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JP3630298B2 - Bonding method of resin molded products - Google Patents

Bonding method of resin molded products Download PDF

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Publication number
JP3630298B2
JP3630298B2 JP2000200900A JP2000200900A JP3630298B2 JP 3630298 B2 JP3630298 B2 JP 3630298B2 JP 2000200900 A JP2000200900 A JP 2000200900A JP 2000200900 A JP2000200900 A JP 2000200900A JP 3630298 B2 JP3630298 B2 JP 3630298B2
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JP
Japan
Prior art keywords
resin material
resin
resin member
alloy
permeable
Prior art date
Legal status (The legal status 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 status listed.)
Expired - Lifetime
Application number
JP2000200900A
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Japanese (ja)
Other versions
JP2002018961A (en
Inventor
秀生 中村
奈津彦 片平
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyota Motor Corp
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Toyota Motor Corp
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Filing date
Publication date
Application filed by Toyota Motor Corp filed Critical Toyota Motor Corp
Priority to JP2000200900A priority Critical patent/JP3630298B2/en
Publication of JP2002018961A publication Critical patent/JP2002018961A/en
Application granted granted Critical
Publication of JP3630298B2 publication Critical patent/JP3630298B2/en
Anticipated expiration legal-status Critical
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/341—Measures for intermixing the material of the joint interlayer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
    • B29C65/1616—Near infrared radiation [NIR], e.g. by YAG lasers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • B29C65/168—Laser beams making use of an absorber or impact modifier placed at the interface
    • 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
    • B29C66/124—Tongue and groove joints
    • B29C66/1244—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
    • B29C66/12449—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue being asymmetric
    • 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
    • B29C66/124—Tongue and groove joints
    • B29C66/1246—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove
    • B29C66/12469—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being asymmetric
    • 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
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • 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
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/65—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles with a relative motion between the article and the welding tool
    • B29C66/652—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles with a relative motion between the article and the welding tool moving the welding tool around the fixed article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B29C66/712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
    • 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
    • B29C66/72—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 structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • 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
    • B29C66/72—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 structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72143—Fibres of discontinuous lengths
    • 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
    • B29C66/73921—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 characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/50—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by aesthetic components not otherwise provided for, e.g. decorative trim, partition walls or covers
    • F21S41/55—Attachment thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1609—Visible light radiation, e.g. by visible light lasers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1632—Laser beams characterised by the way of heating the interface direct heating the surfaces 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B29C65/1638—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding focusing the laser beam on the interface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
    • B29C66/939—Measuring or controlling the joining process by measuring or controlling the speed characterised by specific speed values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
    • B29L2031/3481—Housings or casings incorporating or embedding electric or electronic elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/747—Lightning equipment

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Electromagnetism (AREA)
  • General Engineering & Computer Science (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

PROBLEM TO BE SOLVED: To mutually bond resin materials low in compatibility while utilizing the irradiation with laser beam. SOLUTION: A first resin member 11 comprises a transmission resin material having transmissivity to laser beam being a heating source and a second resin member 12 comprises a non-transmission resin material having no transmissivity to laser beam. An alloy resin material 13 consists of a first resin material constituting the first resin member 11 and a second resin material constituting the second resin member 12 and the first and second resin materials are mutually low in compatibility. In such a state that the alloy resin material 13 is arranged between the first and second resin members 11 and 12, the alloy resin material 13 is irradiated with laser beam on the side of the first resin member 11 comprising the transmission resin material to integrally bond the first and second resin members 11 and 12 mutually low in compatibility through the alloy resin material by laser welding while heating and melting the whole of the alloy resin material 13.

Description

【０００１】
【発明の属する技術分野】
本発明は樹脂成形品の接合方法に関し、詳しくはレーザ光の照射を利用して、互いに相溶性の小さい樹脂材同士を接合する樹脂成形品の接合方法に関する。
【０００２】
【従来の技術】
近年、軽量化及び低コスト化等の観点より、自動車部品等、各種分野の部品を樹脂化して樹脂成形品とすることが頻繁に行われている。また、樹脂成形品の高生産性化等の観点より、樹脂成形品を予め複数に分割して成形し、これらの分割成形品を互いに接合する手段が採られることが多い。
【０００３】
このような樹脂よりなる分割成形品を互いに接合する手段として、レーザ溶着を利用する方法が特開昭６０−２１４９３１号公報に示されている。この接合方法は、レーザ光に対して透過性のある透過性樹脂材と、レーザ光に対して透過性のない非透過性樹脂材とを重ね合わせ、該透過性樹脂材側からレーザ光を照射することにより、透過樹脂材と非透過樹脂材との当接面を加熱溶融させて両者を一体的に接合するものである。
【０００４】
【発明が解決しようとする課題】
しかしながら、上記レーザ溶着による樹脂成形品の接合方法は、互いに相溶性のある樹脂材同士を接合するものである。したがって、上記従来のレーザ溶着方法によっては、互いに相溶性の小さい樹脂材同士を良好に接合することができなかった。
【０００５】
