Patent Application
20190308373
The present invention relates to a method for producing a joined body containing a thermoplastic resin. More particularly, the present invention relates to a method for producing a joined body excellent in productivity and joint strength, and can be suitably used as methods for producing structural members represented by automobiles.
Shaped products containing thermoplastic resins are widely used in various fields, and in recent years, particularly, in a machinery field, so-called fiber-reinforced thermoplastic resin shaped products (hereinafter, also referred to as fiber-reinforced thermoplastics) containing thermoplastic resins serving as matrixes and reinforcing fibers such as carbon fibers have attracted attention. For example, methods of forming closed cross-sectional structures to improve stiffness in joining fiber-reinforced thermoplastics, required to produce parts and structural members for automobiles, have been proposed. Mechanical joining using bolts, nuts, rivets, and the like, chemical joining using adhesives, and thermal joining using hot plate welding, IR welding, vibration welding, ultrasonic welding, and the like to join fiber-reinforced thermoplastics containing thermoplastic resins as matrixes have been proposed. Of them, ultrasonic welding is widely used in various industrial fields since it does not need any other materials and its cycle time is short and it has other advantages.
Ultrasonic welding is a method of welding a joining object body to another joining object body that is in contact therewith, in which a resonator called a welding horn is pressed against the joining object bodies while high-frequency mechanical vibration is given from the resonator, and the mechanical vibration transferred to the joining object bodies is converted into heat energy to heat and melt a part of the joining object bodies.
Of ultrasonic welding, a method of performing welding more efficiently by forming protrusions called energy directors on the surfaces of joining object bodies, integrally with the joining object bodies, to obtain stable and high joint strength and intensively vibrating and melting the energy directors when applying an ultrasonic wave is known (Patent Literature 1).
Patent Literature 2 discloses a method of joining two fiber-reinforced thermoplastic resins by joining a thermoplastic resin material to a joining surface of at least one fiber-reinforced thermoplastic resin in advance to join the two fiber-reinforced thermoplastic resins.
Also, Non-Patent Literature 1 discloses a method of disposing a monofilament fabric mesh or film composed of nylon 6 or nylon 66 on a joining surface of a molded plate composed of carbon-fiber-reinforced nylon 6, and performing welding by applying an ultrasonic wave to the molded plate.
However, with respect to the joining method using energy directors formed integrally with joining object bodies as disclosed in Patent Literature 1, there are the following problems.
(1) In order to form energy directors on surfaces of joining object bodies, it is required to produce molds subjected to fine processing. Therefore, there is a problem that the cost increases.
(2) In the case of forming energy directors, particularly, on end parts of large-sized members, during shaping, a pressure distribution is likely to occur. Therefore, there is a problem that their shape and size are likely to become unstable and are likely to vary.
(3) Sometimes, particularly, large-sized members warp and deform due to various factors, whereby their joining surfaces having energy directors cannot be brought into contact with other joining object members. Therefore, sometimes, joint strength is insufficient, or joining is impossible.
(4) In the case where parts of a joined part obtained by welding using energy directors interposed therebetween separate from each other, it is impossible to newly provide energy directors on the separated surfaces. Therefore, a repair by reformation of energy directors in molding is difficult.
Also, in the joining method disclosed in Patent Literature 2, in joining two fiber-reinforced thermoplastic resins, two processes, i.e. a process of joining a thermoplastic resin material layer to joining surfaces and a subsequent process of joining the two fiber-reinforced thermoplastic resins are required. Therefore, the processing becomes complicated, and more time and cost are required. Also, the surface of the thermoplastic resin material disposed between two joining surfaces does not have protrusions to function as energy directors, and thus stable and high joint strength is unlikely to be obtained.
Further, in the method of Non-Patent Literature 1, a fabric mesh formed of thermoplastic resin monofilaments is inserted between bodies to be joined such that it can be used as an energy director. However, in the case of some fabrics, due to their weaving structures, crimp parts in which monofilaments cross each other exist. In the crimp parts, since monofilaments are likely to move relatively with each other, there is a problem that a loss in vibration energy applied occurs, thereby resulting in a decrease in joint strength. Also, in the case of fabric meshes, it is possible to produce relatively thin fabric meshes, but it is difficult to obtain thick fabric meshes.
Therefore, an object of the present invention is to provide a method for producing a joined body, which is low in cost, and is excellent in productivity, and can join joining object bodies stably with high joint strength even in joining all parts of joining object bodies or joining warped joining object bodies, and makes it possible to easily perform a repair even though joined surfaces separate from each other locally.
The inventors of this application found that it is possible to solve the above-mentioned problems by the following means, as the result of earnest studies, and reached the present invention.
<1>
A method for producing a joined body, the method including: disposing a joining member between a member A containing a thermoplastic resin and a member B containing a thermoplastic resin, the joining member having a sheet part containing a thermoplastic resin and a plurality of protrusion parts on at least one surface of the sheet part integrally formed with the sheet part, the protrusion parts containing a thermoplastic resin; and melting at least a part of the joining member to join the member A and the member B to obtain a joined body thereof.
<2>
The method for producing a joined body according to <1>, wherein the thickness of the sheet part is in a range from 5 μm to 5000 μm.
<3>
The method for producing a joined body according to <1> or <2>, wherein the maximum height of the protrusion parts is in a range from 50 μm to 500 μm.
<4>
The method for producing a joined body according to any one of <1> to <3>, wherein, with respect to at least one surface of the joining member, the ratio of the sum of the projected areas of the protrusion parts to the area of the sheet part which is defined by the following formula (S1) is in a range from 25% to 95%.
(Ratio of Sum of Projected Areas of Protrusion Parts to Area of Sheet Part)=[(Sum of Projected Areas of Protrusion Parts on One Surface of Sheet Part)/(Area of One Surface of Sheet Part)]×100(%) Formula (S1)
<5>
The method for producing a joined body according to any one of <1> to <4>, wherein both surfaces of the sheet part of the joining member have the protrusion parts.
