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CN102803022A - 复合透气膜及使用该复合透气膜的透气结构 - Google Patents

复合透气膜及使用该复合透气膜的透气结构 Download PDF

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Publication number
CN102803022A
CN102803022A CN2010800254101A CN201080025410A CN102803022A CN 102803022 A CN102803022 A CN 102803022A CN 2010800254101 A CN2010800254101 A CN 2010800254101A CN 201080025410 A CN201080025410 A CN 201080025410A CN 102803022 A CN102803022 A CN 102803022A
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CN
China
Prior art keywords
film
main part
porous chips
compound breath
breath film
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CN2010800254101A
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English (en)
Inventor
古山了
森山顺一
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Nitto Denko Corp
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Nitto Denko Corp
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Publication of CN102803022A publication Critical patent/CN102803022A/zh
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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V31/00—Gas-tight or water-tight arrangements
    • F21V31/03—Gas-tight or water-tight arrangements with provision for venting
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Optics & Photonics (AREA)
  • Electromagnetism (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • General Engineering & Computer Science (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)
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Abstract

透气结构(13)具备：具有透气用的开口部(11h)的树脂部件(11)和以堵塞开口部(11h)的方式安装在树脂部件(11)上的复合透气膜(6)。复合透气膜(6)具备：包含氟树脂膜的主体部(2)和叠合在主体部(2)上的超高分子量聚乙烯多孔片(3)。超高分子量聚乙烯多孔片(3)具有黑色。在主体部(2)与超高分子量聚乙烯多孔片(3)之间，形成有使两者一体化的激光熔敷部(4)。

Description

复合透气膜及使用该复合透气膜的透气结构
技术领域
本发明涉及复合透气膜及使用该复合透气膜的透气结构。
背景技术
在收容灯、传感器、ECU(电子控制单元，electronic control unit)等汽车的电子部件的壳体中，安装有用于确保壳体内部与外部的透气、同时阻止异物侵入壳体内部的透气构件。专利文献1中公开了这种透气构件的一例。
如图9所示，专利文献1中公开的透气构件具备：配置有透气膜102的支撑体103和覆盖透气膜102的保护部104。将这样的透气构件101隔着O形圈105固定在壳体106的开口部107上。气体从透气膜102透过，由此能够确保壳体106的透气。保护部104防止透气膜102因外力(例如洗车时的水喷射)而受到损伤或者透气膜102的透气性因尘垢的堆积而降低。
现有技术文献
专利文献
专利文献1：日本特开2004-47425号公报
发明内容
近年来，随着各种制品的小型化的流行，要求降低透气构件的高度。图9所示的现有透气构件101的高度的降低虽然可以通过省略保护部104来实现，但在透气膜102的耐久性方面存在问题。
另外，作为降低透气构件的高度的尝试，还试着通过嵌件模塑使透气膜和支撑体一体化。但是存在如下问题：嵌件模塑时透气膜由于定位销等而受到损伤，容易产生耐水不良等缺陷。
鉴于上述情况，本发明的目的在于，提供容易降低透气结构的高度且具有高强度的复合透气膜及使用该复合透气膜的透气结构。
即，本发明提供一种复合透气膜，具备：
包含氟树脂膜的主体部，
具有黑色且叠合在所述主体部上的超高分子量聚乙烯多孔片，和
通过介于所述主体部与所述超高分子量聚乙烯多孔片之间而使两者一体化的激光熔敷部。
另一方面，本发明提供一种透气结构，
具备：
具有透气用的开口部的树脂部件，和
以堵塞所述开口部的方式安装在所述树脂部件上的透气膜；
所述透气膜由上述本发明的复合透气膜构成。
发明效果
根据上述本发明的复合透气膜，在包含氟树脂膜的主体部上叠合有超高分子量聚乙烯多孔片(以下称为UHMWPE多孔片)。与PET无纺布等现有的增强材料相比，UHMWPE多孔片具有高强度。因此，通过组合UHMWPE多孔片和主体部，能得到高强度的复合透气膜。另外，UHMWPE多孔片也不容易成为透气性降低的原因。
进而，UHMWPE多孔片和主体部通过激光熔敷部而一体化。氟树脂膜(主体部)与UHMWPE多孔片的热层压中，加热和加压的条件难以设定，有时粘合不充分。为了进行主体部与UHMWPE多孔片的粘合而在两者间冒然地加热和加压还有可能使氟树脂膜受到损伤，因此不适合。与此相对，根据本发明，不进行氟树脂膜与UHMWPE多孔片的热层压即可完成一体化，因而能够排除上述问题。另外，由于UHMWPE多孔片具有暗色，因此能够通过吸收激光简单地进行UHMWPE的局部熔融，从而能够以良好的精度形成激光熔敷部。
附图说明
图1是具有本发明第一实施方式的透气结构的壳体的整体立体图。
图2是图1所示的壳体的透气结构(以及复合透气膜)的剖面图。
图3是复合透气膜的主体部的剖面图。
图4A是复合透气膜的制造工序图。
图4B是接续于图4A的制造工序图。
图5是高效地制造多个复合透气膜的方法的说明图。
图6A是使用复合透气膜的透气构件(透气结构)的立体图。
图6B是图6A所示的透气构件(透气结构)的分解立体图。
图7是使用图6A所示的透气构件的壳体的剖面图。
图8是耐水试验方法的说明图。
图9是现有的透气构件的剖面图。
具体实施方式
