WO2020261821A1 - 接合構造体 - Google Patents

接合構造体 Download PDF

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Publication number
WO2020261821A1
WO2020261821A1 PCT/JP2020/019853 JP2020019853W WO2020261821A1 WO 2020261821 A1 WO2020261821 A1 WO 2020261821A1 JP 2020019853 W JP2020019853 W JP 2020019853W WO 2020261821 A1 WO2020261821 A1 WO 2020261821A1
Authority
WO
WIPO (PCT)
Prior art keywords
perforation
perforations
curable resin
structure according
joint
Prior art date
Application number
PCT/JP2020/019853
Other languages
English (en)
French (fr)
Inventor
佐藤　大輔
Original Assignee
オムロン株式会社
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 オムロン株式会社 filed Critical オムロン株式会社
Priority to KR1020217035159A priority Critical patent/KR102603133B1/ko
Priority to US17/609,792 priority patent/US20220227094A1/en
Priority to CN202080033587.XA priority patent/CN113840682B/zh
Priority to EP20832345.1A priority patent/EP3992473A4/en
Publication of WO2020261821A1 publication Critical patent/WO2020261821A1/ja

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
    • B23K26/0622—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B23K26/382—Removing material by boring or cutting by boring
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/362—Laser etching
    • B23K26/364—Laser etching for making a groove or trench, e.g. for scribing a break initiation groove
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/40—Removing material taking account of the properties of the material involved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/40—Removing material taking account of the properties of the material involved
    • B23K26/402—Removing material taking account of the properties of the material involved involving non-metallic material, e.g. isolators
    • 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
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • 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
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/024—Thermal pre-treatments
    • B29C66/0246—Cutting or perforating, e.g. burning away by using a laser or using hot air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/128—Stepped joint cross-sections
    • B29C66/1282—Stepped joint cross-sections comprising at least one overlap joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/128—Stepped joint cross-sections
    • B29C66/1284—Stepped joint cross-sections comprising at least one butt joint-segment
    • B29C66/12841—Stepped joint cross-sections comprising at least one butt joint-segment comprising at least two butt joint-segments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/14—Particular design of joint configurations particular design of the joint cross-sections the joint having the same thickness as the thickness of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30325—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • 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
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/00—Layered products comprising a layer of metal
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/00—Layered products comprising a layer of metal
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B11/00—Connecting constructional elements or machine parts by sticking or pressing them together, e.g. cold pressure welding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B11/00—Connecting constructional elements or machine parts by sticking or pressing them together, e.g. cold pressure welding
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F16B21/00—Means for preventing relative axial movement of a pin, spigot, shaft or the like and a member surrounding it; Stud-and-socket releasable fastenings
    • F16B21/10—Means for preventing relative axial movement of a pin, spigot, shaft or the like and a member surrounding it; Stud-and-socket releasable fastenings by separate parts
    • F16B21/16—Means for preventing relative axial movement of a pin, spigot, shaft or the like and a member surrounding it; Stud-and-socket releasable fastenings by separate parts with grooves or notches in the pin or shaft
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/36—Electric or electronic devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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    • B23K2103/02—Iron or ferrous alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B23K2103/08—Non-ferrous metals or alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/30—Organic material
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2701/00—Use of unspecified macromolecular compounds for preformed parts, e.g. for inserts
    • B29K2701/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • 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
    • B32B2457/00—Electrical equipment

Definitions

  • the present invention relates to a bonded structure and its use.
  • Patent Document 1 describes a step of continuously irradiating a joint surface of a metal molded body, which is a first molded body, with a laser beam at an irradiation rate of 200 mm / sec or more using a continuous wave laser, and a step of continuously irradiating a laser beam in a previous step. It has a step of forming an adhesive layer on the joint surface of the metal molded body irradiated with, and a step of adhering the second molded body to the joint surface of the metal molded body which is the first molded body coated with the adhesive in the previous step. , A method for producing a composite molded body is disclosed.
  • both the tensile strength when pulled in the direction parallel to the joint surface and the tensile strength when pulled in the direction perpendicular to the joint surface are excellent. It is said that a composite molded product can be provided.
  • the present invention on the one hand, has been made in view of such circumstances, and an object of the present invention is to provide a joint structure having excellent thermal shock resistance and exhibiting high joint strength.
  • the bonded structure according to one aspect of the present invention has a first member, which is a metal material having a plurality of perforations having an opening diameter of 30 to 100 ⁇ m formed on the surface, and an opening on the surface.
  • a third member and a surface on which the first member is perforated which is the same or different metal material or thermoplastic resin as the first member and has a plurality of independent perforations having a diameter of 30 to 100 ⁇ m.
  • FIG. 1 schematically illustrates an example of a cross section of the joined structure according to the embodiment.
  • FIG. 2 schematically illustrates an example of a cross section of the joined structure according to the embodiment.
  • FIG. 3 schematically illustrates an example of a cross section of the joined structure according to the embodiment.
  • FIG. 4 schematically illustrates an example of a cross section of the joined structure according to the embodiment.
  • FIG. 5 schematically illustrates an example of a cross section of the joined structure according to the embodiment.
  • FIG. 6 schematically illustrates an example of a cross section of the joined structure according to the embodiment.
  • FIG. 7 schematically illustrates an example of a cross section of the joined structure according to the embodiment.
  • FIG. 8 schematically illustrates an example of a cross section of the joined structure according to the embodiment.
  • FIG. 9 schematically illustrates an example of a cross section of the joined structure according to the embodiment.
  • FIG. 10 schematically illustrates an example of a cross section of the joined structure according to the embodiment.
  • FIG. 11 schematically shows the manufacturing process of the bonded structure in the first embodiment.
  • FIG. 12 schematically shows the manufacturing process of the bonded structure in Comparative Example 1.
  • FIG. 13 schematically shows the manufacturing process of the bonded structure in Example 5.
  • FIG. 14 schematically shows a cross section of the bonded structure in Comparative Example 1.
  • FIG. 15 schematically shows a cross section of the bonded structure in Comparative Example 2.
  • FIG. 1 schematically illustrates an example of a cross section of the joined structure according to the embodiment.
  • the first member 1 is a metal material having a plurality of perforations having an opening diameter of 30 to 100 ⁇ m formed on the surface, and a plurality of perforations having an opening diameter of 30 to 100 ⁇ m are formed on the surface.
  • An example is a bonded structure including a second member 2 which is a sex resin. In other words, the first member 1 and the third member 3 are joined via the second member 2.
  • FIG. 1 shows a cross section parallel to the depth direction of the perforation.
  • the second member 2 which is a curable resin is filled in the perforations formed in the first member 1 and the third member 3 and cured, a physically strong anchor effect can be obtained. As a result, it is possible to obtain a bonded structure having excellent thermal shock resistance and exhibiting high bonding strength. Further, by performing surface processing for forming perforations on the surfaces of the first member 1 and the third member 3, impurities on the surface can be removed and the adhesive strength can be improved. Further, since a plurality of perforations are formed on the surfaces of the first member 1 and the third member 3, the stress related to the joint portion is dispersed, and a joint structure in which stress concentration is avoided can be provided.
  • the first member is a metal material having a plurality of perforations having an opening diameter of 30 to 100 ⁇ m formed on the surface thereof.
  • the metal material include iron-based metal, stainless-based metal, copper-based metal, aluminum-based metal, magnesium-based metal, and alloys thereof.
