WO2017150289A1

WO2017150289A1 - Resin-bonded product and manufacturing method therefor

Info

Publication number: WO2017150289A1
Application number: PCT/JP2017/006481
Authority: WO
Inventors: 橋本　将臣; 三四郎長井; 皓太郎高石
Original assignee: 株式会社エンプラス
Priority date: 2016-03-04
Filing date: 2017-02-22
Publication date: 2017-09-08
Also published as: JP2017154447A

Abstract

[Problem] To provide a resin-bonded product in which a portion of high dimensional precision and a portion with a complex shape are integrally formed. [Solution] A first resin member 2 is disposed on a forming table 6 of a powder sintering lamination apparatus 5. A powder layer-forming step for forming a resin powder layer 10 on the bonding surface 3 of the first resin member 2 and a solidified layer-forming step for forming a solidified layer 13 by irradiating laser light 12 on the resin powder layer 10 to fire and harden the resin powder layer 10 in the portions irradiated with the laser light 12 are performed repeatedly. As a result, a second resin member 4, which is a three-dimensional formed object made by laminating and integrating multiple solidified layers 13, is formed and the second resin member 4 is bonded to the bonding surface 3 of the first resin member 2.

Description

Resin bonded product and manufacturing method thereof

The present invention relates to a resin bonded product in which a portion with high dimensional accuracy and a complicated shape portion are integrally formed, and a manufacturing method thereof.

In recent years, an apparatus (powder sintering laminating apparatus) for forming a three-dimensional structure using a powder sintering laminating method has been widely used. This powder sintering and laminating apparatus carries a powder material contained in a powder material tank onto a modeling table with a blade, forms a powder layer of a predetermined thickness on the modeling table with a blade, and then uses laser light irradiation means. A plurality of solidified layers are laminated and integrated by repeating the process of irradiating a predetermined portion of the powder layer on the modeling table with laser light and baking (solidifying) the powder layer of the portion irradiated with the laser light. A three-dimensional structure is formed on a modeling table (see Patent Document 1).

A three-dimensional structure formed using such a powder sinter lamination method cannot be made by conventional injection molding or cutting because three-dimensional CAD software is used to operate the laser light irradiation means. Intricately shaped parts are easily formed.

JP 2011-26668 A

However, although the three-dimensional structure formed using the powder sintering lamination method has a large degree of freedom in shape, the shape accuracy and surface roughness are inferior to those of injection molded products and machined products, and high dimensional accuracy is obtained. It was difficult to apply to the required engagement location.

Therefore, an object of the present invention is to provide a resin bonded product in which a portion with high dimensional accuracy and a complicated shape portion are integrally formed, and a method for manufacturing the same.

In the present invention, the second resin member 4 is bonded to the bonding surface 3 of the first resin member 2, and the first resin member 2 and the second resin member 4 are integrated at the bonding surface 3. The present invention relates to a method for manufacturing the bonded product 1. In the present invention, the first resin member 2 is disposed on the modeling table 6 of the powder sinter laminating device 5, and the powder layer that forms the resin powder layer 10 on the joining surface 3 of the first resin member 2. Repeating the forming step and the solidified layer forming step of irradiating the resin powder layer 10 with the laser light 12 and baking and solidifying the resin powder layer 10 where the laser light 12 is irradiated to form the solidified layer 13. Thus, the second resin member 4 as a three-dimensional structure formed by stacking and integrating a plurality of solidified layers 13 is formed, and the second resin member 4 is bonded to the first resin member 2. 3 is joined.

The present invention also relates to a resin bonded product 1 in which a second resin member 4, which is a three-dimensional structure, is bonded to the bonding surface 3 of the first resin member 2 by a powder sintering lamination method.

