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JP5547883B2 - 樹脂材の溶着方法 - Google Patents

樹脂材の溶着方法 Download PDF

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Publication number
JP5547883B2
JP5547883B2 JP2008246904A JP2008246904A JP5547883B2 JP 5547883 B2 JP5547883 B2 JP 5547883B2 JP 2008246904 A JP2008246904 A JP 2008246904A JP 2008246904 A JP2008246904 A JP 2008246904A JP 5547883 B2 JP5547883 B2 JP 5547883B2
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Japan
Prior art keywords
resin material
welding
laser beam
fitting
resin
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Expired - Fee Related
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JP2008246904A
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JP2010076246A (ja
Inventor
浩司 浦瀬
康志 永野
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Panasonic Corp
Panasonic Holdings Corp
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Panasonic Corp
Matsushita Electric Industrial Co Ltd
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Priority to JP2008246904A priority Critical patent/JP5547883B2/ja
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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
    • B29C66/50—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
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
    • B29C66/1162—Single bevel to bevel joints, e.g. mitre joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/118—Single monotone curved joints
    • B29C66/1182—Single monotone curved joints the joint being C-shaped
    • 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
    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1226—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one bevelled joint-segment
    • B29C66/12261—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one bevelled joint-segment the two joint-segments being bevelled, e.g. the two joint-segments forming a V
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2424—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain
    • B29C66/24243—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a quadrilateral
    • B29C66/24244—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a quadrilateral forming a rectangle
    • 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
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B29C66/53461—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat joining substantially flat covers and/or substantially flat 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
    • B29C66/73—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
    • 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
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B29K2033/04—Polymers of esters
    • B29K2033/12—Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2059/00—Use of polyacetals, e.g. POM, i.e. polyoxymethylene or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/006—PBT, i.e. polybutylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material

