WO2013122196A1 - 通電加熱接合装置及び方法 - Google Patents

通電加熱接合装置及び方法 Download PDF

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Publication number
WO2013122196A1
WO2013122196A1 PCT/JP2013/053679 JP2013053679W WO2013122196A1 WO 2013122196 A1 WO2013122196 A1 WO 2013122196A1 JP 2013053679 W JP2013053679 W JP 2013053679W WO 2013122196 A1 WO2013122196 A1 WO 2013122196A1
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WO
WIPO (PCT)
Prior art keywords
joined
temperature
pressure
joining
bonded
Prior art date
Application number
PCT/JP2013/053679
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English (en)
French (fr)
Inventor
芳伸 水野
修 栗山
Original Assignee
Ｅｃｏ－Ａ株式会社
大川三基株式会社
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 Ｅｃｏ－Ａ株式会社, 大川三基株式会社 filed Critical Ｅｃｏ－Ａ株式会社
Priority to US14/376,661 priority Critical patent/US9889638B2/en
Priority to DE112013001015.1T priority patent/DE112013001015T5/de
Publication of WO2013122196A1 publication Critical patent/WO2013122196A1/ja

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    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/22—Heated wire resistive ribbon, resistive band or resistive strip
    • B29C65/221—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip
    • B29C65/224—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip being a resistive ribbon, a resistive band or a resistive strip
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/52—Joining tubular articles, bars or profiled elements
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    • B29C66/52—Joining tubular articles, bars or profiled elements
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • H—ELECTRICITY
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    • B29C66/818—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8181—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
    • B29C66/81811—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects of the welding jaws
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 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
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • 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
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure

Definitions

  • the present invention relates to an energization heating joining apparatus and method for joining a member to be joined made of metal and a member to be joined made of resin.
  • a heat welding method in which a metal member is heated to a temperature higher than the melting temperature of the resin, the resin member is brought into contact with the surface of the metal member, and the contact portion of the resin member is melted and joined.
  • Patent Document 1 has a metal compound film and a molecular adhesive in this order from the metal member side at the joint between the metal member and the resin member, and the resin member is in a portion where the resin member is in contact with the molecular adhesive. It is described that bonding is performed so as to have a local re-hardened portion formed by being locally melted and then cured.
  • Patent Document 1 has a problem that the materials of the metal member and the resin member are very limited.
  • an object of the present invention is to provide an energization heating joining apparatus and method capable of joining a resin member to a metal member without deformation of the material of the metal member and the resin member.
  • the energization heating joining apparatus of the present invention is an energization heating joining apparatus for joining a first joined member made of metal and a second joined member made of resin, and sandwiches the first joined member.
  • a temperature sensor that detects the temperature of the first member to be bonded, and the pressure unit is controlled so as to apply pressure to the bonding surface after the temperature detected by the temperature sensor reaches a preset temperature.
  • a control unit is an energization heating joining apparatus for joining a first joined member made of metal and a second joined member made of resin, and sandwiches the first joined member.
  • the energization heating joining apparatus of the present invention since the pressure is not applied to the joining surface until the temperature of the first joined member reaches a preset temperature, there are few portions where the temperature of the second joined member increases. . Therefore, deformation such as bending and compression hardly occurs in the second bonded member.
  • the energization heating bonding apparatus of the present invention further includes a power source for supplying current to the electrodes, and when the temperature detected by the temperature sensor is equal to or lower than the preset temperature, the power source is activated and the temperature sensor detects It is preferable to stop the power supply when the measured temperature exceeds the preset temperature.
  • the power supply for supplying current to the electrodes is activated and stopped, so that the temperature of the first member to be joined is reliably set to the preset temperature. Can be maintained.
  • a pressure sensor that detects a pressure applied to the bonding surface is provided, and when the pressure sensor exceeds a preset pressure, the control unit applies pressure to the bonding surface. It is preferable to control the pressurizing unit so as not to impart the pressure.
  • the control unit when a preset time has elapsed after applying pressure to the bonding surface, the control unit pressurizes the pressure so as not to apply pressure to the bonding surface. It is preferable to control the part.
  • the preset temperature is not less than the softening temperature of the second member to be joined and lower than the melting temperature of the second member to be joined.
  • the preset temperature may be a softening temperature of the second member to be joined or a temperature that is about ten to several tens of degrees higher than the softening temperature, and is more preferably a temperature that is significantly lower than the melting temperature.
  • the electric heating and joining apparatus of the present invention it is preferable to join the first member to be joined and the second member to be joined in an air atmosphere.
  • the joining portion between the first member to be joined and the second member is not necessary to make the joining portion between the first member to be joined and the second member to be a vacuum atmosphere or an inert gas atmosphere, so that the apparatus can be simplified.
  • an oxide film does not generate
  • the pressurizing unit has an elastic body, and pressure is applied to the bonding surface by an elastic force of the elastic body.
  • the energization heating bonding method of the present invention is an energization heating bonding method for bonding a first bonded member made of metal and a second bonded member made of resin, and is electrically connected to the first bonded member.
  • the first member to be bonded is energized by sandwiching the first member to be connected between a plurality of electrodes that can be electrically connected to each other, and after the temperature of the first member to be set reaches a preset temperature, Pressure is applied to the joint surface with the second member to be joined.
  • the energization heating joining method of the present invention since the pressure is not applied to the joining surface until the temperature of the first joined member reaches a preset temperature, there are few portions where the temperature of the second joined member increases. . Therefore, deformation such as bending and compression hardly occurs in the second bonded member.
  • FIG. 1 is a schematic cross-sectional view of an electric heating and joining apparatus according to a first embodiment of the present invention.
  • FIG. 3 is an enlarged cross-sectional perspective view of upper and lower electrodes, a pressing block, and a member to be joined.
  • the block diagram of an electric heating joining apparatus The flowchart which shows the electric heating joining method which concerns on 1st Embodiment of this invention.
  • the schematic sectional drawing of the electric heating joining apparatus which concerns on 2nd Embodiment of this invention.
  • the block diagram of an electric heating joining apparatus The schematic sectional drawing which shows the press state of an electric heating joining apparatus.
  • the energization heating joining device 1 is a device for joining a member to be joined M1 made of metal and a member to be joined M2 made of resin.
  • the electric heating bonding apparatus 1 includes an electrode unit 10, a pressure unit 20, a temperature sensor 30, and a control unit 40. These are mounted on a gantry (not shown).
  • the material to be joined M1 is not particularly limited as long as it can be energized.
  • Examples of the material of the member to be joined M1 include steel materials such as stainless steel, simple nonferrous metals such as copper, aluminum, and zinc, and metal materials such as various alloys including aluminum, nickel, chromium, titanium, and copper.
  • the material of the joined member M2 is not particularly limited as long as it is a resin.
  • Examples of the material of the bonded member M2 include various synthetic resins and natural resins including polyphenylene sulfide (PPS) polyamide (PA).
  • the joined member M1 has a cylindrical shape having a step.
  • the to-be-joined member M2 is a cylindrical shape which has a level
  • the electrode unit 10 includes a pair of upper and lower electrodes 11 and 12 and a push-up mechanism 13 that pushes up the lower electrode 12.
  • the push-up mechanism 13 includes a spring 13a and a block body 13b for restricting the spring 13a to a preset length shorter than the free length between the lower electrode 12 and the spring 13a.
  • the pressure acting on the bonded member M1 from the lower electrode 12 pushed up by the push-up mechanism 13 varies depending on the material and shape of the bonded member M2, but is, for example, 5N to 100N. This pressure can be changed by replacing the spring 13a.
  • the upper electrode 11 includes an upper energizing electrode 11a made of copper, molybdenum, tungsten or the like, and a resistor 11b fixed to the lower portion of the upper energizing electrode 11a.
  • the lower electrode 12 includes a lower energizing electrode 12a made of copper, molybdenum, tungsten, or the like, and a resistor 12b fixed to the upper portion of the lower energizing electrode 12a.
  • the lower part of the lower energizing electrode 12a is fixed to the base 15 via an insulator 14 made of bakelite or the like.
  • a gap of, for example, 1 mm or more is provided between the upper and lower energization electrodes 11a, 12a and the member to be joined M1 so that no discharge occurs.
  • the resistors 11b and 12b are made of a material that generates heat when energized, for example, carbon, a carbon composite material, silicon carbide, stainless steel, or the like.