<6>
The method for producing a joined body according to any one of <1> to <5>, wherein the ratio of the distance between joining surfaces of the member A and the member B in the joined body to the height of the joining member before joining which is defined by the following formula (S2) is 95% or less.
(Ratio of Distance between Joining Surfaces of Member A and Member B in Joined Body to Height of Joining Member before Joining)=[(Distance between Joining Surfaces of Member A And Member B in Joined Body)/(Height of Joining Member before Joining)]×100(%) Formula (S2)
<7>
The method for producing a joined body according to any one of <1> to <6>, wherein a method of melting at least one part of the joining member is a method of applying vibration energy.
<8>
The method for producing a joined body according to any one of <1> to <7>, wherein at least one of the member A, the member B, and the joining member contains reinforcing fibers.
According to the present invention, it is possible to provide a method for producing a joined body, which is low in cost, and is excellent in productivity, and can join joining object bodies stably with high joint strength even in joining all parts of joining object bodies or joining warped joining object bodies, and makes it possible to easily perform a repair even though joined surfaces separate from each other locally.
Also, according to the present invention, it is possible to provide a method for producing a joined body, excellent in joint strength and the degree of freedom in design and applicable for mass production.
Hereinafter, embodiments of the present invention will be described sequentially. A method for producing a joined body according to the present invention is a method for producing a joined body, the method including disposing a joining member between a member A containing a thermoplastic resin and a member B containing a thermoplastic resin, the joining member including a sheet part containing a thermoplastic resin and a plurality of protrusion parts integrally formed with the sheet part on at least one surface of the sheet part, the protrusion parts containing a thermoplastic resin; and melting at least a part of the joining member to join the member A and the member B to obtain a joined body thereof.
[Joining Member]
A joining member which is used in the method for producing a joined body according to the present invention is a joining member having a sheet part containing a thermoplastic resin and a plurality of protrusion parts formed on at least one surface of the sheet part integrally with the sheet part and containing a thermoplastic resin.
(Sheet Part)
A sheet part of a joining member is a part containing at least a thermoplastic resin.
Although the thickness of a sheet part is not particularly limited, in terms of handling easiness of the joining member and a practical fitting range in assembling bodies to be joined, it is preferable that the thickness of the sheet part be in a range from 5 μm to 5000 μm, and it is more preferable that the thickness of the sheet part be in a range from 40 μm to 4000 μm, and it is further preferable that the thickness of the sheet part be in a range from 100 μm to 3000 μm. For example, in a joining member I shown in
In the case where a joining object body (a member A and a member B) is warped, the thickness of a sheet part of a joining member of the present invention can be adjusted to fill the gap between the member A and the member B caused by the warpage. Therefore, even in the case where welding is naturally difficult like the case where there is a gap, it is possible to easily obtain a joined body with high joint strength.
The size and shape of sheet part of the joining member are not particularly limited.
As the joining member of the present invention, joining members having arbitrary sizes and shapes according to the shapes and sizes of parts to be joined can be used. Therefore, joined body has very high joint strength and a very high degree of freedom in design. Also, after joining, even though joined surfaces separate from each other, it is possible to easily repair by cutting a necessary joining member into a size according to the size of the separated parts and disposing the joining member between the separated parts.
<Thermoplastic Resins>
The types of thermoplastic resins which can be contained in sheet parts are not particularly limited, and as examples thereof, vinyl-chloride-based resins, vinylidene-chloride-based resins, vinyl-acetate-based resins, polyvinyl-alcohol-based resins, polystyrene-based resins, acrylonitrile-styrene-based resins (AS resins), acrylonitrile-butadiene-styrene-based resins (ABS resins), acrylate-based resins, methacryl-based resins, polyethylene-based resins, polypropylene-based resins, various thermoplastic-polyamide-based resins, polyacetal-based resins, polycarbonate-based resins, polyethylene-terephthalate-based resins, polyethylene-naphthalate-based resins, polybutylene-naphthalate-based resins, polybutylene-terephthalate-based resins, polyarylate-based resins, polyphenylene-ether-based resins, polyphenylene-sulfide-based resins, polysulfone-based resins, polyethersulfone-based resins, polyetheretherketone-based resins, polylactate-based resins, and so on can be taken. Above all, nylon (thermoplastic polyamide), polycarbonate, polyoxymethylene, polyphenylene sulfide, polyphenylene ether, denaturated-polyphenyleneether, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyethylene, polypropylene, polystyrene, polymethyl methacrylate, AS resins, ABS resins, and the like can be preferably taken.
In view of cost and physical properties, at least one selected from a group consisting of nylon, polypropylene, polycarbonate, and polyphenylene sulfide is more preferable. Also, as nylon (hereinafter, also referred to simply as PA), at least one selected from a group consisting of PA6 (also referred to as polycaproamide, polycaprolactam, or poly-ε-caprolactam), PA26 (polyethylene adipamide), PA46 (polytetramethylene adipamide), PA66 (polyhexamethylene adipamide), PA69 (polyhexamethylene azelamide), PA610 (polyhexamethylene sebacamide), PA611 (polyhexamethylene undecamide), PA612 (polyhexamethylene dodecamide), PA11 (polyundecanamide), PA12 (polydodecanamide), PA1212 (polydodecamethylene dodecamide), PA6T (polyhexamethylene terephthalamide), PA6I (polyhexamethylene isophthalamide), PA912 (polynonamethylene dodecamide), PA1012 (polydecamethylene dodecamide), PAST (polynonamethylene terephthalamide), PA9I (polynonamethylene isophthalamide), PAlOT (polydecamethylene terephthalamide), PA10I (polydecamethylene isophthalamide), PA11T (polyundecamethylene terephthalamide), PAM (polyundecamethylene isophthalamide), PA12T (polydodecamethylene terephthalamide), PA12I (polydodecamethylene isophthalamide), and polyamide MXD6 (polymethaxylylene adipamide) is preferable. These thermoplastic resins may include additives such as stabilizers, flame retardants, pigments, and fillers, if necessary. These thermoplastic resins may be used alone or in combination of two or more thereof.
