Patent Application
20210154944
The present invention relates to an ultrasonic welding method, a structure welded by the ultrasonic welding method, and an ultrasonic welding machine. In the method, welding is performed by pressing an ultrasonically vibrating tool horn directly onto the surfaces of a pair of thermoplastic resin members, or indirectly with another thermoplastic resin member interposed therebetween. More specifically, the present invention relates to the following ultrasonic welding method, a structure welded by the ultrasonic welding method, and an ultrasonic welding machine. In the ultrasonic welding method, the same distance and positional relationship are kept between the facing end surfaces of a pair of thermoplastic resin members before and after ultrasonic welding. In addition, conditions of anvil-side surfaces of the pair of thermoplastic resin members are kept unchanged before and after the ultrasonic welding so as not to be burned and discolored.
Suitcases with casters are widely used for overseas trips. Each suitcase needs to be distinguishable from others so that it can be smoothly picked up by the owner from a baggage carousel at an airport. For this purpose, a lot of unique suitcases with plastic containers in unique shapes, patterns, unevenness, or colors are available. However, suitcase manufacturers sell their products attached with the same brand nameplate. The suitcases, with casters, produced by the same manufacturer and having completely the same appearance and brand nameplate may come out one after another onto a baggage carousel at an airport. In such a case, it is difficult to distinguish the suitcases with the same appearance and the same brand nameplate from each other.
As shown in
It is known that burning occurs if excessive heat is generated when stacked plastic sheets or thin plastic plates, which are sandwiched between an anvil and a tool horn, are welded using the tool horn vibrating ultrasonically (see, e.g., Patent Document 1).
The following technique may be used to weld a pair of thermoplastic resin members placed on an anvil with their end surfaces facing each other. That is, for example, as shown in
In
For easier understanding, the following description assumes that the thermoplastic resin member 10 is a “white plate” and the thermoplastic resin member 11 as a “red plate”. As long as generating heat and melting upon application of ultrasonic vibration, the thermoplastic resin members 10 and 11 may have any hardness, thickness, shape, color, pattern, transparency, material, or other characteristics.
Although the anvil 70 may not be shown in
In (a) of
In (b) of
In an ultrasonic welding machine according to the background art shown in
In addition, the tool horn 20 transmits the ultrasonic vibration energy along the thicknesses of the thermoplastic resin members 10, 11, and 12. Accordingly, the heat is generated in the entire region where the thermoplastic resin members 10, 11 and 12 are stacked one another right under the pressing surface of the tool horn 20. Thus, upon application of excessive ultrasonic vibration energy, the surfaces (p), abutting on the anvil, of the thermoplastic resin members 10 and 11 may be burned and discolored. As shown in
PATENT DOCUMENT 1: Japanese Utility Model Publication No. S55-129607
It is an objective of the present invention to provide an ultrasonic welding method, a structure welded by the ultrasonic welding method, and an ultrasonic welding machine, in which the same distance and positional relationship between facing end surfaces of a pair of thermoplastic resin members are kept before and after the ultrasonic welding, and in which conditions of the anvil-side surfaces of the pair of thermoplastic resin members are kept unchanged before and after the ultrasonic welding.
According to the ultrasonic welding method, the structure welded by the ultrasonic welding method, and the ultrasonic welding machine according to the present invention, a pair of thermoplastic resin members are placed on an anvil. A pressing force of a tool horn vibrating ultrasonically in a direction not perpendicular to but along upper surfaces of the pair of thermoplastic resin members is applied to the upper surfaces. The application of ultrasonic vibration energy allows melting of a vicinity of the upper surfaces of the pair of thermoplastic resin members. A welded structure part is formed on an unwelded structure part, thereby welding the pair of thermoplastic resin members in an overlap structure including the welded structure part arranged on the unwelded structure part.
The ultrasonic vibration energy is supplied from the pressing surface of the tool horn in the direction along the surfaces of the pair of thermoplastic resin members, and is not directed in a thickness direction of the pair of thermoplastic resin members. Accordingly, heat is generated near the surfaces, abutting on the pressing surface of the tool horn, of the thermoplastic resin members, but less heat is generated near the anvil-side surfaces of the thermoplastic resin members. The melted thermoplastic resin members are present near the surfaces, abutting on the pressing surface of the tool horn, of the thermoplastic resin members and do not break into the gap between the facing end surfaces of the pair of thermoplastic resin members. This configuration keeps the positional relationship and generates less heat near the anvil-side surfaces of the thermoplastic resin members so that the surfaces are neither burned nor discolored.
