の厚さは、強度、通気性、耐水性、レーザー透過性等の要求される特性を考慮して、０．０２～１．０ｍｍ（または０．０５～０．２ｍｍ）の範囲にあるとよい。本体部２の通気度は、ＪＩＳ Ｐ ８１１７に規定されたガーレー試験機法により得られるガーレー値にて０．１～５００ｓｅｃ／１００ｃｍ3の範囲にあるとよい。本体部２の耐水圧は、１．０ｋＰａ以上あるとよい。
　図９を参照して説明したように、従来の通気部材には、通気膜を保護するための部材が設けられている。水滴等の異物から直接衝撃を受けることによって通気膜がダメージを受けるのを防ぐためである。これに対し、本実施形態によれば、本体部２がＵＨＭＷＰＥ多孔質シート３で保護されているので、複合通気膜６が他の部材で覆われていなかったとしても、複合通気膜６がダメージを受けにくい。複合通気膜６を覆うための他の部材を省略することによって、部品点数の削減、通気構造の高さの低減が可能である。もちろん、図２に示す通気構造１３において、複合通気膜６を覆う部材が設けられていてもよい。
　ＵＨＭＷＰＥ多孔質シート３の厚さに特に限定はないが、０．０２～３．０ｍｍ（または０．０５～１．０ｍｍ）の範囲にあるとよい。複合通気膜６の強度を十分に確保する観点から、ＵＨＭＷＰＥ多孔質シート３の厚さｔ２が本体部２の厚さｔ１よりも大きい方が好ましい。例えば、２≦（ｔ２／ｔ１）≦５０を満たすように、厚さｔ１およびｔ２を定めることができる。
　ここで、「超高分子量ポリエチレン」とは、平均分子量５０万以上のポリエチレンのことをいう。超高分子量ポリエチレンの平均分子量は、通常、２００～１０００万の範囲である。平均分子量は、例えば、ＡＳＴＭ Ｄ４０２０（粘度法）に規定された方法で測定できる。本明細書では、超高分子量ポリエチレンを「ＵＨＭＷＰＥ（Ultra High Molecular Weight Poly-ethylene）」と略記している。
　ＵＨＭＷＰＥ多孔質シート３は、ＵＨＭＷＰＥ粉末の焼結体から製造できる。ＵＨＭＷＰＥ粉末の焼結体は、金型に充填したＵＨＭＷＰＥ粉末（平均粒径３０～２００μｍ）をＵＨＭＷＰＥの融点付近の温度（例えば１３０～１６０℃）で焼結させることによって得られる。得られた焼結体は、通常、ブロック状である。ブロック状の焼結体を切削加工によってシート状に成形すれば、ＵＨＭＷＰＥ多孔質シートが得られる。この製造方法（粉末焼結法）によれば、得られたＵＨＭＷＰＥ多孔質シートの気孔率は２０～５０％の範囲になる。
　また、ＵＨＭＷＰＥ多孔質シート３は、所定波長のレーザーを本体部２よりも吸収しやすくなるように、黒色を有する。具体的には、ＵＨＭＷＰＥ多孔質シート３は黒色に着色されている。着色は、レーザー溶着部４を形成するべき部分のみに行われていてもよいが、全体の着色を行う方が容易である。上述したＵＨＭＷＰＥ多孔質シート３の製造において、ＵＨＭＷＰＥ粉末と着色剤とを混ぜ、焼結体を作製すればよい。なお、焼結温度で分解しない着色剤を選ぶことが必要であり、例えば、キャボット社より入手できるBlack Pearls L、Black Pearls 1000等のカーボンブラックを好適に使用できる。１００重量部のＵＨＭＷＰＥ粉末に対し、これらの着色剤を例えば１～１０重量部の範囲で含ませることができる。
　なお、「黒色を有する」とは、黒色に着色するための着色剤を含んでいることを意味する。一般的には、ＪＩＳ Ｚ ８７２１ 明度（無彩色）に規定された黒色度で、１～４を「黒」、５～８を「グレー」、９以上を「白」と判断する。本発明では、ＵＨＭＷＰＥ多孔質シート３がグレーまたは黒（黒色度８以下）であり、レーザーの吸収効率の観点から、黒（黒色度４以下）であることが好ましい。