  • the metal material may be a metal molded body, zinc die-cast, aluminum die-cast, powder metallurgy, or the like.
  • the third member is the same or different metal material or thermoplastic resin as the first member having a plurality of perforations having an opening diameter of 30 to 100 ⁇ m formed on the surface.
  • the metal material used as the third member the metal material exemplified in the metal material used in the first member can be mentioned.
  • the third member may be the same metal material as the first member, or may be a different metal material.
  • thermoplastic resin examples include PVC (polyvinyl chloride), PS (polypropylene), AS (acrylonitrile / styrene copolymer), ABS (acrylonitrile / butadiene / styrene copolymer), PMMA (polymethylmethacrylate), and the like.
  • PE polypropylene
  • PP polypropylene
  • PC polypropylene
  • m-PPE modified polyphenylene ether
  • PA6 polyetherketone 6
  • PA66 polyamide 66
  • POM polyacetal
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • PSF polyetherketone
  • PAR polyetherlate
  • PEI polyetherimide
  • PPS polyphenylene sulfide
  • PES polyetherketone
  • PEEK polyetheretherketone
  • PAI polyetherimide
  • LCP liquid crystal polymer
  • PVDC polyvinylidene chloride
  • PTFE polytetrafluoroethylene
  • PCTFE polychlorotrifluoroethylene
  • PVDF polyvinylidene fluoride
  • thermoplastic resin may be TPE (thermoplastic elastomer), and examples of TPE include TPO (olefin type), TPS (styrene type), TPEE (ester type), TPU (urethane type), and the like. Examples thereof include TPA (nylon type) and TPVC (vinyl chloride type).
  • the second member is a curable resin that joins the surface on which the perforations of the first member are formed and the surface on which the perforations of the third member are formed.
  • the curable resin may be a reactive curable resin.
  • the reactive curable resin include a thermosetting resin that forms a crosslinked structure and cures by heating, and a photocurable resin that forms a crosslinked structure and cures by irradiating light.
  • the reactive curable resin examples include epoxy (EP) resin, polyurethane (PUR) resin, urea formaldehyde (UF) resin, melamine formaldehyde (MF) resin, phenol formaldehyde (PF) resin, and unsaturated polyester (UP).
  • EP epoxy
  • PUR polyurethane
  • UF formaldehyde
  • MF melamine formaldehyde
  • PF phenol formaldehyde
  • unsaturated polyester examples thereof include resins, silicone (SI) resins, and acrylic resins.
  • the reactive curable resin may be a fiber reinforced plastic (FRP).
  • the curable resin may be an epoxy resin.
  • the reactive curable resin is preferably an epoxy resin from the viewpoint of achieving both oil resistance, chemical resistance and heat impact resistance in a well-balanced manner.
  • a filler may be further added to the second member.
  • the filler include inorganic fillers (glass fibers, inorganic salts, etc.), metal-based fillers, organic-based fillers, carbon fibers, and the like.
  • the viscosity of the curable resin before curing is preferably 10,000 to 300,000 mPa ⁇ s, more preferably 25,000 to 90,000 mPa ⁇ s, and even more preferably 50,000 to 75,000 mPa ⁇ s at 25 ° C. ⁇ S.
  • the viscosity (mPa ⁇ s) can be measured, for example, at 25 ° C. by using a rotational viscometer (Brookfield meter) (manufactured by Eiko Seiki Co., Ltd.).
  • the shore D hardness of the curable resin after curing is preferably 30 to 90, more preferably 50 to 90, and even more preferably 70 to 90.
  • the shore D hardness is measured according to JIS K6253.
  • the opening diameter of the perforation is preferably 30 to 100 ⁇ m.
  • the perforations are independent of each other. That is, when viewed from a direction perpendicular to the surface on which the perforations are formed, the openings of the perforations do not overlap, and the boundary line between the perforations is clear. Therefore, the perforation is different from a continuous groove. Since the perforations are independent of each other, the surface areas of the first member and the third member are increased. As a result, the area of contact between the first member and the third member and the second member is expanded, which has the effect of improving the physical joint strength.
  • the shape of the opening of the perforation is not particularly limited, and may be, for example, circular or polygonal. If the shape of the opening is circular, it is easy to form a perforation.
  • the diameter of the cross section perpendicular to the depth direction of the perforation may be constant from the opening toward the depth direction, and increases from the opening toward the depth direction and then decreases. It may also be smaller, or may be smaller in the depth direction from the opening.
  • the diameter of the cross section perpendicular to the depth direction of the perforation increases in the depth direction from the opening and then decreases.
  • the shape of the perforation preferably has a constriction in the depth direction. With this configuration, the effect of locking the second member is exhibited.
  • the change in the diameter of the cross section perpendicular to the depth direction of the perforation from the opening to the depth direction may be curved or linear.
  • the pitch of the perforations is not particularly limited, and can be appropriately changed according to the opening diameter of the perforations, the volumes of the first member and the third member, and the like.
  • the lower limit of the perforation pitch is a distance at which the perforations do not overlap.
  • the perforation pitch is preferably 50 to 200 ⁇ m, more preferably 50 to 150 ⁇ m, and even more preferably 50 to 80 ⁇ m.
  • the perforation pitch can be adjusted, for example, by controlling the irradiation interval of laser irradiation.
  • the depth of the perforation is not particularly limited, and can be appropriately changed according to the opening diameter of the perforation, the volumes of the first member and the third member, and the like.
  • the perforation depth is preferably 30-100 ⁇ m.
  • the shape of the perforations in the first member and the third member may be the same.
  • the first member is formed with a perforation having a circular opening and a shape in which the diameter of a cross section perpendicular to the depth direction is curvedly reduced in the depth direction.
  • the third member having a circular opening and a perforation having a shape in which the diameter of the cross section perpendicular to the depth direction is curvedly reduced in the depth direction, as in the case of the first member 1. 3 may be joined via the second member 2.
  • the perforation may have the shape shown in FIGS. 2 to 10.
  • FIGS. 2 to 10 schematically show an example of a cross section of the joint structure according to the embodiment parallel to the depth direction of the perforation.
  • the shape of the perforation is such that the opening is circular and the diameter of the cross section perpendicular to the depth direction is curvedly increased in the depth direction and then decreased. Often, it may have a conical shape as shown in FIG.
  • the shapes of the perforations in the first member and the third member may be different.
  • the first member 1 in which a conical perforation is formed and the opening have a circular opening, and the diameter of the cross section perpendicular to the depth direction is curved toward the depth direction.
  • a third member 3 in which a perforation having a shape that becomes larger and then becomes smaller may be joined via the second member 2.
  • the punching pitches of the first member and the third member may be the same or different from each other.
  • the first member The drilling pitch of the member 1 may be smaller than the drilling pitch of the third member 3.
  • the depth of perforation in the first member and the third member may be the same or different from each other.
  • the first member The depth of the perforation in the member 1 may be deeper than the depth of the perforation in the third member 3.
  • both the perforation pitch and the perforation depth in the first member and the third member may be different between the first member and the third member.
  • the drilling pitch of the first member 1 is smaller than the drilling pitch of the third member 3.
  • the depth of the perforation in the first member 1 may be deeper than the depth of the perforation in the third member 3.
  • the first member 1 and the third member 3 may be joined via the second member 2 on a surface other than the surface on which the perforation is formed.
  • another member 5 may be joined to the first member 1 via the second member 2.
  • the above-mentioned perforations may also be formed on the surface of the other member 7.
