Patent Application
20180207847
The present invention relates to a production method of a bonded structure and a bonded structure.
In the past, there is a known bonded structure bonded with a first member and a second member which contain different materials (for example referring to patent document 1).
The patent document 1 discloses a bonding method bonding a dissimilar material such as resin with a metal material. Specifically speaking, laser scanning processing is carried out on the surface of the metal material in a cross shape, such that a plurality of bulges (concave convex parts) are formed on the surface. Besides, when the dissimilar material is bonded with the meal material with the bulges, the dissimilar material enters into a concave part, and plays an anchor effect, and therefore, a bonding strength between the metal material and the dissimilar material is improved.
However, in a conventional bonding method, when a perforation (concave part) is formed on the metal surface through laser, there is a following problem: the perforation is hard to deepen relative to an opening diameter of the surface, and the bonding strength is hard to improve.
The present invention aims to solve the problem, and the present invention aims to provide a production method of a bonded structure, which is capable of improving the bonding strength and the bonded structure.
The production method of a bonded structure of the present invention is a production method of a bonded structure bonded with a first member and a second member and comprises: a step for forming aperforation with an opening in the surface of the first member by irradiating the surface of the first member with a laser in which one pulse is configured from a plurality of sub-pulses; and a step for filling and curing the second member in the perforation of the first member.
By the constitution in this way, the laser in which one pulse is configured from a plurality of sub-pulses is used to form the perforation, therefore, the perforation can be deepened relative to an opening diameter of the surface, and thus the bonding strength is improved.
In the production method of a bonded structure, a protrusion part facing to the inside can be formed on an inner peripheral surface of the perforation.
In the production method of a bonded structure, the first member can be metal, thermoplastic resin or thermosetting resin.
In the production method of a bonded structure, the second member can be the thermoplastic resin or thermosetting resin.
In the production method of a bonded structure, one period of the sub-pulses can be lower than 15 ns.
In the production method of a bonded structure, the number of the sub-pulses of one pulse can be more than 2 and lower than 50.
The bonded structure of the present invention can be manufactured by any production method of a bonded structure.
Through the constitution in this way, the perforation is formed by using the laser in which one pulse is configured from a plurality of sub-pulses, therefore, the perforation can be deepened relative to the opening diameter of the surface, and the bonding strength is improved.
According to the production method of a bonded structure and the bonded structure, the bonding strength can be improved.
Hereinafter, the embodiments of the present invention are explained with reference to drawings.
Firstly, a bonded structure 100 of a first embodiment of the present invention is explained with reference to
The bonded structure 100 as shown in
A material of the first member 10 is metal, thermoplastic resin or thermosetting resin. A material of the second member 20 is the thermoplastic resin and thermosetting resin.
Examples of the metal are listed as follows: ferrous series metal, stainless steel series metal, copper series metal, aluminium series metal, magnesium series metal, and alloy of them. Besides, the metal can be metal forming bodies or zinc die-cast, aluminium die-cast, powder metallurgy, etc.
Examples of the thermoplastic resin are listed as follows: Polyvinyl Chloride (PVC), Polystyrene (PS), Acrylonitrile Styrene (AS), Acrylonitrile Butadiene Styrene (ABS), Polymethyl Methacrylate (PMMA), Polyethylene (PE), Polypropylene (PP), Polycarbonate (PC), m-Polyphenylene Ether (m-PPE), Polyamide 6 (PA6), Polyamide 66 (PA66), Polyacetal (POM), Polyethylene Terephthalate (PET), Polybutylene Terephthalate (PBT), Polysulfone (PSF), Polyarylate (PAR), Polyetherimide (PEI), Polyphenylene Sulfide (PPS), Polyethersulfone (PES), Polyether Ether Ketone (PEEK), Polyamideimide (PAI), Liquid Crystal Polymer (LCP), Polyvinylidene Chloride (PVDC), Polytetrafluorethylene (PTFE), Polychlorotrifluroehtylene (PCTFE) and Polyvinylidene Fluoride (PVDF). Besides, Thermoplastic Elastomer (TPE) can also be used, and examples of the TPE are listed as follows: Thermoplastic Polyolefin (TPO) (olefin series), Thermoplastic Polystyrene (TPS) (styrene series), Thermoplastic Poly Ester Elastomer (TPEE) (ester series), Thermoplastic Polyurethane (TPU) (carbamate series), Thermoplastic Polyamide (TPA) (nylon series) and Thermoplastic Polyvinyl Chloride (TPVC) (chloroethylene series).