本発明は上記実情に鑑みてなされたものであり、レーザ光照射を利用しつつ、互いに相溶性の小さい樹脂材同士を接合することのできる樹脂成形品の接合方法を提供することを解決すべき技術課題とするものである。
【０００６】
【課題を解決するための手段】
（１）上記課題を解決する請求項１記載の樹脂成形品の接合方法は、加熱源としてのレーザ光に対して透過性のある透過樹脂材と、該レーザ光に対して透過性のない非透過樹脂材との当接界面を、該透過樹脂材側からの該レーザ光の照射により加熱溶融させて溶着するレーザ溶着を利用して、互いに相溶性の小さい第１樹脂材料及び第２樹脂材料よりなる第１樹脂部材及び第２樹脂部材を一体的に接合する樹脂成形品の接合方法であって、上記第１樹脂部材と上記第２樹脂部材との間に、上記第１樹脂材料及び上記第２樹脂材料よりなるアロイ樹脂材を介在させる配置工程と、上記レーザ光照射により、少なくとも上記第１樹脂部材と上記アロイ樹脂材との第１当接界面及び上記第２樹脂部材と該アロイ樹脂材との第２当接界面を加熱溶融させる照射工程とからなることを特徴とするものである。
好適な態様において、前記第１樹脂部材及び前記第２樹脂部材のうちの一方が透過樹脂材よりなるとともに他方が非透過樹脂材よりなり、かつ、前記アロイ樹脂材が透過樹脂材又は非透過樹脂材よりなる。
好適な態様において、前記第１樹脂部材及び前記第２樹脂部材の双方が透過樹脂材及び非透過樹脂材のうちの一方よりなり、かつ、前記アロイ樹脂材が透過樹脂材及び非透過樹脂材のうちの他方よりなる。
好適な態様において、前記アロイ樹脂材はシート状、粉末状又はペースト状である。
好適な態様において、前記アロイ樹脂材は断面略三角形の略三角柱形状であり、この略三角形状を構成する三面のうちの二面が前記際１樹脂部材とのテーパ状第１当接界面及び第２樹脂部材とのテーパ状第２当接界面である。
【０００９】
【発明の実施の形態】
（１）請求項１記載の樹脂成形品の接合方法は、加熱源としてのレーザ光に対して透過性のある透過樹脂材と、該レーザ光に対して透過性のない非透過樹脂材との当接界面を、該透過樹脂材側からの該レーザ光の照射により加熱溶融させて溶着するレーザ溶着を利用して、互いに相溶性の小さい第１樹脂材料及び第２樹脂材料よりなる第１樹脂部材及び第２樹脂材を一体的に接合するもので、配置工程と、照射工程とからなる。
【００１０】
配置工程では、第１樹脂部材と第２樹脂部材との間に、第１樹脂材料及び第２樹脂材料よりなるアロイ樹脂材を介在させる。
【００１１】
照射工程では、レーザ光照射により、少なくとも第１樹脂部材とアロイ樹脂材との第１当接界面及び第２樹脂部材とアロイ樹脂材との第２当接界面を加熱溶融させる。アロイ樹脂材は第１樹脂材料及び第２樹脂材料よりなるので、第１樹脂部材とアロイ樹脂材との第１当接界面が加熱溶融されれば、この第１当接界面では互いに相溶性のあるアロイ樹脂材中の第１樹脂材料と第１樹脂部材とを溶着させることができ、一方第２樹脂部材とアロイ樹脂材との第２当接界面が加熱溶融されれば、この第２当接界面では互いに相溶性のあるアロイ樹脂材中の第２樹脂材料と第２樹脂部材とを溶着させることができる。
【００１２】
こうして、第１樹脂材料及び第２樹脂材料よりなるアロイ樹脂材を介して、互いに相溶性の小さい第１樹脂部材及び第２樹脂部材をレーザ溶着により一体的に接合することが可能となる。
【００１３】
上記透過樹脂材の種類としては、熱可塑性を有し、加熱源としてのレーザ光を所定の透過率以上で透過させうるものであれば特に限定されない。例えば、ナイロン６（ＰＡ６）やナイロン６６（ＰＡ６６）等のポリアミド（ＰＡ）、ポリエチレン（ＰＥ）、ポリプロピレン（ＰＰ）、スチレン−アクリロニトリル共重合体、ポリエチレンテレフタレート（ＰＥＴ）、ポリスチレン、ＡＢＳ、アクリル（ＰＭＭＡ）、ポリカーボネート（ＰＣ）、ポリブチレンテレフタレート（ＰＢＴ）等を挙げることができる。なお、必要に応じて、着色したものを用いてもよい。
【００１４】
上記非透過樹脂材の種類としては、熱可塑性を有し、加熱源としてのレーザ光を透過させずに吸収しうるものであれば特に限定されない。例えば、ナイロン６（ＰＡ６）やナイロン６６（ＰＡ６６）等のポリアミド（ＰＡ）、ポリエチレン（ＰＥ）、ポリプロピレン（ＰＰ）、スチレン−アクリロニトリル共重合体、ポリエチレンテレフタレート（ＰＥＴ）、ポリスチレン、ＡＢＳ、アクリル（ＰＭＭＡ）、ポリカーボネート（ＰＣ）、ポリブチレンテレフタレート（ＰＢＴ）、ＰＰＳ等に、カーボンブラック、染料や顔料等の所定の着色材を混入したものを挙げることができる。
【００１５】
上記したような透過樹脂材及び非透過樹脂材のうちから、適宜互いに相溶性の小さい樹脂材料同士の組み合わせを選んで、第１樹脂部材及び第２樹脂部材を構成する第１樹脂材料及び第２樹脂材料とするとともに、該第１樹脂材料及び該第２樹脂材料によりアロイ樹脂材を構成することができる。
【００１６】
互いに相溶性の小さい樹脂材料同士の組み合わせとして、具体的にはＰＣとＰＡ６やＰＡ６６等のＰＡとの組み合わせ、ＰＣとＰＰとの組み合わせ、ＰＣとＰＥＴとの組み合わせ、ＰＣとＡＢＳとの組み合わせ、ＰＣとＰＢＴとの組み合わせ、ＰＰとＰＡ６やＰＡ６６等のＰＡとの組み合わせ、ＰＰとＰＢＴとの組み合わせ、ＰＢＴとＰＡ６やＰＡ６６等のＰＡとの組み合わせ、ＰＡとＰＰＳとの組合せ等を挙げることができる。
【００１７】
アロイ樹脂材における第１樹脂材料と第２樹脂材料との配合割合は、１０：９０〜９０：１０程度とすることができるが、２５：７５〜７５：２５程度とすることが好ましく、５０：５０とすることが最適である。
【００１８】
なお、アロイ樹脂材は、相溶化剤等又は架橋材を添加したり、あるいは相溶化剤及び架橋材を添加したりすることにより製造することができる。
【００１９】
そして、請求項１記載の樹脂成形品の接合方法において、上記第１樹脂部材、上記第２樹脂部材及び上記アロイ樹脂材は、三者のうち少なくとも一つを加熱源としてのレーザ光に対して透過性のある透過樹脂材とし、かつ、三者のうち少なくとも一つを該レーザ光に対して透過性のない非透過樹脂材とすることができる。具体的には、▲１▼第１樹脂部材及び第２樹脂部材のうちの一方が透過樹脂材よりなるとともに他方が非透過樹脂材よりなり、かつ、アロイ樹脂材が透過樹脂材又は非透過樹脂材よりなる第１の態様と、▲２▼第１樹脂部材及び第２樹脂部材の双方が透過樹脂材及び非透過樹脂材のうちの一方よりなり、かつ、アロイ樹脂材が透過樹脂材及び非透過樹脂材のうちの他方よりなる第２の態様とすることができる。
【００２０】
ここに、上記レーザ溶着は、加熱源としてのレーザ光を透過樹脂材側から照射して、該透過樹脂材内を透過したレーザ光を非透過樹脂材の該透過樹脂材との当接界面に到達、吸収させ、該非透過樹脂材の当接界面にエネルギーとして蓄積させることにより、該非透過樹脂材の当接界面を加熱溶融させるとともに、この非透過樹脂材の当接界面からの熱伝達により透過樹脂材の当接界面を加熱溶融させて、両者を溶着するものである。
【００２１】
▲１▼上記第１の態様においては、第１樹脂部材及び第２樹脂部材のうちの一方とアロイ樹脂材との当接界面が透過樹脂材同士又は非透過樹脂材同士の当接界面となり、かつ、第１樹脂部材及び第２樹脂部材のうちの他方とアロイ樹脂材との当接界面が透過樹脂材及び非透過樹脂材同士の当接界面となる。これらのうち透過樹脂材及び非透過樹脂材同士の当接界面は、上述したように透過樹脂材側からのレーザ光照射によりレーザ溶着することができる。しかし、透過樹脂材同士の当接界面や非透過樹脂材同士の当接界面は、上述したレーザ溶着の作用のみによって溶着することができない。このとき、アロイ樹脂材が非透過樹脂材の場合は、透過樹脂材側から照射されたレーザ光が透過樹脂材及び非透過樹脂材同士の当接界面側からアロイ樹脂材に吸収されることにより、該アロイ樹脂材の全体が加熱溶融されれば、反対側の非透過樹脂材同士の当接界面も加熱溶融させることができる。一方、アロイ樹脂材が透過樹脂材の場合は、上述したレーザ溶着の作用により、まず透過樹脂材及び非透過樹脂材同士の当接界面側において該非透過樹脂材を加熱溶融させ、この当接界面からの熱伝導によりアロイ樹脂材の全体を加熱溶融させることができれば、反対側の透過樹脂材同士の当接界面も加熱溶融させることができる。
【００２２】
すなわち、上記第１の態様の場合は、透過樹脂材側からのレーザ光照射によりアロイ樹脂材の全体を加熱溶融させる必要があり、このようにアロイ樹脂材の全体が加熱溶融されれば、該アロイ樹脂材を介して、互いに相溶性の小さい第１樹脂部材と第２樹脂部材とを一体的に接合させることができる。
【００２３】
そこで、上記第１の態様においては、アロイ樹脂材の厚さを０．５ｍｍ以下とすることが好ましく、０．２ｍｍ以下とすることがより好ましい。アロイ樹脂材の厚さが０．５ｍｍを超えると、透過樹脂材側からのレーザ光照射によりアロイ樹脂材の全体を加熱溶融させることが著しく困難となり、またたとえアロイ樹脂材の全体を加熱溶融させることができたとしても、レーザ光の照射時間等、エネルギー的に非効率となる。一方、アロイ樹脂材の厚さが薄すぎると、アロイ樹脂材を介して互いに相溶性の小さい第１樹脂部材及び第２樹脂部材を接合させるというアロイ樹脂材本来の作用効果を期待できなくなることから、アロイ樹脂材の厚さは０．０５ｍｍ以上とすることが好ましく、０．１ｍｍ以上とすることがより好ましい。
【００２４】
また、上記第１の態様におけるアロイ樹脂材の形状は、取り扱いの容易性等を考慮すればシート状とすることが好ましいが、粉末状又はペースト状であってもよい。
【００２５】
さらに、上記第１の態様においては、アロイ樹脂材を非透過樹脂材とすることが好ましい。アロイ樹脂材が非透過樹脂材であれば、透過樹脂材側から照射されたレーザ光が直接アロイ樹脂材に吸収されるため、アロイ樹脂材の全体を加熱溶融させるのに時間的に有利になると考えられるからである。
【００２６】
▲２▼上記第２の態様においては、第１樹脂部材とアロイ樹脂材との当接界面及び第２樹脂部材とアロイ樹脂材との当接界面がいずれも透過樹脂材及び非透過樹脂材同士の当接界面となることから、上述したレーザ溶着の作用により、第１樹脂部材とアロイ樹脂材との当接界面及び第２樹脂部材とアロイ樹脂材との当接界面を溶着することができる。このため、上記第２の態様の場合は、必ずしもアロイ樹脂材の全体を加熱溶融させる必要はない。ただし、上記第２の態様の場合であっても、接合強度の向上の観点より、アロイ樹脂材の全体を加熱溶融させる方が望ましい。
【００２７】
そこで、上記第２の態様において、アロイ樹脂材の全体を加熱溶融させる場合は、上記第１の態様と同様、アロイ樹脂材の厚さを０．０５〜０．５ｍｍとすることが好ましく（より好ましくは０．１〜０．２ｍｍ）、アロイ樹脂材の形状をシート状、粉末状又はペースト状とすることが好ましい。
【００２８】
一方、上記第２の態様において、アロイ樹脂材の全体を加熱溶融させない場合は、アロイ樹脂材を断面略三角形の略三角柱形状とし、この略三角柱形状を構成する三面のうちの二面を、第１樹脂部材とのテーパ状第１当接界面及び第２樹脂部材とのテーパ状第２当接界面とすることが好ましい。
【００２９】
こうすることで、アロイ樹脂材が透過樹脂材よりなるとともに第１樹脂部材及び第２樹脂部材が非透過樹脂材よりなる場合は、非透過樹脂材よりなる第１樹脂部材及び第２樹脂部材のテーパ状第１当接界面及びテーパ状第２当接界面が向く側の一方向のみからレーザ光を照射することにより、透過樹脂材よりなるアロイ樹脂材中を透過したレーザ光を第１樹脂部材及び第２樹脂部材のテーパ状第１当接界面及びテーパ状第２当接界面の双方に到達、吸収させて、該テーパ状第１当接界面及び該テーパ状第２当接界面におけるレーザ溶着を行うことが可能となる。また、アロイ樹脂材が非透過樹脂材よりなるとともに第１樹脂部材及び第２樹脂部材が透過樹脂材よりなる場合は、非透過樹脂材よりなるアロイ樹脂材のテーパ状第１当接界面及びテーパ状第２当接界面が向く側の一方向からレーザ光を照射することにより、透過樹脂材よりなる第１樹脂部材中を透過したレーザ光をアロイ樹脂材のテーパ状第１当接界面に到達、吸収させるとともに、透過樹脂材よりなる第２樹脂部材中を透過したレーザ光をアロイ樹脂材のテーパ状第２当接界面に到達、吸収させて、該テーパ状第１当接界面及び該テーパ状第２当接界面におけるレーザ溶着を行うことが可能となる。ただし、アロイ樹脂材を透過樹脂材とするとともに第１樹脂部材及び第２樹脂部材を非透過樹脂材とする前者の態様によれば、非透過樹脂材よりなる第１樹脂部材及び第２樹脂部材のテーパ状第１当接界面及びテーパ状第２当接界面のうち一方のテーパ状当接界面におけるレーザ光の反射を利用して他方のテーパ状当接界面へのレーザ光吸収を促進させることができ、レーザ照射時間の短縮化等を図ることが可能となるため、好ましい。
【００３０】
なお、上記一方向のみからのレーザ光照射とは、レーザ光の照射途中で一つの当接界面に対する照射角を変更したり、又は二つの当接界面のそれぞれに対して同一若しくは異なる照射角でレザー光を照射したりすることなく、二つの当接界面のうちから任意に選ばれた一つの当接界面に対して一定の照射角で照射するある一方向からの一のレーザ光により二つの接合面を同時に照射することを意味する。
【００３１】
また、加熱源として用いるレーザ光の種類としては、レーザ光を透過させる透過樹脂材の吸収スペクトルや板厚（透過長）等との関係で、透過樹脂材内での透過率が所定値以上となるような波長を有するものが適宜選定される。例えば、ＹＡＧ：Ｎｄ３＋レーザ（レーザ光の波長：１０６０ｎｍ）や半導体レーザ（レーザ光の波長：５００〜１０００ｎｍ）を用いることができる。
【００３２】
なお、レーザの出力、照射密度や加工速度（移動速度）等の照射条件は、樹脂の種類等に応じて適宜設定可能である。
【００５６】
【実施例】
以下、実施例により本発明を具体的に説明する。
【００５７】
（実施例１）
本実施例は、請求項１、２又は４記載の樹脂成形品の接合方法を具現化したもので、レーザ溶着を利用しつつ、アロイ樹脂材を介して互いに相溶性の小さい第１樹脂部材及び第２樹脂部材を一体的に接合するものである。また、この実施例は、第１樹脂部材及び第２樹脂部材のうちの一方が透過樹脂材よりなるとともに他方が非透過樹脂材よりなり、かつ、アロイ樹脂材が透過樹脂材又は非透過樹脂材よりなる第１の態様を具現化したものである。
【００５８】
図１は、自動車用ヘッドライトを切断した斜視図であり、図２は接合構造を示す要部断面図である。
【００５９】
このヘッドライトは、左右に２分割されていて、左側分割体である第１樹脂部材１１と右側分割体である第２樹脂部材１２とから外郭が構成された中空体である。第１樹脂部材１１及び第２樹脂部材１２は、互いに整合して嵌合し合う当接端部１１ａ及び１２ａをそれぞれ有し、この当接端部１１ａ及び１２ａ同士がアロイ樹脂材１３を介してレーザ溶着により一体的に接合されている。
【００６０】
第１樹脂部材１１を構成する第１樹脂材料はポリカーボネート（ＰＣ）よりなり、またこの第１樹脂部材１１は加熱源としてのレーザ光に対して透過性のある透過樹脂材である。