According to the present invention, it is possible to provide a resin bonded product in which a high dimensional accuracy portion (first resin member) and a complicated shape portion (second resin member) are integrally formed.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view for explaining a resin bonded product and a manufacturing method thereof according to a first embodiment of the present invention, in which FIG. 1 (a) is an external perspective view showing the resin bonded product, and FIGS. It is a figure for demonstrating the manufacturing method of a resin joined product. FIGS. 2A and 2B are views for explaining a resin bonded product and a manufacturing method thereof according to a second embodiment of the present invention, FIG. 2A is an external perspective view showing the resin bonded product, and FIGS. 2B to 2H are FIGS. It is a figure for demonstrating the manufacturing method of a resin joined product. FIGS. 3A and 3B are views for explaining a resin bonded product and a manufacturing method thereof according to a third embodiment of the present invention, in which FIG. 3A-1 is an external perspective view of a plurality of first resin members, and FIG. 2) is an external perspective view of a plurality of resin bonded articles, FIG. 3 (b-1) is a front view of a plurality of first resin members, and FIG. 3 (b-2) is a front view of the plurality of resin bonded articles. . It is a figure for demonstrating the resin joining article and its manufacturing method which concern on 4th Embodiment of this invention, and Fig.4 (a) is before forming a 2nd resin-made member in the joint surface of a 1st resin-made member. Sectional drawing which shows a state, FIG.4 (b) is sectional drawing which shows a state after forming the 2nd resin-made member in the joint surface of the 1st resin-made member. It is a figure for demonstrating the resin joined product and its manufacturing method which concern on the modification of 4th Embodiment of this invention, Fig.5 (a) forms the 2nd resin-made member in the joint surface of a 1st resin-made member. Sectional view (same sectional view as FIG. 4 (a)) showing the state before the process, FIG. 5 (b) shows the state after forming the second resin member on the joint surface of the first resin member It is a figure (sectional drawing corresponding to FIG.4 (b)). It is a figure which shows the 1st resin member which concerns on other embodiment of this invention, and is a figure which shows the 1st resin member integrally provided in the upper part of the metal base member.

[First Embodiment]
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
Drawing 1 is a figure for explaining the manufacturing method of resin joined article 1 concerning a 1st embodiment of the present invention. In the resin bonded product 1 shown in FIG. 1A, a second resin member 4 is bonded to a bonding surface 3 of a first resin member 2 that has been injection molded. The first resin member 2 is a columnar member formed with high precision by injection molding in advance. The second resin member 4 is a columnar member having a smaller diameter than that of the first resin member 2, and is joined to the first resin member 2 through the steps shown in FIGS. 1B to 1H.・ Integrated. The first resin member 2 is made of, for example, PEEK (polyether ether ketone), PPS (polyphenylene sulfide), PA (polyamide), PBT (polybutylene terephthalate), or PP (polypropylene) that is a crystalline resin. The Further, the first resin member 2 may use an amorphous resin that can be joined to the second resin member 4.

First, as shown in FIG.1 (b), the injection-molded 1st resin member 2 is powder resin material 7 (For example, PEEK (polyetheretherketone) which is crystalline resin, PPS (polyphenylene sulfide), With the joining surface 3 facing up on the modeling table 6 of the powder sintered laminating apparatus 5 that forms a three-dimensional model using PA (polyamide), PBT (polybutylene terephthalate), PP (polypropylene)). Be placed.

Next, as shown in FIG. 1 (c), the powder sintering and laminating apparatus 5 places the powder resin material 7 on the modeling table 6 until the first resin member 2 on the modeling table 6 is covered with the powder resin material 7. The powder resin material 7 on the bonding surface 3 of the first resin member 2 is leveled by a blade 8 (or a roller) that moves in the horizontal direction (direction along the X axis in FIG. 1C), A resin powder layer 10 having a desired thickness is formed on the joint surface 3 of the first resin member 2 (powder layer forming step).

Next, as shown in FIG. 1 (c), the laser beam 12 is irradiated from the laser beam irradiation means 11 onto the resin powder layer 10 on the bonding surface 3 of the first resin member 2. Then, the boundary portion between the joint surface 3 of the first resin member 2 and the resin powder layer 10 is melted by the laser beam 12 and integrated. Moreover, as shown in FIG.1 (d), the resin powder layer 10 on the joining surface 3 of the 1st resin-made members 2 is baked and hardened with the laser beam 12, and becomes the solidified layer 13 (solidified layer formation process). . The laser beam irradiation means 11 is controlled to operate based on input data such as three-dimensional CAD data, and can move with respect to the modeling table 6. Further, the modeling table 6 is configured to be able to move up and down along the Y-axis direction of FIG. 1C, and the thickness of the resin powder layer 10 formed on the bonding surface 3 of the first resin member 2. It descends sequentially by the minute.

Next, as shown in FIGS. 1E to 1H, a powder layer forming step of forming a resin powder layer 10 on the joint surface 3 of the first resin member 2, and a laser beam 12 on the resin powder layer 10 is performed. The solidified layer forming step of forming the solidified layer 13 by baking and solidifying the portion of the resin powder layer 10 irradiated with the laser beam 12 is repeated. As a result, the second resin member 4 as a three-dimensional structure formed by laminating and integrating the plurality of solidified layers 13 is formed, and the second resin member 4 is joined to the bonding surface 3 of the first resin member 2. The first resin member 2 and the second resin member 4 are integrated.