　ＵＨＭＷＰＥ粉末の焼結体から製造されたＵＨＭＷＰＥ多孔質シート３は、耐薬品性、耐摩耗性、離型性等のＵＨＭＷＰＥの優れた特性を保持している。また、多孔質化することで、通気性、クッション性、摺動性等の特性も獲得している。本実施形態では、ＵＨＭＷＰＥ多孔質シート３が表面に露出するように、第１筐体部品１１に対する複合通気膜６の姿勢が定められている。そのため、樹脂多孔質シート３が耐薬品性に優れていることは、本実施形態の通気構造１３にとって好ましいことである。高い摺動性をＵＨＭＷＰＥ多孔質シート３が有していることによって、複合通気膜６に異物が付着しにくくなる。
　また、ＵＨＭＷＰＥ多孔質シート３は、一般的な補強材であるポリエチレン不織布等に比べて、硬く、高強度を有する。同じ強度のＵＨＭＷＰＥ多孔質シート３とポリエチレン不織布とを比較すると、ＵＨＭＷＰＥ多孔質シート３の方が圧倒的に薄く、かつ通気性にも優れる。複合通気膜６を保護するためのカバーを設けない場合、複合通気膜６が外部の雰囲気（例えば自動車のエンジンルーム）に直接晒されるため、複合通気膜６自身に十分な物理強度が要求される。ポリエチレン不織布等の従来の補強材で十分な強度を得るには、相当の厚みが必要となり、通気性が犠牲になる問題がある。これに対し、ＵＨＭＷＰＥ多孔質シート３には、強度と通気性とを高い次元で両立できる利点がある。
　フッ素樹脂膜を含む本体部２とＵＨＭＷＰＥ多孔質シート３との貼り合わせには、レーザー溶着法が極めて有効である。なぜなら、ＵＨＭＷＰＥ多孔質シートと本体部２との熱ラミネーションでは、加熱および加圧条件の選択が難しいからである。強度の観点で比較的厚いＵＨＭＷＰＥ多孔質シートを用いると、熱ラミネーションを行う際に熱が伝わりにくく、貼り合わせが不十分になることがある。本体部２とＵＨＭＷＰＥ多孔質シート３との貼り合わせを行うために両者の間に熱および圧力を闇雲にかけるのも、フッ素樹脂膜２ａがダメージを受けるおそれがあるのでよくない。本実施形態によれば、本体部２とＵＨＭＷＰＥ多孔質シート３との熱ラミネーションを行わずに済むので、そうした問題を排除できる。
　次に、第１筐体部品１１および第２筐体部品１２は、熱可塑性樹脂やエラストマーの成形品である。熱可塑性樹脂として、ＰＢＴ（ポリブチレンテレフタレート）、ＰＥＴ（ポリエチレンテレフタレート）、ＰＰＳ（ポリフェニレンサルファイド）、ＰＳＵ（ポリサルフォン）、ＰＰ（ポリプロピレン）、ＰＥ（ポリエチレン）、ＡＢＳ（アクリロニトリル・ブタジエン・スチレン共重合体）が挙げられる。エラストマーとして、クロロプレンゴム、イソプレンゴム、スチレン・ブタジエンゴム、天然ゴムを主成分として含むゴム組成物が挙げられる。これらの樹脂を用い、射出成形等の公知の成形方法で筐体部品１１，１２を製造しうる。
　筐体部品１１，１２の材料には、さらに、顔料、補強用充填材および他の添加剤等が含まれていてもよい。顔料の具体例は、カーボンブラックやチタンホワイトである。補強用充填材の具体例は、ガラス粒子やガラス繊維である。他の添加材の具体例は、撥水剤や絶縁材である。
　次に、図４Ａおよび図４Ｂを参照して、図２に示す通気構造を製造する方法について説明する。図４Ａに示すように、まず、フッ素樹脂膜を含む本体部２と、ＵＨＭＷＰＥ多孔質シート３とを準備し、これらを重ねる。本体部２およびＵＨＭＷＰＥ多孔質シート３は、例えば、等しい直径を有する円形である。本体部２とＵＨＭＷＰＥ多孔質シート３との積層体に透光治具９を載せる。透光治具９に適度な圧力を加えて、本体部２とＵＨＭＷＰＥ多孔質シート３とを密着させる。
　透光治具９は、本体部２とＵＨＭＷＰＥ多孔質シート３との位置関係を保持するためのものであり、放熱用の開口部９ｈを有する。透光治具９は、典型的にはレーザーを透過させる透明なガラス板でできている。このような透光治具９を用いることによって、本体部２にダメージが及ぶのを防止できる。
　次に、図４Ｂに示すように、透光治具９を介して本体部２とＵＨＭＷＰＥ多孔質シート３との界面にレーザーＬＢを照射する。本体部２側から入射したレーザーＬＢは、本体部２とＵＨＭＷＰＥ多孔質シート３との界面近傍において、主にＵＨＭＷＰＥ多孔質シート３の表層部を溶かす。これにより、レーザー溶着部４（図２）が形成される。
