WO2012140873A1 - レーザ接合方法 - Google Patents
レーザ接合方法 Download PDFInfo
- Publication number
- WO2012140873A1 WO2012140873A1 PCT/JP2012/002496 JP2012002496W WO2012140873A1 WO 2012140873 A1 WO2012140873 A1 WO 2012140873A1 JP 2012002496 W JP2012002496 W JP 2012002496W WO 2012140873 A1 WO2012140873 A1 WO 2012140873A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- laser
- thermoplastic resin
- bonding
- joining
- joining method
- Prior art date
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Images
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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
- 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
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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
- B29C66/70—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
- B29C66/73117—Tg, i.e. glass transition temperature
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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
- B29C66/70—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
- B29C66/73117—Tg, i.e. glass transition temperature
- B29C66/73118—Tg, i.e. glass transition temperature of different glass transition temperature, i.e. the glass transition temperature of one of the parts to be joined being different from the glass transition temperature of the other part
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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
- B29C66/70—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
- B29C66/7316—Surface properties
- B29C66/73161—Roughness or rugosity
- B29C66/73162—Roughness or rugosity of different roughness or rugosity, i.e. the roughness or rugosity of the surface of one of the parts to be joined being different from the roughness or rugosity of the surface of the other part
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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
- 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
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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
- B29C66/70—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
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
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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
- B29C66/812—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
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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
- 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
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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
- 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
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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
- 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
- B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one 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
- 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
- B29C65/82—Testing the joint
- B29C65/8207—Testing the joint by mechanical methods
- B29C65/8215—Tensile tests
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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
- B29C66/70—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
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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
- B29C66/70—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
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
- B29C66/7422—Aluminium or alloys of aluminium
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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
- B29C66/70—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
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
- B29C66/7428—Transition metals or their alloys
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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
- B29C66/70—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
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
- B29C66/7428—Transition metals or their alloys
- B29C66/74281—Copper or alloys of copper
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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
- B29C66/70—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
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
- B29C66/7428—Transition metals or their alloys
- B29C66/74283—Iron or alloys of iron, e.g. steel
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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
- B29C66/70—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
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
- B29C66/7428—Transition metals or their alloys
- B29C66/74285—Noble metals, e.g. silver, gold, platinum or their alloys
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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
- B29C66/70—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
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/746—Joining plastics material to non-plastics material to inorganic materials not provided for in groups B29C66/742 - B29C66/744
- B29C66/7461—Ceramics
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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
- B29C66/812—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
- B29C66/8122—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 composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
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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
- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
- B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
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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
- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
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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
- B29C66/90—Measuring or controlling the joining process
- B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
- B29C66/934—Measuring or controlling the joining process by measuring or controlling the speed by controlling or regulating the speed
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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
- B29C66/90—Measuring or controlling the joining process
- B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
- B29C66/939—Measuring or controlling the joining process by measuring or controlling the speed characterised by specific speed values or ranges
Definitions
- the present invention relates to a laser joining technique characterized by welding or joining a thermoplastic resin or a resin and a metal with a laser.
- thermoplastic resins are widely used in general industrial applications such as automobiles, electrical equipment, medical and biotechnology equipment because of their excellent processability and large degree of freedom in shape. There is no field where thermoplastic resins are not used. It is so popular that it is a familiar material. Originally used as a substitute for natural materials such as wood and paper, many special products that can only be made using plastic materials have now been developed. Therefore, if the best materials can be used in design development with the best processing methods, there is a possibility of creating new products that have never existed before.
- Patent Document 1 discloses that a laser beam is irradiated in a state in which an alloy material is interposed between a second resin material having a low compatibility with the first resin member. It is described that joining is possible.
- Patent Document 2 the acrylic resin bites into the concavo-convex surface by irradiating with a laser in a state where another resin material or metal material having the concavo-convex surface roughened with an acrylic resin and sandpaper is in close contact with the resin. It is described that a simple bond is formed.
- Patent Document 3 an intermediate material for laser bonding having an elastic modulus of 1000 MPa or less is provided between a first member that is impermeable to laser light and a second member that is made of the same or different material as the first member. It is shown that the intermediate member is melted and joined by providing.
- Patent Document 4 describes that surface modification treatment is used for the resin before laser welding, but it is effective for improving the strength.
- Patent Document 2 The technique disclosed in Patent Document 2 is effective when a thermoplastic resin having an oxygen functional group such as acrylic is used as the resin on the laser transmission side, but a thermoplastic resin having no oxygen functional group. It was found that the bonding strength was low when using.
- Patent Document 4 it is possible to weld different types of resins by using a surface modification treatment on the resin before laser welding. However, if a large gap is generated between the resins, There were many cases, and improvement was desired.
- the present inventor forms an oxide layer containing more oxygen functional groups than the bulk material on the joining surface side of the thermoplastic resin using a dry surface modification treatment on at least one thermoplastic resin before laser irradiation, By irradiating with laser while pressing with the other thermoplastic resin or metal in a state containing an intermediate material with low viscosity, it can be firmly joined and on top of that, robust joining against the generation of gaps is possible I found out.
- the present invention it is possible to improve the adhesion at the interface of the joint, reduce the welding failure due to the presence of the gap, and obtain a highly reliable joint.
- thermoplastic resins of this invention It is a figure which shows one Example of the laser joining method of the thermoplastic resins of this invention. It is a figure which shows the evaluation result of the intensity
- thermoplastic resin and metal laser joining method of this invention It is a figure which shows one Example of the thermoplastic resin and metal laser joining method of this invention. It is a figure which shows the other Example of the laser joining method of the thermoplastic resin and metal of this invention. It is a figure which shows the other Example of the thermoplastic joining method of the thermoplastic resins of this invention, or a thermoplastic resin and a metal. It is a schematic diagram of the flow cell for DNA sequencers which assumed application of the laser joining method of the present invention. It is a figure which shows the other Example of the schematic diagram of the flow cell for DNA sequencers which assumed application of the laser joining method of this invention.