In this configuration, even after the ultrasonic welding, the distance and positional relationship between the facing end surfaces of the pair of thermoplastic resin members are kept unchanged before and after the ultrasonic welding. In addition, conditions of the surfaces, not abutting on another thermoplastic resin member, of the pair of thermoplastic resin members are kept unchanged before and after the ultrasonic welding.
The present invention provides an ultrasonic welding method, a structure welded by the ultrasonic welding method, and an ultrasonic welding machine. The distance and positional relationship between facing end surfaces of a pair of thermoplastic resin members can be kept unchanged before and after the ultrasonic welding. In addition, conditions of the anvil-side surfaces of the pair of thermoplastic resin members can be kept unchanged before and after the ultrasonic welding.
In
In
In
Depending on the direction of the ultrasonic vibration, how the ultrasonic vibration is transmitted differs. Depending on how the ultrasonic vibration is transmitted, how heat is generated in and transmitted to the pair of thermoplastic resin members 10 and 11 and the other thermoplastic resin member 12, how the materials melt, and how the materials are welded together differ. When the tool horn vibrates ultrasonically in two opposite directions along the surfaces (i.e., in parallel to the surfaces) of the thermoplastic resin members 10, 11, and 12, the ultrasonic vibration energy is transmitted in the two opposite directions along the surfaces (i.e., parallel to the surfaces) of the thermoplastic resin members 10, 11, and 12.
Note that the tool horn 30 according to this first embodiment vibrates ultrasonically in the direction along the straight line intersecting the facing surfaces of the pair of thermoplastic resin members 10 and 11, as the two opposite directions along the upper surfaces of the thermoplastic resin members. However, as long as the ultrasonic vibration energy is transmitted in two opposite directions along the surfaces (i.e., in parallel to the surfaces) of the thermoplastic resin members 10, 11, and 12, the two opposite directions may intersect with the facing surfaces at a predetermined angle or be parallel to the facing surfaces as necessary in the welding operation.
The tool horn 30 in
Again, the tool horn 30 according to this embodiment is conically tapered from the columnar base to the top at which the cuboid press is formed. The press applies the pressing force onto the thermoplastic resin member 12 using, as the pressing surface, its lower surface toward the thermoplastic resin (i.e., toward the anvil).
The ultrasonic vibration controller 38, which will be described later, causes the ultrasonic vibrator 37 to ultrasonically vibrate the press of the tool horn 30 at an amplitude of several tens of μm and a frequency within the range from about 20 kHz to about 40 kHz. The lower surface of the press of the tool horn 30 is used as the pressing surface.
The column 70a is on the left of, and integral with, the anvil 70. The mount 70b for the vertical mover is located on the column 70a. An air press, which is the vertical mover 81, is attached to the mount 70b for the vertical mover so as to be directed downward. The support 80 for the tool horn 30 is, as a hanging, fixed and attached to the top of a vertically moving actuator of the air press. In
The ultrasonic vibration controller 38 of the tool horn 30 indicated by the broken line in the column 70a has a control signal line and a power supply line connected to the ultrasonic vibrator 37. When the ultrasonic vibrator 37 is driven, the pressing surface of the tool horn 30 vibrates ultrasonically in two opposite directions along the surfaces of the pair of thermoplastic resin members 10 and 11 and the other thermoplastic resin member 12. The pressing surface of the tool horn 30 presses the region near the facing end surfaces of the pair of thermoplastic resin members 10 and 11 from above the other thermoplastic resin member 12, and applies ultrasonic vibration energy to the other thermoplastic resin member 12 and the region near the facing end surfaces of the pair of thermoplastic resin members 10 and 11. The thermoplastic resin members 10, 11, and 12 undergo processes of heat generation, melting, cooling, and solidification and are then welded together. Accordingly, a recess is formed in the other thermoplastic resin member 12.