　レーザー溶着の条件は、本体部２とＵＨＭＷＰＥ多孔質シート３へのダメージを考慮して調節するとよい。例えば、レーザー出力を２０～３００Ｗ（または２０～５０Ｗ）の範囲、レーザー波長を８００～１１００ｎｍ（または８００～９５０ｎｍ）の範囲、溶着時間を０．０５～５．０秒（または０．１～１．５秒）の範囲でそれぞれ調節しうる。レーザーの種類に特に限定はなく、ＣＯ2レーザーやエキシマレーザーなどのガスレーザーを使用してもよいし、ＹＡＧレーザーなどの固体レーザーを使用してもよい。
　なお、本体部２とＵＨＭＷＰＥ多孔質シート３との積層体から多数個の複合通気膜６を一括して製造することもできる。具体的には、図５に示すように、大面積の積層体Ｗを準備し、製造するべき複合通気膜６の形状に対応した複数の切断予定線ＣＬを定める。切断予定線ＣＬの内側の領域にレーザー溶着部４が形成されるように、各領域に対して順番にレーザー照射工程を行う。レーザー溶着部４の形成後、切断予定線ＣＬに沿って積層体Ｗを打ち抜く。このようにすれば、１つの積層体Ｗから多数個の複合通気膜６を効率よく製造できる。小さい部品をハンドリングする回数が減るので、生産性も向上する。
　図２に示す通気構造１３は、インサート射出成形法によって製造できる。具体的には、第１筐体部品１１を成形するための金型内に複合通気膜６をセットする。金型に射出された樹脂で複合通気膜６の外周部６ｇが包まれるように、第１筐体部品１１を形成するための射出成形工程を行う。本体部２に高強度のＵＨＭＷＰＥ多孔質膜３が組み合わされているので、金型に複合通気膜６をセットするに際して、複合通気膜６がダメージを受けにくい。また、本体部２とＵＨＭＷＰＥ多孔質シート３とが、予めレーザー溶着されているため、ハンドリングしやすい。そのため、通気構造１３の製造工程の自動化が容易である。
　（変形例１）
　図６Ａおよび図６Ｂに示す通気構造２３は、通気用の開口部２１ｈを有する支持体２１と、支持体２１に取り付けられた複合通気膜６とを有する。つまり、通気構造２３は、通気部材（通気栓）として構成されている。複合通気膜６は、図２を参照して説明したものであり、接着剤または粘着テープで支持体２１に固定されている。なお、複合通気膜６と支持体２１とがインサート成形によって一体化されていてもよい。支持体２１が筐体そのものであってもよい。
　（変形例２）
　図７に示す筐体２０１は、第１筐体部品１１、第２筐体部品１２および第１筐体部品１１の開口部１１ｈに取り付けられた通気部材３３（通気構造）を備えている。第１筐体部品１１の開口部１１ｈへの通気部材３３の取り付けは、接着剤や粘着テープを用いて行ってもよいし、熱溶着によって行ってもよい。通気部材３３において、複合通気膜６と支持体３１とはインサート成形によって一体化されている。変形例１および変形例２によると、通気部材２３，３３を製造した時点で非破壊試験（例えば耐水試験や目視観察）を行える利点がある。また、通気構造を設けるべき筐体の設計変更にも対応しやすい。また、通気部材２３，３３を筐体に取り付けるための方法を、接着剤や粘着テープの使用、溶着、熱かしめ等の種々の方法から選択できる。
　本発明の効果を確かめるために、以下のサンプルを作製し、各サンプルの耐水性を調べた。
（サンプル１）
　図２に示す通気構造を製造した。まず、本体部２としてのフッ素樹脂膜２ａ（日東電工社製 テミッシュ（登録商標）ＮＴＦ８１０Ａ、厚さ０．３ｍｍ、φ１３ｍｍ、不織布無し）と、ＵＨＭＷＰＥ多孔質シート３（日東電工社製 サンマップ（登録商標）ＬＣ－Ｔ、厚さ１．０ｍｍ、φ１３ｍｍ）とを、図４Ａおよび図４Ｂを参照して説明した方法でレーザー溶着し、複合通気膜６を得た。ただし、ＵＨＭＷＰＥ多孔質シート３には、予め黒色に着色したものを用いた。