- thermoplastic resin used in the present invention is made of an amorphous or crystalline resin.
- Non-crystalline resins include polystyrene (PS), acrylonitrile styrene (AS), acrylonitrile butadiene styrene copolymer (ABS), polyetherimide (PEI), polycarbonate (PC), polyarylate (PAR), and polymethylmethacrylic.
- Examples include methyl acid (PMMA), cycloolefin polymer (COP), cycloolefin copolymer (COC), polysulfone (PSF), polyethersulfone (PES), polyvinyl chloride (PVC), and polyvinylidene chloride (PVDC).
- PMMA methyl acid
- COP cycloolefin polymer
- COC cycloolefin copolymer
- PSF polysulfone
- PES polyethersulfone
- PVDC polyvinyl chloride
- polyethylene polyethylene
- PP polypropylene
- POM polyoxymethylene
- PET polyethylene terephthalate
- PBT polytrimethylene terephthalate
- PEN polybutylene terephthalate
- PPS polyphenylene sulfide
- PA6 nylon 6
- PA66 nylon 6T
- PEEK polyetheretherketone
- LCP liquid crystal polymer
- PTFE polytetrafluoroethylene
- metals examples include iron, aluminum, copper, nickel, gold, titanium, alloys (stainless steel, brass, aluminum alloys, phosphor bronze, etc.), die casting, and the like.
- metal coatings plating, vapor deposition film, etc.
- ceramics are within the scope of this method.
- the laser welding or bonding conditions are determined in consideration of the transmission / absorption rate and thermal conductivity of the material at the laser irradiation wavelength, and the laser spot size, power, irradiation time, and applied pressure.
- the light source used for laser bonding is preferably an infrared laser including a semiconductor laser, a YAG laser, and a fiber laser.
- the intensity distribution of the laser light source can be changed to various intensity distributions depending on the attached lens such as Gaussian, top hat, ring type, etc. However, the intensity of the top hat type or the central part is easy in that the welded state can be made uniform. It is desirable to use a light source using a ring-type intensity distribution in which is 50% or more of the maximum value.
- the pressurizing material used for pressurization since it is necessary to pressurize in laser welding or joining, it is preferable to use a transparent material for the pressurizing material used for pressurization. However, in consideration of sufficient heat dissipation of the material on the laser irradiation side, it is desirable to use glass having particularly high thermal conductivity. Furthermore, it is desirable that the surface of the pressure member has a mirror finish.
- FIG. 1 is a cross-sectional view showing an embodiment of a method for laser joining of resins according to the present invention.
- the light-transmitting first thermoplastic resin 1 and the second thermoplastic resin 2 having higher light absorption than the first thermoplastic resin 1 are used.
- the surface of the thermoplastic resin 1 is subjected to surface modification treatment to form an oxide layer 3 containing more oxygen at the joint interface than the bulk first thermoplastic resin. Then, pressurization and laser welding are performed.
- the intermediate material 4 it is preferable to use a liquid material (including a colloidal solution (sol)) that can sufficiently fill the gaps 1 and 2 between the thermoplastic resins.
- a liquid material including a colloidal solution (sol)
- a material that transmits light is better as the intermediate material 4.
- the first thermoplastic resin Prior to laser bonding, the first thermoplastic resin is subjected to surface modification treatment, and oxygen is introduced into the surface of the resin.
- surface modification treatment UV ozone treatment, plasma treatment, corona treatment, short pulse (with a pulse width of several hundred picoseconds or less) laser treatment in consideration of environmental properties, damage to parts, and effects on other parts Any one of the dry treatments may be used.
- oxygen functional groups As plasma treatment, oxygen plasma and nitrogen plasma treatment are mainly effective. It is desirable that the oxide layers of the thermoplastic resins 1 and 2 containing oxygen are at least several nm or more.
- the laser irradiation to the bonding interface is performed through the first transparent thermoplastic resin.
- Laser welding occurs when the second thermoplastic resin 2 having high light absorption is melted or softened by laser irradiation and is wetted or adhered to the first thermoplastic resin 1. Therefore, the surface modification treatment is performed at least on the first plastic resin 1 that transmits light, and the surface energy of the first thermoplastic resin 1 ⁇ the surface energy of the second thermoplastic resin 2 having light absorption. There is a need. Even when the second thermoplastic resin 2 having light absorptivity is subjected to the surface modification treatment, the relationship of the surface energy needs to be satisfied.
- the glass transition temperature or melting point of the second thermoplastic resin 2 be equal to or higher than the glass transition temperature or melting point of the first thermoplastic resin 1.
- the glass transition temperature and the melting point clearly exist.
- laser welding it is necessary to satisfy the above relationship in consideration of the glass transition temperature of an amorphous resin and the melting point of a crystalline resin.
- FIG. 2 and 3 show the results of measuring the tensile shear strength by laser welding in a state containing pure water as the intermediate material 4 after the surface modification treatment is performed on the thermoplastic resins 1 and 2.
- FIG. 2 shows the use of COP for the light-transmitting first thermoplastic resin 1 and PPS for the second thermoplastic resin 2 having light absorption. It is the result of evaluating pressure as a parameter.
- the laser beam having a spot size of 1.5 mm and a laser power of 6 W was welded by scanning 1.0 mm at 10 mm / s.
- the welded sample was transferred at a speed of 1.0 mm / min.
- the fracture strength was measured. Further, the welding strength per unit area was calculated from the area after welding and the fracture strength.
- PA6T having a polar group was used for the second thermoplastic resin 2 and was welded at a laser power of 7 W. Other conditions are the same as the case where PPS is used for the second thermoplastic resin 2.