  • the resistor 11b contacts the upper surface of the member to be bonded M1, but is not in contact with the member to be bonded M2, and is formed in a disk shape here.
  • the resistor 12b is configured to contact the lower surface of the member to be bonded M1 but not to the member to be bonded M2, and is formed in a disc shape here.
  • the upper and lower electrodes 11 and 12 are arranged so that their axes are on the same line, and the member to be joined M1 is sandwiched therebetween.
  • the upper and lower energization electrodes 11a and 12a are connected to the power source 16 via cables (not shown), respectively, and are configured to be energized.
  • the power source 16 is an inverter control pulse power source.
  • This power supply 16 includes a rectifier circuit, an inverter having a diode and a thyristor, and is configured such that a pulse characteristic adjusting element such as a pulse waveform, a pulse width, a pulse interval, a current and a voltage to be generated can be changed by a control unit 40 Has been.
  • the pressurizing unit 20 transmits a pressurizing block 21 to which the upper energizing electrode 11a is fixed, a drive source 22 for driving the pressurizing block 21, and a driving force of the drive source 22 to move the pressurizing block 21 up and down. And a ball screw mechanism 23 to be moved.
  • the pressure block 21 is made of copper, molybdenum, tungsten, or the like, and includes a fixing mechanism (not shown) for fixing the upper energizing electrode 11a.
  • the pressure block 21 is formed in a square plate shape for versatility, but may be formed in a disk shape in accordance with the upper surface of the upper energizing electrode 11a.
  • the upper energizing electrode 11a and the pressurizing block 21 are configured to be cooled by circulating a cooling fluid such as pure water or tap water by a cooling mechanism (not shown).
  • the lower energizing electrode 12a is also configured to be cooled by circulating a cooling fluid such as pure water or tap water by a cooling mechanism (not shown).
  • the drive source 22 is a servo motor with a speed reducer here.
  • the servo motor 22 is provided with an encoder 22a and is disposed on a gantry (not shown).
  • the ball screw mechanism 23 includes a screw shaft 23a extending in the vertical direction and having a screw groove formed on the outer peripheral surface, a nut 23b having a screw groove formed on the inner peripheral surface, and a plurality of balls accommodated between the screw grooves. 23c.
  • the nut 23 b is fixed to the upper part of the pressure block 21 via an insulator 24 made of bakelite or the like and a pressure sensor 25.
  • the screw shaft 23a is connected to the rotation shaft of the servo motor 22 via a speed reducer. When the servo motor 22 is driven to rotate, the screw shaft 23a rotates, and the nut 23b, and thus the pressure block 21, moves up and down relatively with respect to the screw shaft 23a.
  • the pressure sensor 25 is, for example, a uniaxial load cell that measures the pressure in the vertical direction, but a multiaxial pressure sensor may be used.
  • the pressure sensor 25 can indirectly detect the pressure applied to the joining surfaces of the members to be joined M1 and M2.
  • Rotational driving force of the servo motor 22 is converted into vertical driving force by the ball screw mechanism 23, and the pressure block 21 moves up and down.
  • the pressurizing unit 20 regulates the displacement of the member to be joined M2 and applies pressure to the joining surface, and functions as a pressurizing unit of the present invention.
  • the temperature sensor 30 detects the temperature of the member to be bonded M1, preferably the temperature near the bonding surface of the member to be bonded M1.
  • the temperature sensor 30 is a non-contact type sensor such as an infrared radiation thermometer.
  • the temperature sensor 30 may be replaced with a contact sensor such as a thermocouple that measures the temperature by contacting the surface of the member to be joined M1, or a non-contact type and a contact type may be used in combination. .
  • the control unit 40 includes a CPU, a ROM, a RAM, an I / O, and the like, and an operation unit 41 and a display unit 42 are electrically connected.
  • the operation unit 41 includes various operation switches such as a start switch and a start switch, an input panel including a touch panel, and the like. Information input from the operation unit 41 is transmitted to the control unit 40.
  • detection signals are input to the control unit 40 from the encoder 22a, the pressure sensor 25, and the temperature sensor 30. Based on these detection signals, information input from the operation unit 41, and control information such as the set pressure Ps, the lower limit set pressure Ps1, the set temperature Ts, and the set holding time Hs stored in the storage unit, the control unit 40 16 and the servo motor 22 are output control signals.
  • the control unit 40 corresponds to the control unit of the present invention.
  • the set temperature Ts is a softening temperature of the member to be joined M2 or a temperature higher by a predetermined temperature of about 1 ° C. to several tens of degrees Celsius than the softening temperature of the member to be joined M2, and is appropriately set in advance through a trial experiment or the like.
  • the set temperature Ts is lower than the melting temperature of the member to be bonded M2, more preferably a temperature significantly lower than the melting temperature of the member to be bonded M2.
  • the temperature sensor 30 directly outputs an off signal for turning off the power supply 16 to the power supply 16 when the detected temperature exceeds the set temperature Ts.
  • the temperature sensor 30 directly outputs an ON signal for turning on the power supply 16 to the power supply 16 when the detected temperature becomes equal to or lower than the set temperature Ts.
  • the display unit 42 is electrically connected to the control unit 40.
  • the display unit 42 includes a digital display panel, a lamp, and the like.
  • the display unit 42 receives information from the control unit 40 based on an input to the control unit 40 or a calculation result in the control unit 40, and displays the information.
  • the worker installs the members to be joined M1 and M2 on the lower electrode 12 (S1). At this time, installation of the members to be joined M1 and M2 may be assisted by positioning pins or the like.
  • the servo motor 22 is driven to lower the upper electrode 11 (S3). Thereby, the member M1 to be joined is held between the upper and lower electrodes 11 and 12. At this time, the pressure acting on the member to be bonded M1 by being sandwiched between the upper and lower electrodes 11 and 12 is a pressure that allows the upper and lower electrodes 11 and 12 and the member to be bonded M1 to reliably contact each other.
  • the power source 16 is started to energize the upper and lower electrodes 11 and 12 (S4).
  • the to-be-joined member M1 is heated and temperature rises.
  • the member to be bonded M2 is not in contact with the member to be bonded M1 with a large pressure, and the temperature in the vicinity of the contact surface with the member to be bonded M1 does not increase so much and deformation does not occur.
  • the servo motor 22 is driven while maintaining the set temperature Ts, and the pressure block 21 is lowered, and the member to be bonded M1 is pressed against the member to be bonded M2 with a predetermined set pressure Ps by the pressure block 21 (S6).
  • the set temperature Ts is maintained by the temperature sensor 30 directly outputting an off signal or an on signal to the power supply 16. Further, whether or not the pressure is the set pressure Ps is determined by monitoring a detection value from the pressure sensor 25.
  • the portion in the vicinity of the step which is the contact surface of the member to be joined M2 with the member to be joined M1 is heated and the temperature rises.
  • the inner peripheral surface of the member to be bonded M2 is hardly heated. Only the part near the step is heated.
  • the lower limit set pressure Ps1 is a pressure P in a state where the portion of the member to be bonded M2 near the contact surface with the member to be bonded M1 is melted, and may be set in consideration of the material, shape, etc. of the member to be bonded M2. . By setting the lower limit set pressure Ps1, the amount of penetration of the member to be joined M2 can be adjusted.
  • the cooling is terminated.
  • the cooling may be terminated when the temperature detected by the temperature sensor 30 is lower than a preset temperature.
  • the determination may be made using only the set temperature Ts or only the lower limit set pressure Ps1.
  • the servo motor 22 is driven to raise the pressure block 21 and raise the upper electrode 11 (S11).
  • the melted portion in the vicinity of the contact surface of the member to be bonded M2 with the member to be bonded M1 is cured at a reduced temperature, and the member to be bonded M1 and the member to be bonded M2 are firmly bonded.
  • the part other than the vicinity of the contact surface of the member to be bonded M2 with the member to be bonded M1 is not melted and there are few parts that are higher than the softening start temperature. Therefore, the member to be bonded M2 has almost no deformation such as distortion, bending, and compression. Does not occur.
  • the softening start temperature of the member to be joined M2 There are few such portions, and deformation such as distortion, bending, and compression hardly occurs in the member to be joined M2. Moreover, since there are few parts exceeding the quality guarantee temperature of the to-be-joined member M2, the quality of the to-be-joined member M2 is maintained favorable.