Examples of the thermosetting resin are listed as follows: Epoxy (EP), Polyurethane (PUR), Urea Formaldehyde (UF), Melamine Formaldehyde (MF), Phenol Formaldehyde (PF), Unsaturated Polyester (UP) and Silicone (SI). Besides, Fiber Reinforced Plastics (FRP) can also be used.
In addition, in the thermoplastic resin and thermosetting resin, an additive can be added. Examples of the additive are listed as follows: inorganic series fillers (glass fiber, inorganic salts, etc.), metal series fillers, organic series fillers, carbon fiber, etc.
The perforation 11 is an approximate round non-through hole when observed from a plane, and a plurality of perforations are formed on a surface 13 of the first member 10. An opening diameter R1 of the surface 13 of the perforation 11 is preferably more than 30 μm and lower than 100 μm because of two reasons: 1. if the opening diameter R1 is lower than 30 μm, then filling ability of the second member 20 is deteriorated sometimes, and an anchor effect is reduced; 2. if the opening diameter R1 is more than 100 μm, then a quantity of the perforations 11 in per unit area is reduced sometimes and the anchor effect is reduced.
Besides, an interval of the perforation 11 (a distance between the center of a prescribed perforation 11 and the center of another perforation 11 adjacent to the prescribed perforation 11) is preferably lower than 200 μm because if the interval of the perforation 11 is more than 200 μm, then the quantity of the perforations 11 in per unit area is reduced sometimes, and the anchor effect is reduced. In addition, an example of the lower limit of the interval of the perforation 11 is a distance that the perforations 11 are not depressed when overlapped. Besides, preferably, the intervals of the perforations 11 are the same because if the perforations 11 are equidistant, then the bonding strength in a shearing direction is in isotropy.
Herein, the perforation 11 of the first embodiment is formed by a manner of connecting an expanding part 111 and a reducing part 112, the expanding part 111 faces to a bottom 113 from the side of a surface 113 in a depth direction (Z direction) and has an increased opening diameter, and the reducing part 112 faces to the bottom 113 from the side of the surface 13 in the depth direction and has a reduced opening diameter. The expanding part 111 is formed in a manner of curve expanding, and the reducing part 112 is formed in a manner of curve reducing.
Besides, the expanding part 111 is configured on the side of the surface 13, and the reducing part 112 is configured on the side of the bottom 113. Therefore, in the perforation 11, an opening diameter (inner diameter) R2 of a boundary part between the expanding part 111 and the reducing part 112 is maximal, and the opening diameter R1 is smaller than the opening diameter R2. Therefore, the protrusion part 12 is configured on the side of the surface 13 of the first member 10. The protrusion part 12 for example is formed by a whole length part all over a peripheral direction, and is shaped into a ring.
The perforation 11 is formed by irradiating the laser for processing. As a variety of the laser, an opinion of pulse oscillation can be considered, fiber laser, Yttrium Aluminum Garnet (YAG), Yttrium orthovanadate (YVO4) laser, semiconductor laser, carbon dioxide laser and excimer laser can be selected, and if a wavelength of the laser is considered, then the fiber laser, the YAG laser, second harmonics of the YAG laser, YVO4 laser and the semiconductor laser can be preferably adopted. In addition, about output of the laser, an irradiating diameter of the laser, a material variety of the first member 10 and a shape (for example thickness) of the first member 10, and the like need to be considered. For example, the upper limit of the output of the laser is 40 W because if the output of the laser is more than 40 W, then the energy is high and the perforation 11 with the protrusion part 12 is difficulty formed.
Besides, the perforation 11 is formed by irradiating laser in which one pulse is configured from a plurality of sub-pulses. As an example of a device emitting such laser, a fiber laser marker MX-Z2000 or MX-Z2050 manufactured by Omron can be listed. Specifically speaking, when laser irradiates the first member 10, the first member 10 is locally molten, and thus formation of the perforation 11 is promoted. At this point, the laser contains a plurality of sub-pulses, therefore, the molten first member 10 is hard to scatter and can be easily accumulated nearby the perforation 11. Besides, when the formation of the perforation 11 is promoted, the molten first member 10 is accumulated in the perforation 11, and thus forms the protrusion part 12. Therefore, by the protrusion part 12, reflection waves of the laser are blocked inside the perforation 11, such that the laser processing is further promoted to a depth direction. That is, energy of the laser is easily concentrated in the depth direction. As a result, in the perforation 11, the depth is increased relative to the opening diameter R1 of the surface. In addition, an irradiating direction of the laser for example is vertical relative to the surface 13, and an axis of the perforation 11 is vertical relative to the surface 13.