【００６１】
第２樹脂部材１２を構成する第２樹脂材料はガラス繊維が３０ｗｔ％、着色剤としてのカーボンブラックが適宜量添加されたＡＢＳよりなり、またこの第２樹脂部材１２は加熱源としてのレーザ光に対して透過性のない非透過樹脂材である。
【００６２】
なお、上記第１樹脂部材１１はヘッドライトのレンズを構成し、上記第２樹脂部材１２はヘッドライトのカバーを構成する。また、上記第１樹脂材料としてのＰＣと第２樹脂材料としてのＡＢＳは互いに相溶性の小さいものである。
【００６３】
また、第１樹脂部材１１の底壁１１ｂの内面には、ＰＣよりなるエクステンション１４が配設され、第２樹脂部材１２の内面には、エポキシ（ＢＭＣ）よりなるリフレクター（反射鏡）１５が配設されている。そして、第２樹脂部材１２及びリフレクター１５の後方壁にそれぞれ貫設された貫孔１２ｂ及び１５ａにはランプ１６が配設されるとともに、第２樹脂材１２の貫孔１２ｂがカバー１７で塞がれている。
【００６４】
図２に示すように、第１樹脂部材１１の当接端部１１ａには、中空体の内側（図２の下側）の基端側（図２の左端側）に段部を残しつつ内側及び外側がテーパ状に切り欠かれるととものその先端部が切り落とされ、先端側へ漸次縮小して突出する形状に形成された嵌合凸部１１ｃが設けられている。この嵌合凸部１１ｃは、先端接合端面１１ｃ１ と、外側及び内側の各テーパ状接合面１１ｃ２ と、内側のテーパ状接合面１１ｃ２ の基端に交差する内側の段状接合端面１１ｃ３ とを有している。
【００６５】
一方、第２樹脂部材１２の当接端部１２ａには、先端側（図２の左端側）へ漸次拡開して突出する形状に形成され、上記嵌合凸部１１ｃと嵌合可能な嵌合凹部１２ｃが設けられている。この嵌合凹部１２ｃは、上記先端接合端面１１ｃ１ と互いに整合する底接合端面１２ｃ１ と、各上記テーパ状接合面１１ｃ２ とそれぞれ互いに整合する外側及び内側の各テーパ状接合面１２ｃ２ と、内側のテーパ状接合面１２ｃ２ の先端に交差し、上記段状接合端面１１ｃ３ と互いに整合する先端接合端面１２ｃ３ とを有している。
【００６６】
そして、第１樹脂部材１１の嵌合凸部１１ｃ及び第２樹脂部材１２の嵌合凹部１２ｃ同士が上記アロイ樹脂材１３を介して嵌合されるとともに、先端接合端面１１ｃ１ 及び底接合端面１２ｃ１ 同士と、外側のテーパ状接合面１１ｃ２ 及び１２ｃ２ 同士と、内側のテーパ状接合面１１ｃ２ 及び１２ｃ２ 同士と、段状接合端面１１ｃ３ 及び先端接合端面１２ｃ３ 同士とが、上記アロイ樹脂材１３を介してそれぞれレーザ溶着により一体的に接合されている。
【００６７】
このアロイ樹脂材１３は、上記第１樹脂材料としてのＰＣと上記第２樹脂材料としてのＡＢＳとからなる。このアロイ樹脂材１３は相溶化剤、架橋材が添加された材料を圧縮成形することにより所定形状に成形した厚さが０．２ｍｍのシート状のもので、第１樹脂材料と第２樹脂材料との配合割合は５０：５０とされている。また、このアロイ樹脂材１３には着色剤としてのカーボンブラックが適宜量添加されており、アロイ樹脂材１３は加熱源としてのレーザ光に対して透過性のない非透過樹脂材とされている。
【００６８】
上記構成を有する本実施例の樹脂成形品は、以下のようにして製造した。まず、第１樹脂部材１１及び第２樹脂部材１２を射出成形によりそれぞれ所定形状に形成した後、第１樹脂部材１１の内面にエクステンションを配設するとともに、第２樹脂材１２の内面にリフレクターを配設した。そして、第１樹脂部材１１の嵌合凸部１１ｃと第２樹脂部材１２の嵌合凸部１２ｃとをアロイ樹脂材１３を介して嵌合し、第１樹脂部材１１と第２樹脂部材１２との間にアロイ樹脂材１３を介在させた。この状態で、透過樹脂材としての第１樹脂部材１１側から第２樹脂部材１２の底接合端面１２ｃ１ 、両テーパ状接合面１２ｃ２ 及び先端接合端面１２ｃ３ に向けてレーザ光を照射した。なお、レーザ光としてはＹＡＧ−ネオジウムレーザ光（波長１０６０ｎｍ）を用いた。照射条件は、出力：２００〜４００Ｗ、加工速度：５ｍ／ｍｉｎとした。
【００６９】
このレーザ光照射により、アロイ樹脂材１３の全体を加熱溶融するとともに、第１樹脂部材１１とアロイ樹脂材１３との第１当接界面及び第２樹脂部材１２とアロイ樹脂部材１３との第２当接界面を加熱溶融して溶着し、アロイ樹脂材１３を介して、第１樹脂部材１１と第２樹脂部材１２とをレーザ溶着により一体的に接合した。
【００７０】
このように互いに相溶性の小さい第１樹脂材料及び第２樹脂材料よりなる第１樹脂部材１１及び第２樹脂部材１２を、レーザ溶着により接合する場合であっても、両者の間にアロイ樹脂材１３を介在させることにより、良好に接合することができた。
【００７１】
また、こうして得られた接合部では、先端接合端面１１ｃ１ 及び底接合端面１２ｃ１ 同士、外側のテーパ状接合面１１ｃ２ 及び１２ｃ２ 同士、内側のテーパ状接合面１１ｃ２ 及び１２ｃ２ 同士、並びに段状接合端面１１ｃ３ 及び先端接合端面１２ｃ３ 同士のレーザ溶着による接合に加えて、第１樹脂部材１１の嵌合凸部１１ｃと第２樹脂部材１２の嵌合凹部１２ｃとの嵌合、及び第１樹脂部材１１の段状接合端面１１ｃ３ と第２樹脂部材１２の先端接合端面１２ｃ３ との係合により構造的にも強固な接合部となっているので、より高い接合強度及び耐圧強度を有している。
【００７２】
また、本実施例の樹脂成形品では、透過性樹脂よりなる第１樹脂部材１１の当接端部１１ａに嵌合凸部１１ｃを設けるとともに、非透過性樹脂よりなる第２樹脂部材１２の当接端部１２ａに嵌合凹部１２ｃを設けている。このため、第１樹脂部材１１の透過性樹脂内におけるレーザ光の散乱に加えて、第２樹脂部材１２の嵌合凹部１２ｃの内面（底接合端面１２ｃ１ 及び各テーパ状接合面１２ｃ２ ）におけるレーザ光の反射を利用することができるので、レーザ光を一方向のみから照射する場合であっても、嵌合凸部１１ｃの外面及び嵌合凹部１２ｃの内面同士を全面的に、かつ、略均等にレーザ溶着することが可能となる。
【００７３】
（実施例２）
本実施例は、請求項１、２又は４記載の樹脂成形品の接合方法を具現化したもので、レーザ溶着を利用しつつ、アロイ樹脂材を介して互いに相溶性の小さい第１樹脂部材及び第２樹脂部材を一体的に接合するものである。また、この実施例は、第１樹脂部材及び第２樹脂部材のうちの一方が透過樹脂材よりなるとともに他方が非透過樹脂材よりなり、かつ、アロイ樹脂材が透過樹脂材又は非透過樹脂材よりなる第１の態様を具現化したものである。
【００７４】
図３は自動車用の電子制御装置（ＥＣＵ）の斜視図であり、図４はこの電子制御装置の断面図である。
【００７５】
この電子制御装置は、ハウジングを構成する第１樹脂部材２１と、蓋を構成する第２樹脂部材２２とから外郭が構成された中空体である。第１樹脂部材２１の側壁の上端面及び第２樹脂部材２２の周縁部には、互いに整合して嵌合し合う環状凹部２１ａ及び環状凸部２２ａがそれぞれ設けられており、この環状凹部２１ａ及び環状凸部２２ａ同士がアロイ樹脂材２３を介してレーザ溶着により一体的に接合されている。
【００７６】
第１樹脂部材２１を構成する第１樹脂材料はポリブチレンテレフタレート（ＰＢＴ）よりなり、またこの第１樹脂部材２１は加熱源としてのレーザ光に対して透過性のない非透過樹脂材である。なお、ＰＢＴは、結晶構造により材料固有値としての光透過性が低いことから、非透過樹脂材として用いた方が良い材料である。
【００７７】
第２樹脂部材２２を構成する第２樹脂材料２２はナイロン６（ＰＡ６）よりなり、またこの第２樹脂部材２２は加熱源としてのレーザ光に対して透過性のある透過樹脂材である。なお、第２樹脂材料２２としてＰＡ６の他にＰＣ又はＡＢＳを採用してもよい。
【００７８】
なお、上記第１樹脂部材２１の側壁には、低コスト化の観点よりコネクタ２４が一体に形成されており（図３参照）、また第１樹脂部材２１内にはこのコネクタ２４に接続された電気回路２５が配設されている（図４参照）。また、上記第１樹脂材料としてのＰＢＴと第２樹脂材料としてのＰＡ６とは互いに相溶性の小さいものである。
【００７９】
上記アロイ樹脂材２３は、上記第１樹脂材料としてのＰＢＴと上記第２樹脂材料としてのＰＡ６とからなる。このアロイ樹脂材２３は相溶化剤、架橋材が添加された材料を圧縮成形することにより所定形状に成形した厚さが０．２ｍｍのシート状のもので、第１樹脂材料と第２樹脂材料との配合割合は５０：５０とされている。また、このアロイ樹脂材１３は加熱源としてのレーザ光に対して透過性のない非透過樹脂材とされている。
【００８０】
上記構成を有する本実施例の樹脂成形品は、以下のようにして製造した。まず、第１樹脂部材２１及び第２樹脂部材２２を射出成形によりそれぞれ所定形状に形成した後、第１樹脂部材２１の内面に電気回路２５を配設した。そして、第１樹脂部材２１の環状凹部２１ａと第２樹脂部材２２の環状凸部２２ａとをアロイ樹脂材２３を介して嵌合し、第１樹脂部材２１と第２樹脂部材２２との間にアロイ樹脂材２３を介在させた。この状態で、透過樹脂材としての第２樹脂部材２２側から第１樹脂部材２１の環状凹部２１ａに向けてレーザ光を照射した。なお、レーザ光としてはＹＡＧ−ネオジウムレーザ光（波長１０６０ｎｍ）を用いた。照射条件は、出力：２００〜４００Ｗ、加工速度：５ｍ／ｍｉｎとした。
【００８１】
このレーザ光照射により、アロイ樹脂材２３の全体を加熱溶融するとともに、第１樹脂部材２１とアロイ樹脂材２３との第１当接界面及び第２樹脂部材２２とアロイ樹脂部材２３との第２当接界面を加熱溶融して溶着し、アロイ樹脂材２３を介して、第１樹脂部材２１と第２樹脂部材２３とをレーザ溶着により一体的に接合した。
【００８２】
このように互いに相溶性の小さい第１樹脂材料及び第２樹脂材料よりなる第１樹脂部材２１及び第２樹脂部材２２を、レーザ溶着により接合する場合であっても、両者の間にアロイ樹脂材２３を介在させることにより、良好に接合することができた。
【００８３】
また、本実施例によれば、以下に示す作用効果も期待できる。
【００８４】
自動車用の電子制御装置においては、装置内への水の侵入を防ぐべく密封性が求められる。このため、従来、ハウジングと蓋との接合は、熱硬化性接着剤により接着したり、あるいは高価なフッ素ゴム系のＯリングを介してボルト及び埋め込みナットで締結したりすることにより行われている。しかし、熱硬化性接着剤を利用する場合は、炉内でのバッジ加熱処理時に電気回路２５のはんだ接合部等に熱影響が発生し易く、また生産性も悪い。また、Ｏリングを介するボルト及び埋め込みナットの締結手段を利用する場合は、部品点数の増加と工程増加で高コストにある。この点、レーザ溶着を利用する本実施例によれば、熱影響により電気回路２５に悪影響が発生したり、部品点数が増加したりすることがないことから、上記従来の問題を解消することができる。
【００８５】
また、自動車用の電子制御装置におけるコネクタ２４には吸水に対する寸法安定性が求められる。このため、コネクタ２４の材料には従来より耐吸水性に優れるＰＢＴ等が採用されている。そして、本実施例のように低コスト化を図るべくコネクタ２４をハウジングとしての第１樹脂部材２１と一体成形しようとすると、第１樹脂部材２１の樹脂材料も当然にＰＢＴとなる。ところが、上述したようにＰＢＴは材料固有値としての光透過性が低く、非透過樹脂材としてしか用いることができない。そして、このＰＢＴと相溶性があり、かつ、レーザ光に対して透過性のある適当な樹脂材料は、一般的には見あたらない。このため、ハウジングの樹脂材料にＰＢＴを採用した場合、従来のレーザ溶着によっては、蓋部材を接合することができない。この点、本実施例によれば、ＰＢＴよりなるハウジングとしての第１樹脂部材２１に対して、互いに相溶性が小さく、かつ、レーザ光に対して透過性のあるＰＡ６よりなる蓋としての第２樹脂部材２２を、アロイ樹脂材２３を介することレーザ溶着することができる。ハウジングとしての第１樹脂部材２１とコネクタ２４とを一体成形して低コスト化を図りつつ、コネクタ２４における吸水に対する寸法安定性を向上させることが可能となる。
【００８６】
なお、上記実施例２において、蓋としての第２樹脂部材２２を構成する第２樹脂材料をＰＡよりも安価なポリプロピレン（ＰＰ）として、より低コスト化を図ることも可能である。
【００８７】
（実施例３）
本実施例は、請求項１、３又は５記載の樹脂成形品の接合方法を具現化したもので、レーザ溶着を利用しつつ、アロイ樹脂材を介して互いに相溶性の小さい第１樹脂部材及び第２樹脂部材を一体的に接合するものである。また、この実施例は、第１樹脂部材及び第２樹脂部材の双方が透過樹脂材及び非透過樹脂材のうちの一方よりなり、かつ、アロイ樹脂材が透過樹脂材及び非透過樹脂材のうちの他方よりなる第２の態様を具現化したものである。
【００８８】
本実施例に係る樹脂成形品は、自動車用インテークマニホールドを構成する第１樹脂部材３１と、エアークリーナーを構成する第２樹脂部材３２とをアロイ樹脂材３３を介してレーザ溶着により一体的に接合したものである。
【００８９】
図５に示すように、本実施例におけるアロイ樹脂材３３は、断面三角形の三角柱形状を呈している。この三角形状を構成する三面のうちの一面及び該一面に当接する第１樹脂部材３１の当接端面は、互いに整合して当接し合うテーパ状第１当接界面３３ａ及び３１ａをなし、また該三面のうちの他の一面及び該一面に当接する第２樹脂部材３２の当接端面は、互いに整合して当接し合うテーパ状第２当接界面３３ｂ及び３２ａをなしている。そして、第１樹脂部材３１のテーパ状第１当接界面３１ａ及びアロイ樹脂材３３のテーパ状第１当接界面３３ａ同士がレーザ溶着により一体的に接合されるとともに、第２樹脂部材３２のテーパ状第２当接界面３２ａ及びアロイ樹脂材３３のテーパ状第２当接界面３３ｂ同士がレーザ溶着により一体的に接合されている。
【００９０】
上記第１樹脂部材３１を構成する第１樹脂材料は、ガラス繊維が３０ｗｔ％、着色材としてのカーボンブラックが適宜量添加されたナイロン６（ＰＡ６）よりなり、またこの第１樹脂部材１１は加熱源としてのレーザ光に対して透過性のない非過樹脂材である。
【００９１】
また、上記第２樹脂部材３２を構成する第２樹脂材料は、ガラス繊維が３０ｗｔ％、着色剤としてのカーボンブラックが適宜量添加されたポリプロピレン（ＰＰ）よりなり、またこの第２樹脂部材３２は加熱源としてのレーザ光に対して透過性のない非透過樹脂材である。
【００９２】
なお、上記第１樹脂材料としてのＰＡ６と第２樹脂材料としてのＰＰは互いに相溶性の小さいものである。
【００９３】
また、上記アロイ樹脂材３３は、上記第１樹脂材料としてのＰＡ６と上記第２樹脂材料としてのＰＰとからなる。このアロイ樹脂材２３は圧縮成形により所定形状に成形したもので、第１樹脂材料と第２樹脂材料との配合割合は５０：５０とされている。また、このアロイ樹脂材３３には着色剤としてのカーボンブラックが添加されておらず、アロイ樹脂材３３は加熱源としてのレーザ光に対して透過性のある透過樹脂材とされている。
【００９４】
なお、上記第１樹脂部材３１及び上記第２樹脂部材３２の板厚は３ｍｍ程度であり、上記アロイ樹脂材３３の幅（断面三角形の一辺の長さ）は４ｍｍ程度である。