In
As shown in (b) of
As shown in (c) of
The ultrasonic vibration energy is supplied from the pressing surface of the tool horn 30 in a direction along the surfaces of the pair of thermoplastic resin members 10 and 11, that is, horizontally in
The ultrasonic welding machine according to the first embodiment of the present invention can keep the distance between the facing end surfaces of the pair of thermoplastic resin members 10 and 11 unchanged before and after the ultrasonic welding. The ultrasonic welding machine can also keep conditions of the surfaces, not abutting on the other thermoplastic resin member 12, of the pair of thermoplastic resin members 10 and 11 unchanged before and after the ultrasonic welding.
As a second embodiment of the present invention,
The tool horn 35 according to this embodiment has a pressing surface with projections and recesses. Accordingly, a recess 50c has a surface with projections and recesses corresponding to the projections and recesses of the pressing surface of the tool horn 35.
In this embodiment, the ultrasonic vibration energy is applied from the tool horn 35 in two opposite directions along the upper surface of the thermoplastic resin member 50. Accordingly, heat is generated in an area from the surface, abutting on the pressing surface of the tool horn 35, of the thermoplastic resin member 50 to a region beyond the interface between thermoplastic resin member 50 and the thermoplastic resin members 40 and 41. However, less heat is generated near the anvil-side surfaces of the thermoplastic resin members 40 and 41. The melted thermoplastic resin members are present in the area from the surface, abutting on the pressing surface of the tool horn 35, of the thermoplastic resin member 50 to the region beyond the interface between the thermoplastic resin member 50 and the thermoplastic resin members 40 and 41, and do not break into the gap between the facing end surfaces of the pair of thermoplastic resin members 40 and 41. Since less heat is generated near the anvil-side surfaces of the thermoplastic resin members 40 and 41, burning or discoloration of the surfaces does not occur.
As in
The ultrasonic welding method, the structure welded by the ultrasonic welding method, and the ultrasonic welding machine according to the present invention can keep the distance between the facing end surfaces of the pair of thermoplastic resin members unchanged before and after the ultrasonic welding. In addition, the method, structure, and machine can keep conditions of the anvil-side surfaces of the pair of thermoplastic resin members unchanged before and after the ultrasonic welding.
While the pressing surface of the tool horn 30 is the rectangular plane in the first embodiment of the present invention, the pressing surface of the tool horn 35 is an uneven surface with alternating projections and recesses in the second embodiment of the present invention. On the pressing surface that is the uneven surface with alternating projections and recesses, the thermoplastic resin pushed away by the projections easily moves into the spaces of the recesses adjacent to the projections. If the pressing surface of the tool horn is a rectangular plane, the entire rectangular plane needs to sink into a recess, thereby requiring a greater pressing force. If the pressing surface is an uneven surface with alternating projections and recesses, the pressing force of the projections pushing the resin suffices. That is, the welding operation proceeds with a smaller pressing force.
Specifically, in a case in which the pressing surface of the tool horn 35 is an uneven surface with alternating projections and recesses as shown in
As shown in
Both the projections and recesses of the pressing surface of the tool horn 35, that is, the entire pressing surface of the tool horn 35 abuts on the thermoplastic resin members. The process then enters the phase of pushing down the thermoplastic resin members having the same area as in the case of using the rectangular plane as the pressing surface of the tool horn 35. Until the projections of the pressing surface of the tool horn 35 sink by Δh, a smaller pressing force suffices to melt the thermoplastic resin. Once both the projections and recesses of the pressing surface of the tool horn 35, that is, the entire pressing surface of the tool horn 35 abuts on the thermoplastic resin members, the load resistance increases, thereby requiring a greater pressing force.
In this time point, the recess 50c is already formed in the upper surface of the other thermoplastic resin member 50, and the other thermoplastic resin member 50 melts. The pair of thermoplastic resin members 40 and 41 under the thermoplastic resin member 50 also melt together.
As the welding operation, in this time point, the ultrasonic vibration is stopped to cool, solidify, and weld the resin members. At this time, a smaller pressing force suffices for the welding operation. Depending on the required welding operation conditions, the tool horn 35 may turn to ascend upon detection that a load resistance is increased by the entire pressing surface of the tool horn 35 pressed onto the thermoplastic resin members. In this case, application of a smaller pressing force suffices to end the welding operation.