图1是具有本发明一个实施方式的透气结构的壳体的整体立体图。图2是图1所示的透气结构的剖面图。如图1所示，壳体200具备：复合透气膜6、第一壳体部件11(壳体的上部)以及第二壳体部件12(壳体的底部)。透气结构13由复合透气膜6以及第一壳体部件11形成。复合透气膜6一方面允许空气、水蒸汽在壳体200的内部和外部之间来往，另一方面防止液体、尘垢等异物侵入壳体200的内部。由于复合透气膜6的这种作用，能够在不允许异物侵入的情况下使壳体200内部的气氛与外部的气氛相等。
如图2所示，透气结构13具有：复合透气膜6和安装有复合透气膜6的第一壳体部件11。第一壳体部件11起到支撑复合透气膜6的支撑体的作用。第一壳体部件11中设有用于在壳体200(图1)的内部和外部之间进行透气的开口部11h。复合透气膜6以堵塞该开口部11h的方式安装在第一壳体部件11上。具体而言，复合透气膜6的外周部6g嵌入第一壳体部件11中。即，通过嵌件模塑，使复合透气膜6与第一壳体部件11一体化。这样，能够使复合透气膜6与第一壳体部件11牢固地接合。另外，复合透气膜6没有突出于透气结构13的表面。换言之，复合透气膜6位于低于第一壳体部件11表面的位置，因此外力难以波及到复合透气膜6。
复合透气膜6具有包含氟树脂膜的主体部2和叠合在主体部2上的树脂多孔片3。在本实施方式中，仅在主体部2的一个表面上设有树脂多孔片3。树脂多孔片3由超高分子量聚乙烯(UHMWPE)多孔片形成。复合透气膜6以UHMWPE多孔片3露出于壳体200的外部的方向固定在第一壳体部件11上。复合透气膜6的形状典型地为圆形，但只要能够堵塞开口部11h，也可以是方形等其他形状。
在主体部2与UHMWPE多孔片3之间形成有激光熔敷部4。激光熔敷部4通过介于主体部2与UHMWPE多孔片3之间而使两者一体化。为了良好地吸收激光，UHMWPE多孔片3被着色为黑色。在本实施方式中，激光熔敷部4形成于复合透气膜6的外周部6g。激光熔敷部4俯视为环形，且嵌入第一壳体部件11中。仅在嵌入第一壳体部件11中的外周部6g形成激光熔敷部4时，激光熔敷部4不会妨碍透气，因此优选。
如图3所示，主体部2可以具有氟树脂膜2a和设于氟树脂膜2a的一个表面上的增强材料2b。例如，以UHMWPE多孔片3、氟树脂膜2a和增强材料2b的顺序将它们叠合时，具有能够从两面保护氟树脂膜2a的优点。另外，增强材料2b可以设于氟树脂膜2a的两个表面，也可以省略。即，主体部2可以仅由氟树脂膜2a构成。由于主体部2由UHMWPE多孔片3支撑，因此能够省略增强材料2b，从而能够减少部件数量。此外，为了使规定波长的激光相对地难以被吸收，主体部2可以为白色。在设置增强材料2b的情况下，优选增强材料2b也为白色。
氟树脂膜2a是具有透气性的膜，典型地为多孔膜。作为可以用于氟树脂膜2a的氟树脂，可以列举聚四氟乙烯(PTFE)、聚氯三氟乙烯、四氟乙烯-六氟丙烯共聚物、四氟乙烯-乙烯共聚物。其中，优选能够以较小的面积确保高透气性、阻止异物侵入壳体200内部的能力也优良的PTFE。PTFE多孔膜可以通过拉伸法、提取(抽出)法等公知的成形方法制造。对于氟树脂膜2a，可以实施斥油处理或斥水处理。
增强材料2b是由聚酯、聚乙烯、芳族聚酰胺等树脂制成的构件。通过设置增强材料2b，氟树脂膜2a的操作变得容易。增强材料2b的形态，只要能够维持透气膜6的透气性则没有特别的限定，例如为织物、无纺布、网(ネット)或网状物(メッシュ)，典型地为无纺布。
氟树脂膜2a与增强材料2b可以通过热层压粘合，也可以使用胶粘剂粘合。优选通过均匀分散于面内的熔敷部或胶粘部将氟树脂膜2a与增强材料2b粘合。熔敷部或胶粘部的面积例如在总面积的5～20％的范围内时，不易发生耐水性不充分或者产生剥离。
考虑到强度、透气性、耐水性、激光透射性等所要求的特性，主体部2的厚度优选在0.02～1.0mm(或0.05～0.2mm)的范围内。主体部2的透气度以通过JIS P 8117中规定的格利试验机法得到的格利值计优选在0.1～500秒/100cm3的范围内。主体部2的耐水压优选为1.0kPa以上。