  • the other member 7 may be a metal material or a thermoplastic resin exemplified as the first member or the third member.
  • the third member 3 is joined to the other member 7 via another adhesive 8 on a surface different from the surface joined to the first member 1. May be good.
  • the above-mentioned perforation may be formed on a surface of the third member 3 other than the surface joined to the first member 1.
  • the other adhesive 8 may be the curable resin exemplified as the second member.
  • the joint structure is manufactured by, for example, a manufacturing method including a step of joining a surface on which a perforation of the first member is formed and a surface on which a perforation of the third member is formed via the second member. Can be done.
  • the perforation is preferably formed by laser irradiation.
  • the laser type for forming the perforation fiber laser, YAG laser, YVO 4 laser, a semiconductor laser, a carbon dioxide gas laser, it is possible to select an excimer laser or the like, in consideration of the wavelength of the laser, a fiber laser or the like preferable.
  • the second member is applied to the surface on which the perforation of the first member is formed, the surface on which the perforation of the third member is formed, or both, and then the surface on which the perforation of the first member is formed is first coated.
  • the three members are overlapped so that the surfaces on which the perforations are formed are in contact with each other.
  • the region where the first member and the third member are overlapped may be pressurized. After that, the bonded structure can be obtained by curing the second member.
  • the OH groups in the second member may be exposed by irradiation with ultraviolet rays or the like. Alternatively, heating or evacuation may be performed during and / or after the second member has been applied. By these treatments, the surface tension when the perforation is filled with the second member is reduced, and the perforation is easily filled with the second member.
  • the method of curing the second member is not particularly limited as long as the second member is sufficiently cured.
  • junction structure can be used, for example, in switches, photoelectric sensors and proximity sensors.
  • a photoelectric sensor has a structure in which internal parts such as a substrate are sealed by a metal housing.
  • internal parts such as a substrate are sealed by a metal housing.
  • it is welded or joined with an adhesive without processing the surface.
  • internal parts such as substrates may be damaged by heat.
  • the method of joining with an adhesive without processing the surface is easy to peel off, and there is room for improvement in joining strength.
  • switches, photoelectric sensors, and proximity sensors there are parts that require joining of metal and resin in addition to joining of metals, and conventionally, metal and resin have been directly joined. However, in such a method, the metal and the resin tend to be easily peeled off.
  • the switch, photoelectric sensor or proximity sensor provided with the bonding structure has high bonding strength and can reduce thermal damage to internal parts.
  • the bonded structure according to one aspect of the present invention is independent of the first member, which is a metal material having a plurality of perforations having an opening diameter of 30 to 100 ⁇ m on the surface, and an independent member having an opening diameter of 30 to 100 ⁇ m on the surface.
  • a third member which is the same or different metal material or thermoplastic resin as the first member in which a plurality of perforations are formed, a surface on which the perforations of the first member are formed, and a perforation of the third member are formed.
  • a second member, which is a curable resin for joining the surface, is provided.
  • the curable resin can be cured by a cross-linking reaction.
  • the curable resin is applied to the surfaces on which the perforations are formed and cured, so that the curable resin is filled in the perforations and a physically strong anchor effect can be obtained.
  • a bonded structure having excellent thermal shock resistance and exhibiting high bonding strength.
  • impurities on the surface of the member can be removed and the adhesive strength can be improved.
  • the stress related to the joint portion is dispersed, and it is possible to provide a joint structure in which stress concentration is avoided.
  • the opening diameter of the perforation can be measured as the maximum diameter of the perforation opening on the surface of the metal material.
  • the curable resin may be a reactive curable resin.
  • the reactive curable resin can be cured by forming a crosslinked structure by energy from the outside.
  • the reactive curable resin may be an epoxy resin. According to this configuration, in addition to heat and shock resistance, oil resistance and chemical resistance can be ensured.
  • the epoxy resin may contain at least one epoxy group.
  • the viscosity of the curable resin before curing may be 25,000 to 90,000 mPa ⁇ s at 25 ° C. According to this configuration, since the perforations are easily filled with the curable resin, the anchor effect is easily exhibited and the bonding strength is improved.
  • the shore D hardness of the curable resin after curing may be 30 to 90. According to this configuration, in addition to heat and shock resistance, oil resistance and chemical resistance can be ensured.
  • the diameter of the cross section perpendicular to the depth direction of the perforation may increase in the depth direction from the opening and then decrease, or may decrease in the depth direction from the opening. It may become smaller toward. According to this configuration, the anchor effect is easily exhibited, so that the stability of thermal shock resistance is ensured.
  • the perforation pitch may be 50 to 200 ⁇ m.
  • the lower limit of the drilling pitch is the distance at which the drilling does not overlap. According to this configuration, since the perforations are arranged regularly, the stress related to the joint is uniformly dispersed, and it is easy to avoid stress concentration.
  • the perforation pitch can be measured as the distance from the center of the perforation to the center of the perforation adjacent to the perforation.
  • the switch according to one aspect of the present invention includes the joint structure.
  • the photoelectric sensor according to one aspect of the present invention includes the joint structure.
  • the proximity sensor according to one aspect of the present invention includes the joint structure.
  • FIG. 11 is a diagram showing a manufacturing process of the bonded structure in the first embodiment.
  • Step 1001 of FIG. 11 shows a step of forming a perforation 4 on the surfaces of the first member 1 and the third member 3.
  • the first member 1 is SUS304 (50 mm ⁇ 25 mm, thickness 3 mm)
  • the third member 3 is SUS304 (50 mm ⁇ 25 mm, thickness 1 mm)
  • the second member 2 is a thermosetting epoxy adhesive (viscosity before curing 35,000 mPa, Shore D hardness 80) was used.
  • a plurality of perforations 4 were formed on the surface of each member so that the perforation pitch was 65 ⁇ m.
  • Step 1002 of FIG. 11 shows a step of joining the surface on which the perforation of the first member 1 is formed and the surface on which the perforation of the third member 3 is formed.
  • the second member 2 is applied to the surface of the first member 1 on which the perforation 4 is formed, and as shown in step 1002 of FIG. 11, the third member 3 is applied to the surface of the first member 1 on which the perforation 4 is formed.
  • the surfaces on which the perforations 4 were formed were overlapped and pressed so as to be in contact with each other.
  • the second member 2 was cured by heating in an oven at 70 ° C. for 90 minutes to prepare a bonded structure.
  • Table 1 shows the pulsed laser irradiation conditions for forming the perforation.
  • the joint structure of Example 1 was the structure shown in FIG.
  • Examples 2 to 4 Three bonded structures were produced by the same method as in Example 1 except that the pulsed laser irradiation conditions for forming the perforations were changed. Table 1 shows the pulsed laser irradiation conditions for forming the perforation.
  • the joint structures of Examples 2 to 4 had the structures shown in FIGS. 2 to 4, respectively.
  • FIG. 12 is a diagram showing a manufacturing process of the bonded structure in Comparative Example 1.
  • Step 1003 of FIG. 12 shows a step of forming a perforation on the surfaces of the first member 1 and the third member 3.
  • laser irradiation was performed using a YAG laser ML-2150A (manufactured by Miyachi Technos), and as shown in step 1003 of FIG. 12, the width of the recesses 5 was 0.4 mm, and the adjacent recesses 5 were formed.
  • An uneven shape was formed on the joint surface of the members by continuous wave processing so that the width of the convex portion 6 between them was 0.15 mm. That is, a groove shape was formed.