- the PPS and PA6T of the second thermoplastic resin 2 are of high thermal conductivity grade containing ceramics as a filler, contain carbon black, and are colored black. When the surface modification treatment is performed on the COP, the surface energy is higher than that of the PPS and PA6 subjected to the surface modification treatment.
- the thermal conductivity of water is 0.67 W / mK at 80 ° C., which is about 20 times larger than that of air.
- the intermediate material 4 the heat of the second thermoplastic resin 2 having light absorption is obtained. It is possible to facilitate heat conduction during expansion. Therefore, the intermediate material 4 is desirably made of a liquid material having a viscosity of 1000 mPa ⁇ s or less and a thermal conductivity of at least 0.2 W / mK. Further, by using the intermediate material 4, it is possible to reduce the influence of reflection at the interface of the joint surface of the first thermoplastic resin 1, and it is possible to weld more effectively.
- the inclusion of the intermediate material 4 is a robust method that can reduce the rate of reduction of the welding strength even when a gap is generated.
- the intermediate material 4 is used in advance so as to be in close contact with each other, it is also advantageous that no displacement occurs during pressurization. In that case, depending on the process, it may be advantageous in that it can be positioned in advance before pressurization.
- the thermoplastic resin material as a form of the thermoplastic resin material. This method is particularly effective when it is difficult to ensure close contact with pressure, such as when a film with low rigidity is used. Recently, a porous film such as a non-woven fabric has been used in many products.
- the method according to the present embodiment makes it possible to perform highly reliable welding even when a porous film is used from a different material.
- the proportion of polar groups increases, so depending on the resin to be welded, the initial strength may be To increase.
- a part of the film peels off in an atmosphere containing a lot of water vapor such as a high temperature and high humidity test.
- FIG. 4 only a part of the second thermoplastic resin 2 is subjected to surface modification treatment, and oxidation of the second thermoplastic resin 2 in the laser irradiation region is performed.
- a region with or without the layer 6 is provided, and laser irradiation is preferably performed so as to span both the region where the surface modification is performed and the region where the surface modification is not performed.
- Such a form is an effective means especially in a sealing structure.
- fine irregularities 7 are formed on the first thermoplastic resin 1 side, and the first thermoplastic resin 1 has a roughness> light absorption property. It is also effective to set the roughness of the second thermoplastic resin 2.
- the fine irregularities 4 may be subjected to a texture process. In that case, the unevenness is preferably Ra 3 ⁇ m or less. By forming the unevenness, the distance between the members increases, but by using the intermediate material 4, it is possible to suppress a decrease in heat conduction.
- thermoplastic resin material is liable to adsorb foreign matter due to electrification, and there may be a remaining parting material at the time of molding. In this case, there is a problem that it is difficult to weld. Therefore, this configuration is an effective method for welding not only different kinds of thermoplastic resins but also the same kind of thermoplastic resins. In particular, even in the case of the same kind of resin, the surface energy is small and the intermediate material 4 is particularly effective in a configuration in which the intermediate material 4 is difficult to get wet. Further, not only thermoplastic resins but also thermosetting resins are included in the effective range.
- FIG. 6 is a cross-sectional view showing an embodiment of the resin and metal laser bonding method of the present invention.
- the surface of the first thermoplastic resin 1 before joining is subjected to a surface modification treatment, and the liquid intermediate material 4 is interposed between the first thermoplastic resin 1 and the metal 8, and the metal 8 side. Pressurize.
- the laser beam 11 is incident from the metal 8 side to perform laser bonding.
- the metal 8 is preferably as thin as 4 mm or less.
- the metal 8 surface to be irradiated with the laser beam 11 is black-treated in advance, the laser absorptance is increased and the necessary laser power is lowered, which is a desirable form.
- the transmittance of the first thermoplastic resin 1 with respect to the laser beam is as high as 50% or more, the laser beam 11 may be irradiated from the first thermoplastic resin 1 side as in the first embodiment. In that case, the thickness of the metal 8 does not matter.
- thermoplastic resin 1 melts or softens, and wets and bonds to the metal 8. Therefore, as shown in FIG. 7, it is effective in improving the strength to provide fine irregularities 12 at the interface on the metal 8 side.
- the fine irregularities 12 are more preferably subjected to blasting or laser processing.
- the roughness of the metal is preferably set to Ra 5 ⁇ m or less.
- the wetted surface is promoted more effectively. Further, not only the wetting is emphasized and the interface strength is improved, but also the anchor effect is exhibited, so that the bonding strength is further improved. Therefore, it is a desirable configuration because the joint strength in all directions is improved by combining the interface strength improvement and the anchor effect.
- FIG. 8 is a cross-sectional view showing another embodiment of the laser bonding method between resins or resins and metals according to the present invention.
- the first thermoplastic resin 1 is pressurized by the pressurizing material 10 in the direction in which the first thermoplastic resin 1 is joined (the lower direction in the drawing).
- the transmittance of the first thermoplastic resin 1 with respect to the laser beam 11 is relatively low, such as about 20%, when the laser beam 11 is irradiated, the required power increases depending on the combination, and the thermoplastic resin 1 on the laser irradiation side is increased. This causes the outermost surface of the material to be carbonized, which may cause problems such as inability to perform laser bonding or adhesion to a pressure material.
- thermoplastic resin 1 even when it pressurizes with the glass which is the pressurization material 10 with high heat conductivity, it is impossible for the surface of glass and the thermoplastic resin 1 to contact at an interface level. For this reason, the surface of the thermoplastic resin 1 on the laser irradiation side is also subjected to a surface modification treatment so that the intermediate material 14 is contained between the pressure material 10 and the glass so that the gap is completely filled. It becomes effective to join. By doing in this way, it becomes possible to suppress carbonization of the thermoplastic resin 1 by the reduction of the reflection of the interface of the thermoplastic resin 1 and the intermediate material 14, and the improvement of the heat dissipation to glass.