In
In
In
If there is a need to sink all the projections and recesses, the tool horn continues to descend even after the time indicated by t2 until the pressing force increases to a predetermined magnitude. For example, at the time indicated by the amount t3 of sinking, the tool horn 35 stops descending and turns to ascend so that the projections and recesses sink into the thermoplastic resin member 50 and that the welding operation ends.
First, as the first procedure, whether to cause (1) only the projections to sink or (2) the projections and recesses to sink at a predetermined amount is selected as the amount of sinking. The result of selection is input from an input (not shown) of the machine (step ST1) and the welding operation starts (step ST2). Accordingly, the tool horn 35 starts vibrating ultrasonically and descends toward the upper surface of the thermoplastic resin member (step ST3). When the projections of the tool horn 35 abut on the upper surface of the thermoplastic resin member 50, the pressing force required for the tool horn 35 to push the thermoplastic resin member 50 gradually increases. Then, the pressing force (F0) exceeds a predetermined pressing force (F1). A pressure sensor (not shown) detects that the pressing force (F0) has exceeded the pressing force (F1) (step ST4). If causing “only the projections to sink” is selected in step ST1 (YES in step ST5), the vertical movement of the tool horn 35 is turned from descending toward the upper surface of the thermoplastic resin member 50 to ascending (step ST7). After that, the ultrasonic vibration driving of the tool horn 35 is turned off to end the welding operation (step ST8). This procedure allows only the projections of the pressing surface of the tool horn 35 to sink into the thermoplastic resin member 50.
On the other hand, in the case in which causing “the projections and recesses to sink at a predetermined amount” is selected and the result of selection is input (No in step ST5), the procedure proceeds to step ST3 so that the tool horn continues to descend unless the pressing force (F0) exceeds a predetermined pressing force (F2) (YES in step ST6). Once the pressing force (F0) exceeds the predetermined pressing force (F2) (NO in step ST6), the vertical movement of the tool horn 35 turns from descending toward the upper surface of the thermoplastic resin member to ascending (step ST7). After that, the ultrasonic vibration driving of the tool horn 35 is turned off to end the welding operation (step ST8). This procedure allows the projections and recesses of the pressing surface of the tool horn 35 to sink into the thermoplastic resin member 50 at the predetermined amount.
Note that the pressing surface of the tool horn 35 may have the following shapes: as shown in
In an ultrasonic welding machine according to a third embodiment of the present invention, a tool horn 36 vibrates ultrasonically in parallel to the facing surfaces of a pair of thermoplastic resin members 40 and 41.
With respect to the relationship between the direction in which the tool horn 36 vibrates and a direction in which end surfaces of the thermoplastic resin member 50 extend, even if the angle between the direction in which the tool horn 36 vibrates and the direction in which the end surfaces of the thermoplastic resin member 50 extend is changed by, for example, making the directions intersect with each other at another angle, the distance between the facing end surfaces is kept unchanged before and after the welding according to the present invention, and the anvil-side surface of the thermoplastic resin is neither burned nor discolored before and after the welding.
In
The frame-like positioning jig cover 60 is a metal frame with a window 60a in almost the same shape as the outer shape of the thermoplastic resin member 12. The other thermoplastic resin member 12 communicates with the outside through the window 60a. The window 60a surrounds, as a window frame, the periphery of the other thermoplastic resin member 12.
The frame-like positioning jig cover 60 supports and maintains the other thermoplastic resin member 12 at a given position while the other thermoplastic resin member 12 receives the ultrasonic vibration energy of the tool horn 30. In a case in which the tool horn 30 vibrates at a greater amplitude, the jig cover regulates, as a side anvil, the position of the other thermoplastic resin member. The jig cover is thus advantageous in promoting the heat generation at the other thermoplastic resin member 12. The frame-like positioning jig cover 60 may be used as necessary.
The first to fourth embodiments of the present invention show that the pair of thermoplastic resin members face each other, that another thermoplastic resin member is placed on the pair of thermoplastic resin members, that the tool horn is pressed onto the other thermoplastic resin member to supply the ultrasonic vibration energy in two opposite directions along the surface of the other thermoplastic resin member.