  • Step 1004 of FIG. 2 shows a step of joining the surface on which the uneven shape of the first member is formed and the surface on which the uneven shape of the third member is formed.
  • the second member 2 is applied to the surface on which the uneven shape of the first member 1 is formed, and as shown in step 1004 of FIG. 12, the third member 3 is applied to the surface on which the uneven shape of the first member 1 is formed.
  • the surfaces were overlapped and pressurized so that the surfaces on which the uneven shape was formed were in contact with each other.
  • the second member 2 was cured by heating in an oven at 70 ° C. for 90 minutes to prepare a bonded structure.
  • Table 2 shows the conditions for laser irradiation.
  • the joint structure of Comparative Example 1 had the structure shown in FIG. Note that FIG. 14 shows a cross section parallel to the depth direction of the recess and the longitudinal direction of the recess.
  • Comparative Example 2 A bonded structure was prepared by the same method as in Example 1 except that the surface was treated by sandblasting instead of forming the perforations in Example 1.
  • Table 2 shows the conditions for sandblasting.
  • sandblasting was performed under the condition that the center line average roughness (Ra) representing the surface roughness was 5 to 10 ⁇ m.
  • the joint structure of Comparative Example 2 had the structure shown in FIG. Note that FIG. 15 shows a cross section parallel to the depth direction of the recess.
  • FIG. 13 is a diagram showing a manufacturing process of the bonded structure in the fifth embodiment.
  • the first member 1 is SUS304 (50 mm ⁇ 25 mm, thickness 3 mm)
  • the third member 3 is a PBT plate (50 mm ⁇ 25 mm, thickness 3 mm) containing 30% by weight of glass filler
  • the second member 2 is a thermosetting epoxy adhesive ( The viscosity before curing was 35,000 mPa and the shore D hardness was 80).
  • the coefficient of linear expansion of the first member was half that of the second member and the third member.
  • a plurality of perforations 4 were formed on the surface of each member so that the perforation pitch of the first member was 65 ⁇ m and that of the third member was 130 ⁇ m.
  • Step 1006 of FIG. 13 shows a step of joining the surface on which the perforation of the first member is formed and the surface on which the perforation of the third member is formed.
  • the second member 2 is applied to the surface on which the perforation 4 of the first member 1 is formed, and the perforation 4 of the first member 1 is formed as shown in step 1006 of FIG.
  • the surface on which the perforation 4 of the third member 3 was formed was overlapped and pressurized so as to be in contact with the surface. Then, in an oven, it was heated at 70 ° C. for 90 minutes to cure the second member to prepare a bonded structure.
  • Table 3 shows the pulsed laser irradiation conditions for forming the perforation.
  • Example 6 A bonded structure was produced in the same manner as in Example 5 except that the conditions for pulsed laser irradiation were changed. Table 3 shows the pulsed laser irradiation conditions for forming the perforation.
  • the thermal shock test was carried out in one cycle of treating at ⁇ 40 ° C. for 30 minutes and then at 70 ° C. for 30 minutes, and the other conditions were carried out based on JIS C 60068-2-14.
  • the tensile test was performed using an electromechanical universal testing machine 5900 manufactured by Instron. Specifically, the test was performed at a tensile speed of 5 mm / min in the shearing direction, and when the second member was broken or when the second member was completely peeled off from the surface of the first member and / or the third member (joining). The test was terminated when the interface broke).