In this way, by irradiating the laser in which one pulse is configured from a plurality of sub-pulses, the depth of the perforation 11 can be increased relative to the opening diameter R1 of the surface, therefore, the anchor effect is improved, and the bonding strength can be improved. Further, under a heat cycle environment, even if a peeling stress caused by a linear expansion coefficient of the first member 10 and the second member 20 is generated, the bonding strength can be maintained. That is, the durability under the heat cycle environment is improved.
In addition, a processing condition of the fiber laser marker is preferably that one period of the sub pulse is lower than 15 ns because if one period of the sub pulse is more than 15 ns, then the energy is easily dissipated due to heat conduction, and the perforation 11 with the protrusion part 12 is hard to form. In addition, one period of the sub pulse is the total time of the irradiating time of once sub pulse and an interval from the ending of irradiating of such sub pulse to the starting of the irradiating of the next sub pulse.
Besides, a processing condition of the fiber laser marker is preferably that the number of the sub-pulses of one pulse is more than 2 and lower than 50 because if the number of the sub-pulses is more than 50, then the unit output of the sub-pulses is reduced, and the perforation 11 with the protrusion part 12 is hard to form.
Besides, the second member 20 is bonded with the surface 13 of the first member 10 with the perforation 11. The second member 20 is bonded with the first member 10 through for example injection molding, hot plate welding, laser welding, injection molding hardening, ultrasonic welding or vibration welding. Therefore, the second member 20 is cured under a condition of being filled into the perforation 11.
Such bonded structure 100 for example is suitable for a condition that a resin cover (not shown) is bonded with a metal case of a photoelectric sensor (not shown). At this point, the metal case is equivalent to the first member 10, and the resin cover is equivalent to the second member 20.
—The Production Method of the Bonded Structure—
Next, the production method of the bonded structure 100 of the first embodiment is explained with reference to
Firstly, as shown in
Afterwards, the second member 20 is filled into the perforation 11 of the first member 10, and the second member 20 is cured. Therefore, the first member 10 and the second member 20 are bonded to form the bonded structure 100 (with reference to
Next, a bonded structure 200 of a second embodiment of the present invention is explained with reference to
The bonded structure 200 is as shown in
The perforation 31 of the second embodiment is formed by a manner of connecting a reducing part 311, an expanding part 312 and a reducing part 313, the reducing part 311 faces to a bottom 314 from the side of a surface 33 in a depth direction (Z direction) and has a reduced opening diameter, the expanding part 312 faces to a bottom 314 from the side of the surface 33 in the depth direction and has an increased opening diameter, and the reducing part 313 faces to the bottom 314 from the side of the surface 33 in the depth direction and has a reduced opening diameter. The reducing part 311 is formed in a manner of linear reducing, the expanding part 312 is formed in a manner of curve expanding, and the reducing part 313 is formed in a manner of curve reducing.
Besides, the reducing part 311, the expanding part 312 and the reducing part 313 are configured from the side of the surface 33 to the bottom 314 in sequence. Therefore, in the perforation 31, an opening diameter (inner diameter) R4 of a boundary part between the reducing part 311 and the expanding part 312 is smaller than an opening diameter R3 of the surface 33 and an opening diameter R5 of a boundary part between the expanding part 312 and the reducing part 313. Therefore, the protrusion part 32 is configured in a position entering the side of the bottom 314. The protrusion part 32 for example is formed by a whole length part all over a peripheral direction, and is shaped into a ring.
In addition, other constitutions of the first member 30 are same as the first member 10.
—The Production Method of the Bonded Structure—
Next, the production method of the bonded structure 200 of the second embodiment is explained with reference to
At first, as shown in
In addition, in the second embodiment, the difference from the first embodiment is that the protrusion part 32 is configured in a position entering the side of the bottom 314, but such difference for example is caused by the difference of the material of the first member 30 or an irradiation condition of the laser.
Afterwards, the second member 30 is filled into the perforation 31 of the first member 30, and the second member 20 is cured. Therefore, the first member 30 and the second member 20 are bonded to form the bonded structure 200 (with reference to
Next,
In the experiment example 1, a bonded structure 500 (referring to
At first, the production method of the bonded structure 500 of the embodiments 1-4 is explained.
In the bonded structure 500 of the embodiments 1-4, SUS304 is used as the material of a first member 501. The first member 501 is formed into a plate shape as shown in
Besides, laser irradiates a prescribed region R on the surface of the first member 501. The prescribed region R is an area bonded by the bonded structure 500, and is set into 12.5×20 mm. The shared laser irradiating conditions in the embodiments 1-4 are as follows.