  • the temperature T of the member to be joined M1 is maintained at the set temperature Ts with an accuracy of, for example, + -1 ° C., so that the portion near the joining surface of the member to be joined M2 is softened under the optimum conditions. Therefore, foaming does not occur. Therefore, the bonding strength is good.
  • the joining is performed at a temperature lower than the melting temperature of the member to be joined M2, no oxide film is generated on the joining surface, and the joining can be performed in a normal air atmosphere. Therefore, it is not necessary to make the bonding portion in a vacuum atmosphere or an inert gas atmosphere, and the apparatus can be simplified.
  • the corner of the member to be joined M1 is sharpened while the corner of the member to be joined M2 is rounded, the corner of the member to be joined M1 strongly presses against the corner of the member to be joined M2.
  • the parts are securely joined together. And since joining of these corner parts extends in the circumference shape, the airtightness of the joined member becomes favorable.
  • the energization heating joining apparatus 101 is an apparatus for joining a rectangular plate-like member M1 made of metal and a rectangular plate-like member M2 made of resin. Since the electric heating bonding apparatus 101 is similar to the electric heating bonding apparatus 1 described above, the same or corresponding members are denoted by the same reference numerals, and only different portions will be described.
  • the energization heating bonding apparatus 101 includes an electrode unit 110, a pressure unit 120, a temperature sensor 30, and a control unit 40. These are mounted on a gantry (not shown).
  • the electrode unit 110 includes a pair of upper and lower electrodes 111 and 112 and a vertical movement mechanism 113 that moves the upper electrode 111 up and down.
  • the vertical movement mechanism 113 is an air cylinder.
  • the upper electrode 111 includes an upper energizing electrode 111a made of copper, molybdenum, tungsten, or the like, and a resistor 111b fixed to the lower portion of the upper energizing electrode 11a.
  • the upper energizing electrode 111a is fixed to the lower end portion of the piston 113a of the air cylinder 113 via an insulator 115 made of bakelite or the like.
  • the lower electrode 112 includes a lower energizing electrode 112a made of copper, molybdenum, tungsten, or the like, and a resistor 112b fixed on the lower energizing electrode 112a.
  • the lower portion of the lower energizing electrode 112a is fixed to a gantry (not shown) via an insulator 114 made of bakelite or the like.
  • the resistor 111b of the upper electrode 111 is configured to contact the upper surface of the member to be bonded M1 but not to the member to be bonded M2.
  • the resistor 111b is in contact with about half of the upper surface of the member to be bonded M1. It is formed in a rectangular plate shape.
  • the resistor 112b of the lower electrode 112 is configured to be in contact with the lower surface of the member to be bonded M1, but not to be in contact with the member to be bonded M2.
  • the lower energizing electrode 112a of the lower electrode 112 is configured such that the bonded member M2 disposed on the bonded member M1 is stably disposed on the upper surface thereof. Specifically, guide pieces 112c for positioning both side surfaces of the joined member M2 are formed on the lower energizing electrode 112a. Further, the lower energization electrode 112a is configured not to contact the member to be bonded M2 in the vicinity of the bonding surface so that the molten member M2 to be bonded does not adhere.
  • the upper and lower electrodes 111 and 112 are arranged with their center axes eccentric. However, since the upper and lower surfaces of the bonded member M1 are in surface contact with the resistors 111b and 112b, the upper and lower electrodes 111 and 112 are stable between the upper and lower electrodes 111 and 112. Is pinched. Then, by energizing the upper and lower energization electrodes 111a and 112a with the member to be bonded M1 sandwiched between the resistors 111b and 112b, about half of the portion including the bonding surface of the member to be bonded M1 can be uniformly heated. .
  • the pressurizing unit 120 transmits the pressurizing block 121 in contact with the member to be joined M2, the drive source 22 for driving the pressurizing block 121, and the driving force of the drive source 22, and moves the pressurizing block 21 up and down. And a ball screw mechanism 23 to be moved.
  • the pressure block 121 is made of copper, molybdenum, tungsten, or the like, and includes a pressure plate 121a that is in surface contact with the upper surface of the member to be joined M2, a block body 121b that is provided integrally with the pressure plate 121a, and a pressure plate. It is comprised from the elastic body 121c arrange
  • the pressure plate 121a is configured to contact the upper surface of the member to be bonded M2, but not to contact the member to be bonded M1 and the upper electrode 11.
  • the pressure plate 121a is formed in a rectangular plate shape so as to come into contact with the upper surface located above the joining surface of the joined member M2.
  • the elastic body 121c applies an elastic force in a direction in which the pressure plate 121a and the block body 121b are separated from each other, and includes a spring, for example, a spiral spring. Although not shown, the pressure plate 121a and the block body 121b are configured not to be separated beyond the maximum gap therebetween.
  • Rotational driving force of the servo motor 22 is converted into vertical driving force by the ball screw mechanism 23, and the pressure block 121 moves up and down.
  • the pressurization unit 120 regulates the displacement of the member to be joined M2 by the elastic force of the elastic body 121c and applies pressure to the joint surface, and functions as a pressurization unit of the present invention.
  • the air cylinder 113 is driven to lower the upper electrode 111 (S3).
  • the member M1 to be joined is sandwiched between the upper and lower electrodes 111 and 112.
  • the pressure acting on the member to be bonded M1 by being sandwiched between the upper and lower electrodes 111 and 112 is such a pressure that the upper and lower electrodes 111 and 112 and the member to be bonded M1 are reliably in contact with each other.
  • the power supply 16 is started and the upper and lower electrodes 111 and 112 are energized while maintaining the state where the member to be joined M1 is sandwiched between the upper and lower electrodes 111 and 112 (S5). Thereby, the to-be-joined member M1 is heated and temperature rises. In this state, the member to be bonded M2 is simply placed on the member to be bonded M1, and the temperature in the vicinity of the contact surface with the member to be bonded M1 does not rise so much and naturally deforms. Does not occur.
  • the servo motor 22 is driven and pressurized while maintaining the set temperature Ts.
  • the block 121 is lowered and the member to be bonded M2 is pressed against the member to be bonded M1 with a predetermined set pressure Ps by the pressure plate 121a (S6).
  • the presence of the elastic body 121c prevents a large pressure exceeding the set pressure Ps from acting on the member to be joined M2 abruptly.
  • the servo motor 22 is driven to raise the pressure block 121 and the air cylinder 113 is driven to raise the upper electrode 111 (S11).
  • the melted portion in the vicinity of the contact surface of the member to be bonded M2 with the member to be bonded M1 is cured at a reduced temperature, and the member to be bonded M1 and the member to be bonded M2 are firmly bonded. Since the part other than the vicinity of the contact surface of the member to be bonded M2 with the member to be bonded M1 is not softened and there are few parts that are higher than the softening start temperature, the member to be bonded M2 has almost no deformation such as distortion, bending, and compression. Does not occur.
  • the to-be-joined member M1 is not pressed against the to-be-joined member M2 until the temperature T of the to-be-joined member M1 becomes set temperature Ts (S5: YES), softening of the to-be-joined member M2 is carried out. There are few portions that are equal to or higher than the start temperature, and deformation such as distortion, bending, and compression hardly occurs in the bonded member M2. Moreover, since there are few parts exceeding the quality guarantee temperature of the to-be-joined member M2, the quality of the to-be-joined member M2 is maintained favorable.
  • this invention is not limited to this.
  • the present invention is not limited to this, and the lower electrodes 12, 112 may be operated, and the upper and lower electrodes 11, 12, 111, 112 may be operated together.
  • the mechanism for reciprocating the pressure blocks 21 and 121 is not limited to this, and a known mechanism may be used.
  • a linear movement guide mechanism may be used.
  • the pressure plate 121a and the block body 121b may be integrated without providing the elastic body 121c, and the force generated by driving the servo motor 22 may be applied as pressure to the joint surface as it is.
  • the present invention is not limited to this, and the portion including the bonding surfaces of the members to be bonded M1 and M2 may be bonded as a vacuum atmosphere or an inert gas atmosphere such as nitrogen or argon.
  • the energization heating joining device 1,101 may include a vacuum unit that performs at least a portion including the joining surfaces of the members to be joined M1, M2.
  • a vacuum unit that performs at least a portion including the joining surfaces of the members to be joined M1, M2.
  • the vacuum unit may be composed of, for example, a chamber surrounding the entire energization heating bonding apparatus 1, 101, a vacuum apparatus that evacuates the chamber, and a vacuum breaker that breaks the vacuum state in the chamber.