如参照图9说明过的那样，现有的透气构件中设有用于保护透气膜的构件。用于防止透气膜因受到水滴等异物的直接冲击而受到损伤。与此相对，根据本实施方式，主体部2由UHMWPE多孔片3保护，因此即使复合透气膜6没有被其他构件所覆盖，复合透气膜6也不容易受到损伤。通过省略用于覆盖复合透气膜6的其他构件，能够减少部件数量、降低透气结构的高度。当然，在图2所示的透气结构13中，也可以设置覆盖复合透气膜6的构件。
UHMWPE多孔片3的厚度没有特殊限定，但优选在0.02～3.0mm(或0.05～1.0mm)的范围内。从充分确保复合透气膜6的强度的观点出发，优选UHMWPE多孔片3的厚度t2大于主体部2的厚度t1。例如，可以规定厚度t1和t2，使其满足2≤(t2/t1)≤50。
在此，“超高分子量聚乙烯”是指平均分子量为50万以上的聚乙烯。超高分子量聚乙烯的平均分子量通常为200～1000万的范围。平均分子量可以通过例如ASTM D4020(粘度法)中规定的方法测定。在本说明书中，将超高分子量聚乙烯简记为“UHMWPE(Ultra HighMolecular Weight Poly-ethylene)”。
UHMWPE多孔片3可以由UHMWPE粉末的烧结体制造。UHMWPE粉末的烧结体通过将填充到模具中的UHMWPE粉末(平均粒径30～200μm)在UHMWPE的熔点附近的温度(例如130～160℃)下烧结而得到。所得烧结体通常为块状。只要将块状的烧结体通过切削加工成形为片状，即可得到UHMWPE多孔片。根据该制造方法(粉末烧结法)，所得UHMWPE多孔片的孔隙率为20～50％的范围。
另外，为了使UHMWPE多孔片3比主体部2更容易吸收规定波长的激光，UHMWPE多孔片3具有黑色。具体而言，UHMWPE多孔片3被着色为黑色。着色可以仅对要形成激光熔敷部4的部分进行，但进行整体着色更容易。在上述的UHMWPE多孔片3的制造中，将UHMWPE粉末与着色剂混合来制作烧结体即可。另外，需要选择在烧结温度下不分解的着色剂，例如，可以适合使用能够从キャボット公司获得的Black Pearls L、Black Pearls 1000等炭黑。相对于100重量份的UHMWPE粉末，可以在例如1～10重量份的范围内含有这些着色剂。
需要说明的是，“具有黑色”是指含有用于着色成黑色的着色剂。一般而言，以JIS Z 8721明度(无彩色)中规定的黑色度计，将1～4判断为“黑”、5～8判断为“灰”、9以上判断为“白”。本发明中，UHMWPE多孔片3为灰或黑(黑色度8以下)，从激光的吸收效率的观点出发，优选为黑(黑色度4以下)。
由UHMWPE粉末的烧结体制造的UHMWPE多孔片3，保持有耐化学品性、耐磨损性、脱模性等UHMWPE的优良特性。另外，通过多孔化，还获得了透气性、缓冲性、滑动性等特性。在本实施方式中，以UHMWPE多孔片3露出于表面的方式规定了复合透气膜6相对于第一壳体部件11的姿势。因此，树脂多孔片3具有优良的耐化学品性对于本实施方式的透气结构13而言是优选的。通过使UHMWPE多孔片3具有高滑动性，异物变得难以附着在复合透气膜6上。
另外，UHMWPE多孔片3与通常的增强材料聚乙烯无纺布等相比较硬且具有高强度。将相同强度的UHMWPE多孔片3和聚乙烯无纺布进行比较时，UHMWPE多孔片3明显更薄，并且透气性也优良。在没有设置用于保护复合透气膜6的罩的情况下，复合透气膜6直接暴露于外部气氛(例如汽车的发动机舱)中，因此复合透气膜6本身要求具有充分的物理强度。就聚乙烯无纺布等现有的增强材料而言，为了得到充分的强度，需要相当的厚度，存在牺牲透气性的问题。相对于此，UHMWPE多孔片3具有能够以高水平兼具强度和透气性的优点。