Specifically, in the first to fourth embodiments and the variations, the ultrasonic welding method, the structure welded by the ultrasonic welding method, and the ultrasonic welding machine have been described. In the method, the pair of thermoplastic resin members are butt welded as follows. That is, the pair of thermoplastic resin members are placed on the anvil with their end surfaces facing each other. The other thermoplastic resin member is placed on a region where end surfaces of the pair of thermoplastic resin members face each other. The pressing surface of the tool horn vibrating ultrasonically in two opposite directions not perpendicular to but along the upper surface of the other thermoplastic resin member is pressed onto the upper surface. The pressing force of the tool horn vibrating ultrasonically is applied to melt the vicinity of the upper surface of the other thermoplastic resin member. A welded structure part is therefore formed on an unwelded structure part to obtain an overlap structure including the welded structure part arranged on the unwelded structure part.
This configuration provides the following advantages: (1) the same distance is kept between the facing end surfaces before and after the welding; and (2) the anvil-side surface of the thermoplastic resin is neither burned nor discolored before and after the welding.
A fifth embodiment of the present invention does not employ the other thermoplastic resin member described above. The pair of thermoplastic resin members are replaced with a pair of a thermoplastic resin members 10a and 10b, which are a white plate and a red plate, respectively, and each of which has an L-shaped cross section. The thicker parts of the L-shaped cross sections, that is, a thicker white part 10ax and a thicker red part 11ax face each other. The pressing surface of the tool horn 30 is pressed onto the upper surfaces of the thicker parts 10ax and 11ax of the L-shaped cross sections. Ultrasonic vibration energy is applied in two opposite directions along the upper surfaces of the thicker parts of the L-shaped cross sections to generate heat near the upper surfaces of the thicker parts of the L-shaped cross sections. The upper surfaces therefore melt, and a recess is formed. Welding is performed in this manner.
The thicker parts of the L-shaped cross sections serve as the other thermoplastic resin member 12 shown in the first and second embodiments of the present invention. As shown in (b) of
In
Technical aspects of the welding in this embodiment are similar to those in the first and second embodiments of the present invention. Although not described in detail, similarly to the first and second embodiments, this embodiment provides the following advantages: (1) the same distance is kept between the facing end surfaces before and after the welding; and (2) the anvil-side surface of the thermoplastic resin is neither burned nor discolored before and after the welding.
In an ultrasonic welding machine according to a sixth embodiment of the present invention, the thicker parts of the thermoplastic resin members, each having the L-shaped cross section, according to the fifth embodiment are replaced with a plurality of fitting parts fitting into each other.
In the sixth embodiment, the facing thicker parts of the pair of the thermoplastic resin member 10b and 11b, each having the L-shaped cross section, have the plurality of fitting parts 10bw and 11br, respectively, fitting into each other. When the fitting parts melt, the resin members are firmly integrated with a higher bonding strength. In particular, as shown in the perspective view of
In the sixth embodiment, the end surfaces of the pair of thermoplastic resin members 10b and 11b, which are objects to be welded, have the fitting parts 10bw and 11br, respectively. The fitting parts 10bw and 11br in the end surfaces of the pair of thermoplastic resin members 10b and 11b fit into each other. In this state, to the upper surfaces of the fitting parts of the pair of thermoplastic resin members 10b and 11b, the pressing force of the tool horn vibrating ultrasonically in two opposite directions along the upper surfaces is applied. Accordingly, the vicinity of the upper surfaces of the respective fitting parts 10bw and 11br of the pair of thermoplastic resin members 10b and 11b melt to be welded together, with the fitting parts 10bw and 11br fitting into each other.