- FIG. 9 is a perspective view showing an example when the periphery of the flow path portion 16 of the DNA sequencer flow cell 15 is sealed using the laser bonding method of the present invention.
- FIG. 10 is a top view of the flow cell 15 for DNA sequencer. The reagent enters and exits from the hole 17 and flows through the flow path 16 inside the sealing weld 18.
- the second thermoplastic resin 2 has a structure in which a region 21 subjected to the surface treatment and a region 20 not subjected to the surface modification treatment are provided and the portion is additionally sealed.
- Reference numeral 19 denotes an additional sealing portion.
- the intermediate material 4 often does not want to use an adhesive.
- a volatile material such as a solvent with low flammability such as pure water or alcohol.
- an adhesive it is effective to use an adhesive as the intermediate material 4 in the case of a sensor or connector on which electronic components are mounted.
- an adhesive is used, a curing process is required after welding, but in addition to the direct bonding by laser, the strength improvement effect by bonding also contributes, so that a very large strength can be obtained.
- there is a direct bonding portion it is possible to obtain high airtightness and solvent resistance as compared with the case of sealing with an adhesive alone.
- thermoplastic resin metals Due to the complexity of product structures in recent years, designs have been made taking advantage of the respective merits of thermoplastic resin metals, and their secondary processing techniques have become important.
- Laser joining is a technology that has recently attracted attention, but there is a problem that gap management is very difficult depending on the structure.
- joining by laser is a clean technique compared to other secondary processing techniques, there is also an advantage that the environmental load is small.
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Abstract
熱可塑性樹脂同士もしくは樹脂と金属との界面強度を向上させ、強固に接合可能とした上で、隙間の存在による接合不良を大幅に低減可能とするレーザ接合方法を提供する。これを解決するために、接合前に、少なくとも第一の熱可塑性樹脂の接合界面側には、表面改質処理を施すことによりバルク熱可塑性樹脂に比べ酸素官能基を多く含有した酸化層を形成する工程を有し、第二の熱可塑性樹脂もしくは金属の間に液状の中間材を介在させた状態で、加圧し、レーザ照射して接合を行う。
Description
本発明は、熱可塑性から成る樹脂同士もしくは樹脂と金属をレーザにより溶着もしくは接合することを特徴とするレーザ接合技術に関するものである。
熱可塑性樹脂は、優れた加工性と形状の自由度が大きいため、自動車や電機機器や医療・バイオ機器など一般産業用途に広く用いられており、熱可塑性樹脂が使われていない分野はないと言えるほど普及し、身近な材料となっている。当初は、木材や紙などの天然素材の代替として利用されていたが、今やプラスチック材料でなければつくり得ないという特殊な製品も数多く開発されるようになった。そのため、最適な材料を最適な加工方法で設計開発に生かせれば、今までにない新しい製品を生み出す可能性が残されている。