A thermoplastic resin which is contained in a sheet part and a thermoplastic resin which is contained in at least one of a member A and a member B may be the same as each other or may be different from each other. However, in terms of restrictions in a thermal welding process and guarantee of joint strength according to the heat histories of resins, it is preferable that the difference between the melting point of a thermoplastic resin which is contained in a sheet part and the melting point of a thermoplastic resin which is contained in at least one of a member A and a member B is 50° C. or less, and it is more preferable that the difference is 20° C. or less.
Sheet parts may contain components other than thermoplastic resins.
Components other than thermoplastic resins which sheet parts may contain are not particularly limited, and as examples thereof, reinforcing fibers, fillers, flame retardants, anti-UV agents, stabilizers, releasing agents, pigments, softeners, plasticizers, surfactants, antioxidants, and so on can be taken.
In the present invention, it is possible to use additives which the member A and the member B do not contain in forming sheet parts or/and protrusion parts of the joining member, thereby capable of imparting various functions.
As examples of reinforcing fibers, carbon fibers, glass fibers, aramid fibers, and so on can be taken; however, in terms of dynamic properties and reduction in weight, carbon fibers are preferable.
<Carbon Fibers>
Carbon fibers are not particularly limited, and as specific examples thereof, PAN-based carbon fibers and pitch-based carbon fibers can be taken. Above all, since PAN-based carbon fibers are light, they can be suitably used for reduction in the weight of joined body, and so on. Also, one kind of carbon fibers may be used, or two or more kinds of carbon fibers may be used together. Morphologies of carbon fibers are not particularly limited, and continuous fibers or discontinuous fibers may be used.
In general, it is suitable that the average fiber diameters of continuous fibers are in a range from 5 μm to 20 μm.
Also, in the case of discontinuous carbon fibers, carbon fibers in a thermoplastic resin may be in any one of a state of being oriented in a specific direction, a state of being two-dimensionally and randomly dispersed in the plane, and a state of being three-dimensionally and randomly dispersed. As discontinuous carbon fibers, carbon fibers having an average fiber diameter in a range from 5 μm to 20 μm and having an average fiber length in a range from 0.05 mm to 20 mm, more preferably, in a range from 0.1 mm to 10 mm may be preferably used. If the average fiber length is 0.05 mm or more, the reinforcing effect is excellent, and if the average fiber length is 20 mm or less, it is very easy to form sheet parts and protrusion parts.
Preferably, discontinuous carbon fibers contain a carbon fiber bundle (A) consisting of fibers, the number of which is equal to or larger than a critical single fiber number which is defined by the following formula (a), and a carbon fiber bundle (B1) consisting of fibers, the number of which is smaller than the critical single fiber number, mixed therein with or without carbon single fibers (B2), and the ratio of the carbon fiber bundle (A) to the total amount of carbon fibers in a range from 20 Vol % to 99 Vol %, more preferably, in a range from 30 Vol % to 90 Vol %, and the average number of fibers (N) in the carbon fiber bundle (A) satisfies the following formula (b).
Critical Single Fiber Number=600/D (a)
0.6×104/D2<N<6×105/D2 (b)
(D represents the average fiber diameter (μm) of carbon fibers.)
More preferably, the range of the average number of fibers (N) satisfies: 0.6×104/D2<N<1×105/D2.
As carbon fibers, a combination of continuous fibers and discontinuous fibers may also be used.
Sheet parts can be produced by, for example, injection molding or extrusion molding, or can be produced together with protrusion parts by press molding.
(Protrusion Parts)
Protrusion parts of a joining member contain at least a thermoplastic resin, and are integrally formed with the sheet part on at least one surface of the sheet part.
In the present invention, in the case of performing joining by a method of applying vibration energy like ultrasonic welding, it is preferable that protrusion parts of the joining member function as energy directors. In this case, energy directors have a form of protrusions to be brought into contact with a joining surface in order to implement a uniform molten state and efficient welding. In joining smooth surfaces, if vibration energy such as an ultrasonic wave is applied, due to surface roughness and the like, melting positions of resins become uneven, and thus it is impossible to obtain uniform and stable joint strength. Also, in the case where rise in the heat radiation temperature of joining surfaces is slow and the process requires too much time, the efficiency is bad, and deterioration of the resins is caused. Meanwhile, in the case of joining surfaces having energy directors formed thereon, since melting positions of resins always become the vertexes of protrusion shapes and are fixed, applied vibration energy intensively acts on those parts, whereby uniform molten states are obtained. Therefore, it becomes possible to obtain stable welding strength. Also, since generation of heat to the resin melting temperatures of joining surfaces is achieved in a very short time, it becomes possible to perform welding efficiently. Therefore, it is possible to suppress deterioration of resins.
In the present invention, a joining member has a plurality of protrusion parts on at least one surface of a sheet part, and may have protrusion parts only on one surface of the sheet part (see
The shapes of protrusion parts are not particularly limited, and as examples thereof, columnar shapes extending along the normal direction of a surface of the sheet part (for example, circular column shapes or prismatic column shapes), conical or pyramidal shapes (for example, cone shapes or pyramid shapes), truncated cone shapes, truncated pyramid shapes, or rod shapes extending along a surface of the sheet part (The shapes may be linear or may be curved. The shapes of cross sections in the direction normal to the surface of the sheet part are not particularly limited.), plate shapes, shapes having curved surfaces or spherical surfaces (spherical cap shapes), and so on can be taken. Also, all protrusion parts may have the same shape, or a joining member may have protrusion parts having different shapes.