In the sixth embodiment shown in
The recesses, which are the cubic spaces, and the projections, whose outer shapes are cubic, have planar side surfaces. Thus, when the fitting part 10bw and the fitting part 11br are apart from each other in the direction opposite to the three white arrows in
In
Again, in the sixth embodiment, the pair of thermoplastic resin members 10b and 11b, which are objects to be welded, have, at their ends, the fitting parts 10bw and 11br, respectively, which are separated and independent from each other and not connected to each other. The pair of the objects to be welded are placed on an anvil 70 with the fitting parts 10bw and 11br fitting into each other. The pressing surface of the tool horn 30 vibrating ultrasonically in a direction not perpendicular to but along the upper surfaces of the fitting parts 10bw and 11br of the pair of thermoplastic resin members 10b and 11b, which are the objects to be welded, is pressed onto the upper surfaces. The pressing force of the tool horn 30 vibrating ultrasonically is applied to melt the vicinity of the upper surfaces of the respective fitting parts 10bw and 11br of the pair of thermoplastic resin members 10b and 11b, which are the objects to be welded. A welded structure part is thus formed on an unwelded structure part to obtain an overlap structure including the welded structure part arranged on the unwelded structure part. In this manner, the respective fitting parts 10bw and 11br of the pair of thermoplastic resin members 10b and 11b, which are the objects to be welded, are welded into this overlap structure.
This configuration provides the following advantages: (1) the same distance is kept between the facing end surfaces before and after the welding; and (2) the anvil-side surface of the thermoplastic resin is neither burned nor discolored before and after the welding; and in addition, (3) the facing surfaces of the pair of thermoplastic resin members are firmly integrated.
As necessary, the planar parts and the fitting parts 10bw and 11br of the thermoplastic resin members 10b and 11b may be made of different materials. If the planar parts of the thermoplastic resin members 10b and 11b are made of a fragile, breakable, and less weldable material, the fitting parts 10bw and 11br may be made of another material that compensates the properties that the planar parts of the thermoplastic resin members 10b and 11b lack. This configuration allows excellent welding between the fitting parts 10bw and 11br.
Although not being a method of welding into a brand nameplate, the following welding method is required for other purposes. That is, a pair of vinyl sheets as objects to be welded have, at their ends, the fitting parts, which are thermoplastic resin members, and are welded together, with the fitting parts fitting into each other. Similarly, a method is required in which tent sheets have, at their ends, the fitting parts, which are thermoplastic resin members, and are welded together, with the fitting parts fitting into each other. The vinyl sheets and tent sheets may be made of various materials. Even if the planar parts of the pair of objects to be welded are not the thermoplastic resin members, such the planar parts are also applicable as the sixth embodiment of the present invention, as long as the fitting parts 10bw and 11br which are the thermoplastic resin members can be firmly attached to the associated planar parts.
(First Variation of Sixth Embodiment of Present Invention)
In an ultrasonic welding machine according to a first variation of the sixth embodiment of the present invention, pairs of thermoplastic resin members 10c and 11c, and 10d and 11d have fitting parts 10cw and 11cr, and 10dw and 11dr, respectively. The fitting parts are almost in the same shape as the fitting part (i.e., the white fitting part) 10bw of the thermoplastic resin member 10b, that is, one of the fitting parts 10bw and 11br fitting into each other in the sixth embodiment shown in
The facing thicker parts of the pairs of thermoplastic resin members 10c and 11c, and 10d and 11d, each having the L-shaped cross section, have the fitting parts 10cw and 11cr, and 10dw and 11dr, respectively, fitting into each other. This configuration is advantages in increasing the welding strength between the thermoplastic resin members 10c and 11c, and 10d and 11d.
Note that the fitting parts 10cw, 11cr, 10dw, and 11dr may be in any shape.
In
In the sixth embodiment and its variation described above, the ultrasonic welding method, the structure welded by the ultrasonic welding method, and the ultrasonic welding machine have been described in which the pair of objects to be welded have, at their ends, the fitting parts that are the thermoplastic resin members.
The sixth embodiment of the present invention provides the following advantages: (1) the same distance is kept between the facing end surfaces before and after the welding; and (2) the anvil-side surface of the thermoplastic resin is neither burned nor discolored before and after the welding; and in addition, (3) the facing surfaces of the pair of thermoplastic resin members are firmly integrated.