特に、近年の製品の構造の複雑化及び低コスト化の流れにより、熱可塑性樹脂のメリットを生かした設計がなされ、熱可塑性樹脂同士もしくは熱可塑性樹脂と金属に対応した2次加工技術が重要となってきている。その中でも、近年、レーザを用いる方法を検討されることが多くなってきた。異種材料の接合として、特許文献1には、第1の樹脂部材と相溶性の小さい第2の樹脂材の間に、互いのアロイ材料を介在させた状態で、レーザ光を照射することにより、接合可能なことが記載されている。特許文献2には、アクリル樹脂とサンドペーパーで荒らされた凹凸面を持つ他の樹脂材料もしくは金属材を密着させた状態で、レーザ照射することにより、アクリル樹脂が凹凸面に食い込むことで、強固な接合が形成されることが記載されている。特許文献3には、レーザ光に対して非透過性の第1部材と、第1部材と同一又は異なる材料からなる第2部材との間に、弾性率が1000MPa以下のレーザ接合用中間材を設けることで、中間部材を溶融させ、接合することが示されている。特許文献4には、レーザ溶着前の樹脂に表面改質処理を用いるが、強度向上には有効なことが記載されている。
上記特許文献1で開示されている技術では、互いのアロイ材料を介在させることが述べられているが、組み合わせによっては、アロイ材が作製できないなど、材質に大きな制限があった。また、固体であるアロイ材を介在させると、加圧時にずれが生じてしまう問題もあることがわかった。さらに、アロイ材自体が特殊であるため、コストも高くなるという課題もあった。
上記特許文献2で開示されている技術では、レーザ透過側の樹脂に、アクリルのような酸素官能基を持つ熱可塑性樹脂を用いた場合では有効であるが、酸素官能基を持たない熱可塑性樹脂を用いた場合には、接合強度が低いことが判明した。
上記特許文献3で開示されている技術では、中間部材としてエラストマーを用いるが、エラストマー自体の弾性率が小さいため、弾性率に依存するせん断強度が比較的小さいという課題があった。また、エラストマー自体が特殊であるため、コストも高くなるという課題があった。
上記特許文献4で開示されている技術では、レーザ溶着前の樹脂に表面改質処理を用いることで異種樹脂の溶着は可能となるが、樹脂同士において隙間が大きく発生する場合は、溶着不良となることが多々あり、改善が望まれていた。
本発明者は、レーザ照射前に少なくとも一方の熱可塑性樹脂にドライな表面改質処理を用いて熱可塑性樹脂の接合面側にバルク材に比べ酸素官能基を多く含んだ酸化層を形成し、もう一方の熱可塑性樹脂もしくは金属との間に粘度の低い中間材を含有した状態で加圧しながらレーザ照射することにより、強固に接合でき、その上隙間の発生に対してロバストな接合が可能なことを見出した。
本発明によれば、接合部の界面の密着性を向上させるとともに、隙間の存在による溶着不良を低減でき、信頼性の高い接合を得ることが可能となる。
本発明の実施の形態について以下に説明する。本発明で用いる熱可塑性樹脂は、非結晶性もしくは結晶性樹脂からなる。非結晶性樹脂としては、ポリスチレン(PS)、アクリロニトリルスチレン(AS)、アクリロニトリルブタジエンスチレン共重合体(ABS)、ポリエーテルイミド(PEI)、ポリカーボネート(PC)、ポリアリレート(PAR)、ポリメチルメタアクリル酸メチル(PMMA)、シクロオレフィンポリマー(COP)、シクロオレフィンコポリマー(COC)、ポリサルホン(PSF)、ポリエーテルサルホン(PES)、ポリ塩化ビニル(PVC)、ポリ塩化ビニルデン(PVDC)が挙げられる。結晶性樹脂としては、ポリエチレン(PE)、ポリプロプレン(PP)、ポリオキシメチレン(POM)、ポリエチレンテレフタレート(PET)、ポリトリメチレンテレフタレート(PTT)、ポリブチレンテレフタレート(PBT)、ポリエチレンナフタレート(PEN)、ポリフェニレンサルファイド(PPS)、ナイロン6(PA6)、ナイロン66(PA66)、ナイロン6T(PA6T)、ポリエーテルエーテルケトン(PEEK)、液晶ポリマー(LCP)、ポリテトラフルオロエチレン(PTFE)が挙げられる。また、それらのアロイ材やフィラーを含んだ熱可塑性樹脂も対象となる。樹脂の形態としては、一般的な成形品のみならず、フィルム(多孔質膜を含む)も対象となる。一般的には、成形性や透明性は非結晶性樹脂が優れているのに対し、結晶性樹脂は耐熱性や耐薬品性に優れている。さらに、樹脂は熱可塑性のみならず熱硬化樹脂を用いても良い。
金属としては、鉄、アルミニウム、銅、ニッケル、金、チタン、合金(ステンレス鋼、真鍮、アルミニウム合金、リン青銅など)、ダイカストなど挙げることができる。また、本発明では、金属被膜(メッキ、蒸着膜など)も対象となる。なお、金属のみならずセラミクスも本手法の範囲である。
レーザ溶着もしくは接合の条件は、材料のレーザ照射波長における透過・吸収率、熱伝導率を考慮した上で、レーザスポットサイズ、パワー、照射時間、加圧力を決定する。レーザ接合に用いる光源は、半導体レーザ、YAGレーザ、ファイバーレーザを含めた赤外領域のレーザが好ましい。レーザ光源の強度分布は、ガウシアン、トップハット、リング型など付属するレンズによって様々な強度分布にすることが可能であるが、溶着状態を均一にしやすいという点で、トップハット型もしくは中央部の強度が最大値の50%以上となるリング型の強度分布を用いた光源を使用することが望ましい。
また、レーザ溶着もしくは接合では、加圧を行う必要があるため、加圧に用いる加圧材は、透明な材料を用いるのが良い。但し、レーザ照射側の材質の十分な放熱を考慮すると、特に熱伝導率が高いガラスを用いることが望ましい。さらに、加圧材の表面は鏡面仕上げにしておくことが望ましい。
図1は、本発明の樹脂同士のレーザ接合方法の実施例を示す断面図である。本実施例では、光透過性の第一の熱可塑性樹脂1と、第一の熱可塑性樹脂1よりも光吸収性が大きい第二の熱可塑性樹脂2からなり、レーザ溶着前に、少なくとも第一の熱可塑性樹脂1の接合界面側に、表面改質処理を施し、バルクの第一の熱可塑性樹脂に比べ、接合界面に酸素を多く含んだ酸化層3を形成し、液状の中間材4を介した状態で、加圧し、レーザ溶着する。