<Laser Irradiating Conditions>
Laser: fiber laser (wavelength 1062 nm)
Frequency: 10 kHz
Output: 3.8 W
Scanning speed: 650 mm/sec
Scanning times: 20 times
Irradiating interval: 65 μm
Besides, as shown in Table 1, in the first embodiment, the number of the sub-pulses is set to be 20, and one period of the sub-pulses is set into 15.0 ns. In the second embodiment, the number of the sub-pulses is set to be 2, and one period of the sub-pulses is set into 15.0 ns. In the third embodiment, the number of the sub-pulses is set to be 20, and one period of the sub-pulses is set into 10.5 ns. In the fourth embodiment, the number of the sub-pulses is set to be 50, and one period of the sub-pulses is set into 15.0 ns.
In addition, the frequency is a frequency of a pulse containing a plurality of sub-pulses. That is, in the irradiating condition, the laser (pulse), containing a plurality of sub-pulses, irradiates at an interval of 65 μm for ten thousands times while moving for 650 mm in one second. In addition, the scanning times are times that the laser irradiates a same part repeatedly. Besides, in the embodiments 1, 2 and 4, the irradiating time of the sub-pulses for one time is 7.5 ns, and an irradiating interval of the sub-pulses is 7.5 ns. And in embodiment 3, the irradiating time of the sub-pulses for one time is 3 ns, and an irradiating interval of the sub-pulses is 7.5 ns.
In this way, by irradiating the laser in which one pulse is configured from a plurality of sub-pulses, a perforation is formed in a prescribed region R of the first member 501, and in the perforation, the protrusion part is formed.
Besides, insert molding, the second member 502 is bonded with the surface of the first member 501. In the bonded structure 500 of the embodiments 1-4, DURANEX (registered trademark) 3316 manufactured by PBT (WinTech Polymer) is taken as a material of the second member 502. Besides, J35EL3 manufactured by Japan Steel Works is taken as a molding machine. The molding conditions are as follows.
<Molding Conditions>
Pre-drying: 120° C.×5 h
Die temperature: 120° C.
Cylinder temperature: 270° C.
Maintained pressure: 100 MPa
The bonded structure 500 of the embodiments 1-4 is manufactured in this way. In addition, the second member 502 is formed into a plate shape, and has a length of 100 mm, a width of 25 mm and a thickness of 3 mm.
Next, the production method of the comparison example 1 is explained.
In the bonded structure of the comparison example 1, the materials of the first member and the second member use the same materials as the first to fourth embodiments, and the molding conditions are set to be same. Besides, in the bonded structure of the comparison example 1, fiber laser without a pulse control function is used to form the perforation. That is, the perforation is formed by irradiating the laser (single pulse), not containing a plurality of sub-pulses, of one pulse. Therefore, on the first member of the comparison example 1, the perforation with a mortar shape (conical) is formed.
Besides, the bonded structure 500 of the embodiments 1-4 and the bonded structure of the comparison structure are subjected to bonding evaluation.
In addition, the bonding strength is determined by an electromechanical universal tester 5900 manufactured by Instron. Specifically speaking, the experiment is carried out at a tension speed of 5 mm/min in a shearing direction, and the experiment is ended when the second member is broken or a boundary interface is broken. Besides, the maximal strength in the test is adopted as the bonding strength.
Besides, a thermal impact test is carried out by using a thermal impact device TSD-100 manufactured by Espec. Specifically speaking, low temperature exposure below −40° C. for 30 minutes and high temperature exposure below 85° C. for 30 minutes are carried out for 100 times repeatedly.
Besides, in order to judge reliability under a thermal circulation environment, qualification and unqualification are carried out according to the following criterion.
Qualified (◯): “the bonding strength after the thermal impact test”/“the bonding strength before the thermal impact test” is larger than or equal to 90%
Unqualified (x): “the bonding strength after the thermal impact test”/“the bonding strength before the thermal impact test” is smaller than 90%
As shown in Table 1, the bonded structure 500 of the embodiments 1-4 is compared with that of the comparison example 1, and the depth of the perforation relative to the opening diameter of the surface is increased because in the bonded structure 500 of the embodiments 1-4, by irradiating the laser in which one pulse is configured from a plurality of sub-pulses, the protrusion part is formed in the perforation, reflection waves of the laser are blocked inside the perforation, and the laser processing is further promoted to the depth direction.
Besides, the bonded structure 500 of the embodiments 1-4 is compared with that of the comparison example 1, and the bonding strength before the thermal impact test is improved than that after the thermal impact test because in the bonded structure 500 of the embodiments 1-4, the depth of the perforation is increased relative to the opening diameter of the surface, therefore, the anchor effect is increased and the bonding strength is improved.