With respect to the height of protrusion parts, in terms of stability in the dimensions of joining object parts before and after welding, it is preferable that the maximum height of protrusion parts from a surface of a sheet part is in a range from 50 μm to 500 μm, and it is more preferable that the maximum height is in a range from 100 μm to 300 μm. If the maximum height of protrusion parts is equal to or larger than 50 μm, when melting the joining member, protrusion parts are likely to be starting points of melting, and thus the joining member are welded stably and with high joint strength. Meanwhile, if the maximum height of protrusion parts is equal to or smaller than 500 μm, it is possible to decrease the welding time required to completely melt the protrusion parts. Therefore, the productivity is high, and it is possible to suppress deterioration of thermoplastic resins constituting the protrusion parts. For example, in a joining member 1 shown in
Also, in the present invention, in the case of using a method of applying vibration energy, particularly, a vibration welding method, as a method of melting a joining member, it is possible to further increase the maximum height of protrusion parts. In this case, for example, it is possible to set the maximum height of the protrusion parts in a range from 50 μm to 5000 μm.
In the present invention, the number of protrusion parts is not particularly limited, and the number of protrusion parts which is preferable can be suitably designed such that stable and high joint strength is obtained in a selected combination of a protrusion part height and the projected areas of protrusion parts.
In the present invention, the ratio of protrusion parts which are formed on a sheet part needs to be suitably adjusted according to the purpose and the like of a joining member of the present invention, and is not particularly limited, and it is preferable that, with respect to at least one surface of a joining member, the ratio of the sum of the projected areas of protrusion parts to the area of a sheet part, which is defined by the following formula (S1), is in a range from 25% to 95%, and it is more preferable that the ratio is in a range from 30% to 85%. If the above-mentioned ratio is in the above-mentioned range, when melting the joining member, the protrusion parts become starting points of melting, and thus it is possible to obtain sufficient joint strength.
(Ratio of Sum of Projected Areas of Protrusion Parts to Area of Sheet Part)=[(Ratio of Sum of Projected Areas of Protrusion Parts on One Surface of Sheet Part)/(Area of One Surface of Sheet Part)]×100(%) Formula (S1)
In a joining member having protrusion parts formed on only one surface of a sheet part, the “Area of Sheet Part” is the area of the surface having the protrusion parts. In the case of a joining member having protrusion parts formed on both surfaces of a sheet part, the ratio of the projected areas of protrusion parts is determined for each surface.
The “Projected Areas of Protrusion Parts” are the areas of projection diagrams obtained by projecting the protrusion parts from the direction of the normal line to the surface of the sheet part on which the protrusions are formed, and the “Sum of Projected Areas of Protrusion Parts” is the sum of the areas of the projection diagrams of all of the protrusion parts on one surface of the sheet part.
Specific examples and a preferred range of the kinds of thermoplastic resins which can be contained in protrusion parts are the same as the above-mentioned specific examples and preferred range of the kinds of thermoplastic resins which can be contained in sheet parts.
A thermoplastic resin which is contained in protrusion parts and a thermoplastic resin which is contained in sheet parts may be the same as each other or may be different from each other; however, in terms of restrictions in a thermal welding process and guarantee of joint strength according to the heat histories of resins, it is preferable that the difference between the melting point of the thermoplastic resin which is contained in protrusion parts and the melting point of the thermoplastic resin which is contained in sheet parts is 50° C. or less, and it is more preferable that the difference is 20° C. or less. Also, a thermoplastic resin which is contained in protrusion parts and a thermoplastic resin which is contained in the member A or/and the member B may be the same as each other or may be different from each other; however, in terms of restrictions in a thermal welding process and guarantee of joint strength according to the heat histories of resins, it is preferable that the difference between the melting point of a thermoplastic resin which is contained in protrusion parts and the melting point of a thermoplastic resin which is contained in the member A or/and the member B be 50° C. or less, and it is more preferable that the difference be 20° C. or less.
Protrusion parts may contain components other than thermoplastic resins, and the components other than thermoplastic resins are the same as the above-mentioned components other than thermoplastic resins which sheet parts may contain.
(Method of Preparing Joining Member)
The method of preparing a joining member is not particularly limited. For example, it is possible to prepare the joining member by performing press molding or injection molding of thermoplastic resins. Also, it is possible to prepare the joining member by molding a thermoplastic resin into a sheet shape and then forming protrusion parts by embossing or the like. Especially, the method of preparing the joining member by embossing is preferable since continuous production of the joining member is easy and it is possible to decease the production cost.
[Member A]
The member A contains at least thermoplastic resins.
Specific examples and a preferred range of the kinds of thermoplastic resins which can be contained in the member A are the same as the above-mentioned specific examples and preferred range of the kinds of thermoplastic resins which can be contained in sheet parts.
The member A may contain components other than thermoplastic resins, and the components other than thermoplastic resins are the same as the above-mentioned components other than thermoplastic resins which sheet parts may contain.
It is preferable that the member A contains reinforcing fibers, and it is more preferable that the member A contains carbon fibers.
With respect to carbon fibers, besides the items described with respect to carbon fibers which sheet parts may contain, the following items are preferable.
In the case where carbon fibers are continuous fibers, the member A may have a form of knitted fabric or woven fabric, or may have a form of a sheet formed by arranging carbon fibers in one direction, i.e. a so-called UD sheet. As UD sheets, UD sheets formed by stacking a plurality of layers such that the fiber arrangement directions in the individual layers cross each other alternately (for example, by stacking the layers such that the fiber arrangement directions in the individual layers cross each other at right angles alternately) can be used.
A member A may be a combination of one member containing continuous fibers and another member containing discontinuous fibers obtained by stacking or the like.