中間材4は、互いの熱可塑性樹脂間1、2の隙間を十分に埋められる液状(コロイド溶液(ゾル)も含む)の材料を用いるのが良い。そのためには、特に、粘度1000mPa・s以下の部材を用いるのが良く、純水、アルコールなど可燃性の低い溶剤、プライマー、接着剤は好適な材料である。その場合、中間材4として光を透過する材料の方が良い。
レーザ接合前に、第一の熱可塑性樹脂に表面改質処理を行い、樹脂の表面に酸素を導入する。表面改質処理としては、環境性、部品へのダメージ、他の部品への影響を考慮すると、UVオゾン処理、プラズマ処理、コロナ処理、短パルス(パルス幅が数100ピコ秒以下)レーザ処理のいずれかのドライ処理を用いると良い。プラズマ処理としては、酸素官能基を導入することが最も重要なことを考慮すると、主に酸素プラズマ、窒素プラズマ処理が有効である。熱可塑性樹脂1、2の酸素が含有された酸化層は少なくとも数nm以上あることが望ましい。そのような処理を施すことで、第一の熱可塑性樹脂1の主鎖や側鎖のCC、CH結合を切り、CO、COO、C=Oなどの酸素官能基を生成・増加させ、表面エネルギーが増大する。また、例えば、熱可塑性樹脂1、2にPPSを用いた場合はSO3Hと極性の大きい極性基も新たに生成する。そのため、本構成では、樹脂に極性基を持っていない異種樹脂材の組み合わせの場合は特に有効である。なお、表面改質処理前には、第一の熱可塑性樹脂1もしくは第二の熱可塑性樹脂2には、一度アルコールなどで脱脂することが望ましい。
接合界面へのレーザ照射は、光透過性の第一の熱可塑性樹脂を介して行う。レーザ溶着は、レーザ照射により、光吸収性が大きい第二の熱可塑性樹脂2が溶融もしくは軟化し、第一の熱可塑性樹脂1に濡れるもしくは密着することで起こる。そのため、表面改質処理は、光透過する第一の可塑性樹脂1に少なくとも実施し、第一の熱可塑性樹脂1の表面エネルギー≧光吸収性を持つ第二の熱可塑性樹脂2の表面エネルギーとする必要がある。光吸収性を持つ第二の熱可塑性樹脂2にも表面改質処理を実施した場合にも、上記表面エネルギーの関係とする必要がある。さらに、異種樹脂を溶着する場合、第二の熱可塑性樹脂2のガラス転移温度もしくは融点≧第一の熱可塑性樹脂1のガラス転移温度もしくは融点とした組み合わせとしておくことが望ましい。一般的に、非結晶性樹脂の場合にはガラス転移温度のみ存在し、明確な融点は示さないのに対して、結晶性樹脂の場合は、ガラス転移温度と融点が明確に存在する。レーザ溶着においては、非結晶性樹脂はガラス転移温度を、結晶性樹脂の場合は、融点を考慮して、上記関係を満たす必要がある。
熱可塑性樹脂1や2に表面改質処理を実施後、中間材4として純水を含有した状態でレーザ溶着し、引張りせん断強度を測定した結果を図2及び3に示す。図2は、光透過性の第一の熱可塑性樹脂1にCOPを、光吸収性を持つ第二の熱可塑性樹脂2にPPSを用い、各樹脂へのプラズマ処理の実施有無、中間材有無、加圧力をパラメータとして評価した結果である。なお、スポットサイズ1.5mm、レーザパワー6Wのレーザ光を、10mm/sで1.0mm走査することで溶着した。その溶着したサンプルを、速度1.0mm/min.で引張り、その破壊強度を測定した。また、溶着後の面積と破壊強度から単位面積当たりの溶着強度を算出した。図3は、第二の熱可塑性樹脂2に、極性基も持つPA6Tを用い、レーザパワー7Wで溶着した。他の条件は、第二の熱可塑性樹脂2にPPSを用いた場合と同様である。第二の熱可塑性樹脂2のPPSとPA6Tはフィラーとしてセラミクスを含んだ高熱伝導グレードのものを用いており、また、カーボンブラックを含有し、黒色に着色している。COPに表面改質処理を施した場合は、表面改質処理を施したPPSとPA6よりも表面エネルギーが大きい状態としている。
図2及び図3より、少なくとも極性基を含んでいない第一の熱可塑性樹脂1であるCOPにプラズマ処理を実施しない場合、接合できず(接合強度0)、表面改質処理をすることは有効であることがわかった。第一の熱可塑性樹脂に表面改質を行った場合には、いずれも接合ができている。中間材4として用いた純水の存在により、表面改質処理の効果がなくなることはなく、高い溶着強度が得られることを見出した。その上、加圧力を小さくした場合は、中間材4である純水が存在した方が強度の低下の割合が小さいことも見出した。
中間材4を含有せず、成形時のひけなどにより隙間が発生してしまう場合、隙間部分は空気が存在する。空気の熱伝導率は例えば100℃で0.032W/mKと非常に小さいため、レーザ照射時に、光吸収性を持つ第二の熱可塑性樹脂2の熱膨張によって、第一の熱可塑性樹脂1への接触が起こらない場合、第一の熱可塑性樹脂1への十分な熱伝導が起こらず、光吸収性を持つ第二の熱可塑性樹脂2は、異常な発熱により熱分解し、溶着不良となる。また、密着した場合でも局所的にのみの場合は、不十分な溶着となる。一方で、水の熱伝導率は80℃で0.67W/mKと、空気に比べ20倍程度大きく、中間材4として使用することで、光吸収性を持つ第二の熱可塑性樹脂2の熱膨張時に、熱伝導を起こしやすくすることが可能となる。したがって、中間材4は、粘度が1000mPa・s以下であるとともに、熱伝導率が少なくとも0.2W/mK以上の液状の材質を用いることが望ましい。また、中間材4を介することで、第一の熱可塑性樹脂1の接合面の界面での反射の影響を減らすことが可能となり、より効果的に溶着することも可能となる。
以上より、中間材4を含有することは、隙間が発生した場合でも、溶着強度の低減の割合を小さくできるロバストな方法である。また、事前に中間材4を併用することで、密着しているため、加圧時に位置ずれが起こらないこともメリットである。その場合、加圧前に事前に位置だしできるという点で工程によっては有利となる場合もある。なお、本実施例では、熱可塑性樹脂材の形態として。剛性の低いフィルムを用いた場合など、加圧による密着を確保することが困難な場合において特に有効な方法である。また、最近では多くの製品に例えば不織布のような多孔質膜が使われるようになっている。多孔質膜の場合は、レーザの散乱により溶着部までレーザ光が届かないという問題がある。そのため、中間材を含有することにより、屈折率差による光の反射を減らすことができ、効率の良い光透過も可能となる。そのため、本実施例による方法により、異種材でかつ多孔質膜を用いた場合でも信頼性の高い溶着が可能となる。