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

Description

本発明は、複数の樹脂材を組み立てる際に用いられる樹脂材の溶着方法に関するものである。
従来より、複数の樹脂材を組み立てるにあたって、レーザ光を用いた溶着方法が採用されている（例えば、特許文献１参照）。図５（ａ）に二つの樹脂材１、２をレーザ光により溶着する方法の一例を示す。この場合、一方の樹脂材１はレーザ光Ｌを比較的吸収しやすい高吸収率の樹脂材で形成されるものであって、他方の樹脂材２はレーザ光Ｌを比較的透過しやすい高透過率の樹脂材で形成されている。
そして、まず、二つの樹脂材１、２を重ね合わせて配置する。次に、図５（ｂ）に示すように、樹脂材１、２の接合面にレーザー照射装置ＬＭからレーザ光Ｌを照射する。このレーザ光Ｌは高透過率の樹脂材２を通過させて接合面に照射するようにする。これにより、接合面において高吸収率の樹脂材１がレーザ光Ｌを吸収して発熱し、この熱により接合面で樹脂材１、２を溶融させ、この後、図５（ｃ）に示すように、溶融した樹脂を硬化又は固化することにより溶着部１０を形成して樹脂材１、２を溶着することができる。また、二つの樹脂材１、２を重ね合わせた状態で押さえ治具などにより樹脂材１、２を加圧することにより、接合面を圧着しながら溶着することができる。
特開２００５−２８８９３４号公報
しかし、上記の従来例では、レーザ光による溶着の際に、樹脂の溶着部より煤が発生し、レーザ光を集光するレンズが汚れたり、各樹脂材１、２の厚みなどの成型精度等の成型状態により、レーザ光の透過率や吸収率が変化したりした場合に、接合面でのレーザ光の焦点がずれるなどのレーザ光の照射条件が部分的に不充分になることがあり、溶着性が不安定となるおそれがあった。
本発明は上記の点に鑑みてなされたものであり、安定したレーザ光による溶着を行うことができる樹脂材の溶着方法を提供することを目的とするものである。
本発明の請求項１に係る樹脂材の溶着方法は、一方の樹脂材と他方の樹脂材とのレーザ光による溶着方法であり、前記一方の樹脂材と前記他方の樹脂材との接合面全体は、前記一方の樹脂材に形成された円弧状のテーパー面を有する嵌合凸部と、前記他方の樹脂材に形成された円弧状のテーパー面を有する嵌合凹部の、それぞれのテーパー面どうしの接合面で構成され、前記接合面へのレーザ光の入射方向において、前記接合面とレーザ照射装置との距離は、前記接合面全域で連続的に変化する構成であり、前記嵌合凸部と前記嵌合凹部のテーパー面同士を接合した後、そのテーパー面にレーザ光を照射することにより前記樹脂材を溶融して複数の樹脂材を前記テーパー面で溶着することを特徴とするものである。
請求項１の発明では、テーパー面を接合してその接合面にレーザ光を照射して溶着するので、レーザ光を集光するレンズの汚れや樹脂材の成型状態によりレーザ光の透過率や吸収率が変化しても、接合面へのレーザ光の入射方向において、接合面全体でレーザー照射装置からの距離が連続的に異なるため、接合面のいずれかの部分でレーザ光の照射条件が満たされる可能性が高くなって溶着部を形成するためのポイントを確保することができ、不充分な溶着部分が少なくなって、安定したレーザ光による溶着を行うことができるものである。
請求項１の発明では、嵌合凸部と嵌合凹部との嵌合によりテーパー面の位置決めを容易に行うことができ、樹脂材の溶着が行いやすくなるものである。
請求項１の発明では、一定角度の傾斜を有するテーパー面であると成形用型の継ぎ目部分で成型時にバリが発生しやすくなるが、滑らかな傾斜面である円弧状とすることで成形用型の継ぎ目がなくなって成型時のバリ発生を防止することができるものである。
以下、本発明を実施するための最良の形態を説明する。
図１に、二つの樹脂材１、２を溶着する方法について例示する。
一方の樹脂材１は他方の樹脂材２よりも比較的レーザ光Ｌの透過率が低くて吸収率が高いものを用いることができ、これにより、溶着時に樹脂材１がレーザ光Ｌを十分に吸収して発熱することができるものである。このような樹脂材１は、例えば、ポリブチレンテレフタレート（ＰＢＴ）、ポリエチレンテレフタレート（ＰＥＴ）、ポリオキシメチレン（ＰＯＭ）、ポリプロピレン（ＰＰ）、ポリスチレン（ＰＳ）、ポリカーボネート（ＰＣ）、ポリメタクリル酸メチル（ＰＭＭＡ）などの樹脂材料の成型品を用いることができる。
もう一方の樹脂材２は他方の樹脂材１よりも比較的レーザ光Ｌの吸収率が低くて透過率が高いものを用いることができ、レーザ光Ｌの透過率が３０〜７０％程度であることが好ましい。これにより、溶着時に樹脂材２がレーザ光Ｌを十分に透過して接合面に到達することができることができるものである。このような樹脂材２は上記と同様の樹脂材料の成型品を用いることができる。
本発明では、樹脂材１、２の溶着する面がテーパー面（傾斜面）３、４として形成されている。図１（ａ）では、樹脂材１、２を上下に配置して溶着するものであるため、下側の樹脂材１の上面がテーパー面３として形成されており、上側の樹脂材２の下面がテーパー面４として形成されている。テーパー面３とテーパー面４は同じ傾斜角を有し、レーザ光Ｌの入射方向に対して０°よりも大きくて９０°よりも小さい傾斜角にするのが好ましく、より好ましくは３０〜６０°である。また、テーパー面３とテーパー面４は同じ方向に向いて傾斜してればよい。尚、図１（ａ）のものでは樹脂材１、２は四角枠状に形成されているが、これに限定されるものではなく、各種の形状を採用することができる。
そして、樹脂材１、２を溶着するにあたっては、次のようにして行う。まず、一方の樹脂材１の上に他方の樹脂材２を載置する。このとき、レーザ光Ｌの透過率の高い樹脂材２をレーザ光Ｌの吸収率の高い樹脂材１の上に重ね合わせて、テーパー面３とテーパー面４とを接合する。この場合、図１（ｂ）に示すように、テーパー面３とテーパー面４とはほとんど隙間なく密着するか、隙間があいていても略平行に対向するものである。