  • the vacuuming device is, for example, a vacuum pump that exhausts the gas in the chamber through a supply / exhaust pipe (not shown).
  • the vacuum breaker is, for example, a gas supply pump that supplies gas into the chamber via a supply / exhaust pipe.
  • the vacuum breaker may be a valve or the like provided in the supply / exhaust pipe in order to introduce outside air into the chamber.
  • a vacuum sensor such as a Pirani type that detects the degree of vacuum (pressure) in the chamber, and to provide a door for taking in and out the joined members M1 and M2 on the front side of the chamber.
  • the temperature sensor 30 may be installed outside the viewing window of the chamber.
  • the shapes of the members to be joined M1 and M2 may be any shape such as a pipe shape, a bulk shape, a thick plate shape, and a thin plate shape, and are subjected to any processing such as grooving or drilling. May be.
  • the upper and lower electrodes 11, 12, 111, 112 and the pressurizing units 20, 120 may be appropriately configured according to the shape of the members to be joined M 1, M 2 and the shape and position of the joined portion.
  • two or more members to be joined M2 may be joined to the member to be joined M1 at the same time.
  • the member to be joined M1 and the member to be joined M2 were joined using the above-described current heating joining device 101.
  • the material of the member to be joined M1 is aluminum (A1050), tough pitch copper (C1100), stainless steel (SUS304), or ordinary steel plate (SPCC), and the material of the member to be joined M2 is polyphenylene sulfide (PPS) or polyamide ( PA) 66.
  • a strip with a length of 49 mm, a width of 12 mm and a thickness of 1.5 mm is prepared as the member to be joined M1
  • a strip with a length of 49 mm, a width of 12 mm and a thickness of 3 mm is prepared as the member to be joined M2 and these strips are joined.
  • the surfaces were arranged and joined so as to have a length of 12 mm and a width of 12 mm.
  • the set temperature Ts, the set holding time Hs, the applied current I to the upper and lower electrodes 111 and 112, and the set pressure Ps were set as shown in Table 1.
  • the base material of the joined member M2 was broken in all examples. From this, it was found that the bonding strength was strong.
  • Control unit control unit 113 ... Air cylinder (vertical movement mechanism), 121a ... Pressure plate, 121b ... Block body, 121c ... Elastic body M1 ... members to be welded (first member to be joined), M2 ... workpieces (second member to be joined).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

通電加熱接合装置１は、金属からなる被接合部材Ｍ１と樹脂からなる被接合部材Ｍ２とを接合する。通電加熱接合装置１は、被接合部材Ｍ１を挟持して、被接合部材Ｍ１と電気的に導通可能な上下電極１１，１２と、被接合部材Ｍ１と被接合部材Ｍ２との接合面に圧力を付与する加圧ユニット２０と、被接合部材Ｍ１の温度を検知する温度センサ３０と、温度センサ３０が検知した温度が予め設定した設定温度Ｔｓになった後、接合面に圧力を付与させるように加圧ユニット２０を制御する制御ユニット４０とを備える。

Description

通電加熱接合装置及び方法
　本発明は、金属からなる被接合部材と樹脂からなる被接合部材とを接合する通電加熱接合装置及び方法に関する。
　自動車部品や電気機器などの多く分野において、高強度、高剛性を保ちながら、軽量化することが要求されている。そこで、金属からなる部材の一部を樹脂とするために、金属部材と樹脂部材を接合することが行われている。
　例えば、金属部材を樹脂の溶融温度以上に加熱し、金属部材の表面に樹脂部材を接触させて樹脂部材の接触部分を溶解して接合する熱溶着法が知られている。
　さらに、特許文献１には、金属部材と樹脂部材との接合部に、金属部材側から順に金属化合物皮膜と分子接着剤とを有し、樹脂部材が分子接着剤と接する部分に、樹脂部材が局部的に溶融した後硬化して形成される局部再硬化部を有するように接合することが記載されている。
特開２０１１－２３５５７０号公報
　しかし、熱溶着法では、金属部材全体を樹脂の溶融温度以上に加熱するので、金属表面からの輻射熱で、樹脂部材の溶着部分以外の部分が変形する場合があるという問題がある。さらに、温度上昇に伴い金属部材の表面が酸化等に起因し変色する場合があるという問題がある。
　一方、特許文献１に記載の接合方法は、金属部材と樹脂部材の材質が非常に限定されるという問題がある。
　本発明は、以上の点に鑑み、金属部材と樹脂部材の材質が限定されず、変形することなく樹脂部材を金属部材に接合することが可能な通電加熱接合装置及び方法を提供することを目的とする。