In the case where carbon fibers are discontinuous and are two-dimensionally and randomly dispersed, carbon fibers may have a form of a member obtained by press molding, or carbon fibers may have a form of a sheet formed by wet papermaking, or may have a form of a sheet or a mat (hereinafter, also referred to collectively as a mat) formed by arranging discontinuous carbon fibers such that the carbon fibers are dispersed and overlap. In this case, the average fiber diameter is in a range from 5 μm to 20 μm, and the average fiber length is preferably in a range from 1 mm to 100 mm, and is more preferably in a range from 3 mm to 100 mm, and is further preferably in a range from 10 mm to 100 mm, and is still further preferably in a range from 12 mm to 50 mm. In the latter mat, the average fiber length of carbon fibers which are contained in the mat is important, and in the case where the average fiber length is longer than 1 mm, the mat can easily fulfill a role as carbon fibers, and sufficient strength is likely to be obtained. In contrast, in the case where the average fiber length is shorter than 100 mm, the flowability during molding is good, and thus a desired shaped product can be easily obtained.
The member A may be a three-dimensional isotropic carbon fiber mat formed by, for example, entangling carbon fibers into the shape of cotton such that the long axis directions of carbon fibers are disposed randomly in the directions of X, Y, and Z, and in the case of using press molding to be described below, mats in which carbon fibers have average fiber lengths in an above-mentioned range and are oriented substantially two-dimensionally and randomly (hereinafter, referred to as random mats) are preferable.
Here, being oriented substantially two-dimensionally and randomly indicates a state in which, carbon fibers are not oriented in specific directions such as one direction in an in-plane direction of fiber-reinforced thermoplastic but are oriented randomly, and are disposed in the plane without generally expressing specific directionality.
In a random mat, all or most of carbon fibers may be in a state of being opened in a single fiber form, and particularly, an isotropic random mat in which fiber bundles which are bundles of a certain number or more of single fibers and fiber bundles which are in a single fiber form or are close to the single fiber form are mixed at a predetermined ratio is preferable. Such isotropic random mats and producing methods thereof are disclosed in detail in the specifications of WO2012/105080 and Japanese Patent Application Laid-Open No. 2013-49208.
Such a preferred random mat is an isotropic random mat containing carbon fiber bundles (A) consisting of fibers, the number of which is equal to or larger than a critical single fiber number which is defined by the following formula (a), and carbon fiber bundles (B 1) consisting of fibers, the number of which is smaller than the critical single fiber number, mixed therein with or without carbon single fibers (B2), and the ratio of the total amount of fibers of the carbon fiber bundle (A) in the isotropic random mat is in a range from 20 Vol % to 99 Vol %, more preferably, in a range from 30 Vol % to 90 Vol %, and the average number of fibers (N) in the carbon fiber bundle (A) satisfies the following formula (b).
Critical Single Fiber Number=600/D (a)
0.6×104/D2<N<6×105/D2 (b)
(D represents the average fiber diameter (μm) of carbon fibers.)
More preferably, the range of the average number of fibers (N) satisfies: 0.6×104/D2<N<1×105/D2.
The average fiber diameter of carbon fibers is in a range from 5 μm to 20 μm, more preferably, in a range from 5 μm to 12 μm.
In the member A, the weight per unit of carbon fibers is in a range from 25 g/m2 to 10000 g/m2, and the ratio of the total amount of carbon fibers in the carbon fiber bundle (A) consisting of fibers, the number of which is equal to or larger than the critical single fiber number which is defined by the above-mentioned formula (a), is in the above-mentioned range, and the average number of fibers (N) in the carbon fiber bundle (A) satisfies the above-mentioned formula (b). Therefore, the balance between moldability and mechanical strength of the member A serving as a composite material is good. It is preferable that the weight per unit of carbon fibers be in a range from 25 g/m2 to 4500 g/m2.
It is preferable that the content of a thermoplastic resin in a member A be in a range from 3 parts by weight to 1000 parts by weight with respect to 100 parts by weight of carbon fibers.
In the member A, volume fraction of carbon fibers (hereinafter, also referred to simply as “Vf”) which are defined by the following formula (1) are not particularly limited; however, it is preferable that volume fraction of carbon fibers (Vf) is in a range from 10 Vol % to 70 Vol %.
Vf=100×(Volume of Carbon Fibers)/((Volume of Carbon Fibers)+(Volume of Thermoplastic Resin)) Formula (1)
In the case where a volume fraction of carbon fibers is equal to or larger than 10 Vol %, desired mechanical properties are easily obtained. Meanwhile, in the case where a volume fraction is equal to or smaller than 70 Vol %, since the amount of thermoplastic resin is sufficient and dry carbon fibers do not increase, it is preferable. A more preferred range of volume fraction of carbon fibers (Vf) in the member A is from 20 Vol % to 60 Vol %, and a further preferred range 30 Vol % to 50 Vol %.
The sizes and shapes of the member A are not particularly limited.
For example, in the case where the member A have plate shapes, the thicknesses of the member A are not particularly limited; however, in general, it is preferable that the thicknesses be in a range from 0.5 mm to 20 mm, and it is more preferable that the thicknesses be in a range from 0.5 mm to 10 mm, and it is further preferable that the thicknesses be in a range from 0.5 mm to 5 mm, and it is a still further preferable that the thickness be in a range from 1 mm to 5 mm
[Member B]
The member B contains at least a thermoplastic resin.
The member B is similar to the member A described above.
The thermoplastic resin contained in the member A and the thermoplastic resin contained in the member B may be the same as each other or may be different from each other; however, in terms of restrictions in a thermal welding process and guarantee of joint strength according to the heat histories of resins, it is preferable that the difference between the melting point of the thermoplastic resin contained in the member A and the melting point of the thermoplastic resin contained in the member B is 50° C. or less, and it is more preferable that the difference is 20° C. or less.