次に、テーパー面３とテーパー面４の接合面にレーザ光Ｌを照射する。このとき、レーザ光Ｌは、レーザ光Ｌの透過率の高い樹脂材２を通過させてテーパー面３とテーパー面４の接合面に照射するようにする。また、レーザ光Ｌは溶着が必要な部分の総てに照射されるように、レーザ光Ｌを樹脂材１、２に対して走査するようにする。そして、このようにしてテーパー面３とテーパー面４の接合面にレーザ光Ｌを照射すると、レーザ光Ｌの吸収率の高い樹脂材２がレーザ光Ｌを吸収して発熱し、この発熱により、樹脂材１と樹脂材２の一方又は両方が溶融する。この後、樹脂の溶融部分を発熱により硬化したりあるいは降温により固化したりすることにより、図１（ｃ）に示すように、溶着部１０を形成する。そして、この溶着部１０により樹脂材１と樹脂材２とを溶着することができるものである。溶着時のレーザの種類、使用周波数の範囲、強さの範囲などは、樹脂材１、２の種類や厚み等によって適宜設定可能であるが、レーザーパワーは約１０〜３０Ｗにすることができる。
本発明では、テーパー面３、４を接合し、この接合面にレーザ光Ｌを照射して溶着するので、図２（ａ）に示すように、テーパー面３、４のレーザ光Ｌの照射される範囲（レーザ光径ＬＤの範囲）のＡ点とＢ点とではレーザ照射装置ＬＭからの距離が異なるため、レーザ光Ｌの焦点がずれるなどの照射条件がばらついても、Ａ点とＢ点の間のいずれかの部分でレーザ光Ｌの照射条件が最適になって溶着できる可能性がある。すなわち、レーザ照射装置ＬＭの光学系を介してレーザ光Ｌを照射する場合、焦点調整なども行っているが、樹脂材１、２の成型精度やレーザ光Ｌを集光するレンズが汚れるなどの様々な要因でレーザ光Ｌの入射方向（深さ方向）に焦点距離がことなることになる。図２（ｂ）の従来例では、レーザ光Ｌの照射される範囲（レーザ光径ＬＤの範囲）のＡ’点とＢ’点とではレーザ照射装置ＬＭからの距離が一定であるため、焦点がずれると、Ａ’点とＢ’点の間で溶着されないことがあり、溶着が不安定になるおそれがある。
図３（ａ）（ｂ）に他の実施の形態の一例を示す。この溶着方法では、一方の樹脂材１に嵌合凸部５を設けると共に他方の樹脂材２に嵌合凹部６を設け、嵌合凸部５と嵌合凹部６とを嵌合した状態で溶着するものである。断面形状において嵌合凸部５は二つのテーパー面３、３により先端面（凸面）が形成されている。また、断面形状において嵌合凹部６は二つのテーパー面４、４により底面（凹面）が形成されている。嵌合凸部５と嵌合凹部６とを嵌合すると、テーパー面３とテーパー面４とが一つずつほとんど隙間なく密着するか、隙間があいていても略平行に対向するものである。図３（ａ）に示すように、透光率の高い樹脂材２の下面に嵌合凹部６を形成すると共に吸収率の高い樹脂材１の上面に嵌合凸部５を形成することができ、逆に、図３（ｂ）に示すように、透光率の高い樹脂材２の下面に嵌合凸部５を形成すると共に吸収率の高い樹脂材１の上面に嵌合凹部６を形成することができる。テーパー面３、３の間の角度α及びテーパー面４、４の間の角度βは、α＞βでα＋β＝３６０°となる範囲であれば、αとβを任意に設定することができるが、例えば、α＝２４０〜３００°、β＝６０〜１２０°とするのが好ましい。
図４（ａ）（ｂ）に他の実施の形態の一例を示す。この溶着方法では、一方の樹脂材２に嵌合凸部５を設けると共に他方の樹脂材１に嵌合凹部６を設け、嵌合凸部５と嵌合凹部６とを嵌合した状態で溶着するものであるが、断面形状において嵌合凸部５のテーパー面３である先端面が凸の円弧状面として形成されていると共に、嵌合凹部６のテーパー面４である底面が凹の円弧状面として形成されている。嵌合凸部５と嵌合凹部６とを嵌合すると、テーパー面３とテーパー面４とがほとんど隙間なく密着するか、隙間があいていても略平行に対向するものである。図４（ａ）に示すように、透光率の高い樹脂材２の下面に嵌合凹部６を形成すると共に吸収率の高い樹脂材１の上面に嵌合凸部５を形成することができ、逆に、図４（ｂ）に示すように、透光率の高い樹脂材２の下面に嵌合凸部５を形成すると共に吸収率の高い樹脂材１の上面に嵌合凹部６を形成することができる。テーパー面３及テーパー面４の曲率半径Ｒは無限大（∞）未満、好ましくは、Ｒ２００〜１０００ｍｍとすることができる。
本発明において、溶着時にテーパー面３、４を加圧して密着させるのが好ましく、これにより、テーパー面３、４を強固に溶着することができる。この場合、例えば、ワーク（樹脂材１、２を接合した物）の上にガラス板等の透明板を配し、ワークの下側と透明板の上側をプレス機等で挟み込むようにして加圧させることができる。また、テーパー面３、４での圧力を例えば２００〜５００ｋＰａとすることができる。
本発明の実施の形態の一例を示し、（ａ）は斜視図、（ｂ）（ｃ）は一部の断面図である。 （ａ）は本発明を示す一部の断面図、（ｂ）は従来例を示す一部の断面図である。 同上の他の実施の形態の一例を示し、（ａ）（ｂ）は一部の断面図である。 同上の他の実施の形態の一例を示し、（ａ）（ｂ）は一部の断面図である。 従来例を示し、（ａ）は斜視図、（ｂ）（ｃ）は一部の断面図である。
符号の説明
１ 樹脂材
２ 樹脂材
３ テーパー面
４ テーパー面
５ 嵌合凸部
６ 嵌合凹部

Claims (1)

  1. 一方の樹脂材と他方の樹脂材とのレーザ光による溶着方法であり、
    前記一方の樹脂材と前記他方の樹脂材との接合面全体は、
    前記一方の樹脂材に形成された円弧状のテーパー面を有する嵌合凸部と、前記他方の樹脂材に形成された円弧状のテーパー面を有する嵌合凹部の、それぞれのテーパー面どうしの接合面で構成され、
    前記接合面へのレーザ光の入射方向において、前記接合面とレーザ照射装置との距離は、前記接合面全域で連続的に変化する構成であり、
    前記嵌合凸部と前記嵌合凹部のテーパー面同士を接合した後、そのテーパー面にレーザ光を照射することにより前記樹脂材を溶融して複数の樹脂材を前記テーパー面で溶着することを特徴とする樹脂材の溶着方法。
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