　本発明の通電加熱接合装置は、金属からなる第１の被接合部材と樹脂からなる第２の被接合部材とを接合する通電加熱接合装置であって、前記第１の被接合部材を挟持して、前記第１の被接合部材と電気的に導通可能な複数の電極と、前記第１の被接合部材と前記第２の被接合部材との接合面に圧力を付与する加圧部と、前記第１の被接合部材の温度を検知する温度センサと、前記温度センサが検知した温度が予め設定した温度になった後、前記接合面に圧力を付与させるように前記加圧部を制御する制御部とを備えることを特徴とする。
　本発明の通電加熱接合装置によれば、第１の被接合部材の温度が予め設定した温度になるまで、接合面に圧力を付与しないので、第２の被接合部材の温度上昇する部分は少ない。よって、第２の被接合部材には屈曲、圧縮などの変形がほとんど生じない。
　また、本発明の通電加熱接合装置において、前記電極に電流を供給する電源を備え、前記温度センサが検知した温度が前記予め設定した温度以下のとき、前記電源を作動し、前記温度センサが検知した温度が前記予め設定した温度を超えたとき、前記電源を停止させることが好ましい。
　この場合、温度センサが検知した温度と予め設定した温度とを参照して、電極に電流を供給する電源の作動、停止を行うので、第１の被接合部材の温度を予め設定した温度に確実に維持することができる。
　また、本発明の通電加熱接合装置において、前記接合面に付与される圧力を検知する圧力センサを備え、前記圧力センサが予め設定した圧力を超えたとき、前記制御部は、前記接合面に圧力を付与しないように前記加圧部を制御することが好ましい。
　この場合、第２の被接合部材の接合面付近の部分の溶融量を制限することが可能となり、第２の被接合部材の過大な溶け込みを確実に防止することができる。
　また、本発明の通電加熱接合装置において、前記接合面に圧力を付与させた後、予め設定された時間を経過したとき、前記制御部は、前記接合面に圧力を付与しないように前記加圧部を制御することが好ましい。
　この場合、第２の被接合部材の接合面付近の部分の溶融量を制限することが可能となり、第２の被接合部材の過大な溶け込みを確実に防止することができる。
　また、本発明の通電加熱接合装置において、前記予め設定した温度は、前記第２の被接合部材の軟化温度以上、且つ前記第２の被接合部材の溶融温度未満であることが好ましい。
　この場合、予め設定した温度に達した第１の被接合部材から接合面を介して第２の被接合部材に伝熱されて、第２の被接合部材が軟化温度以上となって軟化して接合面に付与された圧力によって接合が可能となる。そして、第２の被接合部材は、溶融温度を超えて温度上昇しないので、過大な変形や溶け込みなどが生じない。尚、予め設定した温度は、第２の被接合部材の軟化温度又は軟化温度より十度から数十度程度高い温度であればよく、溶融温度より大幅に低い温度であることがより好ましい。
　また、本発明の通電加熱接合装置において、大気雰囲気で前記第１の被接合部材と前記第２の被接合部材とを接合することが好ましい。
　この場合、第１の被接合部材と第２の被接合部材との接合部分を真空雰囲気や不活性ガス雰囲気にする必要がないので、装置を簡素化すること可能となる。尚、第２の被接合部材の溶融温度未満の温度で接合するので、接合面に酸化被膜は発生しない。
　また、本発明の通電加熱接合装置において、前記加圧部は弾性体を有し、前記弾性体の弾性力によって前記接合面に圧力を付与することが好ましい。
　この場合、接合面に急激に大きな圧力が付与されることが防止され、第２の被接合部材の過大な溶け込みを確実に防止することができる。
　本発明の通電加熱接合方法は、金属からなる第１の被接合部材と樹脂からなる第２の被接合部材とを接合する通電加熱接合方法であって、前記第１の被接合部材と電気的に導通可能な複数の電極間に前記第１の被接合部材を挟持して通電し、前記第１の被接合部材の温度が予め設定した温度になった後、前記第１の被接合部材と前記第２の被接合部材との接合面に圧力を付与することを特徴とする。
　本発明の通電加熱接合方法によれば、第１の被接合部材の温度が予め設定した温度になるまで、接合面に圧力を付与しないので、第２の被接合部材の温度上昇する部分は少ない。よって、第２の被接合部材には屈曲、圧縮などの変形がほとんど生じない。
本発明の第１実施形態に係る通電加熱接合装置の概略断面図。 上下電極、押圧ブロック、及び被接合部材を拡大断面斜視図。 通電加熱接合装置のブロック図。 本発明の第１実施形態に係る通電加熱接合方法を示すフローチャート。 本発明の第２実施形態に係る通電加熱接合装置の概略断面図。 通電加熱接合装置のブロック図。 通電加熱接合装置の押圧状態を示す概略断面図。
　（第１実施形態）
　以下、本発明の第１実施形態である通電加熱接合装置１について説明する。
　図１から図３を参照して、通電加熱接合装置１は、金属からなる被接合部材Ｍ１と樹脂からなる被接合部材Ｍ２とを接合する装置である。通電加熱接合装置１は、電極ユニット１０、加圧ユニット２０、温度センサ３０及び制御ユニット４０を備えている。これらは図示しない架台に搭載されている。
　被接合部材Ｍ１は、通電可能な金属であれば、その材質は特に限定されない。被接合部材Ｍ１の材質として、例えば、ステンレス鋼などの鉄鋼材料、 銅、アルミニウム、亜鉛などの単体非鉄金属、アルミニウム、 ニッケル、クロム、チタン、銅等を含む各種合金などの金属材料が挙げられる。
　被接合部材Ｍ２は、樹脂であれば、その材質は特に限定されない。被接合部材Ｍ２の材質として、例えば、ポリフェニレンサルファイド（ＰＰＳ）ポリアミド（ＰＡ）を含む各種合成樹脂や天然樹脂が挙げられる。
　被接合部材Ｍ１は、ここでは、段差を有する円柱形状である。そして、被接合部材Ｍ２は、ここでは、内部に段差を有する円筒形状である。被接合部材Ｍ１を被接合部材Ｍ２に入れ込むことにより、被接合部材Ｍ１，Ｍ２の段差同士が当接すると共に、被接合部材Ｍ１の外周面と被接合部材Ｍ２の内周面とが接触する。そして、被接合部材Ｍ１の上下両端部は、被接合部材Ｍ２から突出する。尚、被接合部材Ｍ１，Ｍ２の接合面は、粗面であることが好ましいが、鏡面であってもよい。
　電極ユニット１０は、上下一対の電極１１，１２と、下電極１２を押し上げる押上機構１３とから構成されている。押上機構１３は、ここでは、ばね１３ａと、ばね１３ａを下電極１２との間で自由長より短い予め設定された長さに規制するためのブロック体１３ｂとか構成されている。尚、押上機構１３によって押し上げられる下電極１２から被接合部材Ｍ１に作用する圧力は、被接合部材Ｍ２の材質や形状に応じて異なるが、例えば５Ｎ乃至１００Ｎである。そして、この圧力は、ばね１３ａを交換することによって変更可能である。
　上電極１１は、ここでは、銅、モリブデン、タングステンなどからなる上通電電極１１ａと、上通電電極１１ａの下部に固定された抵抗体１１ｂとから構成されている。
　下電極１２は、ここでは、銅、モリブデン、タングステンなどからなる下通電電極１２ａと、下通電電極１２ａの上部に固定された抵抗体１２ｂとから構成されている。下通電電極１２ａの下部は、ベークライト等からなる絶縁体１４を介して基礎台１５に固定されている。
　上下通電電極１１ａ，１２ａと被接合部材Ｍ１との間に放電が生じないように、これらの間には、例えば１ｍｍ以上の隙間が設けられている。
　抵抗体１１ｂ，１２ｂは、通電により発熱する材質、例えば、カーボン、カーボン複合材、炭化ケイ素、ステンレスなどからなる。そして、抵抗体１１ｂは、被接合部材Ｍ１の上面に接触するが、被接合部材Ｍ２には接触しないように構成され、ここでは、円板状に形成されている。抵抗体１２ｂは、被接合部材Ｍ１の下面に接触するが被接合部材Ｍ２には接触しないように構成され、ここでは、円板状に形成されている。
　上下電極１１，１２は、その軸線が同一線上となるように配置されており、その間に被接合部材Ｍ１が挟持される。そして、上下通電電極１１ａ，１２ａは、それぞれ図示しないケーブルを介して電源１６に接続されており、通電可能に構成されている。被接合部材Ｍ１を抵抗体１１ｂ，１２ｂで挟んだ状態で上下通電電極１１ａ，１２ａに通電することにより、被接合部材Ｍ１全体を均一に加熱することができる。
　電源１６は、ここでは、インバータ制御パルス電源である。この電源１６は、整流回路、ダイオードやサイリスタを有するインバータを備えており、発生させるパルスのパルス波形、パルス幅、パルス間隔、電流、電圧等のパルス特性調整要素が制御ユニット４０により変更可能に構成されている。