Further it is judged that in the bonded structure 500 of the embodiments 1-4, even after the thermal impact test, the bonding strength before the thermal impact test is kept more than 90%. Relatively, compared with the bonded structure of the comparison example 1, after the thermal impact test, the bonding strength is greatly reduced. Therefore, like the bonded structure 500 of the embodiments 1-4, the laser in which one pulse is configured from a plurality of sub-pulses is used to form a deep perforation, and therefore, the durability under the thermal circulation environment is improved.
In the experiment example 2, a bonded structure of the embodiments 5-8 corresponding to the second embodiment and a bonded structure of a comparison example 2 are manufactured and respective bonding evaluation is carried out. In addition, the bonding evaluation is performed like experiment example 1 and the result is as shown in Table 2.
In the experiment example 2, the material of the first member is changed to be different from the experiment example 1. Specifically speaking, in the bonded structure of the experiment example 2, FORTRON (registered trademark) 1140 manufactured by PPS (Polyplastics) is taken as the material of the first member. Besides, along with the change of the first member, the shared laser irradiating conditions in embodiments 5-8 are set as follows.
<Laser Irradiating Conditions>
Laser: fiber laser (wavelength 1062 nm)
Frequency: 10 kHz
Output: 1.1 W
Scanning speed: 650 mm/sec
Scanning times: 3 times
Irradiating interval: 65 μm
Besides, as shown in Table 2, in the fifth embodiment, the number of the sub-pulses is set to be 20, and one period of the sub-pulses is set into 15.0 ns. In the sixth embodiment, the number of the sub-pulses is set to be 2, and one period of the sub-pulses is set into 15.0 ns. In the seventh embodiment, the number of the sub-pulses is set to be 20, and one period of the sub-pulses is set into 10.5 ns. In the eighth embodiment, the number of the sub-pulses is set to be 50, and one period of the sub-pulses is set into 15.0 ns.
As shown in Table 2, the bonded structure of the embodiments 5-8 is compared with that of the comparison example 2, and the depth of the perforation relative to the opening diameter of the surface is increased because in the bonded structure 500 of the embodiments 5-8, by irradiating the laser in which one pulse is configured from a plurality of sub-pulses, the protrusion part is formed in the perforation, reflection waves of the laser are blocked inside the perforation, and the laser processing is further promoted to the depth direction.
Besides, the bonded structure of the embodiments 5-8 is compared with that of the comparison example 2, and the bonding strength before the thermal impact test is increased than that after the thermal impact test because in the bonded structure of the embodiments 5-8, the depth of the perforation is increased relative to the opening diameter of the surface, therefore, the anchor effect is increased and the bonding strength is improved.
Further it is judged that in the bonded structure of the embodiments 5-8, even after the thermal impact test, the bonding strength before the thermal impact test is kept more than 90%. Relatively, in the bonded structure of the comparison example 2, after the thermal impact test, the bonding strength is greatly reduced. That is, even under the condition that the resin PPS is used as the material of the first member, the laser in which one pulse is configured from a plurality of sub-pulses is used to form a deep perforation, and therefore, the bonding strength is improved, and the durability under the thermal circulation environment is improved.
In addition, the embodiments disclosed herein are exampled in all aspects and are not a basis of a defining explanation. Therefore, a technical scope of the present invention is not explained through the embodiments merely but is defined based on a recording of a scope of claims. Besides, the technical scope of the present invention contains all changes in the meaning and scope equivalent to the scope of the claims.
For example, in the first embodiment, the surface 13 can be both flat and bent. In addition, the second embodiment 2 is also the same.
Besides, the first embodiment shows an example formed by a manner of connecting the expanding part 111 and the reducing part 112 but is not limited thereto, and a part extending straightforward along the depth direction can be formed between the expanding part and the reducing part. In addition, the second embodiment is the same.
Besides, the first embodiment shows an example that the periphery of the perforation 11 is flat, but is not limited thereto, and can be like the first member 10a of the first variable example as shown in
Besides, the first embodiment shows an example that the axis of the perforation 11 is vertical relative to the surface 13, but it not limited thereto, and can be like the first member 10b of a second variable example as shown in
Besides, the first embodiment shows an example that the protrusion part 12 is formed in the perforation 11, but is not limited thereto, and can be like a first member 10c of a third variable as shown in
Besides, like a first member 10d of a fourth variable example of the first embodiment as shown in
The present invention can use a production method of a bonded structure bonded with a first member and a second member, which contain different materials, and the bonded structure.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-169280 | Aug 2014 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2015/073042 | 8/17/2015 | WO | 00 |