In the present invention, it is preferable that at least one of the member A, the member B, and the joining member contain reinforcing fibers, and it is more preferable that at least one of the member A, the member B, and the joining member contain carbon fibers.
[Welding Method]
In the present invention, the joining member described above is arranged between the member A and the member B, and at least a part of the joining member is melted to join the member A and the member B, to obtain a joined body of the member A and the member B.
The method of melting the joining member is not particularly limited; however, in terms of the efficiency of energy which melts the joining member which is a joining media, the method of applying vibration energy is preferable, and the vibration welding method is more preferable, and the ultrasonic welding method is further preferable. The reason is that according to the ultrasonic welding method, since the shapes and sizes of the member A and the member B have less restrictions, and any member A and any member B can be used regardless of theirs shapes, it is possible to produce a joined body to be used in a wide variety of applications according to the present invention.
An example of the case of performing the method for producing a joined body according to the present invention using the ultrasonic welding method will be described with reference to
As shown in
In
The ultrasonic welding method is a method of applying high-frequency mechanical vibration from a resonator called a welding horn (4 of
Here, control factors for performing welding by applying an ultrasonic wave include the frequency of the ultrasonic wave, the amplitude of the ultrasonic wave, the application time of the ultrasonic wave, sample pressing pressure, and so on. Joint strength tends to increase as the amplitude of the ultrasonic wave, the application time, and the sample pressing pressure increase; however, in view of a device to be used, the thickness of a sheet part and the shape and size of protrusion parts in a joining member, a desired cycle time, and so on, the factors can be suitably controlled such that stable welding can be achieved.
Control conditions in ultrasonic welding include frequency, welding time, amplitude, pressing force, and so on, and preferred conditions may be conditions in which the frequency may be in a range from 15 kHz to 50 kHz, and the welding time may be in a range from 0.1 seconds to 5 seconds, and the amplitude may be in a range from 30 μm to 100 μm, and the pressing force may be in a range from 500 N to 2000 N. In terms of productivity in welding, it is more preferable that the frequency be in a range from 20 kHz to 40 kHz, and the pressing force be in a range from 0.5 seconds to 2 seconds, and the welding pressure be in a range from 500 N to 1500 N.
Also, in ultrasonic welding, to fix the positions of joining object bodies to fix the welding position, jigs called anvils may be used.
[Joined Body]
In a joined body which can be produced according to the present invention, it is preferable that the ratio of the distance between joining surfaces of the member A and the member B in the joined body to the height of a joining member before joining, which is defined by the following formula (S2), is 95% or less, and it is more preferable that the above-mentioned ratio is 80% or less. If the above-mentioned ratio is 95% or less, sufficient welding is performed, and the joined body is excellent in joint strength.
Here, the “height of the joining member before joining” means the sum of the height of the protrusion part and the height (thickness) of the sheet part in the joining member. For example, in the joining member 1 shown in
(Ratio of Distance between Joining Surfaces of Member A and Member B in Joined Body to Height of Joining Member before Joining)=[(Distance between Joining Surfaces of Member A and Member B in Joined Body)/(Height of Joining Member before Joining)]×100(%) Formula (S2):
Hereinafter, the present invention will be described in more detail by giving production examples, examples, reference examples, and comparative examples; however, the present invention is not limited to them.
Individual values in each of the examples, the reference examples, and the comparative examples were determined according to the following methods.
(1) Average Fiber Length of Reinforcing Fibers in Each Fiber-Reinforced Resin Material
The average fiber length of reinforcing fibers in each fiber-reinforced resin material was determined by heating the fiber-reinforced resin material in a furnace at 500° C. for 1 hour to remove a thermoplastic resin, randomly extracting 100 reinforcing fibers, measuring the lengths of the extracted 100 reinforcing fibers to the unit of 1 mm with a caliper, and averaging the lengths. In the case where the average fiber length was shorter than 1 mm, the lengths of reinforcing fibers were measured to the unit of 0.1 mm under an optical microscope.
(2) Volume Fraction of Reinforcing Fibers in Each Fiber-Reinforced Resin Material
As for the volume fraction of reinforcing fibers in each fiber-reinforced resin material, the density of the fiber-reinforced resin material was obtained by a submerged replacement method, and from the relationship between the density of only reinforcing fibers and the density of only the resin measured in advance, the volume fraction of reinforcing fibers was calculated.
(3) Tensile Shear Strength of Fiber-Reinforced Resin Joined-Body
Tensile shear strength was measured according to No. M406-87 in “The Society of Automotive Engineers of Japan” issued in March, 1987 by Society of Automotive Engineers of Japan, Inc. Specifically, determination of tensile shear strength (tensile shear bonding strength) was performed at a tension rate of 5 mm/s, and from the area of a welded part obtained by a method of the following (4), tensile shear strength per unit area (MPa) was obtained.
(4) Projected Area of Welded Part
From each obtained fiber-reinforced resin joined-body, a member A or a member B which is a joining object body was peeled. The joining surface was visually observed from the direction perpendicular to the joining surface. The longest axis in the welded area was measured as a long side, and an axis perpendicular to the longest axis of the welded area was measured as a short side, to the unit of 0.1 mm according to rules. Thereafter the welded area was calculated as an area enclosed by an ellipse having the long side and the short side.
Hereinafter, production examples of the member A and member B which are joining object bodies will be described.
In Production Example 1, a production example of joining object bodies with integrated protrusions to function as energy directors will be described.