第一の熱可塑性樹脂1に加え、第二の熱可塑性樹脂2にも表面改質処理を事前に実施し溶着した場合、極性基の割合が多くなるため、溶着する樹脂によっては、初期強度は増加する。しかし、高温高湿試験など水蒸気が多く含まれる雰囲気で一部が剥離する場合がある。そのような場合には、図4で示したように、第二の熱可塑性樹脂2の一部のみに表面改質処理を実施し、レーザ照射領域のうち、第二の熱可塑性樹脂2の酸化層6の有無の領域を設け、表面改質を行った領域と行わない領域の両方のまたがるようにレーザ照射すると良い。このような形態は特に封止構造で有効な手段である。
また、熱可塑性樹脂の組み合わせによっては、図5のように、第一の熱可塑性樹脂1側に微細な凹凸7を形成し、第一の熱可塑性樹脂1の粗さ>光吸収性を持つ第二の熱可塑性樹脂2の粗さとしておくことも有効である。この微細な凹凸4は、シボ加工を用いると良い。その場合凹凸はRa3μm以下としておくと良い。凹凸を形成することにより、部材間の距離が大きくなるが、中間材4を用いることで、熱伝導の低下を抑えることができる。
通常、熱可塑性樹脂材は、帯電により異物が吸着しやすく、また、成形時の離形材の残りが存在する場合があり、その場合、溶着しにくいという問題がある。そのため、本構成は、異種熱可塑性樹脂のみならず同種の熱可塑性樹脂同士の溶着にも有効な方法である。特に、同種樹脂でも表面エネルギーが小さく、中間材4が濡れにくい構成では特に有効である。また、熱可塑性樹脂のみならず、熱硬化樹脂も有効な範囲に含まれる。
図6は、本発明の樹脂と金属のレーザ接合方法の実施例を示す断面図である。接合前の第一の熱可塑性樹脂1の接合界面側に、表面改質処理を施し、第一の熱可塑性樹脂1と金属8の間に液状の中間材4を介した状態で、金属8側を加圧する。実施例1とは異なり、金属8側からレーザ光11を入射させてレーザ接合する。このような構成とすることで、レーザ溶着の課題の一つである熱可塑性樹脂材の透過率の問題は解決する。但し、この場合、金属8の厚みは4mm以下と薄い方が良い。さらに、レーザ光11を照射する金属8面は事前に黒色処理を行っておくと、レーザの吸収率が上がって必要なレーザパワーを下げられ、望ましい形態である。一方で、第一の熱可塑性樹脂1のレーザ光に対する透過率が50%以上と高い場合は、実施例1と同様に第一の熱可塑性樹脂1側からレーザ光11を照射しても良い。その場合は、金属8の厚みは問題とならない。
なお、金属8の表面に異物などが付着している場合は、事前にアルコールなどで脱脂することが望ましい。さらに、金属8側にも表面改質処理を実施することも有効である。ただし、異物が強固に付着している場合や付着物が無機物である場合は、RIE(Reactive Ion Etching)方式のプラズマ処理やレーザ処理が最も好適な方法となる。
樹脂と金属のレーザ接合では、熱可塑性樹脂1のガラス転移温度もしくは融点と金属8の融点に大きな差があるため、熱可塑性樹脂1側が溶融もしくは軟化し、金属8に濡れて接合する。そのため、図7のように、金属8側の界面に微細な凹凸12を設けることも強度向上において有効である。凹凸の形成により、部材間の距離は大きくなるが、中間材4を用いることで、熱伝導の低下を抑えることができる。微細な凹凸12は、ブラストもしくはレーザ処理などを実施しておくことがより好適である。金属の粗さとしては、Ra5μm以下としておくと良い。
このように、金属8の界面に微細な凹凸12を形成することで、実表面積が大きくなるため、濡れる表面はより濡れる効果が促進される。また、濡れが強調され、界面強度が向上するだけでなく、アンカー効果も発現するため、接合強度はより向上する。したがって、界面強度向上とアンカー効果の複合化により、すべての方向の接合強度が向上するため、望ましい構成である。
以上のような方法とすることで、樹脂同士の場合と同様に隙間が存在した場合でも、信頼性の高い樹脂1と金属8の接合を得ることが可能となる。
図8は、本発明の樹脂同士もしくは樹脂と金属のレーザ接合方法の他の実施例を示す断面図である。図8では、加圧材10により、第一の熱可塑性樹脂1を接合を行う方向(図面の下の方向)へ加圧している。第一の熱可塑性樹脂1のレーザ光11に対する透過率が20%程度と比較的低い場合、レーザ光11を照射すると、組み合わせによっては、必要なパワーが大きくなり、レーザ照射側の熱可塑性樹脂1の最表面が炭化してしまい、レーザ接合できないもしくは加圧材に密着してしまうなど問題となる場合がある。また、熱伝導率の高い加圧材10であるガラスで加圧した場合でも、ガラスと熱可塑性樹脂1の表面が界面レベルで接触することは不可能である。そのため、熱可塑性樹脂1のレーザ照射側の表面にも表面改質処理を施し、加圧材10であるガラスとの間に中間材14を含有させ、隙間を完全に埋めた状態とした上で、接合することが有効となる。このようにすることにより、熱可塑性樹脂1と中間材14との界面の反射の低減やガラスへの放熱性向上により、熱可塑性樹脂1の炭化を抑制することが可能となる。
図9は、本発明のレーザ接合方法を用いて、DNAシーケンサ用フローセル15の流路部16の周りを封止した時の一例を示す斜視図である。また、図10は、DNAシーケンサ用フローセル15の上面図である。試薬は、孔17から出入りし、封止溶着部18の内側の流路16を流れる。
第二の熱可塑性樹脂2には、表面処理を実施した領域21と表面改質処理を実施しない領域20を設けて、その部分を追加で封止する構造とすると良い。19は追加封止部である。そのような構造とすることにより、流路部16の封止部18、19が外部から湿度の影響を受けにくい構成とすることが可能となる。なお、その場合も図4で示したように、流路内の試薬が接触する領域は、第二の熱可塑性樹脂2には表面処理を実施せず、溶着すると良い。