【００９５】
上記構成を有する本実施例の樹脂成形品は、以下のようにして製造した。まず、第１樹脂部材３１及び第２樹脂部材３２を射出成形によりそれぞれ所定形状に形成した後、第１樹脂部材３１と第２樹脂部材３２との間にアロイ樹脂材３３を配設した。そして、透過樹脂材としてのアロイ樹脂材３３側から第１樹脂材３１のテーパ状第１当接界面３１ａ及び第２樹脂部材３２のテーパ状第２当接界面３２ａに向けてレーザ光を照射した。なお、レーザ光としてはＹＡＧ−ネオジウムレーザ光（波長１０６０ｎｍ）を用いた。照射条件は、出力：２００〜４００Ｗ、加工速度：５ｍ／ｍｉｎとした。
【００９６】
このレーザ光照射により、第１樹脂部材３１及びアロイ樹脂材３３のテーパ状第１当接界面３１ａ及び３３ａ同士を加熱溶融して溶着するとともに、第２樹脂材３２及びアロイ樹脂材３３のテーパ状第２当接界面３２ａ及び３３ｂ同士を加熱溶融して溶着し、アロイ樹脂材３３を介して、第１樹脂部材３１と第２樹脂部材３２とをレーザ溶着により一体的に接合した。
【００９７】
なお、本実施例では、アロイ樹脂材３３は、テーパ状第１当接界面３３ａ付近及びテーパ状第２当接界面３３ｂ付近のみを加熱溶融してアロイ樹脂材３３の全体を加熱溶融させない態様としたが、接合強度の向上等の観点よりアロイ樹脂材３３の全体を加熱溶融することもできる。
【００９８】
このように互いに相溶性の小さい第１樹脂材料及び第２樹脂材料よりなる第１樹脂部材３１及び第２樹脂部材３２を、レーザ溶着により接合する場合であっても、両者の間にアロイ樹脂材３３を介在させることにより、良好に接合することができた。
【００９９】
また、本実施例においては、アロイ樹脂材３３の断面形状を略三角形状にするとともに、アロイ樹脂材３３を透過樹脂材としていることから、非透過樹脂材よりなる第１樹脂部材３１及び第２樹脂部材３２のテーパ状第１当接界面３１ａ及びテーパ状第２当接界面３２ａが向く側の一方向のみからレーザ光を照射することにより、透過樹脂材よりなるアロイ樹脂材３３中を透過したレーザ光を第１樹脂部材３１及び第２樹脂部材３２のテーパ状第１当接界面３１ａ及びテーパ状第２当接界面３２ａの双方に到達、吸収させて、該第１テーパ状当接界面３１ａ及び該第２テーパ状当接界面３２ａにおけるレーザ溶着を行うことが可能となる。さらに、レーザ光の照射時には、非透過樹脂材よりなる第１樹脂部材３１及び第２樹脂部材３２のテーパ状第１当接界面３１ａ及びテーパ状第２当接界面３２ａのうち一方のテーパ状当接界面におけるレーザ光の反射を利用して他方のテーパ状当接界面へのレーザ光吸収を促進させることができ、レーザ照射時間の短縮化等を図ることが可能となる。
【０１００】
（参考例１）
本参考例は、レーザ光照射を利用しつつ、補強繊維を介して互いに相溶性の小さい第１樹脂部材及び第２樹脂部材を一体的に接合するものである。
【０１０１】
射出成形法により、板厚が３ｍｍの第１樹脂部材４１及び第２樹脂部材４２を準備した。
【０１０２】
この第１樹脂部材４１は、母材樹脂としてのＰＡ６（融点：２２５℃）にガラス繊維（ＧＦ）よりなる補強繊維４３を３０ｍａｓｓ％添加したもので、加熱源としてのレーザ光に対して透過性のあるものである。一方、第２樹脂部材４２は、母材樹脂としてのＰＢＴ（融点：２２５℃）に補強繊維４３を３０ｍａｓｓ％添加するとともに、着色材としてのカーボンブラックを適宜量添加したもので、加熱源としてのレーザ光に対して透過性のないものである。
【０１０３】
なお、第１樹脂部材４１を構成する第１樹脂材料としてのＰＡ６と、第２樹脂部材４２を構成する第２樹脂材料としてのＰＢＴとは、互いに相溶性の小さいものである。
【０１０４】
また、上記補強繊維４３は、いずれも長さ分布が５０〜４００μｍの範囲であり、平均長さが２００μｍのものである。補強繊維４３のうち後述する溶融部４４の幅（２００μｍ）よりも短いものの占める割合は、第１樹脂部材４１又は第２樹脂部材４２中に添加される補強繊維４３全体を１００ｍａｓｓ％としたとき、５０ｍａｓｓ％である。
【０１０５】
そして、この補強繊維４３の表面には、補強繊維４３と第１樹脂部材４１及び第２樹脂部材４２の双方と化学結合可能な官能基を有するカップリング剤よりなる図示しない結合助長層（厚さ２μｍ程度）が予め形成されている。なお、本実施例では、カップリング剤として、官能基としてアミノ基を有するシランカップリング剤を用いた。
【０１０６】
一方、波長が１．０６μｍのＹＡＧ：Ｎｄ３＋レーザ光を発するレーザトーチ４５を準備した。
【０１０７】
そして、図６に示すように、第２樹脂部材４２の上に第１樹脂部材４１を重ね合わせるように両者を当接させるとともに、第１樹脂部材４１及び第２樹脂部材４２を図示しないクランプ手段でクランプした。この状態で、レーザトーチ４５から発射されるレーザ光を透過樹脂材としての第１樹脂部材４１側から照射し、第１樹脂部材４１及び第２樹脂部材４２の当接界面を加熱溶融させて溶融部４４とした。
【０１０８】
ここに、上記レーザ光照射は、レーザ光照射により溶融した溶融部４４の温度を測定しながら行った。そして、この溶融部４４の温度が、上記第１樹脂材料及び上記第２樹脂材料のうち融点の低い方の樹脂材料の融点（２２５℃）よりも６０℃高い温度となるように、レーザ出力、照射密度や加工速度を調整し、これにより溶融部４４の幅を２００μｍ程度とした。こうして溶融部４４において、図７に示すように、母材樹脂に保持されていた補強繊維４３を母材樹脂の溶融により該母材樹脂から開放して浮き立たせ無配向状態とした。
【０１０９】
その後、溶融部４４を冷却、固化して、第１樹脂部材４１と第２樹脂部材４２との接合を完了した。
【０１１０】
こうして、第１樹脂部材４１と第２樹脂部材４２との当接界面が補強繊維４３により橋渡しされて機械結合されるとともに、該補強繊維と該第１樹脂部材４１及び該第２樹脂部材４２との材料界面が上記結合助長層中の官能基を介して化学結合させることにより、互いに相溶性の小さい該１樹脂部材４１及び第２樹脂部材４２をレーザ光照射を利用して一体的に接合することができた。
【０１１１】
（参考例２）
本実施例は、レーザ光照射を利用しつつ、補強繊維を介して互いに相溶性の小さい第１樹脂部材及び第２樹脂部材を一体的に接合するものである。
【０１１２】
本参考例は、上記参考例１において、第１樹脂部材４１及び第２樹脂部材４２の当接界面にも、第１樹脂部材４１及び第２樹脂部材４２の双方と化学結合可能な官能基を有するカップリング剤よりなる結合助長層（厚さ２μｍ程度）を予め形成しておくもので、その他の構成は上記参考例１と同様である。
【０１１３】
なお、本参考例で用いたカップリング剤は、官能基としてアミノ基を有するシラン系カップリング剤である。
【０１１４】
したがって、本参考例によれば、第１樹脂部材４１及び第２樹脂部材４２同士の材料界面においても化学的結合力を付与せしめることができ、両者の接合強度を向上させることが可能となる。
【０１１５】
【発明の効果】
以上詳述したように請求項１乃至５記載の樹脂成形品の接合方法によれば、互いに相溶性の小さい第１樹脂部材及び第２樹脂部材同士を、アロイ樹脂材を両者間に介在させることで、極めて生産性の高いレーザ溶着を利用して一体的に接合することができる。
【図面の簡単な説明】
【図１】本発明の実施例１に係る樹脂成形品を部分的に切断した斜視図である。
【図２】上記実施例１に係る樹脂成形品の要部断面図である。
【図３】本発明の実施例２に係る樹脂成形品の斜視図である。
【図４】上記実施例２に係る樹脂成形品の断面図である。
【図５】本発明の実施例３に係る樹脂成形品の要部断面図である。
【図６】参考例１に係る樹脂成形品の接合方法を説明する断面図である。
【図７】上記参考例１に係る樹脂成形品の接合部を模式的に示す断面図である。
【符号の説明】
１１，２１，３１、４１…第１樹脂部材
１２，２２，３２，４２…第２樹脂部材
１３，２３，３３…アロイ樹脂材
４３…補強繊維[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for bonding resin molded products, and more particularly to a method for bonding resin molded products in which resin materials having low compatibility are bonded to each other using laser light irradiation.
[0002]
[Prior art]
In recent years, from the viewpoints of weight reduction and cost reduction, it has been frequently performed to resin parts of various fields such as automobile parts to form resin molded products. Further, from the viewpoint of increasing the productivity of resin molded products, it is often the case that a resin molded product is divided into a plurality of parts and molded, and these divided molded products are joined together.
[0003]
Japanese Patent Application Laid-Open No. 60-214931 discloses a method using laser welding as means for joining divided molded products made of such resin. In this bonding method, a transparent resin material that is transparent to laser light and a non-transparent resin material that is not transparent to laser light are overlapped, and laser light is irradiated from the transparent resin material side. By doing so, the contact surface between the permeable resin material and the non-permeable resin material is heated and melted to integrally bond the two.
[0004]
[Problems to be solved by the invention]
However, the method for joining resin molded products by laser welding is to join resin materials having compatibility with each other. Therefore, depending on the conventional laser welding method, resin materials having low compatibility with each other cannot be satisfactorily bonded.
[0005]
This invention is made | formed in view of the said situation, and should solve the bonding method of the resin molded product which can join the resin materials with low compatibility mutually, utilizing a laser beam irradiation. It is a technical issue.
[0006]
[Means for Solving the Problems]
(1) A method for joining resin molded products according to claim 1 for solving the above-mentioned problems is a transmissive resin material that is transmissive to laser light as a heating source and a non-transmissive material that is not transmissive to the laser light A first resin material and a second resin material that are less compatible with each other by utilizing laser welding in which the contact interface with the transparent resin material is heated and melted by irradiation with the laser light from the transparent resin material side. A resin molded product joining method for integrally joining a first resin member and a second resin member, wherein the first resin material and the second resin member are interposed between the first resin member and the second resin member. An arrangement step of interposing an alloy resin material made of a second resin material, and at least a first contact interface between the first resin member and the alloy resin material and the second resin member and the alloy resin by the laser light irradiation. The second contact interface with the material is melted by heating And it is characterized in that comprising the irradiation step that.