  • ⁇ and ⁇ represent the following states, respectively.
  • ⁇ When the second member does not peel off from the surface of the first member and / or the third member, and the second member is destroyed.
  • X When the second member is peeled from the surface of the first member and / or the third member (the second member is peeled from the surface of the first member and / or the third member, and the second member is also destroyed. Including state).
  • One aspect of the present invention can be used for all products sealed in a metal housing using an adhesive.

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  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Thermal Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laser Beam Processing (AREA)
  • Laminated Bodies (AREA)
  • Connection Of Plates (AREA)
  • Standing Axle, Rod, Or Tube Structures Coupled By Welding, Adhesion, Or Deposition (AREA)

Abstract

耐熱衝撃性に優れた、高い接合強度を有する接合構造体を提供する。本発明の一実施形態に係る接合構造体は、表面に開口径が３０～１００μｍである複数の穿孔が形成された金属材料である第１部材と、表面に開口径が３０～１００μｍである独立した複数の穿孔が形成された、前記第１部材と同じもしくは異なる金属材料または熱可塑性樹脂である、第３部材と、前記第１部材の穿孔が形成された表面と前記第３部材の穿孔が形成された表面とを接合する硬化性樹脂である、第２部材と、を備える。

Description

接合構造体
　本発明は接合構造体およびその利用に関する。
　特許文献１には、第一成形体である金属成形体の接合面に対して、連続波レーザを使用して２００ｍｍ／ｓｅｃ以上の照射速度でレーザ光を連続照射する工程、前工程においてレーザ光が照射された金属成形体の接合面に接着剤層を形成する工程、前工程において接着剤を塗布した第一成形体である金属成形体の接合面に第二成形体を接着する工程を有する、複合成形体の製造方法が開示されている。
日本国公開特許公報「特開２０１５－２１３９６１号公報」
　特許文献１に係る複合成形体の製造方法によると、接合面に対して平行方向に引っ張ったときの引張強度と、接合面に対して垂直方向に引っ張ったときの引張強度との両方が優れた複合成形体を提供することができるとされている。
　しかしながら、特許文献１に係る発明は、第二成形体には加工がされていないため、熱衝撃などによる膨張収縮力が加わった際に、第二成形体側の接合強度が十分得られない可能性がある。また、第一成形体の接合面を連続波レーザで粗面化していることで、第一成形体の接合面は不均一な形状である。それにより、熱衝撃などによる膨張収縮力が加わった際に、第一成形体は応力集中点を有するため、接合強度の向上には未だ改善の余地がある。
　したがって、本件発明者は、従来の方法では、耐油性および耐薬品性を有する接着剤を用いたとしても、耐熱衝撃性を有する接合強度の優れた複合成形体を得ることは、困難であることを見出した。
　本発明は、一側面では、このような実情を鑑みてなされたものであり、その目的は、耐熱衝撃性に優れた、高い接合強度を示す接合構造体を提供することである。
　上述した課題を解決するために、本発明の一側面に係る接合構造体は、表面に開口径が３０～１００μｍである複数の穿孔が形成された金属材料である第１部材と、表面に開口径が３０～１００μｍである独立した複数の穿孔が形成された、前記第１部材と同じもしくは異なる金属材料または熱可塑性樹脂である、第３部材と、前記第１部材の穿孔が形成された表面と前記第３部材の穿孔が形成された表面とを接合する硬化性樹脂である、第２部材と、を備える。
　本発明の一態様によれば、耐熱衝撃性に優れた、高い接合強度を有する接合構造体を提供することができる。
図１は、実施形態に係る接合構造体の断面の一例を模式的に例示する。 図２は、実施形態に係る接合構造体の断面の一例を模式的に例示する。 図３は、実施形態に係る接合構造体の断面の一例を模式的に例示する。 図４は、実施形態に係る接合構造体の断面の一例を模式的に例示する。 図５は、実施形態に係る接合構造体の断面の一例を模式的に例示する。 図６は、実施形態に係る接合構造体の断面の一例を模式的に例示する。 図７は、実施形態に係る接合構造体の断面の一例を模式的に例示する。 図８は、実施形態に係る接合構造体の断面の一例を模式的に例示する。 図９は、実施形態に係る接合構造体の断面の一例を模式的に例示する。 図１０は、実施形態に係る接合構造体の断面の一例を模式的に例示する。 図１１は、実施例１における接合構造体の製造工程を模式的に表す。 図１２は、比較例１における接合構造体の製造工程を模式的に表す。 図１３は、実施例５における接合構造体の製造工程を模式的に表す。 図１４は、比較例１における接合構造体の断面を模式的に表す。 図１５は、比較例２における接合構造体の断面を模式的に表す。
　以下、本発明の一側面に係る実施の形態（以下、「本実施形態」とも表記する）を、図面に基づいて説明する。
　§１　適用例
　まず、図１を用いて、本発明の一態様に係る接合構造体の概要を説明する。図１は、実施形態に係る接合構造体の断面の一例を模式的に例示する。
　図１では、表面に開口径が３０～１００μｍである複数の穿孔が形成された金属材料である第１部材１と、表面に開口径が３０～１００μｍである複数の穿孔が形成された、前記第１部材と同じもしくは異なる金属材料または熱可塑性樹脂である、第３部材３と、前記第１部材の穿孔が形成された表面と前記第３部材の穿孔が形成された表面とを接合する硬化性樹脂である、第２部材２と、を備える接合構造体が例示されている。換言すれば、第１部材１と第３部材３とは、第２部材２を介して接合されている。なお、図１では、穿孔の深さ方向に平行な断面が示されている。
　第１部材１および第３部材３に形成された穿孔内に硬化性樹脂である第２部材２が充填され、硬化するため、物理的に強固なアンカー効果が得られる。これにより、耐熱衝撃性に優れた、高い接合強度を示す接合構造体を得ることができる。また、第１部材１および第３部材３の表面に穿孔を形成する表面加工を行うことにより、表面の不純物が除去され、接着強度を向上することができる。また、第１部材１および第３部材３の表面に複数の穿孔が形成されていることにより、接合部に係る応力が分散し、応力集中を回避した接合構造体を提供することができる。
　なお、硬化性樹脂としては、金属には接着しやすいが樹脂には接着しづらい接着剤も存在する。そのため、第１部材および第３部材が異なる材料である場合、化学的な結合のみによる接着では、接着剤の選定に制約が生じ得る。しかし、前記接合構造体では、前記アンカー効果による物理的な結合をさらに有することで、接着剤の選択肢が広がり、耐油性および耐薬品性を有する接着剤を選択することが可能となる。結果として、耐油性および耐薬品性を有し、かつ耐熱衝撃性に優れた、高い接合強度を示す接合構造体を得ることができる。