According to the manufacturing method of the resin bonded product 1 according to the present embodiment as described above, a portion with high dimensional accuracy (the first resin member 2 that is injection-molded) and a complicated shape portion (the first as a three-dimensional structure). It is possible to provide the resin bonded product 1 in which the two resin members 4) are integrally formed.

Moreover, the manufacturing method of the resin bonded product 1 which concerns on this embodiment as mentioned above is a separate process of the 1st molded product (1st resin-made member) and 2nd molded product (2nd resin-made member) which were formed separately. Therefore, the manufacturing cost of the resin bonded product 1 can be reduced as compared with the case of bonding (for example, hot plate welding, ultrasonic welding). That is, the part for which shape accuracy and surface roughness are required is the first molded product (injection molded product or machined product), and the complex shaped three-dimensional model formed by the powder sintering lamination method is used as the second molded product. After forming separately, the first molded product and the second molded product are joined in separate steps to produce a resin joined product (separate from the method for producing the resin joined product 1 according to this embodiment). The first manufacturing method causes a problem that the number of steps increases, production efficiency deteriorates, and product cost increases when compared with the manufacturing method of the resin bonded product 1 according to the present embodiment.

In addition, after the whole is formed using the powder sintering lamination method, the other second (this embodiment is finished with high accuracy by performing post-processing such as cutting on a portion where high dimensional accuracy is required. The second manufacturing method different from the method for manufacturing the resin bonded product 1 may cause a problem that it is difficult to chuck the jig for processing, and post-processing cannot be performed. However, according to the manufacturing method of the resin bonded product 1 according to the present embodiment, the second resin member 4 as a three-dimensional structure is powder-sintered and laminated on the bonding surface 3 of the first resin member 2 with high dimensional accuracy. Therefore, there is no problem as in the other second manufacturing method described above.

[Second Embodiment]
FIG. 2 is a view for explaining a method of manufacturing the resin bonded product 1 according to the second embodiment of the present invention. In the resin bonded product 1 shown in FIG. 2A, one end or the other end of the arch-shaped second resin member 4 is formed on the bonding surfaces 3 and 3 of the pair of

first resin members

2 and 2 formed by injection molding. By being joined, the pair of

first resin members

2 and 2 are connected (integrated) by the second resin member 4. The first resin member 2 is a cylindrical member formed in advance with high accuracy by injection molding, like the first resin member 2 of the first embodiment. The second resin member 4 is formed in an arch shape through the steps of FIGS. 2B to 2H, and one end is joined and integrated with one of the pair of

first resin members

2 and 2. The other end is joined and integrated with the other of the pair of

first resin members

2 and 2.

First, as shown in FIG. 2 (b), the pair of injection-molded

first resin members

2, 2 are on the modeling table 6 of the powder sintering and laminating apparatus 5 with the joint surface 3 facing upward. Be placed. The powder sinter laminator 5 has the same configuration as that of the powder sinter laminator 5 used in the method for manufacturing the resin bonded product 1 according to the first embodiment. Input data that matches the shape of the resin bonded product is used.

Next, as shown in FIG. 2 (c), the powder sintering laminating apparatus 5 applies the powder resin material 7 until the pair of

first resin members

2, 2 on the modeling table 6 are covered with the powder resin material 7. The blade 8 (or the powder resin material 7 which is supplied onto the modeling table 6 and moves the powder resin material 7 on the joining

surfaces

3 and 3 of the pair of

first resin members

2 and 2 in the horizontal direction (direction along the X axis in the figure) (or The resin powder layer 10 having a desired thickness is formed on the joining

surfaces

3 and 3 of the pair of first resin members 2 and 2 (powder layer forming step).

Next, as shown in FIG. 2C, the laser light 12 from the laser light irradiation means 11 is applied to the resin powder layers 10 and 10 on the

joint surfaces

3 and 3 of the pair of

first resin members

2 and 2. Irradiated. The boundary portions between the

joint surfaces

3 and 3 of the pair of

first resin members

2 and 2 and the resin powder layers 10 and 10 are melted by the laser beam 12 and integrated. Further, as shown in FIG. 2 (d), the resin powder layers 10, 10 on the

joint surfaces

3, 3 of the pair of

first resin members

2, 2 are baked and hardened with a laser beam 12 to form a solidified layer 13. , 13 are formed (solidified layer forming step). The laser beam irradiation means 10 is controlled in operation based on input data such as three-dimensional CAD data, and can be moved according to the position where the laser beam is irradiated.