As reinforcing fibers, fibers having an average fiber length of 30 mm obtained by cutting STS40-24KS (having an average fiber diameter of 7 μm and a density of about 1750 kg/m3) of PAN-based carbon fibers “Tenax” (registered trademark) produced by Toho Tenax Co., Ltd. were used, and as a thermoplastic resin, nylon 6 resin A1030 (having a density of about 1130 kg/m3) produced by Unitika Ltd. was used. Carbon fibers and nylon 6 resin were mixed such that the volume fraction of carbon fibers in the total volume of carbon fibers and nylon 6 resin becomes 35%, and the mixture was compressed under a pressure of 2.0 MPa while being heated by a press machine heated to 280° C., for 5 minutes, thereby a fiber-reinforced resin material containing carbon fibers oriented two-dimensionally and randomly in the in-plane direction was prepared.
The molded plate obtained was cut to a size of 390 mm×300 mm, and was dried in a hot air drier for 4 hours, and then the molded plate was heated to 280° C. by an infrared heater. The heated molded plate was introduced into a mold in which concaves were carved so as to form protrusions as energy directors. The temperature of the mold was set to 140° C., and the mold was pressed with a pressure of 5 MPa, thereby a plate-like shaped product having a size 400 mm×400 mm×2.5 mm was obtained. This shaped product was cut into rectangular pieces having a size of 100 mm×25 mm. An end part of each rectangular shaped product in the longitudinal direction, i.e. a part predetermined as a joining surface had protrusions as energy directors, and the area thereof was 25 mm×25 mm. The protrusions serving as energy directors had spherical cap shapes and the maximum height of 0.2 mm, and the ratio of the projected areas of the protrusions to the area of the joining surface was 60%. In this way, members I were prepared as joining object bodies. The results are shown in Table 1.
Also, on the other end part of a rectangular shaped product having the size of 100 m×25 mm, a rectangular tab having a size of 38 mm×25 mm was attached with an adhesive (PLEXUS MA530), and on each member I, a tensile lap-shear strength test was conducted.
Members II were produced as joining object bodies in the same way as that in Production Example 1 except that protrusions to function as energy directors were not formed during press molding. The results are shown in Table 1.
Members III were produced as joining object bodies in the same way as that in Production Example 2 except that carbon fibers having an average fiber length of 20 mm were used. The results are shown in Table 1.
Members IV were produced as joining object bodies in the same way as that in Production Example 2 except that carbon fibers were mixed so as to have a volume fraction of 45% with respect to the total volume of carbon fibers and nylon 6 resin. The results are shown in Table 1.
100 parts by weight of fibers obtained by cutting STS40-24KS of carbon fibers “Tenax” (registered as a trade mark) produced by Toho Tenax Co., Ltd. and having an average fiber length 10 mm and 320 parts by weight of nylon 6 resin A1030 produced by Unitika Ltd. were put as carbon fibers and a thermoplastic resin into a twin-screw kneading extruder, and were kneaded, whereby a fiber-reinforced resin composition was prepared. Of this resin composition, the carbon fibers were in the form of single fibers, and the volume fraction of the carbon fibers was 17%. The obtained fiber-reinforced resin composition was introduced into a mold of 120 mm×120 mm, and a shaped product having 120 mm×120 mm×2.5 mm was produced by a 110-ton electric injection molding machine produced by The Japan Steel Works, LTD. (JSW180H produced by The Japan Steel Works, LTD.). This shaped product was cut into rectangular pieces having a size of 100 mm×25 mm, whereby members V were prepared as joining object bodies. The results are shown in Table 1. Also, on the other end part of a member V in the longitudinal direction, a rectangular tab having a size of 38 mm×25 mm was attached with an adhesive (PLEXUS MA530), and a tensile lap-shear test was conducted. The average fiber length of carbon fibers in the members V was 0.9 mm as shown in Table 1.
Members VI were produced as joining object bodies in the same way as that in Production Example 5 except that polycarbonate (L-1225Y produced by Teijin Ltd.) was used as a thermoplastic resin and 380 parts by weight of polycarbonate was used with respect to 100 parts by weight of carbon fibers. The results are shown in Table 1.
Members VII were produced as joining object bodies in the same way as that in Production Example 5 except that polycarbonate (L-1225Y produced by Teijin Ltd.) was used as a thermoplastic resin and 200 parts by weight of polycarbonate was used with respect to 100 parts by weight of carbon fibers. The results are shown in Table 1.
Hereinafter, production examples of the joining member will be described.
Nylon 6 resin A1030 produced by Unitika Ltd. was put into a twin-screw kneading extruder, and was extruded out from a T-die, whereby sheets having a width of 400 mm and a thickness of 0.1 mm were obtained. A plurality of sheets obtained was stacked according to the thickness of the sheet part of the joining member, and was disposed in each of molds prepared so as to have cavities for forming protrusions as energy directors, and after mold clamping, the molds were held at a mold temperature of 280° C. under a pressure of 0.5 MPa for 20 minutes, and were cooled to 100° C. or less, whereby the joining member having sheet parts having a size of 400 mm×400 mm and protrusion parts formed on the sheet parts integrally with the sheet parts were obtained.
The clearances between the upper parts and lower parts of molds to be used and the sizes and distributions of cavities in the molds were suitably adjusted to obtain shapes and heights (maximum heights) of protrusion parts, the thicknesses of sheet parts, protrusion part formation surfaces (one surface or both surfaces), the ratios of the sums of the projected areas of protrusion parts to the areas of the sheet parts (the ratios of the projected areas of protrusion parts) disclosed in Table 2. In this way, joining members VIII-1 to VIII-8 were produced.
Joining member IX were produced in the same way as that in Production Example 8-2 except that sheets having a width of 400 mm and a thickness of 0.1 mm, obtained by putting 100 parts by weight of fibers obtained by cutting STS40-24KS of carbon fibers “Tenax” (registered as a trade mark) produced by Toho Tenax Co., Ltd. and having an average fiber length of 10 mm and 355 parts by weight of nylon 6 resin A1030 produced by Unitika Ltd., as carbon fibers and a thermoplastic resin, into a twin-screw kneading extruder, and extruding the mixture from a T-die, were used. The results are shown in Table 2.