　§２構成例
　＜第１部材＞
　前記第１部材は、表面に開口径が３０～１００μｍである複数の穿孔が形成された金属材料である。前記金属材料の一例としては、鉄系金属、ステンレス系金属、銅系金属、アルミ系金属、マグネシウム系金属、および、それらの合金が挙げられる。また、金属材料は、金属成形体であってもよく、亜鉛ダイカスト、アルミダイカスト、粉末冶金などであってもよい。
　＜第３部材＞
　前記第３部材は、表面に開口径が３０～１００μｍである複数の穿孔が形成された前記第１部材と同じもしくは異なる金属材料または熱可塑性樹脂である。前記第３部材として用いられる金属材料の一例としては、第１部材で用いられる金属材料で例示した金属材料が挙げられる。第３部材は、第１部材と同じ金属材料であってもよいし、異なる金属材料であってもよい。
　前記熱可塑性樹脂の一例としては、ＰＶＣ（ポリ塩化ビニル）、ＰＳ（ポリスチレン）、ＡＳ（アクリロニトリル・スチレン共重合体）、ＡＢＳ（アクリロニトリル・ブタジエン・スチレン共重合体）、ＰＭＭＡ（ポリメチルメタクリレート）、ＰＥ（ポリエチレン）、ＰＰ（ポリプロピレン）、ＰＣ（ポリカーボネート）、ｍ－ＰＰＥ（変性ポリフェニレンエーテル）、ＰＡ６（ポリアミド６）、ＰＡ６６（ポリアミド６６）、ＰＯＭ（ポリアセタール）、ＰＥＴ（ポリエチレンテレフタレート）、ＰＢＴ（ポリブチレンテレフタレート）、ＰＳＦ（ポリサルホン）、ＰＡＲ（ポリアリレート）、ＰＥＩ（ポリエーテルイミド）、ＰＰＳ（ポリフェニレンサルファイド）、ＰＥＳ（ポリエーテルサルホン）、ＰＥＥＫ（ポリエーテルエーテルケトン）、ＰＡＩ（ポリアミドイミド）、ＬＣＰ（液晶ポリマー）、ＰＶＤＣ（ポリ塩化ビニリデン）、ＰＴＦＥ（ポリテトラフルオロエチレン）、ＰＣＴＦＥ（ポリクロロトリフルオロエチレン）、および、ＰＶＤＦ（ポリフッ化ビニリデン）が挙げられる。また、前記熱可塑性樹脂は、ＴＰＥ（熱可塑性エラストマ）であってもよく、ＴＰＥの一例としては、ＴＰＯ（オレフィン系）、ＴＰＳ（スチレン系）、ＴＰＥＥ（エステル系）、ＴＰＵ（ウレタン系）、ＴＰＡ（ナイロン系）、および、ＴＰＶＣ（塩化ビニル系）が挙げられる。
　＜第２部材＞
　前記第２部材は、前記第１部材の穿孔が形成された表面と前記第３部材の穿孔が形成された表面とを接合する硬化性樹脂である。
　前記硬化性樹脂は反応性硬化性樹脂であってもよい。前記反応性硬化性樹脂としては、例えば、加熱により架橋構造を形成して硬化する熱硬化性樹脂、および光を照射することにより架橋構造を形成して硬化する光硬化性樹脂等が挙げられる。
　前記反応性硬化性樹脂の一例としては、エポキシ（ＥＰ）樹脂、ポリウレタン（ＰＵＲ）樹脂、ユリアホルムアルデヒド（ＵＦ）樹脂、メラミンホルムアルデヒド（ＭＦ）樹脂、フェノールホルムアルデヒド（ＰＦ）樹脂、不飽和ポリエステル（ＵＰ）樹脂、およびシリコーン（ＳＩ）樹脂、アクリル樹脂が挙げられる。また、反応性硬化性樹脂は、繊維強化プラスチック（ＦＲＰ）であってもよい。
　また、前記硬化性樹脂は、エポキシ樹脂であってもよい。耐油性、耐薬品性および耐熱衝撃性をバランスよく両立させる観点から、前記反応性硬化性樹脂は、エポキシ樹脂が好ましい。
　前記第２部材には、充填剤がさらに添加されていてもよい。前記充填剤の一例としては、無機系充填剤（ガラス繊維、無機塩類など）、金属系充填剤、有機系充填剤、および、炭素繊維などが挙げられる。
　前記硬化性樹脂の硬化前の粘度は、２５℃において、好ましくは１０，０００～３００，０００ｍＰａ・ｓ、より好ましくは２５，０００～９０，０００ｍＰａ・ｓ、さらに好ましくは５０，０００～７５，０００ｍＰａ・ｓである。硬化性樹脂の硬化前の粘度が上記範囲内である場合、穿孔に硬化性樹脂が充填されやすいため、アンカー効果が発揮されやすく、接合強度が向上するという効果を奏する。前記粘度（ｍＰａ・ｓ）は、例えば、２５℃で、回転粘度計（ブルックフィールド計）（英弘精機社製）を用いることにより測定可能である。
　前記硬化性樹脂の硬化後のショアＤ硬度は、好ましくは３０～９０、より好ましくは５０～９０、さらに好ましくは７０～９０である。硬化性樹脂の硬化後のショアＤ硬度が上記範囲である場合、耐熱衝撃性に加え、耐油性および耐薬品性までも確保することができる。なお、ショアＤ硬度は、ＪＩＳＫ６２５３に準拠して測定される。
　＜穿孔＞
　前記穿孔の開口径は、好ましくは３０～１００μｍである。
　前記穿孔は、互いに独立している。つまり、穿孔が形成された表面に垂直な方向から見た場合に、穿孔の開口部が重畳しておらず、穿孔同士の境界線が明確である。よって、前記穿孔は、連続する溝とは異なる。前記穿孔が互いに独立していることにより、第１部材および第３部材の表面積が拡大する。これにより、第１部材および第３部材と、第２部材との接する面積が拡大されるため、物理的な接合強度が向上するという効果を奏する。
　前記穿孔の開口部の形状は、特に限定されず、例えば、円形であってもよく、多角形であってもよい。開口部の形状が円形であれば、穿孔を形成しやすい。また、例えば、前記穿孔の深さ方向に垂直な断面の径が、開口部から深さ方向に向かって一定であってもよく、開口部から深さ方向に向かって大きくなり、次いで小さくなってもよく、または開口部から深さ方向に向かって小さくなってもよい。好ましくは、前記穿孔の深さ方向に垂直な断面の径が、開口部から深さ方向に向かって大きくなり、次いで小さくなっている。換言すれば、穿孔の形状は、深さ方向にくびれを有することが好ましい。この構成により、第２部材がロックされる効果が発現する。すなわち、穿孔の深さ方向に平行な力が働いた場合、穿孔内部で硬化した第２部材が穿孔外部に引き出されづらくなり、物理的な接合強度が向上するという効果を奏する。穿孔の深さ方向に垂直な断面の径の、開口部から深さ方向に向かう変化は、曲線的であってもよく、直線的であってもよい。
　前記穿孔のピッチは、特に限定されず、穿孔の開口径、第１部材および第３部材の体積等に応じて、適宜変更することができる。ただし、前記穿孔のピッチの下限値は、穿孔が重畳しない距離とする。例えば、穿孔のピッチは、好ましくは５０～２００μｍ、より好ましくは５０～１５０μｍ、さらに好ましくは５０～８０μｍである。前記穿孔のピッチは、例えば、レーザ照射の照射間隔を制御することによって、調整可能である。
　穿孔の深さは、特に限定されず、穿孔の開口径、第１部材および第３部材の体積等に応じて、適宜変更することができる。例えば、穿孔の深さは、好ましくは３０～１００μｍである。
　第１部材と第３部材における穿孔の形状は、同じであってもよい。例えば、上述の図１に示すように、開口部が円形であり、深さ方向に垂直な断面の径が、深さ方向に向かって曲線的に小さくなる形状の穿孔が形成された第１部材１と、第１部材１と同様に、開口部が円形であり、深さ方向に垂直な断面の径が、深さ方向に向かって曲線的に小さくなる形状の穿孔が形成された第３部材３とを、第２部材２を介して接合させてもよい。
　穿孔は、図２～１０に示す形状であってもよい。図２～１０は、それぞれ、実施形態に係る接合構造体の、穿孔の深さ方向に平行な断面の一例を模式的に示す。
　穿孔の形状は、図２に示すように、開口部が円形であり、深さ方向に垂直な断面の径が、深さ方向に向かって曲線的に大きくなり、次いで小さくなる形状であってもよく、図３に示すように円錐形状であってもよい。
　あるいは、第１部材と第３部材における穿孔の形状は、異なっていてもよい。例えば、図４に示すように、円錐形状の穿孔が形成された第１部材１と、開口部が円形であり、深さ方向に垂直な断面の径が、深さ方向に向かって曲線的に大きくなり、次いで小さくなる形状の穿孔が形成された第３部材３とを、第２部材２を介して接合させてもよい。
　また、第１部材および第３部材における穿孔のピッチは、同じであってもよく、互いに異なっていてもよい。例えば、図５に示すように、第１部材１と第３部材３の線膨張係数が概ね同じであるが、第１部材１の体積が、第３部材３の体積よりも大きい場合、第１部材１における穿孔のピッチが、第３部材３における穿孔のピッチよりも小さくてもよい。線膨張係数が近い材料同士の接着であっても、それらの材料の体積が異なれば、熱衝撃による膨張収縮量の差が大きくなり得る。上記構成によれば、熱衝撃による膨張収縮量の差を小さくすることができ、さらに耐油性、耐薬品性および耐熱衝撃性を両立した、接合構造体を得ることができる。