Next, as shown in FIGS. 2E to 2H, a powder layer forming step of forming the resin powder layer 10 on the solidified layer 13, and the resin powder layer 10 is irradiated with the laser beam 12 to thereby generate the laser beam. The solidified layer forming step of baking and solidifying the resin powder layer 10 of the portion irradiated with 12 to form the solidified layer 13 is repeated. Thereby, the second resin member 4 as a three-dimensional structure formed by laminating and integrating the plurality of solidified layers 13 is formed in an arch shape, and one end of the second resin member 4 is a pair of first resins. The second resin member 4 is joined to the other joining surface 3 of the pair of

first resin members

2, 2.

According to the manufacturing method of the resin bonded product 1 according to the present embodiment as described above, a plurality of portions (first resin member 2) with high dimensional accuracy are integrated with a complicated shape portion (second resin member 4). It is possible to provide a resin joined product 1 formed by connecting to the resin.

[Third Embodiment]
FIG. 3 is a diagram for explaining a method of manufacturing the resin bonded product 1 according to the third embodiment of the present invention. In the manufacturing method of the resin bonded product 1 according to the present embodiment, a plurality of first resin members 2 having the same shape (columnar shape) are arranged on the modeling table 6 with an interval (FIG. 3 (a-1) and (See (b-1)), by alternately repeating the powder layer forming step and the solidified layer forming step described in the first embodiment, different shapes (or different) are formed on the joint surfaces 3 of the respective first resin members 2 (or The second resin member 4 as a three-dimensional structure having the same shape can be joined and integrated (see FIGS. 3A-2 and 3B-2). Note that the second resin member 4 has a shape (a desired complicated shape) that is difficult to perform injection molding or cutting by appropriately changing the input data for controlling the operation of the laser light irradiation means 11 (three-dimensional CAD data, etc.). ).

Thus, according to this embodiment, the second resin member 4 having a different shape (or the same shape) is bonded to each of the plurality of first resin members 2 having the same shape and high accuracy. It is possible to manufacture a plurality of types of resin bonded articles 1 in the same process.

[Fourth Embodiment]
FIG. 4 is a diagram for explaining a method of manufacturing the resin bonded product 1 according to the fourth embodiment of the present invention. As shown in FIG. 4, the manufacturing method of the resin bonded product 1 according to the present embodiment uses the powder sintered laminating device 5 to replace the second resin member 4 as a three-dimensional structure with the first resin member. In order to form on the 2 joining surfaces 3, the shaping | molding jig | tool 14 which maintains the joining surface 3 of each 1st resin-made members 2 on the same horizontal surface is used. The modeling jig 14 is installed on the modeling table 6 of the powder sintering and laminating apparatus 5, accommodates each first resin member 2, and aligns the joint surfaces 3 of the first resin members 2 on the same horizontal plane. The recessed part 15 of the shape which can be formed is formed (refer Fig.4 (a)).

As shown in FIG. 4 (a), according to the method for manufacturing the resin bonded product 1 according to the present embodiment, first, each first resin member 2 is installed on the modeling table 6 of the powder sintered laminating device 5. The joints 3 are accommodated in the corresponding recesses 15 of the formed modeling jig 14 so that the joint surfaces 3 are aligned on the same horizontal plane. Next, the manufacturing method of the resin-bonded article 1 according to the present embodiment alternately repeats the powder layer forming step and the solidified layer forming step described in the first embodiment, so that each of the first resin members 2 is formed. A second resin member 4 as a three-dimensional structure having different shapes (or the same shape) is joined and integrated on the joint surface 3.

As described above, according to the present embodiment, by aligning the joint surfaces 3 of the plurality of first resin members 2 having different sizes and shapes on the same horizontal surface with the modeling jig 14, a plurality of first shapes having different sizes and shapes can be obtained. The second resin member 4 as a three-dimensional structure having a different shape (or the same shape) can be bonded to the bonding surface 3 of the one resin member 2, and a plurality of types of resin bonded products 1 can be manufactured in the same process.

In addition, in the manufacturing method of the resin bonded product 1 according to the present embodiment, the area on the bonding portion 17 side of the second resin member 4 is smaller than the area of the bonding surface 3 of the first resin member 2 (see FIG. 4). The present invention is not limited to this case, and the present invention can also be applied to a case where the area of the bonding portion 17 side of the second resin member 4 is larger than the area of the bonding surface 3 of the first resin member 2 as shown in FIG. That is, the manufacturing method of the resin bonded product 1 according to the present embodiment is large enough to protrude from the bonding surface 3 of the first resin member 2 to the bonding surface 3 of the first resin member 2 as shown in FIG. The second resin member 4 can be formed.