　加圧ユニット２０は、上通電電極１１ａが固定された加圧ブロック２１と、加圧ブロック２１を駆動させるための駆動源２２と、駆動源２２の駆動力を伝達し、加圧ブロック２１を上下動させるボールねじ機構２３とから構成されている。
　加圧ブロック２１は、銅、モリブデン、タングステンなどからなり、上通電電極１１ａを固定するための図示しない固定機構を備えている。加圧ブロック２１は、ここでは、汎用性を持たせるために正方形板状に形成されているが、上通電電極１１ａの上面に合せて円板状に形成してもよい。
　尚、上通電電極１１ａ及び加圧ブロック２１は、図示しない冷却機構により純水や水道水などの冷却流体が循環されて、冷却可能に構成されている。また、下通電電極１２ａも、図示しない冷却機構により純水や水道水などの冷却流体が循環されて、冷却可能に構成されている。
　駆動源２２は、ここでは減速機付きのサーボモータである。サーボモータ２２には、エンコーダ２２ａが付設されており、図示しない架台に配置されている。
　ボールねじ機構２３は、上下方向に延び外周面にねじ溝が形成されたねじ軸２３ａと、内周面にねじ溝が形成されたナット２３ｂと、これらのねじ溝間に収容された複数のボール２３ｃとから構成されている。ナット２３ｂは、加圧ブロック２１の上部にベークライト等からなる絶縁体２４及び圧力センサ２５を介して固定されている。ねじ軸２３ａは、サーボモータ２２の回転軸に減速機を介して接続されている。サーボモータ２２が回転駆動することにより、ねじ軸２３ａが回転して、ナット２３ｂ、ひいては加圧ブロック２１がねじ軸２３ａに対して相対的に上下移動する。
　圧力センサ２５は、例えば、上下方向の圧力を測定する一軸のロードセルであるが、多軸の圧力センサを用いてもよい。圧力センサ２５により、被接合部材Ｍ１，Ｍ２の接合面に付与される圧力を間接的に検知することができる。
　サーボモータ２２の回転駆動力がボールねじ機構２３で上下方向の駆動力に変換され、加圧ブロック２１が上下動する。
　そして、サーボモータ２２の駆動を停止させると、その後、加圧ブロック２１の位置が維持される。このとき、加圧ユニット２０は、被接合部材Ｍ２の変位を規制して接合面に圧力を付与しており、本発明の加圧部として機能する。
　温度センサ３０は、被接合部材Ｍ１の温度、好ましくは被接合部材Ｍ１の接合面近傍の温度を検知する。温度センサ３０は、ここでは、赤外線放射温度計などの非接触式のものである。尚、温度センサ３０は、被接合部材Ｍ１の表面に接触させて温度を測定する熱電対等の接触式センサで代用してもよく、非接触式のものと接触式のものを併用してもよい。
　制御ユニット４０は、ＣＰＵ、ＲＯＭ、ＲＡＭ、Ｉ／Ｏ等から構成されており、操作部４１及び表示部４２が電気的に接続されている。操作部４１は、ここでは、起動スイッチ、スタートスイッチ等の各種の操作スイッチ、タッチパネル等からなる入力盤などから構成されている。操作部４１から入力された情報は、制御ユニット４０に送信される。
　また、制御ユニット４０には、エンコーダ２２ａ、圧力センサ２５及び温度センサ３０から検知信号が入力される。制御ユニット４０は、これら検知信号、操作部４１から入力された情報及びその記憶部に格納された設定圧力Ｐｓ、下限設定圧力Ｐｓ１、設定温度Ｔｓ、設定保持時間Ｈｓなどの制御情報に基き、電源１６及びサーボモータ２２に制御信号を出力する。尚、制御ユニット４０は、本発明の制御部に相当する。
　ここで、設定温度Ｔｓは、被接合部材Ｍ２の軟化温度、又は被接合部材Ｍ２の軟化温度より１℃～数十℃程度の所定温度高い温度であり、予め試行実験などで適宜設定される。ただし、設定温度Ｔｓは、被接合部材Ｍ２の溶融温度未満であり、より好ましくは被接合部材Ｍ２の溶融温度より大幅に低い温度である。
　温度センサ３０は、検知温度が設定温度Ｔｓを超えたとき、電源１６をオフさせるオフ信号を電源１６に直接出力する。また、温度センサ３０は、検知温度が設定温度Ｔｓ以下となったとき、電源１６をオンさせるオン信号を電源１６に直接出力する。このように、制御ユニット４０を介することなく温度センサ３０から電源１６に信号を直接出力するので、被接合部材Ｍ１の温度Ｔを設定温度Ｔｓに素早く復帰させることが可能となる。従って、被接合部材Ｍ１の温度Ｔが設定温度Ｔｓに常に維持される。
　また、制御ユニット４０には、表示部４２が電気的に接続されている。表示部４２は、ここでは、デジタル表示パネル、ランプなどから構成されている。表示部４２は、制御ユニット４０への入力、又は制御ユニット４０での演算結果に基く情報を制御ユニット４０から受信し、その情報を表示する。
　次に、上述した通電加熱接合装置１を用いて、本発明の第１実施形態に係る通電加熱接合方法を実施する際の処理について図４を参照して説明する。尚、以下のＳ３～Ｓ１１の処理は、制御ユニット４０により実行される。
　先ず、作業者は、下電極１２の上に被接合部材Ｍ１，Ｍ２を設置する（Ｓ１）。尚、このとき、位置決めピンなどによって被接合部材Ｍ１，Ｍ２の設置を補助してもよい。
　作業者により操作部４１のスタートスイッチがＯＮされると（Ｓ２：ＹＥＳ）、サーボモータ２２を駆動させて、上電極１１を下降させる（Ｓ３）。これにより、被接合部材Ｍ１が上下電極１１，１２によって挟持される。尚、このとき、上下電極１１，１２により挟持されることによって被接合部材Ｍ１に作用する圧力は、上下電極１１，１２及び被接合部材Ｍ１が互いに確実に接触する程度の圧力である。
　被接合部材Ｍ１を上下電極１１，１２で挟持した状態を保ちながら、電源１６を始動させて上下電極１１，１２を通電する（Ｓ４）。これにより、被接合部材Ｍ１が加熱されて温度が上昇する。この状態では、被接合部材Ｍ２は、大きな圧力で被接合部材Ｍ１と接触しているわけではなく、被接合部材Ｍ１との接触面付近の部分も然程温度が上昇せず変形も発生しない。
　その後、温度センサ３０が検知する被接合部材Ｍ１の温度Ｔが設定温度Ｔｓになったとき（Ｓ５：ＹＥＳ）、設定温度Ｔｓを維持した状態を保ちながら、サーボモータ２２を駆動させて加圧ブロック２１を下降させ、加圧ブロック２１で被接合部材Ｍ１を所定の設定圧力Ｐｓで被接合部材Ｍ２に押し付ける（Ｓ６）。
　尚、設定温度Ｔｓの維持は、温度センサ３０が、オフ信号又はオン信号を電源１６に直接出力することによって行われる。また、設定圧力Ｐｓであるか否かは、圧力センサ２５からの検知値を監視することで判断される。
　そして、予め設定された所定の設定温度Ｔｓを維持した状態を保ち、且つ被接合部材Ｍ２を加圧ブロック２１で押し付けた状態を、予め設定された所定の設定保持時間Ｈｓ継続する（Ｓ７）。尚、設定保持時間Ｈｓ継続したか否かは、制御ユニット４０の図示しないタイマを参照して判断される。
　この間、被接合部材Ｍ２の被接合部材Ｍ１との接触面である段差付近の部分は加熱されて温度が上昇する。尚、被接合部材Ｍ１の外周面と被接合部材Ｍ２の内周面との間には微少な隙間があり空気の断熱層となるので、被接合部材Ｍ２の内周面はほとんど加熱されず、段差付近の部分のみ加熱される。
　さらに、この間、圧力センサ２５が検出した圧力Ｐが予め設定された所定の下限設定圧力Ｐｓ１未満となった否かを監視する（Ｓ８）。下限設定圧力Ｐｓ１は、被接合部材Ｍ２の被接合部材Ｍ１との接触面付近の部分が溶融した状態での圧力Ｐであり、被接合部材Ｍ２の材質や形状等を考慮して設定すればよい。下限設定圧力Ｐｓ１を設定することにより、被接合部材Ｍ２の溶け込み量を調整することができる。
　設定保持時間Ｈｓ経過後、又は、圧力センサ２５が検出した圧力が下限設定圧力Ｐｓ１未満となったとき、電源１６を停止して、上下電極１１，１２の通電を終了する（Ｓ９）。そして、図示しない冷却機構により下通電電極１２ａ及び加圧ブロック２１に冷却流体が循環させて、被接合部材Ｍ１，Ｍ２を冷却する（Ｓ１０）。
　制御ユニット４０の図示しないタイマを参照して予め設定された冷却時間が経過したとき、冷却を終了する。尚、温度センサ３０が検出した温度が予め設定された温度未満になったとき、冷却を終了してもよい。ただし、設定温度Ｔｓのみ、又は下限設定圧力Ｐｓ１のみで判定してもよい。
　その後、サーボモータ２２を駆動させて加圧ブロック２１を上昇させて上電極１１を上昇させる（Ｓ１１）。
　これにより、被接合部材Ｍ２の被接合部材Ｍ１との接触面付近の溶融した部分は温度が低下して硬化し、被接合部材Ｍ１と被接合部材Ｍ２とは強固に接合される。被接合部材Ｍ２の被接合部材Ｍ１との接触面付近以外の部分は溶融せず、軟化開始温度以上となる部分も少ないので、被接合部材Ｍ２には、歪み、屈曲、圧縮などの変形がほとんど生じない。