In a preferred embodiment, one of the first resin member and the second resin member is made of a permeable resin material and the other is made of a non-permeable resin material, and the alloy resin material is a permeable resin material or a non-permeable resin. Made of wood.
In a preferred embodiment, both the first resin member and the second resin member are made of one of a permeable resin material and a non-permeable resin material, and the alloy resin material is made of a permeable resin material and a non-permeable resin material. Made up of the other.
In a preferred embodiment, the alloy resin material is in the form of a sheet, powder or paste..
In a preferred aspect, the alloy resin material has a substantially triangular prism shape with a substantially triangular cross section, and two of the three surfaces constituting the substantially triangular shape are a tapered first contact interface with the first resin member and a first surface. It is a taper-like 2nd contact interface with 2 resin members.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
(1) A method of joining resin molded products according to claim 1 is a method of joining a transmissive resin material that is transmissive to laser light as a heating source and a non-transmissive resin material that is not transmissive to the laser light. A first resin composed of a first resin material and a second resin material that are less compatible with each other by utilizing laser welding in which the contact interface is heated and melted by irradiation with the laser light from the transparent resin material side. The member and the second resin material are integrally joined, and includes an arrangement process and an irradiation process.
[0010]
In the arranging step, an alloy resin material made of the first resin material and the second resin material is interposed between the first resin member and the second resin member.
[0011]
In the irradiation step, at least a first contact interface between the first resin member and the alloy resin material and a second contact interface between the second resin member and the alloy resin material are heated and melted by laser light irradiation. Since the alloy resin material is composed of the first resin material and the second resin material, if the first contact interface between the first resin member and the alloy resin material is heated and melted, the first contact interface is compatible with each other. The first resin material and the first resin member in a certain alloy resin material can be welded, while the second contact interface between the second resin member and the alloy resin material is heated and melted. At the contact interface, the second resin material and the second resin member in the alloy resin material compatible with each other can be welded.
[0012]
Thus, it becomes possible to integrally bond the first resin member and the second resin member having low compatibility with each other by laser welding through the alloy resin material made of the first resin material and the second resin material.
[0013]
The kind of the transmissive resin material is not particularly limited as long as it has thermoplasticity and can transmit laser light as a heating source at a predetermined transmittance or higher. For example, polyamide (PA) such as nylon 6 (PA6) and nylon 66 (PA66), polyethylene (PE), polypropylene (PP), styrene-acrylonitrile copolymer, polyethylene terephthalate (PET), polystyrene, ABS, acrylic (PMMA) ), Polycarbonate (PC), polybutylene terephthalate (PBT), and the like. In addition, you may use what was colored as needed.
[0014]
The kind of the non-transparent resin material is not particularly limited as long as it has thermoplasticity and can absorb the laser beam as a heating source without transmitting it. For example, polyamide (PA) such as nylon 6 (PA6) and nylon 66 (PA66), polyethylene (PE), polypropylene (PP), styrene-acrylonitrile copolymer, polyethylene terephthalate (PET), polystyrene, ABS, acrylic (PMMA) ), Polycarbonate (PC), polybutylene terephthalate (PBT), PPS, and the like, and carbon black, a predetermined colorant such as a dye or pigment, and the like.
[0015]
A first resin material and a second resin material constituting the first resin member and the second resin member are selected by appropriately selecting a combination of resin materials having low compatibility with each other from the above-described permeable resin material and non-permeable resin material. In addition to the resin material, the first resin material and the second resin material can constitute an alloy resin material.
[0016]
As a combination of resin materials having low compatibility, specifically, a combination of PC and PA such as PA6 or PA66, a combination of PC and PP, a combination of PC and PET, a combination of PC and ABS, PC And a combination of PBT, a combination of PP and a PA such as PA6 and PA66, a combination of PP and PBT, a combination of PBT and a PA such as PA6 and PA66, and a combination of PA and PPS.
[0017]
The blending ratio of the first resin material and the second resin material in the alloy resin material can be about 10:90 to 90:10, preferably about 25:75 to 75:25, and 50: A value of 50 is optimal.
[0018]
In addition, an alloy resin material can be manufactured by adding a compatibilizing agent or the like or a cross-linking material, or adding a compatibilizing agent and a cross-linking material.
[0019]
And in the joining method of the resin molded product according to claim 1, said 1st resin member, said 2nd resin member, and said alloy resin material are with respect to a laser beam which uses at least one among three as a heat source. A transmissive resin material having transparency and at least one of the three materials can be a non-transmissive resin material that is not transmissive to the laser beam. Specifically, (1) one of the first resin member and the second resin member is made of a permeable resin material and the other is made of a non-permeable resin material, and the alloy resin material is a permeable resin material or non-permeable resin. And (2) both the first resin member and the second resin member are made of one of a permeable resin material and a non-permeable resin material, and the alloy resin material is made of a permeable resin material and a non-permeable resin material. It can be set as the 2nd aspect which consists of the other of the permeable resin materials.