Joining member X were produced in the same way as that in Production Example 8-2 except that polycarbonate (L-1225Y produced by Teijin Ltd.) was used as a thermoplastic resin. The results are shown in Table 2.
As the member A and the member B, members II were used, and each of the joining members VIII-1 to VIII-8 and IX was arranged between parts of a member A and a member B predetermined as joining surfaces and facing each other as shown in
The tensile shear strength (joint strength) of each of the prepared joined body was determined by the determination method of the tensile-shear test described in (3). The results are shown in Table 3.
Also, in Table 3, “Ratio of Distances between Joining Surfaces before and after Joining”, “Minimum Distance between Joining Surfaces during Welding”, and “Height of Joining Member before Joining” are also disclosed. “Minimum Distance between Joining Surfaces during Welding” will be described below.
A ratio of distances between joining surfaces before and after joining was calculated by [(Distance between Joining Surfaces after Joining)/(Distance between Joining Surfaces before Joining)]×100(%), and in each of Examples 1 to 13, since the distance between the joining surfaces after joining was the same as the distance between the joining surfaces of the member A and the member B in the joined body, and the distance between the joining surfaces before joining was the same as the height of the joining member before joining, the ratio of the distances between the joining surfaces before and after joining was the same as the value of the formula (S2).
Also, the value of the formula (S2) is “Ratio of Distance between Joining Surfaces of Member A and Member B in Joined Body to Height of Joining Member Before Joining” of the above-mentioned formula (S2).
Joined body (fiber-reinforced specimens for tensile-shear welding tests) were prepared in the same ways as those in Example 1, Example 4, Example 6, and Example 7, respectively, except that the vicinities of joining surfaces of the member A and the member B were fixed by jigs to secure predetermined (minimum) clearances between joining surfaces of the member A and the member B in the joined body, shown in the items “Minimum Distance between Joining Surfaces during Welding”.
Also, the tensile shear strength (joint strength) of each of the prepared joined body was determined in the same determination method as that in Examples 1 to 9. The results are shown in Table 3.
Also, a minimum distance between joining surfaces during welding is a value limiting the distance between a member A and a member B during welding, and is a lower limit of the distance between joining surfaces of a member A and a member B during welding. The distance between a member A and a member B can be freely changed as long as it is equal to or larger than a minimum distance between joining surfaces thereof during welding.
In Table 3, the item “Minimum Distance between Joining Surfaces during Welding” of each of Examples 1 to 9 is “Non-existence”, and this indicates that there is no lower limit to the distance between the member A and the member B during welding (there is no lower limit set).
In the related art, in general, joining surfaces of members to be joined are brought into contact with each other; however, in some cases such as the case where any member is warped, a gap between the joining surfaces is formed. In such cases, if there is a gap which cannot be solved by applying pressure during welding, welding is impossible and a joined body cannot be obtained. In Comparative Examples 1 to 3 to be described below, such situations were simulated, and since the joining member of the present invention were not used, joined body having sufficient joint strength were not obtained.
In contrast, in the present invention, even though there is a gap between a member A and a member B, since it is possible to fill the gap by interposing a joining member between the members, a joined body excellent in joint strength can be obtained, and in Examples 10 to 13, such situations were simulated. In Examples 10 to 13, even when predetermined values were set as minimum distances between joining surfaces during welding, joined body excellent in joint strength were obtained by using the joining member having suitable thicknesses.
A member I and a member II were used as a member A and a member B, respectively, and the member A and the member B were arranged so as to face each other at parts predetermined as joining surfaces, and using an ultrasonic welder (a welder “2000Xdt” produced by Branson Ultrasonics Co., Ltd.), an ultrasonic wave was applied to a part of the stack corresponding to the part of the member A having energy directors from the side where there was the member A by a horn having a diameter of 18 mm, whereby a joined body (a fiber-reinforced piece for a tensile-shear welding test) was obtained. As welding conditions, a frequency of 20 kHz, an amplitude of 60 μm, a welding force of 500 N, a trigger force of 250 N, a vibration application time of 1 second, and a cooling time of 2 seconds were set.
The tensile shear strength (joint strength) of the prepared joined body was determined by the determination method of the tensile-shear test described in (3). The results are shown in Table 3.
Welding was performed in the same way as that in Reference Example 1 except that the vicinities of joining surfaces of the member A and the member B were fixed with jigs to set minimum intervals (distances) between the joining surfaces of the member A and the member B to 0.3 mm, 0.9 mm, and 2.8 mm, respectively. As a result, joined body suitable for tensile-shear tests could not be obtained, and thus “0” were recorded as corresponding joint strength. The results are shown in Table 3.
Joined body was obtained in the same way as that in Example 2 except that members III to V were used as the member B. The results are shown in Table 4.
A joined body was obtained in the same way as that in Example 2 except that members VI were used as a member A and a member B and a joining member X was used between the member A and the member B. The result is shown in Table 4.
A joined body was obtained in the same way as that in Example 17 except that a member VII was used as a member B. The result is shown in Table 4.
According to the present invention, it is possible to provide a method for producing a joined body, which is low in cost, and is excellent in productivity, and can join joining object bodies stably with high joint strength even in joining all parts of joining object bodies or joining warped joining object bodies, and makes it possible to easily perform a repair even though joined surfaces separate from each other locally.
Also, according to the present invention, it is possible to provide a method for producing a joined body, excellent in joint strength and the degree of freedom in design and applicable for mass production.
Although the present invention has been described in detail with reference to the specific embodiment, it is apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the present invention.
This application is based upon Japanese Patent Application No. 2016-113592 filed on Jun. 7, 2016; the entire contents of which are incorporated herein by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016-113592 | Jun 2016 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2017/021212 | 6/7/2017 | WO | 00 |