[Other Embodiments]
The resin-bonded product 1 manufactured by the method for manufacturing the resin-bonded product 1 according to the first to fourth embodiments is appropriately subjected to an annealing process in order to remove internal strain generated in the process of cooling the resin material. The

In addition, the resin bonded product 1 and the manufacturing method thereof according to the first to fourth embodiments have exemplified the first resin member 2 which is injection-molded with high accuracy. However, the present invention is not limited to this, and cutting and grinding are performed. Alternatively, the first resin member 2 molded with high accuracy by extrusion or the like may be used.

Further, in the resin bonded product 1 and the manufacturing method thereof according to the first to fourth embodiments, the first resin member 2 is integrally provided on the metal base member 16 as shown in FIG. The upper surface (surface) may be formed to be the bonding surface 3. In this case, the first resin member 2 is placed on the modeling table 6 via the metal base member 16.

Moreover, although the resin bonded product 1 and the manufacturing method thereof according to the second embodiment have exemplified the mode in which the pair of first resin members 2 are connected by the second resin members 4, the present invention is not limited to this, and three The first resin member 2 described above may be connected by the second resin member 4.

In addition, the resin bonded product 1 according to the first to fourth embodiments represents the bonding surface 3 as a flat horizontal surface, but is not limited thereto, and as long as the resin powder layer 10 can be formed, the bonding surface. 3 may be an inclined surface, a stepped surface, an uneven surface, or the like.

Further, the resin bonded product 1 according to the present invention is not limited to the resin bonded product 1 according to the first to fourth embodiments, and the first resin member 2 is formed of a triangular prism, a quadrangular prism, a hexagon other than a cylindrical one. Various shapes such as pillars may be used. Further, the resin bonded product 1 according to the present invention is not limited to the resin bonded product 1 according to the first to fourth embodiments, and the second resin member 4 is so complicated that it cannot be processed by injection molding or cutting. A shape (for example, a shape that three-dimensionally represents a bird such as a eagle) can be formed.

DESCRIPTION OF SYMBOLS 1 ... Resin bonded product, 2 ... 1st resin member, 3 ... Joining surface, 4 ... 2nd resin member, 5 ... Powder sintering lamination apparatus, 6 ... Molding table, 10 ... Resin Powder layer, 12 ... Laser light, 13 ... Solidified layer

Claims

In the method for manufacturing a resin bonded product, the second resin member is bonded to the bonding surface of the first resin member, and the first resin member and the second resin member are integrated on the bonding surface.
The first resin member is placed on a modeling table of a powder sintering lamination apparatus,
A powder layer forming step of forming a resin powder layer on the joining surface of the first resin member, and irradiating the resin powder layer with laser light, and baking and solidifying the resin powder layer of the portion irradiated with the laser light By repeating the solidified layer forming step of forming the solidified layer,
Forming the second resin member as a three-dimensional structure formed by stacking and integrating a plurality of solidified layers, and joining the second resin member to the joining surface of the first resin member;
A method for producing a resin-bonded product.
In the method for manufacturing a resin bonded product, the second resin member is bonded to the bonding surface of the first resin member, and the first resin member and the second resin member are integrated on the bonding surface.
Arranging a plurality of the first resin members on the shaping table of the powder sinter lamination apparatus,
A powder layer forming step of forming a resin powder layer on the joint surfaces of the plurality of first resin members, and irradiating the resin powder layer with laser light and baking the resin powder layer of the portion irradiated with the laser light By repeatedly performing a solidified layer forming step of solidifying and forming a solidified layer,
While forming the second resin member as a three-dimensional structure formed by laminating and integrating a plurality of solidified layers, the second resin member is joined to the joining surfaces of the plurality of first resin members, Connecting the plurality of first resin members integrally with the second resin member;
A method for producing a resin-bonded product.
The first resin member is supported by a modeling jig so that the bonding surface is parallel to the upper surface of the modeling table, and the resin powder layer having a uniform thickness is formed on the bonding surface.
The method for producing a resin-bonded product according to claim 1 or 2, wherein:
The first resin member is formed by injection molding or cutting,
The method for producing a resin-bonded product according to any one of claims 1 to 3.
5. The resin according to claim 1, wherein the second resin member that is the three-dimensional structure is bonded to the bonding surface of the first resin member, and then annealed. Manufacturing method of joined product.
A resin bonded product, wherein a second resin member, which is a three-dimensional structure, is bonded to the bonding surface of the first resin member by a powder sintering lamination method.
The second resin member as a three-dimensional structure is joined to the joining surfaces of the plurality of first resin members by a powder sintering lamination method, and the plurality of first resin members are the second ones. A resin bonded product characterized by being integrally connected with a resin member.