[0020]
Here, the laser welding is performed by irradiating a laser beam as a heating source from the transmissive resin material side, and transmitting the laser beam transmitted through the transmissive resin material to the contact interface of the non-transmissive resin material with the transmissive resin material. By reaching and absorbing and accumulating energy at the contact interface of the non-permeable resin material, the contact interface of the non-permeable resin material is heated and melted, and heat is transferred from the contact interface of the non-permeable resin material.ThroughThe contact interface of the over-resin material is heated and melted to weld both.
[0021]
(1) In the first aspect, the contact interface between one of the first resin member and the second resin member and the alloy resin material becomes a contact interface between the permeable resin materials or between the non-permeable resin materials, Further, the contact interface between the other of the first resin member and the second resin member and the alloy resin material is the contact interface between the permeable resin material and the non-permeable resin material. Of these, the contact interface between the transmissive resin material and the non-transmissive resin material can be laser-welded by laser light irradiation from the transmissive resin material side as described above. However, the contact interface between the transmissive resin materials and the contact interface between the non-transmissive resin materials cannot be welded only by the action of the laser welding described above. At this time, when the alloy resin material is a non-transmissive resin material, the laser light irradiated from the transmissive resin material side is absorbed by the alloy resin material from the contact interface side between the transmissive resin material and the non-transmissive resin material. If the entire alloy resin material is heated and melted, the contact interface between the non-permeable resin materials on the opposite side can also be heated and melted. On the other hand, when the alloy resin material is a transmissive resin material, the non-permeable resin material is first heated and melted on the contact interface side between the transmissive resin material and the non-transmissive resin material by the above-described laser welding action. If the whole of the alloy resin material can be heated and melted by heat conduction from, the contact interface between the opposite permeable resin materials can also be heated and melted.
[0022]
That is, in the case of the first aspect, it is necessary to heat and melt the entire alloy resin material by laser light irradiation from the transmissive resin material side. The first resin member and the second resin member, which are less compatible with each other, can be integrally joined via the alloy resin material.
[0023]
Therefore, in the first aspect, the thickness of the alloy resin material is preferably 0.5 mm or less, and more preferably 0.2 mm or less. If the thickness of the alloy resin material exceeds 0.5 mm, it becomes extremely difficult to heat and melt the entire alloy resin material by laser light irradiation from the transmission resin material side, and even to heat and melt the entire alloy resin material. Even if it can be done, it becomes inefficient in terms of energy such as the irradiation time of the laser beam. On the other hand, if the thickness of the alloy resin material is too thin, it is impossible to expect the original effect of the alloy resin material of joining the first resin member and the second resin member having low compatibility through the alloy resin material. The thickness of the alloy resin material is preferably 0.05 mm or more, and more preferably 0.1 mm or more.
[0024]
The shape of the alloy resin material in the first aspect is preferably a sheet shape in consideration of ease of handling and the like, but may be a powder shape or a paste shape.
[0025]
Furthermore, in the first aspect, the alloy resin material is preferably a non-permeable resin material. If the alloy resin material is a non-transmissive resin material, the laser light irradiated from the transmissive resin material side is directly absorbed by the alloy resin material, so that it is advantageous in terms of time to heat and melt the entire alloy resin material. It is possible.
[0026]
(2) In the second aspect described above, the contact interface between the first resin member and the alloy resin material and the contact interface between the second resin member and the alloy resin material are both the transparent resin material and the non-permeable resin material. Therefore, the contact interface between the first resin member and the alloy resin material and the contact interface between the second resin member and the alloy resin material can be welded by the above-described laser welding action. . For this reason, in the case of the second aspect, it is not always necessary to heat and melt the entire alloy resin material. However, even in the case of the second aspect, it is desirable to heat and melt the entire alloy resin material from the viewpoint of improving the bonding strength.
[0027]
Therefore, in the second aspect, when the entire alloy resin material is heated and melted, the thickness of the alloy resin material is preferably 0.05 to 0.5 mm, as in the first aspect (more Preferably, the shape of the alloy resin material is preferably a sheet, powder or paste.
[0028]
On the other hand, in the second aspect, when the entire alloy resin material is not heated and melted, the alloy resin material has a substantially triangular prism shape with a substantially triangular cross section, and two of the three surfaces constituting the substantially triangular prism shape are It is preferable to use a tapered first contact interface with one resin member and a tapered second contact interface with the second resin member.
[0029]
By doing so, when the alloy resin material is made of a permeable resin material and the first resin member and the second resin member are made of a non-permeable resin material, the first resin member and the second resin member made of the non-permeable resin material are used. By irradiating the laser beam only from one direction where the tapered first abutting interface and the tapered second abutting interface face, the first resin member transmits the laser beam transmitted through the alloy resin material made of a transmissive resin material. And reach and absorb both the tapered first contact interface and the tapered second contact interface of the second resin member,Tapered firstAbutting interface andTapered secondLaser welding at the contact interface can be performed. When the alloy resin material is made of a non-permeable resin material and the first resin member and the second resin member are made of a permeable resin material, the tapered first contact interface and taper of the alloy resin material made of the non-permeable resin material are used. The laser light transmitted through the first resin member made of a transmissive resin material is irradiated with laser light from one direction on the side where the second contact interface faces.Tapered firstThe laser light that reaches and abuts the abutting interface and passes through the second resin member made of the transmissive resin material is transmitted to the alloy resin material.Tapered secondReach and absorb the contact interface,Tapered firstAbutting interface andTapered secondLaser welding at the contact interface can be performed. However, according to the former aspect in which the alloy resin material is a permeable resin material and the first resin member and the second resin member are non-permeable resin materials, the first resin member and the second resin member made of the non-permeable resin material are used. Using reflection of laser light at one of the tapered first contact interface and the tapered second contact interfaceThe otherThe laser beam absorption to the taper contact interface can be promoted, and the laser irradiation time can be shortened.
[0030]
In addition, the laser beam irradiation from only one direction means changing the irradiation angle with respect to one contact interface during the laser beam irradiation, ortwoWithout irradiating laser light at the same or different irradiation angles on each of the abutting interfaces, a constant irradiation angle with respect to one abutting interface arbitrarily selected from the two abutting interfaces By one laser beam from one direction to irradiatetwoIt means that the joint surface is irradiated simultaneously.
[0031]
In addition, as the type of laser light used as a heating source, the transmittance in the transmissive resin material is not less than a predetermined value in relation to the absorption spectrum and thickness (transmission length) of the transmissive resin material that transmits the laser light. Those having such wavelengths are appropriately selected. For example, YAG: Nd3+A laser (wavelength of laser light: 1060 nm) or a semiconductor laser (wavelength of laser light: 500 to 1000 nm) can be used.
[0032]
Irradiation conditions such as laser output, irradiation density, and processing speed (moving speed) can be set as appropriate according to the type of resin.
[0056]
【Example】
Hereinafter, the present invention will be described specifically by way of examples.
[0057]
Example 1
This embodiment is claimed in claim 1.2 or 4This is an embodiment of the bonding method for resin molded products as described above.resinThe first resin member and the second resin member, which are less compatible with each other, are integrally joined via the material. Also, this exampleFirstOne of the resin member and the second resin member is made of a permeable resin material, the other is made of a non-permeable resin material, and the alloy resin material is made of a permeable resin material or a non-permeable resin material. It is a thing.
[0058]
FIG. 1 is a perspective view of a car headlight cut, and FIG.
[0059]
This headlight is divided into left and right parts, and a first resin member 11 that is a left side divided body andRight sideThis is a hollow body whose outer shell is configured from the second resin member 12 which is a divided body. The first resin member 11 and the second resin member 12 have contact end portions 11a and 12a that are aligned and fitted to each other, and the contact end portions 11a and 12a are connected to each other via the alloy resin material 13. They are joined together by laser welding.
[0060]
The first resin material constituting the first resin member 11 is made of polycarbonate (PC), and the first resin member 11 is a transmissive resin material that is transmissive to laser light as a heating source.
[0061]
The second resin material constituting the second resin member 12 is made of ABS to which glass fiber is added at 30 wt% and carbon black as a colorant is added in an appropriate amount, and the second resin member 12 is used for laser light as a heating source. On the other hand, it is a non-permeable resin material having no permeability.
[0062]
The first resin member 11 constitutes a headlight lens, and the second resin member 12 constitutes a headlight cover. Also, the PC as the first resin material and the second resin material asABSAre less compatible with each other.
[0063]
An extension 14 made of PC is disposed on the inner surface of the bottom wall 11b of the first resin member 11, and a reflector (reflecting mirror) 15 made of epoxy (BMC) is disposed on the inner surface of the second resin member 12. It is installed. The lamps 16 are disposed in the through holes 12b and 15a provided in the rear walls of the second resin member 12 and the reflector 15, respectively, and the through holes 12b of the second resin material 12 are closed by the cover 17. It is.
[0064]
As shown in FIG. 2, the contact end 11a of the first resin member 11 has an inner side while leaving a step on the base end side (left end side in FIG. 2) inside the hollow body (lower side in FIG. 2). In addition, the outer end is cut out in a tapered shape, and the leading end portion is cut off, and a fitting convex portion 11 c formed in a shape that gradually shrinks and protrudes toward the leading end side is provided. The fitting convex portion 11c has a distal end joining end face 11c1, outer and inner tapered joining faces 11c2, and an inner stepped joining end face 11c3 intersecting with the proximal end of the inner tapered joining face 11c2. ing.
[0065]
On the other hand, the contact end portion 12a of the second resin member 12 is formed in a shape that gradually expands and protrudes toward the distal end side (left end side in FIG. 2), and can be fitted to the fitting convex portion 11c. A concavity 12c is provided. The fitting recess 12c includes a bottom joint end face 12c1 aligned with the tip joint end face 11c1, outer and inner tapered joint faces 12c2 aligned with the tapered joint faces 11c2, and an inner tapered shape. It has a tip joint end face 12c3 that intersects the tip of the joint face 12c2 and is aligned with the stepped joint end face 11c3.
[0066]
And the fitting convex part 11c of the 1st resin member 11 and the fitting recessed part 12c of the 2nd resin member 12 are fitted through the said alloy resin material 13, and the front-end | tip joining end surface 11c1 and bottom joining end surface 12c1 are mutually And the outer tapered bonding surfaces 11c2 and 12c2, the inner tapered bonding surfaces 11c2 and 12c2, and the stepped bonding end surface 11c3 and the tip bonding end surface 12c3 are respectively lasered via the alloy resin material 13. They are joined together by welding.
[0067]
The alloy resin material 13 is composed of PC as the first resin material and ABS as the second resin material. The alloy resin material 13 is a sheet-like material having a thickness of 0.2 mm formed by compression molding a material to which a compatibilizing agent and a cross-linking material are added. The first resin material and the second resin material The blending ratio is 50:50. Further, an appropriate amount of carbon black as a colorant is added to the alloy resin material 13, and the alloy resin material 13 is a non-transparent resin material that is not transmissive to laser light as a heating source.