　また、第１部材および第３部材における穿孔の深さは、同じであってもよく、互いに異なっていてもよい。例えば、図６に示すように、第１部材１と第３部材３の線膨張係数が概ね同じであるが、第１部材１の体積が、第３部材３の体積よりも大きい場合、第１部材１における穿孔の深さが、第３部材３における穿孔の深さよりも深くてもよい。上記構成により、熱衝撃による膨張収縮量の差を小さくすることができ、さらに耐油性、耐薬品性および耐熱衝撃性を両立した、接合構造体を得ることができる。
　さらに、第１部材および第３部材における穿孔のピッチおよび穿孔の深さの両方が、第１部材と第３部材とで異なっていてもよい。例えば、図７に示すように、第１部材１の体積が、第３部材３の体積よりも大きい場合、第１部材１における穿孔のピッチが、第３部材３における穿孔のピッチよりも小さく、第１部材１における穿孔の深さが、第３部材３における穿孔の深さよりも深くてもよい。
　あるいは、図８に示すように、穿孔が形成された表面以外の面でも第１部材１および第３部材３が、第２部材２を介して接合していてもよい。また、図９に示すように、第１部材１に、第３部材３に加えて他の部材５が、第２部材２を介して接合していてもよい。この他の部材７の表面にも上述の穿孔が形成され得る。また、他の部材７は、第１部材または第３部材として例示された金属材料または熱可塑性樹脂であってもよい。さらに、図１０に示すように、第３部材３が、第１部材１と接合している面とは別の面で、他の接着剤８を介して、他の部材７と接合していてもよい。第３部材３の第１部材１と接合している面とは別の面にも上述の穿孔が形成され得る。他の接着剤８は、第２部材として例示された硬化性樹脂であってもよい。
　＜接合構造体の製造方法＞
　前記接合構造体は、例えば、前記第２部材を介して、前記第１部材の穿孔が形成された表面と前記第３部材の穿孔が形成された表面とを接合する工程を含む製造方法によって製造され得る。
　前記穿孔は、レーザ照射によって形成されることが好ましい。前記穿孔を形成するためのレーザの種類としては、ファイバレーザ、ＹＡＧレーザ、ＹＶＯ４レーザ、半導体レーザ、炭酸ガスレーザ、エキシマレーザ等を選択することができ、レーザの波長を考慮すると、ファイバレーザ等が好ましい。
　例えば、第１部材の穿孔が形成された表面、第３部材の穿孔が形成された表面、またはその両方に、第２部材を塗布し、次いで第１部材の穿孔が形成された表面に、第３部材の穿孔が形成された表面が接するように重ね合せる。ここで、第１部材と第３部材とを重ね合せた領域を加圧してもよい。その後、第２部材を硬化させることにより、接合構造体を得ることができる。
　また、第２部材を塗布する前に紫外線照射等により、第２部材中のＯＨ基が露出するように処理してもよい。あるいは、第２部材を塗布中および／または塗布した後に、加熱または真空引きを行ってもよい。これらの処理により、穿孔に第２部材が充填される際の表面張力が低減され、穿孔に第２部材が充填されやすくなる。第２部材の硬化の方法は、第２部材が十分に硬化すれば、特に限定されない。
　＜接合構造体の利用＞
　前記接合構造体は、例えば、スイッチ、光電センサおよび近接センサに利用することができる。
　一般的に、光電センサは、基板等の内部部品が、金属筐体によって封止された構造である。従来、金属筐体によって封止する場合、溶接するか、または表面を加工せずに接着剤によって接合していた。しかし、溶接では、基板等の内部部品が熱によりダメージを受けるおそれがあった。また、表面を加工せずに接着剤によって接合する方法では、はがれやすく、接合強度に改善の余地があった。また、スイッチ、光電センサ、および近接センサにおいて、金属同士の接合の他に、金属と樹脂の接合を必要とする部分があり、従来、金属と樹脂を直接的に接合していた。しかし、このような方法では、金属と樹脂とがはがれやすい傾向にある。
　前記接合構造体を備えるスイッチ、光電センサまたは近接センサでは、高い接合強度を有し、さらに内部部品の受ける熱ダメージが軽減され得る。
　本発明は上述した各実施形態に限定されるものではなく、請求項に示した範囲で種々の変更が可能であり、異なる実施形態にそれぞれ開示された技術的手段を適宜組み合わせて得られる実施形態についても本発明の技術的範囲に含まれる。
　〔まとめ〕
　本発明の一側面に係る接合構造体は、表面に開口径が３０～１００μｍである複数の穿孔が形成された金属材料である第１部材と、表面に開口径が３０～１００μｍである独立した複数の穿孔が形成された、前記第１部材と同じもしくは異なる金属材料または熱可塑性樹脂である、第３部材と、前記第１部材の穿孔が形成された表面と前記第３部材の穿孔が形成された表面とを接合する硬化性樹脂である、第２部材と、を備える。
　硬化性樹脂は、架橋反応により硬化し得る。上記構成では、穿孔が形成された表面同士に硬化性樹脂を塗布、硬化することで、硬化性樹脂が穿孔内に充填され、物理的に強固なアンカー効果が得られる。これにより、耐熱衝撃性に優れた、高い接合強度を示す接合構造体を得ることができる。また、表面に穿孔を形成する表面加工を行うことにより、部材の表面の不純物が除去され、接着強度を向上することができる。また、複数の穿孔が形成されていることにより、接合部に係る応力が分散し、応力集中を回避した接合構造体を提供することができる。前記穿孔の開口径は、金属材料の表面における穿孔の開口部の最大の径として測定することができる。
　上記一側面に係る接合構造体において、前記硬化性樹脂は、反応性硬化性樹脂であってよい。反応性硬化性樹脂は、外部からのエネルギーにより架橋構造を形成し、硬化し得る。当該構成により、溶接よりも低い温度で第１部材と第３部材とを接合することができ、接合構造体に含まれる部材への熱ダメージを軽減することができる。
　上記一側面に係る接合構造体において、前記反応性硬化性樹脂は、エポキシ樹脂であってよい。当該構成によれば、耐熱衝撃性に加え、耐油性および耐薬品性までも確保することができる。エポキシ樹脂は、少なくとも一つのエポキシ基を含有し得る。
　上記一側面に係る接合構造体において、前記硬化性樹脂の硬化前の粘度は、２５℃において、２５，０００～９０，０００ｍＰａ・ｓであってもよい。当該構成によれば、穿孔に硬化性樹脂が充填されやすいため、アンカー効果が発揮されやすく、接合強度が向上するという効果を奏する。
　上記一側面に係る接合構造体において、前記硬化性樹脂の硬化後のショアＤ硬度は、３０～９０であってよい。当該構成によれば、耐熱衝撃性に加え、耐油性および耐薬品性までも確保することができる。
　上記一側面に係る接合構造体において、前記穿孔の深さ方向に垂直な断面の径が、開口部から深さ方向に向かって大きくなり、次いで小さくなってもよく、または開口部から深さ方向に向かって小さくなってもよい。当該構成によれば、アンカー効果が発揮されやすいため、耐熱衝撃性の安定性が確保される。
　上記一側面に係る接合構造体において、前記穿孔のピッチは５０～２００μｍであってよい。ただし、穿孔のピッチの下限は穿孔が重畳しない距離とする。当該構成によれば、穿孔が規則的に並ぶため、接合部に係る応力が均一に分散し、応力集中を回避しやすい。前記穿孔のピッチは、穿孔の中心から、その穿孔に隣り合う穿孔の中心までの距離として測定することができる。
　本発明の一側面に係るスイッチは、前記接合構造体を備える。
　本発明の一側面に係る光電センサは、前記接合構造体を備える。
　本発明の一側面に係る近接センサは、前記接合構造体を備える。
　以下、実施例に基づいて本発明をより詳細に説明するが、本発明は以下の実施例に限定されるものではない。
　〔実施例１〕
　図１１は、実施例１における接合構造体の製造工程を表す図である。図１１の工程１００１は、第１部材１および第３部材３の表面に穿孔４を形成する工程を示す。第１部材１としてＳＵＳ３０４（５０ｍｍ×２５ｍｍ、厚み３ｍｍ）、第３部材３としてＳＵＳ３０４（５０ｍｍ×２５ｍｍ、厚み１ｍｍ）、第２部材２として熱硬化性エポキシ接着剤（硬化前の粘度　３５，０００ｍＰａ、ショアＤ硬度　８０）を用いた。第１部材１の長手方向の一端から２ｍｍ×２１ｍｍの範囲、および第３部材３の長手方向の一端から５ｍｍ×２１ｍｍの範囲に、ファイバレーザマーカ　ＭＸ－Ｚ２０００Ｈ（オムロン株式会社製）を用いてパルスレーザ照射を行うことにより、各部材の表面に複数の穿孔４を、穿孔のピッチが６５μｍとなるように形成した。