中間材4は、特に、バイオ系や医療系部品の場合、接着剤は用いたくない場合が多く、その場合は純水やアルコールなど可燃性の低い溶剤など揮発する材質を用いると良い。一方で、電子部品が実装されたセンサやコネクタなどの場合には、中間材4として接着剤を用いることが有効となる。接着剤を用いる場合、溶着後に硬化過程は必要となるが、レーザによる直接接合に加え、接着による強度向上効果も寄与することから非常に大きい強度を得ることが可能となる。また、直接接合の部分が存在するため、接着剤単体で封止した場合に比べ、高い気密性と溶剤耐性を得ることも可能となる。
以上で述べた製品例のみならず、構造上レーザ接合を適用できれば、本方法はそれら製品全般に有効である。
近年の製品の構造の複雑化により、熱可塑性樹脂の金属のそれぞれのメリットを生かした設計がなされ、それらの2次加工技術が重要となってきている。レーザによる接合は、最近注目されている技術ではあるが、構造によっては隙間管理が非常に難しいという課題がある。以上述べた各実施例を用いれば、熱可塑性から成る樹脂同士もしくは樹脂と金属とを、レーザにより接合でき、かつ隙間の影響による信頼性の低減を大幅に抑制することが可能となる。そのため、製品の高信頼化や低コスト化にも寄与することが可能となる。また、レーザによる接合は、他の2次加工技術に比べ、クリーンな技術であるため、環境負荷が小さいというメリットもある。
1…第一の熱可塑性樹脂、2…第二の熱可塑性樹脂、3…第一の熱可塑性樹脂の接合界面の酸化層、4…接合面に介在した中間材、5…溶着部(溶融プール)、6…第二の熱可塑性樹脂の接合界面の酸化層、7…第一の熱可塑性樹脂に形成した微細凹凸、8…金属、9…レーザ接合部、10…加圧材、11…レーザ光、12…金属に形成した微細凹凸、13…第一の熱可塑性樹脂の接合面と反対側の酸化層、14…加圧材と第一の熱可塑性樹脂に介在した中間材、15…DNAシーケンサ用フローセル、16…流路、17…孔、18…封止溶着部、19…追加封止溶着部、20…第二の熱可塑性樹脂の酸化層を形成しない領域、21…第二の熱可塑性樹脂の酸化層を形成する領域。
Claims (17)
- 第一の被接合部材である第一の熱可塑性樹脂の接合界面側に、酸素官能基を導入して酸化層を形成する表面改質工程と、
前記第一の被接合部材と第二の被接合部材の間に中間材を介在させた状態で、加圧し、レーザ照射して前記第一の被接合部材と第二の被接合部材を接合界面で接合する接合工程と、
を含み、
前記中間材は、液状(コロイド溶液状を含む)であることを特徴とするレーザ接合方法。 - 請求項1に記載のレーザ接合方法において、
前記中間材は、粘度1000mPa・s以下であることを特徴とするレーザ接合方法。 - 請求項1または2に記載のレーザ接合方法において、
前記第二の被接合部材は、第二の熱可塑性樹脂であることを特徴とするレーザ接合方法。 - 請求項3に記載のレーザ接合方法において、
前記第一の熱可塑性樹脂のガラス転移温度または融点に比べ、前記第二の熱可塑性樹脂のガラス転移温度または融点が大きい状態で、レーザ接合することを特徴とするレーザ接合方法。 - 請求項3または請求項4に記載のレーザ接合方法において、
前記第二の熱可塑性樹脂の表面エネルギーに比べ、前記第一の熱可塑性樹脂の表面エネルギーを大きくした状態で、レーザ接合することを特徴とするレーザ接合方法。 - 請求項3乃至5のいずれかに記載のレーザ接合方法において、
前記第二の熱可塑性樹脂の表面粗さに比べ、前記第一の熱可塑性樹脂の表面粗さを大きくしたことを特徴とするレーザ接合方法。 - 請求項1または2に記載のレーザ接合方法において、
前記第二の接合部材は、金属であることを特徴とするレーザ接合方法。 - 請求項7に記載のレーザ接合方法において、
前記第一の熱可塑性樹脂の表面エネルギーに比べ、前記金属の表面エネルギーを大きくした状態で、レーザ接合することを特徴とするレーザ接合方法。 - 請求項7または8に記載のレーザ接合方法において、
前記第一の熱可塑性樹脂の表面粗さに比べ、前記金属の表面粗さを大きくした状態で、レーザ接合することを特徴とする樹脂と金属のレーザ接合方法。 - 請求項7乃至9のいずれかにおいて、
前記金属の前記接合界面とは反対側からレーザ照射することを特徴とするレーザ接合方法。 - 請求項1乃至9のいずれかに記載のレーザ接合方法において、
前記第一の熱可塑性樹脂を介して前記接合界面にレーザ照射することを特徴とするレーザ接合方法。 - 請求項1乃至11のいずれかに記載のレーザ接合方法において、
前記第二の被接合部材の接合面の少なくとも一部にも表面改質処理を実施し、表面改質処理された部分にレーザ照射し、接合することを特徴とするレーザ接合方法。 - 請求項11に記載のレーザ接合方法において、
前記第一の熱可塑性樹脂の接合界面と反対側の側に表面改質処理を施し、
当該表面改質を行った領域から前記第一の熱可塑性樹脂に前記レーザを導入して、前記接合界面にレーザ照射し、接合することを特徴とするのレーザ接合方法。 - 請求項1乃至13に記載のレーザ接合方法において、
前記表面改質は、UVオゾン、プラズマ、コロナ処理、短パルスレーザ処理のいずれかのドライ処理であることを特徴とするレーザ接合方法。 - 請求項1乃至14に記載のレーザ接合方法において、
前記第一の熱可塑性樹脂の主鎖には、極性基を含まない熱可塑性樹脂であることを特徴とするレーザ接合方法。 - 請求項1乃至15に記載のレーザ接合方法において、
前記第一の熱可塑性樹脂は、フィルムであることを特徴とするレーザ接合方法。 - 請求項1乃至16に記載のレーザ接合方法において、
レーザ光を照射し走査することにより、前記第一の被接合部材と前記第二の被接合部材を接合する封止部を複数形成することを特徴とするレーザ接合方法。
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