　その後、作業者が接合部材を取り出す（Ｓ１２）。
　従来のように被接合部材Ｍ２を被接合部材Ｍ１に押圧しながら被接合部材Ｍ１を加熱すると、加熱過程における熱が被接合部材Ｍ２に流れ込むため、被接合部材Ｍ２全体の温度が上昇する。そのため、被接合部材Ｍ２は品質保障温度を超えて品質は劣化し、さらに歪み、屈曲、圧縮などの変形が生じる。
　本実施形態では、被接合部材Ｍ１の温度Ｔが設定温度Ｔｓになるまで（Ｓ５：ＹＥＳ）、被接合部材Ｍ１を被接合部材Ｍ２に大きな圧力で押圧しないので、被接合部材Ｍ２の軟化開始温度以上となる部分は少なく、被接合部材Ｍ２に歪み、屈曲、圧縮などの変形がほとんど生じない。また、被接合部材Ｍ２の品質保障温度を超える部分も少ないので、被接合部材Ｍ２の品質は良好に維持される。
　さらに、本実施形態では、被接合部材Ｍ１の温度Ｔを設定温度Ｔｓに、例えば＋－１℃の精度で維持しているので、最適な条件で被接合部材Ｍ２の接合面付近の部分が軟化するので、発泡などが発生しない。そのため、接合強度は良好なものとなる。
　また、被接合部材Ｍ２の溶融温度未満の温度で接合するので、接合面に酸化被膜は発生せず、通常の大気雰囲気で接合することができる。そのため、接合部分を真空雰囲気や不活性ガス雰囲気にする必要がなく、装置を簡素化することが可能となる。
　尚、被接合部材Ｍ１の角部を鋭くする一方、被接合部材Ｍ２の角部に丸みを帯びさせれば、被接合部材Ｍ１の角部が被接合部材Ｍ２の角部に強く押し当り、角部同士が確実に接合される。そして、この角部同士の接合は円周状に亘るので、接合した部材の気密性が良好となる。
　（第２実施形態）
　以下、本発明の第２実施形態である通電加熱接合装置１０１について説明する。
　図５から図７を参照して、通電加熱接合装置１０１は、金属からなる矩形板状の被接合部材Ｍ１と樹脂からなる矩形板状の被接合部材Ｍ２とを接合する装置である。通電加熱接合装置１０１は、上述した通電加熱接合装置１と類似するので、同一又は対応する部材には同一の符号を付し、異なる箇所についてのみ説明する。
　通電加熱接合装置１０１は、電極ユニット１１０、加圧ユニット１２０、温度センサ３０及び制御ユニット４０を備えている。これらは図示しない架台に搭載されている。
　電極ユニット１１０は、上下一対の電極１１１，１１２と上電極１１１を上下動させる上下動機構１１３とから構成されている。上下動機構１１３は、ここでは、エアシリンダである。
　上電極１１１は、ここでは、銅、モリブデン、タングステンなどからなる上通電電極１１１ａと、上通電電極１１ａの下部に固定された抵抗体１１１ｂとから構成される。上通電電極１１１ａは、ベークライト等からなる絶縁体１１５を介して、エアシリンダ１１３のピストン１１３ａの下端部に固定されている。
　下電極１１２は、ここでは、銅、モリブデン、タングステンなどからなる下通電電極１１２ａと、下通電電極１１２ａの上部に固定された抵抗体１１２ｂとから構成される。下通電電極１１２ａの下部は、ベークライト等からなる絶縁体１１４を介して図示しない架台に固定されている。
　上電極１１１の抵抗体１１１ｂは、被接合部材Ｍ１の上面に接触するが、被接合部材Ｍ２には接触しないように構成され、ここでは、被接合部材Ｍ１の上面の約半分に接触するような矩形板状に形成されている。
　下電極１１２の抵抗体１１２ｂは、被接合部材Ｍ１の下面に接触するが、被接合部材Ｍ２には接触しないように構成され、ここでは、被接合部材Ｍ１の下面が略全面接触するような矩形板状に形成されている。
　下電極１１２の下通電電極１１２ａは、その上面に、被接合部材Ｍ１の上に配置された被接合部材Ｍ２が安定的に配置されるように構成されている。具体的には、下通電電極１１２ａには、被接合部材Ｍ２の両側面を位置決めするためのガイド片１１２ｃが形成されている。また、溶融した被接合部材Ｍ２が付着しないように、接合面付近では下通電電極１１２ａは被接合部材Ｍ２と接触しないように構成されている。
　上下電極１１１，１１２は、その中心軸線が偏心して配置されているが、被接合部材Ｍ１は、それぞれの上下面が抵抗体１１１ｂ，１１２ｂと面接触するので、上下電極１１１，１１２の間に安定的に挟持される。そして、被接合部材Ｍ１を抵抗体１１１ｂ，１１２ｂで挟んだ状態で上下通電電極１１１ａ，１１２ａに通電することにより、被接合部材Ｍ１の接合面を含む約半分の部分を均一に加熱することができる。
　加圧ユニット１２０は、被接合部材Ｍ２と接触する加圧ブロック１２１と、加圧ブロック１２１を駆動させるための駆動源２２と、駆動源２２の駆動力を伝達し、加圧ブロック２１を上下動させるボールねじ機構２３とから構成されている。
　加圧ブロック１２１は、銅、モリブデン、タングステンなどからなり、被接合部材Ｍ２の上面に面接触する加圧プレート１２１ａと、加圧プレート１２１ａと一体的に設けられたブロック体１２１ｂと、加圧プレート１２１ａとブロック体１２１ｂとの間に配置された弾性体１２１ｃとかから構成されている。加圧プレート１２１ａは、被接合部材Ｍ２の上面に接触するが、被接合部材Ｍ１及び上電極１１には接触しないように構成されている。加圧プレート１２１ａは、ここでは、被接合部材Ｍ２の接合面の上方に位置する上面に接触するように矩形板状に形成されている。
　弾性体１２１ｃは、加圧プレート１２１ａとブロック体１２１ｂとを離間させる方向に弾性力を作用させるものであり、ばね、例えば渦巻きばねから構成されている。尚、図示しないが、加圧プレート１２１ａとブロック体１２１ｂとはその間の最大隙間超えて離間しないように構成されている。
　サーボモータ２２の回転駆動力がボールねじ機構２３で上下方向の駆動力に変換され、加圧ブロック１２１が上下動する。
　そして、サーボモータ２２の駆動を停止させると、その後、加圧ブロック１２１の位置が維持される。このとき、加圧ユニット１２０は、被接合部材Ｍ２の変位を弾性体１２１ｃの弾性力より規制して接合面に圧力を付与しており、本発明の加圧部として機能する。
　上述した通電加熱接合装置１０１を用いて、本発明の第２の実施形態に係る通電加熱接合方法を実施する際の処理は、上述した本発明の第１の実施形態に係る通電加熱接合方法と類似するので、図４を参照して異なる箇所についてのみ説明する。
　作業者により操作部４１のスタートスイッチがＯＮされると（Ｓ２：ＹＥＳ）、エアシリンダ１１３を駆動させて、上電極１１１を下降させる（Ｓ３）。これにより、被接合部材Ｍ１が上下電極１１１，１１２によって挟持される。尚、このとき、上下電極１１１，１１２により挟持されることによって被接合部材Ｍ１に作用する圧力は、上下電極１１１，１１２及び被接合部材Ｍ１が互いに確実に接触する程度の圧力である。
　そして、被接合部材Ｍ１を上下電極１１１，１１２で挟持した状態を保ちながら、電源１６を始動させて上下電極１１１，１１２を通電する（Ｓ５）。これにより、被接合部材Ｍ１が加熱されて温度が上昇する。この状態では、被接合部材Ｍ２は、単に被接合部材Ｍ１の上に載置されているだけであり、被接合部材Ｍ１との接触面付近の部分も然程温度が上昇せず変形も当然に生じない。
　その後、温度センサ３０が検知する被接合部材Ｍ１の温度Ｔが設定温度Ｔｓになったとき（Ｓ５：ＹＥＳ）、設定温度Ｔｓを維持した状態を保ちながら、サーボモータ２２を駆動させて、加圧ブロック１２１を下降させて、加圧プレート１２１ａで被接合部材Ｍ２を所定の設定圧力Ｐｓで被接合部材Ｍ１に押し付ける（Ｓ６）。尚、このとき、弾性体１２１ｃの存在によって、設定圧力Ｐｓを超える大きな圧力が急激に被接合部材Ｍ２に作用することが防止される。
　そして、予め設定された所定の設定温度Ｔｓを維持した状態を保ち、且つ被接合部材Ｍ２を加圧プレート１２１ａで押し付けた状態を、予め設定された所定の設定保持時間Ｈｓ継続する（Ｓ７）。さらに、この間、圧力センサ２５が検出した圧力Ｐが予め設定された所定の下限設定圧力Ｐｓ１未満となった否かを監視する（Ｓ８）。
　設定保持時間Ｈｓ経過後、又は、圧力センサ２５が検出した圧力が下限設定圧力Ｐｓ１未満となったとき、電源１６を停止して、上下電極１１１，１１２の通電を終了する（Ｓ９）。そして、図示しない冷却機構により下通電電極１２ａ及び加圧ブロック２１に冷却流体が循環させて、被接合部材Ｍ１，Ｍ２を冷却する（Ｓ１０）。