[0068]
The resin molded product of the present example having the above-described configuration was manufactured as follows. First, after the first resin member 11 and the second resin member 12 are formed into predetermined shapes by injection molding, an extension is disposed on the inner surface of the first resin member 11, and a reflector is disposed on the inner surface of the second resin material 12. Arranged. And the fitting convex part 11c of the 1st resin member 11 and the fitting convex part 12c of the 2nd resin member 12 are fitted via the alloy resin material 13, and the 1st resin member 11 and the 2nd resin member 12 and An alloy resin material 13 was interposed between the two. In this state, laser light was irradiated from the first resin member 11 side as the transmissive resin material toward the bottom joint end surface 12c1, the two taper joint surfaces 12c2 and the tip joint end surface 12c3 of the second resin member 12. Note that a YAG-neodymium laser beam (wavelength 1060 nm) was used as the laser beam. Irradiation conditions were: output: 200 to 400 W, processing speed: 5 m / min.
[0069]
By this laser beam irradiation, the entire alloy resin material 13 is heated and melted, and the first resin member 11 and the alloy resin material 13 areContactInterface and second resin member 12 and alloy resin member 13ContactThe interface was heated and melted and welded, and the first resin member 11 and the second resin member 12 were integrally joined by laser welding via the alloy resin material 13.
[0070]
Even when the first resin member 11 and the second resin member 12 made of the first resin material and the second resin material having low compatibility with each other are joined by laser welding, the alloy resin material is interposed between them. By interposing 13, it was possible to bond well.
[0071]
Further, in the joint portion thus obtained, the tip joint end surface 11c1 and the bottom joint end surface 12c1, the outer tapered joint surfaces 11c2 and 12c2, the inner tapered joint surfaces 11c2 and 12c2, and the stepped joint end surface 11c3 and In addition to the joining by laser welding of the tip joining end faces 12c3, the fitting of the fitting convex part 11c of the first resin member 11 and the fitting concave part 12c of the second resin member 12, and the step shape of the first resin member 11 Since the joint end surface 11c3 and the tip joint end surface 12c3 of the second resin member 12 are engaged to form a structurally strong joint portion, the joint end surface 11c3 has higher joint strength and pressure strength.
[0072]
Further, in the resin molded product of the present embodiment, the fitting convex portion 11c is provided at the contact end portion 11a of the first resin member 11 made of permeable resin, and the second resin member 12 made of non-permeable resin is applied. A fitting recess 12c is provided in the contact end portion 12a. For this reason, in addition to the scattering of the laser beam in the transparent resin of the first resin member 11, the laser beam on the inner surface (the bottom bonded end surface 12c1 and each tapered bonded surface 12c2) of the fitting recess 12c of the second resin member 12. Therefore, even when the laser beam is irradiated from only one direction, the outer surface of the fitting convex portion 11c and the inner surface of the fitting concave portion 12c are entirely and substantially even. Laser welding can be performed.
[0073]
(Example 2)
This embodiment is claimed in claim 1.2 or 4This is an embodiment of the bonding method for resin molded products as described above.resinThe first resin member and the second resin member, which are less compatible with each other, are integrally joined via the material. Also, this exampleFirstOne of the resin member and the second resin member is made of a permeable resin material, the other is made of a non-permeable resin material, and the alloy resin material is made of a permeable resin material or a non-permeable resin material. It is a thing.
[0074]
FIG. 3 is a perspective view of an electronic control unit (ECU) for an automobile, and FIG. 4 is a cross-sectional view of the electronic control unit.
[0075]
This electronic control device is a hollow body having an outer shell composed of a first resin member 21 constituting a housing and a second resin member 22 constituting a lid. The upper end surface of the side wall of the first resin member 21 and the peripheral edge portion of the second resin member 22 are respectively provided with an annular recess 21a and an annular protrusion 22a that are aligned and fitted with each other. The annular protrusions 22a are integrally joined to each other by laser welding via the alloy resin material 23.
[0076]
The first resin material constituting the first resin member 21 is made of polybutylene terephthalate (PBT), and the first resin member 21 is a non-transmissive resin material that is not transmissive to laser light as a heating source. PBT is a better material to use as a non-transparent resin material because of its low light transmission as a material eigenvalue due to its crystal structure.
[0077]
The second resin material 22 constituting the second resin member 22 is made of nylon 6 (PA6), and the second resin member 22 is a transmissive resin material that is transmissive to laser light as a heating source. Note that PC or ABS may be adopted as the second resin material 22 in addition to PA6.
[0078]
A connector 24 is integrally formed on the side wall of the first resin member 21 from the viewpoint of cost reduction (see FIG. 3), and is connected to the connector 24 in the first resin member 21. An electric circuit 25 is provided (see FIG. 4). The PBT as the first resin material and PA6 as the second resin material have low compatibility with each other.
[0079]
The alloy resin material 23 is composed of PBT as the first resin material and PA6 as the second resin material. This alloy resin material 23 is a sheet-like material having a thickness of 0.2 mm formed by compression molding a material to which a compatibilizing agent and a crosslinking material are added. The first resin material and the second resin material The blending ratio is 50:50. The alloy resin material 13 is a non-transmissive resin material that does not transmit laser light as a heating source.
[0080]
The resin molded product of the present example having the above-described configuration was manufactured as follows. First, the first resin member 21 and the second resin member 22 were each formed into a predetermined shape by injection molding, and then the electric circuit 25 was disposed on the inner surface of the first resin member 21. And the annular recessed part 21a of the 1st resin member 21 and the annular convex part 22a of the 2nd resin member 22 are fitted via the alloy resin material 23, Between the 1st resin member 21 and the 2nd resin member 22 An alloy resin material 23 was interposed. In this state, laser light was irradiated from the second resin member 22 side as the transmissive resin material toward the annular recess 21 a of the first resin member 21. Note that a YAG-neodymium laser beam (wavelength 1060 nm) was used as the laser beam. Irradiation conditions were: output: 200 to 400 W, processing speed: 5 m / min.
[0081]
By this laser light irradiation, the entire alloy resin material 23 is heated and melted, and the first resin member 21 and the first alloy resin material 23 are joined together.ContactInterface and second resin member 22 and alloy resin member 23ContactThe interface was heated and melted and welded, and the first resin member 21 and the second resin member 23 were integrally joined by laser welding via the alloy resin material 23.
[0082]
Even when the first resin member 21 and the second resin member 22 made of the first resin material and the second resin material having low compatibility with each other are joined by laser welding, an alloy resin material is interposed between them. By interposing 23, good bonding could be achieved.
[0083]
Moreover, according to the present Example, the effect shown below can also be anticipated.
[0084]
In an electronic control device for automobiles, sealing performance is required to prevent water from entering the device. For this reason, conventionally, the housing and the lid are joined by thermosetting adhesive or by fastening with bolts and embedded nuts through an expensive fluororubber-based O-ring. . However, when a thermosetting adhesive is used, a thermal effect is likely to occur in the solder joints of the electric circuit 25 during the badge heating process in the furnace, and the productivity is poor. Moreover, when using the fastening means of the volt | bolt and embedded nut through an O-ring, it is high-cost by the increase in a number of parts and an increase in a process. In this respect, according to the present embodiment using laser welding, the electric circuit 25 is not adversely affected by the heat effect, and the number of parts is not increased. it can.
[0085]
Further, the connector 24 in the automobile electronic control device is required to have dimensional stability against water absorption. For this reason, PBT etc. which are excellent in water absorption resistance are conventionally used as the material of the connector 24. If the connector 24 is to be integrally formed with the first resin member 21 as a housing in order to reduce the cost as in this embodiment, the resin material of the first resin member 21 is naturally PBT. However, as described above, PBT has low light transmittance as a material intrinsic value, and can only be used as a non-transparent resin material. In general, no suitable resin material that is compatible with the PBT and is transmissive to the laser beam is found. For this reason, when PBT is adopted as the resin material of the housing, the lid member cannot be joined by conventional laser welding. In this regard, according to the present embodiment, the second resin lid 21 made of PA6 has low compatibility with the first resin member 21 as the housing made of PBT and is permeable to laser light. The resin member 22 can be laser welded through the alloy resin material 23. It is possible to improve the dimensional stability against water absorption in the connector 24 while reducing the cost by integrally forming the first resin member 21 and the connector 24 as a housing.
[0086]
In the second embodiment, the second resin material constituting the second resin member 22 as the lid can be made of polypropylene (PP) that is less expensive than PA, and the cost can be further reduced.
[0087]
(Example 3)
This embodiment is claimed in claim 1.3 or 5This is an embodiment of the bonding method for resin molded products as described above.resinThe first resin member and the second resin member, which are less compatible with each other, are integrally joined via the material. In this embodiment, both the first resin member and the second resin member are made of one of a permeable resin material and a non-permeable resin material, and the alloy resin material is a permeable resin material or a non-permeable resin material. It embodies the 2nd mode which consists of the other.
[0088]
In the resin molded product according to the present embodiment, the first resin member 31 constituting the intake manifold for the automobile and the second resin member 32 constituting the air cleaner are integrally joined by laser welding via the alloy resin material 33. It is a thing.
[0089]
As shown in FIG. 5, the alloy resin material 33 in this embodiment has a triangular prism shape with a triangular cross section. One surface of the three surfaces constituting the triangular shape and the contact end surface of the first resin member 31 that contacts the one surface form tapered first contact interfaces 33a and 31a that align and contact each other, and The other one of the three surfaces and the contact end surface of the second resin member 32 that contacts the one surface form tapered second contact interfaces 33b and 32a that align and contact each other. The tapered first contact interface 31a of the first resin member 31 and the tapered first contact interface 33a of the alloy resin material 33 are integrally joined together by laser welding, and the taper of the second resin member 32 is obtained. The second contact interface 32a and the tapered second contact interface 33b of the alloy resin material 33 are integrally joined by laser welding.
[0090]
The first resin material constituting the first resin member 31 is made of nylon 6 (PA6) to which glass fiber is added at 30 wt% and carbon black as a colorant is added in an appropriate amount, and the first resin member 11 is heated. It is a non-over-resin material that is not transparent to the laser beam as the source.
[0091]
The second resin material constituting the second resin member 32 is made of polypropylene (PP) to which glass fiber is added in an amount of 30 wt% and carbon black as a colorant is appropriately added. It is a non-transmissive resin material that is not transmissive to laser light as a heating source.
[0092]
Note that PA6 as the first resin material and PP as the second resin material have low compatibility with each other.
[0093]
The alloy resin material 33 is made of PA6 as the first resin material and PP as the second resin material. The alloy resin material 23 is molded into a predetermined shape by compression molding, and the blending ratio of the first resin material and the second resin material is 50:50. Also, carbon black as a colorant is not added to the alloy resin material 33, and the alloy resin material 33 is a transmissive resin material that is transmissive to laser light as a heating source.
[0094]
The plate thickness of the first resin member 31 and the second resin member 32 is about 3 mm, and the width of the alloy resin material 33 (the length of one side of the cross-sectional triangle) is about 4 mm.