　次に、インサート射出成形法によって複合通気膜６と第１筐体部品１１とを一体化し、図２に示す通気構造１３を得た。第１筐体部品１１の材料として、ポリブチレンテレフタレートを用いた。
（サンプル２）
　サンプル１で得た複合通気膜６を用い、図６Ａに示す通気栓（通気構造２３）を作製した。この通気栓を第１筐体部品１１の開口部１１ｈに接着剤で固定した。
（サンプル３）
　従来の通気膜（日東電工社製 テミッシュ（登録商標）ＮＴＦ２１３１Ａ－Ｓ０６、厚さ０．１７ｍｍ、φ１３ｍｍ、片面に不織布有り）を第１筐体部品１１に直接レーザー溶着した。
<<高圧洗車試験>>
　サンプル１～３の通気構造に対して、高圧洗車試験を行った。高圧洗車試験とは、図１６に示すように、通気構造に対して、０°、３０°、６０°および９０°の各角度に配置したノズル８０から水を噴射し、筐体への水の浸入の有無を調べる試験である。筐体の内部には、水を感知するウォーターフィーリングペーストを塗布した。そのペーストが緑から赤に変色した場合に、筐体内に水が入ったと判断した。ノズル８０からの水の噴射条件は、以下の通りであった。
　噴射圧：８ＭＰａ
　水温　：８０℃
　時間（各角度）：３０秒
　流量　：１４リットル／分
<<結果>>
　サンプル１，２は、高圧洗車試験を経ても筐体の中に水が全く入っていなかった。一方、サンプル３は、筐体内に水が少し入った。
　本発明は、ランプ、モーター、センサ、スイッチ、ＥＣＵ、ギアボックス等の自動車部品に適用できる。また、自動車部品以外にも、移動体通信機器、カメラ、電気剃刀、電動歯ブラシ、洗濯機（例えば洗濯機の湿度センサ）等の電気製品に本発明を適用できる。

Claims (7)

  1. 　フッ素樹脂膜を含む本体部と、
    　黒色を有し、前記本体部に重ね合わされた超高分子量ポリエチレン多孔質シートと、
    　前記本体部と前記超高分子量ポリエチレン多孔質シートとに介在することによって両者を一体化しているレーザー溶着部と、
    　を備えた、複合通気膜。
  2. 　前記レーザー溶着部が、当該複合通気膜の外周部における、前記本体部と前記超高分子量ポリエチレン多孔質シートとの間に形成されており、平面視で環形状を有する、請求項１に記載の複合通気膜。
  3. 　前記本体部の厚さｔ１と前記超高分子量ポリエチレン多孔質シートの厚さｔ２とが、ｔ１＜ｔ２の関係を満たす、請求項１に記載の複合通気膜。
  4. 　前記本体部が、前記フッ素樹脂膜だけで構成されている、請求項１に記載の複合通気膜。
  5. 　通気用の開口部を有する樹脂部品と、
    　前記開口部を塞ぐように前記樹脂部品に取り付けられた通気膜とを備え、
    　前記通気膜が、請求項１に記載の複合通気膜によって構成されている、通気構造。
  6. 　前記複合通気膜の外周部が前記樹脂部品に埋め込まれている、請求項５に記載の通気構造。
  7. 　前記樹脂部品に埋め込まれた前記外周部にのみ前記レーザー溶着部が形成されている、請求項６に記載の通気構造。
     
     
PCT/JP2010/003873 2009-06-11 2010-06-10 複合通気膜およびそれを用いた通気構造 Ceased WO2010143437A1 (ja)

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EP20100785969 EP2441625A4 (en) 2009-06-11 2010-06-10 AIR-CONDUCTIVE COMPOSITE FILM AND VENTILATION STRUCTURE THEREWITH
CN2010800254101A CN102803022A (zh) 2009-06-11 2010-06-10 复合透气膜及使用该复合透气膜的透气结构
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