　その後、サーボモータ２２を駆動させて加圧ブロック１２１を上昇させると共に、エアシリンダ１１３を駆動させて上電極１１１を上昇させる（Ｓ１１）。
　これにより、被接合部材Ｍ２の被接合部材Ｍ１との接触面付近の溶融した部分は温度が低下して硬化し、被接合部材Ｍ１と被接合部材Ｍ２とは強固に接合される。被接合部材Ｍ２の被接合部材Ｍ１との接触面付近以外の部分は軟化せず、軟化開始温度以上となる部分も少ないので、被接合部材Ｍ２には、歪み、屈曲、圧縮などの変形がほとんど生じない。
　その後、作業者が接合部材を取り出す（Ｓ１２）。
　これにより、本実施形態によれば、被接合部材Ｍ１の温度Ｔが設定温度Ｔｓになるまで（Ｓ５：ＹＥＳ）、被接合部材Ｍ１を被接合部材Ｍ２に押圧しないので、被接合部材Ｍ２の軟化開始温度以上となる部分は少なく、被接合部材Ｍ２に歪み、屈曲、圧縮などの変形がほとんど生じない。また、被接合部材Ｍ２の品質保障温度を超える部分も少ないので、被接合部材Ｍ２の品質は良好に維持される。
　以上、本発明の実施形態について説明したが、本発明はこれに限定されない。例えば、被接合部材Ｍ１に対する電極の個数や設置部位などに関して限定されない。
　また、上電極１１，１１１を動作させる場合について説明した。しかし、これに限定されず、下電極１２，１１２を動作させてもよく、上下電極１１，１２，１１１，１１２を共に動作させてもよい。
　また、加圧ブロック２１，１２１をボールねじ機構２３で往復動作させる場合について説明した。しかし、加圧ブロック２１，１２１を往復動作させる機構は、これに限定されず、公知の機構を用いればよい。例えば、直線移動ガイド機構を用いてもよい。
　また、第２の実施形態では、弾性体１２１ｃを備える場合について説明した。しかし、弾性体１２１ｃを備えることなく、加圧プレート１２１ａとブロック体１２１ｂとを一体化させて、サーボモータ２２の駆動による力をそのまま、接合面に圧力として付与してもよい。
　また、通常の大気雰囲気で被接合部材Ｍ１，Ｍ２を接合する場合について説明した。しかし、これに限定されず、被接合部材Ｍ１，Ｍ２の接合面を含む部分を真空雰囲気や窒素、アルゴン等の不活性ガス雰囲気として接合してもよい。
　例えば、少なくとも被接合部材Ｍ１，Ｍ２の接合面を含む部分をする真空化ユニットを通電加熱接合装置１，１０１が備えていてもよい。これにより、例え接合温度が被接合部材Ｍ１の融点近傍となっても接合面に酸化被膜が発生することが抑制され、接合が容易且つ強固となる。
　真空化ユニットとしては、例えば、通電加熱接合装置１，１０１全体を取り囲むチャンバと、チャンバ内を真空化させる真空化装置と、チャンバ内の真空状態を破壊する真空破壊装置とから構成すればよい。真空化装置は、例えば、チャンバ内の気体を図示しない給排気管を介して排出する真空ポンプである。真空破壊装置は、例えば、給排気管を介してチャンバ内に気体を供給する気体供給ポンプである。真空破壊装置は、チャンバ内に外気を導入させるために、給排気管に設けたバルブなどであってもよい。
　そして、チャンバ内の真空度（圧力）を検知するピラニー式などの真空センサを設置さし、チャンバの正面側に、被接合部材Ｍ１，Ｍ２を出し入れするための扉が設けることが好ましい。尚、温度センサ３０は、チャンバののぞき窓の外部に設置すればよい。
　また、被接合部材Ｍ１，Ｍ２の形状は、例えば、パイプ状、バルク状、厚板状、薄板状など任意の形状であってもよく、溝加工、穴開け加工など任意の加工が施されていてもよい。そして、被接合部材Ｍ１，Ｍ２の形状及びその接合部の形状や位置に応じて、上下電極１１，１２，１１１，１１２及び加圧ユニット２０，１２０を適宜構成すればよい。
　また、被接合部材Ｍ１に２個以上の被接合部材Ｍ２を同時に接合するものであってもよい。
　（実施例）
　以下、本発明の実施例に挙げて説明する。
　上述した通電加熱接合装置１０１を用いて、被接合部材Ｍ１と被接合部材Ｍ２とを接合した。被接合部材Ｍ１の材質は、アルミニウム（Ａ１０５０）、タフピッチ銅（Ｃ１１００）、ステンレス鋼（ＳＵＳ３０４）、又は普通鋼板（ＳＰＣＣ）であり、被接合部材Ｍ２の材質は、ポリフェニレンサルファイド（ＰＰＳ）又はポリアミド（ＰＡ）６６であった。
　被接合部材Ｍ１として長さ４９ｍｍ、幅１２ｍｍ、厚さ１．５ｍｍの細長片を、被接合部材Ｍ２として長さ４９ｍｍ、幅１２ｍｍ、厚さ３ｍｍの細長片をそれぞれ用意し、これら細長片を接合面が長さ１２ｍｍ、幅１２ｍｍとなるよう配置して接合した。
　設定温度Ｔｓ、設定保持時間Ｈｓ、上下電極１１１，１１２への印加電流Ｉ、設定圧力Ｐｓは、表１に示すように設定した。
　接合した部材を引張剪断試験を行った結果、全ての実施例で被接合部材Ｍ２の母材が破断した。これより、接合強度は強固であることが分かった。
Figure JPOXMLDOC01-appb-T000001
      　　　　　　　　　　　　　　　　　 
　１，１０１…通電加熱接合装置、　１０，１１０…電極ユニット、　１１，１１１…上電極（電極）、　１１ａ，１１１ａ…上通電電極、　１１ｂ，１１１ｂ…抵抗体、　１２，１１２…下電極（電極）、　１２ａ，１１２ａ…下通電電極、　１２ｂ，１１２ｂ…抵抗体、　１３…押上機構、　１３ａ…ばね、　１４，１１４，１１５…絶縁体、　１６…電源、　２０，１２０…加圧ユニット（加圧部）、　２１，１２１…加圧ブロック、　２２…駆動源、サーボモータ、　２２ａ…エンコーダ、　２３…ボールねじ機構、　２４…絶縁体、　２５…圧力センサ、　３０…温度センサ、　４０…制御ユニット（制御部）、　１１３…エアシリンダ（上下動機構）、　１２１ａ…加圧プレート、　１２１ｂ…ブロック体、　１２１ｃ…弾性体、　Ｍ１…被接合部材（第１の被接合部材）、　Ｍ２…被接合部材（第２の被接合部材）。

Claims (8)

  1. 　金属からなる第１の被接合部材と樹脂からなる第２の被接合部材とを接合する通電加熱接合装置であって、
    　前記第１の被接合部材を挟持して、前記第１の被接合部材と電気的に導通可能な複数の電極と、
    　前記第１の被接合部材と前記第２の被接合部材との接合面に圧力を付与する加圧部と、
    　前記第１の被接合部材の温度を検知する温度センサと、
    　前記温度センサが検知した温度が予め設定した温度になった後、前記接合面に圧力を付与させるように前記加圧部を制御する制御部とを備えることを特徴とする通電加熱接合装置。
  2. 　前記電極に電流を供給する電源を備え、
    　前記温度センサが検知した温度が前記予め設定した温度以下のとき、前記電源を作動し、前記温度センサが検知した温度が前記予め設定した温度を超えたとき、前記電源を停止させることを特徴とする請求項１に記載の通電加熱接合装置。
  3. 　前記接合面に付与される圧力を検知する圧力センサを備え、
    　前記圧力センサが予め設定した圧力を超えたとき、前記制御部は、前記接合面に圧力を付与しないように前記加圧部を制御することを特徴とする請求項１又は２に記載の通電加熱接合装置。
  4. 　前記接合面に圧力を付与させた後、予め設定された時間を経過したとき、前記制御部は、前記接合面に圧力を付与しないように前記加圧部を制御することを特徴とする請求項１から３の何れか１項に記載の通電加熱接合装置。
  5. 　前記予め設定した温度は、前記第２の被接合部材の軟化温度以上、且つ前記第２の被接合部材の溶融温度未満であることを特徴とする請求項１から４の何れか１項に記載の通電加熱接合装置。
  6. 　大気雰囲気で前記第１の被接合部材と前記第２の被接合部材とを接合することを特徴とする請求項１から５の何れか１項に記載の通電加熱接合装置。
  7. 　前記加圧部は弾性体を有し、前記弾性体の弾性力によって前記接合面に圧力を付与することを特徴とする請求項１から６の何れか１項に記載の通電加熱接合装置。
  8. 　金属からなる第１の被接合部材と樹脂からなる第２の被接合部材とを接合する通電加熱接合方法であって、
    　前記第１の被接合部材と電気的に導通可能な複数の電極間に前記第１の被接合部材を挟持して通電し、
    　前記第１の被接合部材の温度が予め設定した温度になった後、前記第１の被接合部材と前記第２の被接合部材との接合面に圧力を付与することを特徴とする通電加熱接合方法。
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