　図１１の工程１００２は、第１部材１の穿孔が形成された表面と、第３部材３の穿孔が形成された表面を接合する工程を示す。第１部材１の穿孔４が形成された表面に、第２部材２を塗布し、図１１の工程１００２に示すように、第１部材１の穿孔４が形成された表面に、第３部材３の穿孔４が形成された表面が接するように重ね合せて加圧した。次いで、オーブン内で、７０℃で９０分間加熱し、第２部材２を硬化させることで、接合構造体を作製した。穿孔を形成する際のパルスレーザ照射条件を表１に示す。実施例１の接合構造体は図１に示す構造であった。
　〔実施例２～４〕
　穿孔を形成する際のパルスレーザ照射条件をそれぞれ変更したこと以外は、実施例１と同じ方法で３つの接合構造体を作製した。穿孔を形成する際のパルスレーザ照射条件を表１に示す。実施例２～４の接合構造体は、それぞれ図２～４に示す構造であった。
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-I000002
　〔比較例１〕
　図１２は、比較例１における接合構造体の製造工程を表す図である。図１２の工程１００３は、第１部材１および第３部材３の表面に穿孔を形成する工程を示す。実施例１の穿孔形成に代わり、ＹＡＧレーザＭＬ－２１５０Ａ（ミヤチテクノス製）を用いてレーザ照射を行い、図１２の工程１００３に示すように凹部５の幅が０．４ｍｍ、隣り合う凹部５の間の凸部６の幅が０．１５ｍｍとなるように、連続波加工によって部材の接合表面に凹凸形状を形成した。すなわち、溝形状を形成した。
　図２の工程１００４は、第１部材の凹凸形状が形成された表面と、第３部材の凹凸形状が形成された表面を接合する工程を示す。
　第１部材１の凹凸形状が形成された表面に、第２部材２を塗布し、図１２の工程１００４に示すように、第１部材１の凹凸形状が形成された表面に、第３部材３の凹凸形状が形成された表面が接するように重ね合せて加圧した。次いで、オーブン内で、７０℃で９０分間加熱し、第２部材２を硬化させることで、接合構造体を作製した。レーザ照射の条件を表２に示す。比較例１の接合構造体は図１４に示す構造であった。なお、図１４は、凹部の深さ方向および凹部の長手方向に平行な断面を示す。
　〔比較例２〕
　実施例１の穿孔形成に代わり、サンドブラストにより表面処理したこと以外は、実施例１と同じ方法で接合構造体を作製した。サンドブラストの条件を表２に示す。ここで、サンドブラストは、表面粗さを表す中心線平均粗さ（Ｒａ）が５～１０μｍとなる条件にて行った。比較例２の接合構造体は図１５に示す構造であった。なお、図１５は、凹部の深さ方向に平行な断面を示す。
Figure JPOXMLDOC01-appb-T000003
　〔実施例５〕
　図１３は、実施例５における接合構造体の製造工程を表す図である。第１部材１としてＳＵＳ３０４（５０ｍｍ×２５ｍｍ、厚み３ｍｍ）、第３部材３としてガラスフィラーを３０重量％含むＰＢＴ板（５０ｍｍ×２５ｍｍ、厚み３ｍｍ）、第２部材２として熱硬化性エポキシ接着剤（硬化前の粘度　３５，０００ｍＰａ、ショアＤ硬度　８０）を用いた。ここで、第１部材の線膨張係数は、第２部材および第３部材の２分の１であった。
　第１部材１の長手方向の一端から２ｍｍ×２１ｍｍの範囲、および第３部材３の長手方向の一端から５ｍｍ×２１ｍｍの範囲に、ファイバレーザマーカ　ＭＸ－Ｚ２０００Ｈ（オムロン株式会社製）を用いてパルスレーザ照射を行うことにより、各部材の表面に、第１部材では穿孔のピッチが６５μｍとなるように、第３部材では穿孔のピッチが１３０μｍとなるように、複数の穿孔４を形成した。
　図１３の工程１００６は、第１部材の穿孔が形成された表面と、第３部材の穿孔が形成された表面を接合する工程を示す。実施例１と同様にして、第１部材１の穿孔４が形成された表面に、第２部材２を塗布し、図１３の工程１００６に示すように、第１部材１の穿孔４が形成された表面に、第３部材３の穿孔４が形成された表面が接するように重ね合せて加圧した。次いで、オーブン内で、７０℃で９０分間加熱し、第２部材を硬化させることで、接合構造体を作製した。穿孔を形成する際のパルスレーザ照射条件を表３に示す。
　〔実施例６〕
　パルスレーザ照射の条件を変更した以外は、実施例５と同じ方法で接合構造体を作製した。穿孔を形成する際のパルスレーザ照射条件を表３に示す。
Figure JPOXMLDOC01-appb-T000004
　〔接合性評価〕
　上述の実施例１～６の接合構造体および比較例１～２の接合構造体を用いて、接合性評価を以下の方法で行った。
　熱衝撃試験前と熱衝撃試験１００サイクル後に、得られた接合構造体の引張試験を行い、それによる接合部の破壊状態を評価した。ここで、熱衝撃試験は、－４０℃で３０分処理した後、７０℃で３０分処理することを１サイクルとし、その他の条件はＪＩＳ　Ｃ　６００６８－２－１４に基づき実施した。また、引張試験は、インストロン社製の電気機械式万能試験機５９００を用いて行った。具体的には、せん断方向に引張速度５ｍｍ／ｍｉｎで試験を行い、第２部材の破断した時点、または第１部材および／または第３部材の表面から第２部材が完全に剥離した時点（接合界面が破断した時点）で、試験を終了した。
　結果を、表４に示す。表中、○および×は、それぞれ以下の状態を表す。
○：第１部材および／または第３部材の表面から第２部材が剥離せず、第２部材の破壊が生じた場合。
×：第１部材および／または第３部材の表面から第２部材が剥離した場合（第１部材および／または第３部材の表面から第２部材が剥離し、さらに第２部材の破壊も生じた状態を含む）。
Figure JPOXMLDOC01-appb-T000005
　実施例１～６の接合構造体は、熱衝撃試験前の引張試験および熱衝撃試験１００サイクル後の引張試験のいずれにおいても、接合界面剥離は観察されなかった。
　一方、比較例１の接合構造体は、熱衝撃試験前の引張試験および熱衝撃試験１００サイクル後の引張試験の両方において、接合界面剥離が観察された。比較例２の接合構造体は、熱衝撃試験前の引張試験において、接合界面剥離は観察されなかったが、熱衝撃試験１００サイクル後の引張試験において、接合界面剥離が観察された。
　本発明の一態様は、接着剤を用いて金属筐体に封止される製品全般に利用することができる。
　１　第１部材
　２　第２部材
　３　第３部材
　４　穿孔

Claims (10)

  1. 　表面に開口径が３０～１００μｍである複数の穿孔が形成された金属材料である第１部材と、
    　表面に開口径が３０～１００μｍである複数の穿孔が形成された、前記第１部材と同じもしくは異なる金属材料または熱可塑性樹脂である、第３部材と、
    　前記第１部材の穿孔が形成された表面と前記第３部材の穿孔が形成された表面とを接合する硬化性樹脂である、第２部材と、を備えた接合構造体。
  2. 　前記硬化性樹脂が反応性硬化性樹脂である、請求項１に記載の接合構造体。
  3. 　前記反応性硬化性樹脂がエポキシ樹脂である、請求項１または２に記載の接合構造体。
  4. 　前記硬化性樹脂の硬化前の粘度は、２５℃において、２５，０００～９０，０００ｍＰａ・ｓである、請求項１から３のいずれか１項に記載の接合構造体。
  5. 　前記硬化性樹脂の硬化後のショアＤ硬度は、３０～９０である、請求項１から４のいずれか１項に記載の接合構造体。
  6. 　前記穿孔の深さ方向に垂直な断面の径が、開口部から深さ方向に向かって大きくなり、次いで小さくなる、または開口部から深さ方向に小さくなる、請求項１から５のいずれか１項に記載の接合構造体。
  7. 　前記穿孔のピッチの下限は穿孔が重畳しない距離であり、上限は２００μｍである、請求項１から６のいずれか１項に記載の接合構造体。
  8. 　請求項１から７のいずれか１項に記載の接合構造体を備える、スイッチ。
  9. 　請求項１から７のいずれか１項に記載の接合構造体を備える、光電センサ。
  10. 　請求項１から７のいずれか１項に記載の接合構造体を備える、近接センサ。
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