对于包含氟树脂膜的主体部2与UHMWPE多孔片3的粘合，激光熔敷法是极为有效的。这是因为，UHMWPE多孔片与主体部2的热层压中，加热和加压条件的选择很困难。从强度的观点出发使用较厚的UHMWPE多孔片时，进行热层压时难以导热，有时粘合不充分。为了进行主体部2与UHMWPE多孔片3的粘合而在两者间冒然地加热和加压还有可能使氟树脂膜2a受到损伤，因此不适合。根据本实施方式，不进行主体部2与UHMWPE多孔片3的热层压即可完成粘合，因而能够排除上述问题。
其次，第一壳体部件11和第二壳体部件12是热塑性树脂或弹性体的成形品。作为热塑性树脂，可以列举PBT(聚对苯二甲酸丁二醇酯)、PET(聚对苯二甲酸乙二醇酯)、PPS(聚苯硫醚)、PSU(聚砜)、PP(聚丙烯)、PE(聚乙烯)、ABS(丙烯腈-丁二烯-苯乙烯共聚物)。作为弹性体，可以列举氯丁橡胶、异戊橡胶、苯乙烯-丁二烯橡胶、含有天然橡胶作为主要成分的橡胶组合物。使用这些树脂，通过注塑成形等公知的成形方法，能够制造壳体部件11、12。
壳体部件11、12的材料中，还可以含有颜料、增强用填充材料和其他添加剂等。颜料的具体例为炭黑、钛白。增强用填充材料的具体例为玻璃粒子、玻璃纤维。其他添加材料的具体例为防水剂、绝缘材料。
接着，参照图4A和图4B对制造图2所示的透气结构的方法进行说明。如图4A所示，首先，准备包含氟树脂膜的主体部2和UHMWPE多孔片3，将它们重叠。主体部2和UHMWPE多孔片3例如为具有相同直径的圆形。在主体部2和UHMWPE多孔片3的层叠体上载置透光夹具9。对透光夹具9施加适当的压力，使主体部2与UHMWPE多孔片3密合。
透光夹具9用于保持主体部2和UHMWPE多孔片3的位置关系，其具有散热用的开口部9h。透光夹具9典型地由使激光透过的透明玻璃板形成。通过使用这样的透光夹具9，能够防止损伤波及到主体部2。
然后，如图4B所示，隔着透光夹具9向主体部2与UHMWPE多孔片3的界面照射激光LB。从主体部2侧入射的激光LB，使主体部2与UHMWPE多孔片3的界面附近的、主要是UHMWPE多孔片3的表层部熔化。由此，形成激光熔敷部4(图2)。
激光熔敷的条件，优选考虑对主体部2和UHMWPE多孔片3的损伤而进行调节。例如，可以将激光输出功率在20～300W(或20～50W)的范围内进行调节、将激光波长在800～1100nm(或800～950nm)的范围内进行调节、将熔敷时间在0.05～5.0秒(或0.1～1.5秒)的范围内进行调节。激光的种类没有特殊限定，可以使用CO2激光、准分子激光等气体激光，也可以使用YAG激光等固体激光。
另外，也可以由主体部2与UHMWPE多孔片3的层叠体总括性地制造多个复合透气膜6。具体而言，如图5所示，准备大面积的层叠体W，确定与要制造的复合透气膜6的形状对应的多个切割预定线CL。对各区域依次进行激光照射工序，以在切割预定线CL的内侧区域形成激光熔敷部4。激光熔敷部4形成后，沿着切割预定线CL对层叠体W进行冲裁。这样，能够由1个层叠体W高效地制造多个复合透气膜6。由于减少了小部件的操作次数，因此生产率也提高。
图2所示的透气结构13可以通过嵌件注塑成形法制造。具体而言，在用于使第一壳体部件11成形的模具内设置复合透气膜6。进行用于形成第一壳体部件11的注塑成形工序，以使复合透气膜6的外周部6g被注射到模具中的树脂包覆。由于将高强度的UHMWPE多孔膜3与主体部2组合，因此在模具中设置复合透气膜6时，复合透气膜6不容易受到损伤。另外，主体部2和UHMWPE多孔片3由于预先进行了激光熔敷，因此容易操作。因此，透气结构13的制造工序容易实现自动化。
(变形例1)
图6A和图6B所示的透气结构23具备：具有透气用的开口部21h的支撑体21和安装在支撑体21上的复合透气膜6。即，透气结构23以透气构件(透气栓)的形式构成。复合透气膜6为参照图2说明的复合透气膜，其通过胶粘剂或粘合带固定在支撑体21上。另外，复合透气膜6与支撑体21也可以通过嵌件模塑而一体化。支撑体21可以是壳体本身。