[0095]
The resin molded product of the present example having the above-described configuration was manufactured as follows. First, the first resin member 31 and the second resin member 32 were each formed into a predetermined shape by injection molding, and then the alloy resin material 33 was disposed between the first resin member 31 and the second resin member 32. Then, laser light was irradiated from the alloy resin material 33 side as the transmissive resin material toward the tapered first contact interface 31 a of the first resin material 31 and the tapered second contact interface 32 a of the second resin member 32. . Note that a YAG-neodymium laser beam (wavelength 1060 nm) was used as the laser beam. Irradiation conditions were: output: 200 to 400 W, processing speed: 5 m / min.
[0096]
By this laser light irradiation, the tapered first contact interfaces 31a and 33a of the first resin member 31 and the alloy resin material 33 are heated and melted together, and the tapered shape of the second resin material 32 and the alloy resin material 33 is also obtained. The second contact interfaces 32a and 33b were heated and melted to be welded together, and the first resin member 31 and the second resin member 32 were integrally joined by laser welding via the alloy resin material 33.
[0097]
In this embodiment, the alloy resin material 33 has a mode in which only the vicinity of the tapered first contact interface 33a and the vicinity of the tapered second contact interface 33b are heated and melted and the entire alloy resin material 33 is not heated and melted. However, the entire alloy resin material 33 can be heated and melted from the viewpoint of improving the bonding strength.
[0098]
Even when the first resin member 31 and the second resin member 32 made of the first resin material and the second resin material having low compatibility with each other are joined by laser welding, the alloy resin material is interposed between them. By interposing 33, good bonding could be achieved.
[0099]
In the present embodiment, the cross-sectional shape of the alloy resin material 33 is substantially triangular, and the alloy resin material 33 is a transmissive resin material. Therefore, the first resin member 31 and the second resin member 31 made of a non-permeable resin material are used. By irradiating the laser beam from only one direction of the resin member 32 on the side where the tapered first abutting interface 31a and the tapered second abutting interface 32a face, the alloy member 33 made of a permeable resin material is transmitted. The laser light reaches and absorbs both the tapered first contact interface 31a and the tapered second contact interface 32a of the first resin member 31 and the second resin member 32, and the first tapered contact interface 31a. Further, laser welding can be performed at the second tapered contact interface 32a. Furthermore, at the time of laser light irradiation, one of the tapered first abutting interface 31a and the tapered second abutting interface 32a of the first resin member 31 and the second resin member 32 made of a non-transmissive resin material is applied. The reflection of the laser beam at the contact interface can be used to promote the absorption of the laser beam to the other tapered contact interface, and the laser irradiation time can be shortened.
[0100]
(Reference example 1)
BookreferenceAn example is, LesThe first resin member and the second resin member, which are less compatible with each other, are integrally joined through the reinforcing fiber while utilizing the laser light irradiation.
[0101]
A first resin member 41 and a second resin member 42 having a plate thickness of 3 mm were prepared by an injection molding method.
[0102]
The first resin member 41 is obtained by adding 30 mass% of a reinforcing fiber 43 made of glass fiber (GF) to PA6 (melting point: 225 ° C.) as a base material resin, and is transparent to laser light as a heating source. There is something. On the other hand, the second resin member 42 is obtained by adding 30 mass% of reinforcing fibers 43 to PBT (melting point: 225 ° C.) as a base resin and adding an appropriate amount of carbon black as a coloring material. It is not transparent to laser light.
[0103]
Note that PA 6 as the first resin material constituting the first resin member 41 and PBT as the second resin material constituting the second resin member 42 have low compatibility with each other.
[0104]
The reinforcing fibers 43 have a length distribution in the range of 50 to 400 μm and an average length of 200 μm. The proportion of the reinforcing fiber 43 that is shorter than the width (200 μm) of the melted portion 44 described later is 100 mass% when the entire reinforcing fiber 43 added to the first resin member 41 or the second resin member 42 is 100 mass%. 50 mass%.
[0105]
Further, on the surface of the reinforcing fiber 43, a bonding promoting layer (thickness not shown) made of a coupling agent having a functional group capable of chemically bonding with the reinforcing fiber 43 and both the first resin member 41 and the second resin member 42 is formed. About 2 μm) is formed in advance. In this example, a silane coupling agent having an amino group as a functional group was used as the coupling agent.
[0106]
On the other hand, YAG: Nd having a wavelength of 1.06 μm3+A laser torch 45 that emits laser light was prepared.
[0107]
Then, as shown in FIG. 6, the first resin member 41 and the second resin member 42 are brought into contact with each other so as to overlap the second resin member 42, and the first resin member 41 and the second resin member 42 are not shown in the drawing. Clamped with. In this state, the laser light emitted from the laser torch 45 is irradiated from the first resin member 41 side as a transmissive resin material, and the contact interface between the first resin member 41 and the second resin member 42 is heated and melted to melt the molten portion. 44.
[0108]
Here, the laser beam irradiation was performed while measuring the temperature of the melted portion 44 melted by the laser beam irradiation. The laser output is such that the temperature of the melting portion 44 is 60 ° C. higher than the melting point (225 ° C.) of the resin material having the lower melting point of the first resin material and the second resin material. The irradiation density and processing speed were adjusted so that the width of the melted portion 44 was about 200 μm. In this way, in the melting part 44, as shown in FIG. 7, the reinforcing fibers 43 held in the base material resin are released from the base material resin by the melting of the base material resin and are brought into a non-oriented state.
[0109]
Thereafter, the melting part 44 was cooled and solidified, and the joining of the first resin member 41 and the second resin member 42 was completed.
[0110]
Thus, the abutting interface between the first resin member 41 and the second resin member 42 is bridged and mechanically coupled by the reinforcing fiber 43, and the reinforcing fiber, the first resin member 41, and the second resin member 42 The first resin member 41 and the second resin member 42, which are less compatible with each other, are integrally bonded using laser light irradiation by chemically bonding the material interface via the functional group in the bond promoting layer. I was able to.
[0111]
(Reference example 2)
BookImplementationAn example is, LesThe first resin member and the second resin member, which are less compatible with each other, are integrally joined through the reinforcing fiber while utilizing the laser light irradiation.
[0112]
BookreferenceThe example aboveReference example 1In the above, a bond promoting layer made of a coupling agent having a functional group capable of chemically bonding to both the first resin member 41 and the second resin member 42 at the contact interface between the first resin member 41 and the second resin member 42. (Thickness of about 2 μm) is formed in advance.Reference example 1It is the same.
[0113]
BookreferenceThe coupling agent used in the examples is a silane coupling agent having an amino group as a functional group.
[0114]
So bookreferenceAccording to the example, a chemical bonding force can be applied even at the material interface between the first resin member 41 and the second resin member 42, and the bonding strength between the two can be improved.
[0115]
【The invention's effect】
Claim 1 as detailed above5According to the method for joining resin molded articles described above, the first resin member and the second resin member having low compatibility with each other, and the alloy resin material is interposed between the two, thereby utilizing laser welding with extremely high productivity. And can be joined together.
[Brief description of the drawings]
FIG. 1 is a perspective view in which a resin molded product according to Example 1 of the present invention is partially cut.
FIG. 2 is a cross-sectional view of a principal part of a resin molded product according to the first embodiment.
FIG. 3 is a perspective view of a resin molded product according to Embodiment 2 of the present invention.
4 is a cross-sectional view of a resin molded product according to Example 2. FIG.
FIG. 5 is a cross-sectional view of a main part of a resin molded product according to Example 3 of the present invention.
[Fig. 6]Reference example 1It is sectional drawing explaining the joining method of the resin molded product which concerns on this.
FIG. 7 AboveReference example 1It is sectional drawing which shows typically the junction part of the resin molded product which concerns on this.
[Explanation of symbols]
11, 21, 31, 41 ... 1st resin member
12, 22, 32, 42 ... second resin member
13, 23, 33 ... Alloy resin material
43 ... Reinforcing fiber

Claims (5)

加熱源としてのレーザ光に対して透過性のある透過樹脂材と、該レーザ光に対して透過性のない非透過樹脂材との当接界面を、該透過樹脂材側からの該レーザ光の照射により加熱溶融させて溶着するレーザ溶着を利用して、互いに相溶性の小さい第１樹脂材料及び第２樹脂材料よりなる第１樹脂部材及び第２樹脂部材を一体的に接合する樹脂成形品の接合方法であって、
上記第１樹脂部材と上記第２樹脂部材との間に、上記第１樹脂材料及び上記第２樹脂材料よりなるアロイ樹脂材を介在させる配置工程と、
上記レーザ光照射により、少なくとも上記第１樹脂部材と上記アロイ樹脂材との第１当接界面及び上記第２樹脂部材と該アロイ樹脂材との第２当接界面を加熱溶融させる照射工程とからなることを特徴とする樹脂成形品の接合方法。A contact interface between a transparent resin material that is transmissive to the laser beam as a heating source and a non-transmissive resin material that is not transmissive to the laser beam is formed between the laser beam from the transmissive resin material side. A resin molded product that integrally joins the first resin member and the second resin member made of the first resin material and the second resin material having low compatibility with each other by using laser welding that is heated and melted by irradiation and welding. A joining method,
An arrangement step of interposing an alloy resin material made of the first resin material and the second resin material between the first resin member and the second resin member;
From the irradiation step of heating and melting at least the first contact interface between the first resin member and the alloy resin material and the second contact interface between the second resin member and the alloy resin material by the laser light irradiation. A method for joining resin molded products. 前記第１樹脂部材及び前記第２樹脂部材のうちの一方が透過樹脂材よりなるとともに他方が非透過樹脂材よりなり、かつ、前記アロイ樹脂材が透過樹脂材又は非透過樹脂材よりなることを特徴とする請求項１記載の樹脂成形品の接合方法。One of the first resin member and the second resin member is made of a permeable resin material, the other is made of a non-permeable resin material, and the alloy resin material is made of a permeable resin material or a non-permeable resin material. The method for joining resin molded products according to claim 1, characterized in that: 前記第１樹脂部材及び前記第２樹脂部材の双方が透過樹脂材及び非透過樹脂材のうちの一方よりなり、かつ、前記アロイ樹脂材が透過樹脂材及び非透過樹脂材のうちの他方よりなることを特徴とする請求項１記載の樹脂成形品の接合方法。Both the first resin member and the second resin member are made of one of a permeable resin material and a non-permeable resin material, and the alloy resin material is made of the other of the permeable resin material and the non-permeable resin material. The method for joining resin molded products according to claim 1. 前記アロイ樹脂材はシート状、粉末状又はペースト状であることを特徴とする請求項１、２又は３記載の樹脂成形品の接合方法。4. The method for joining resin molded products according to claim 1, 2 or 3, wherein the alloy resin material is in the form of a sheet, powder or paste. 前記アロイ樹脂材は断面略三角形の略三角柱形状であり、この略三角形状を構成する三面のうちの二面が前記際１樹脂部材とのテーパ状第１当接界面及び第２樹脂部材とのテーパ状第２当接界面であることを特徴とする請求項１又は３記載の樹脂成形品の接合方法。 The alloy resin material has a substantially triangular prism shape with a substantially triangular cross-section, and two of the three surfaces constituting the substantially triangular shape are a tapered first contact interface with the first resin member and the second resin member. 4. The method for joining resin molded products according to claim 1, wherein the second contact interface is a tapered second contact interface .
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