(变形例2)
图7所示的壳体201具备：第一壳体部件11、第二壳体部件12以及安装在第一壳体部件11的开口部11h的透气构件33(透气结构)。透气构件33在第一壳体部件11的开口部11h处的安装，可以使用胶粘剂或粘合带进行，也可以通过热熔敷进行。透气构件33中，复合透气膜6与支撑体31可以通过嵌件模塑而一体化。根据变形例1和变形例2，具有如下优点：在制造出透气构件23、33的阶段能够进行非破坏试验(例如耐水试验、目视观察)。另外，也容易满足对要设置透气结构的壳体的设计进行变更的需要。此外，用于将透气构件23、33安装到壳体中的方法，可以从使用胶粘剂或粘合带、熔敷、热熔(熱かしめ)等各种方法中选择。
实施例
为了确定本发明的效果，制作以下的样品，考察各样品的耐水性。
(样品1)
制造图2所示的透气结构。首先，将作为主体部2的氟树脂膜2a(日东电工公司制テミッシュ(注册商标)NTF810A、厚度0.3mm、φ13mm、没有无纺布)和UHMWPE多孔片3(日东电工公司制サンマップ(注册商标)LC-T、厚度1.0mm、φ13mm)通过参照图4A和图4B说明的方法进行激光熔敷，得到复合透气膜6。其中，UHMWPE多孔片3使用预先着色成黑色的UHMWPE多孔片。
然后，通过嵌件注塑成形法使复合透气膜6与第一壳体部件11一体化，得到图2所示的透气结构13。作为第一壳体部件11的材料，使用聚对苯二甲酸丁二醇酯。
(样品2)
使用样品1中得到的复合透气膜6，制作图6A所示的透气栓(透气结构23)。将该透气栓用胶粘剂固定在第一壳体部件11的开口部11h。
(样品3)
将现有的透气膜(日东电工公司制テミッシュ(注册商标)NTF2131A-S06、厚度0.17mm、φ13mm、一个表面有无纺布)直接激光熔敷到第一壳体部件11上。
《高压洗车试验》
对样品1～3的透气结构进行高压洗车试验。高压洗车试验为如下试验：如图16所示，从以0°、30°、60°和90°各角度配置的喷嘴80对透气结构喷射水，考察有无水侵入壳体。壳体的内部涂布有感知水的水分感知糊料(ゥォ一タ一フィ一リングペ一スト)。该糊料从绿色变为红色时，判断水进入了壳体内。从喷嘴80喷出的水的喷射条件如下。
喷射压力：8MPa
水温：80℃
时间(各角度)：30秒
流量：14升/分钟
《结果》
样品1、2即使经过高压洗车试验也完全没有水进入壳体中。另一方面，样品3的壳体内进入了少量水。
产业实用性
本发明可以应用于灯、电动机、传感器、开关、ECU、齿轮箱等汽车部件。另外，除了汽车部件以外，本发明也可以应用于移动通信设备、照相机、电动剃须刀、电动牙刷、洗衣机(例如洗衣机的湿度传感器)等电气制品。

Claims (7)

1.一种复合透气膜，具备：
包含氟树脂膜的主体部，
具有黑色且叠合在所述主体部上的超高分子量聚乙烯多孔片，和
通过介于所述主体部与所述超高分子量聚乙烯多孔片之间而使两者一体化的激光熔敷部。
2.如权利要求1所述的复合透气膜，其中，所述激光熔敷部形成于该复合透气膜的外周部的、所述主体部与所述超高分子量聚乙烯多孔片之间，且俯视为环形。
3.如权利要求1所述的复合透气膜，其中，所述主体部的厚度t1和所述超高分子量聚乙烯多孔片的厚度t2满足t1＜t2的关系。
4.如权利要求1所述的复合透气膜，其中，所述主体部仅由所述氟树脂膜构成。
5.一种透气结构，
具备：
具有透气用的开口部的树脂部件，和
以堵塞所述开口部的方式安装在所述树脂部件上的透气膜；
所述透气膜由权利要求1所述的复合透气膜构成。
6.如权利要求5所述的透气结构，其中，所述复合透气膜的外周部嵌入所述树脂部件中。
7.如权利要求6所述的透气结构，其中，仅在嵌入所述树脂部件中的所述外周部形成有所述激光熔敷部。
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