In an ultrasonic welding machine according to a seventh embodiment of the present invention, a pair of thicker thermoplastic resin members 10e and 11e face each other. In the fifth and sixth embodiments of the present invention, examples have been described in which the pair of thermoplastic resin members 10a and 11a, each having the L-shaped cross section, are welded, and in which the pairs of thermoplastic resin members 10b and 11b, 10c and 11c, and 10d and 11d with the respective fitting parts are welded. The pairs of thermoplastic resin members have, on their end surfaces, the respective fitting parts. With the fitting parts fitting into each other, the pressing force of the tool horn vibrating ultrasonically in two opposite directions along the upper surfaces of the fitting parts is applied for welding. The configurations will be illustrated below because the same or similar advantages are obtainable also in a case in which the thermoplastic resin members that are thick or thin as a whole face each other.
In the seventh embodiment, the end surfaces of the pair of thicker thermoplastic resin members 10e and 11e face each other. In this state, the pressing force of the tool horn vibrating ultrasonically in two opposite directions along the upper surfaces of the pair of thicker thermoplastic resin members is applied to melt and weld the vicinity of the upper surfaces of the pair of thicker thermoplastic resin members.
The ultrasonic welding machine according to the seventh embodiment provides the following advantages: (1) the same distance is kept between the facing end surfaces before and after the welding; and (2) the anvil-side surface of the thermoplastic resin is neither burned nor discolored before and after the welding; and in addition, (3) the facing surfaces of the pair of thermoplastic resin members are firmly integrated.
(First Variation of Seventh Embodiment of Present Invention)
In an ultrasonic welding machine according to a first variation of the seventh embodiment of the present invention, a pair of thinner thermoplastic resin members 10f and 11f face each other.
In the first variation of the seventh embodiment, the end surfaces of the pair of thinner thermoplastic resin members 10f and 11f face each other. In this state, the pressing force of the tool horn 35 vibrating ultrasonically in two opposite directions along the upper surfaces of the pair of thinner thermoplastic resin members is applied to melt and weld the vicinity of the upper surfaces of the pair of thinner thermoplastic resin members.
The ultrasonic welding machine according to the first variation of the seventh embodiment provides the following advantages: (1) the same distance is kept between the facing end surfaces before and after the welding; and (2) the anvil-side surface of the thermoplastic resin is neither burned nor discolored before and after the welding; and in addition, (3) the overall thickness can be reduced.
(Second Variation of Seventh Embodiment of Present Invention)
In the first variation of the seventh embodiment of the present invention described with reference to
To address the problem, in an ultrasonic welding machine according to a second variation of the seventh embodiment of the present invention, the facing end surfaces of a pair of thinner thermoplastic resin members 10g and 11g have a zigzag shape as seen from above as shown in
In the second variation of the seventh embodiment, the end surfaces of the pair of thinner thermoplastic resin members 10g and 11g face each other with their projections and recesses fitted into the zigzag shape. In this state, the pressing force of the tool horn 35 vibrating ultrasonically in two opposite directions along the upper surfaces of the pair of thinner thermoplastic resin members 10g and 11g is applied to melt and weld the vicinity of the upper surfaces of the pair of thinner thermoplastic resin members 10g and 11g.
However, the pair of thinner thermoplastic resin members, each having the zigzag facing end surface, cannot be used in a conspicuous place such as a brand nameplate in view of the appearance and are thus used for other purposes, for example, for butt welding tent sheets. Although not shown in the figure, with fitting parts of a pair of tent sheets fitted into each other, the tool horn vibrating ultrasonically in a direction along the upper surfaces of the fitting parts is pressed onto the upper surfaces. Accordingly, the fitting parts which are cut to have an edge bent into a predetermined shape and are fitted into each other are integrally welded while keeping the fitted appearance.
The ends of typical tent sheets are welded with the pair of stacked tent sheets and a tool horn or a radio frequency electrode pressed perpendicularly to the stacked surfaces. Accordingly, the welded part cannot be sufficiently pressed to have a thickness closer to the original thickness and is finished thick, which causes ununiform stiffness and discomfort.
In the second variation of the seventh embodiment of the present invention, however, although the facing end surfaces of the pair of thinner thermoplastic resin members 10g and 11g are in the zigzag shape as seen from above as shown in
In the seventh embodiment and the variations, the ultrasonic welding method, the structure welded by the ultrasonic welding method, and the ultrasonic welding machine have been described. In the method, two or more thermoplastic resin members are welded as follows. That is, the two or more thermoplastic resin members are aligned and placed on an anvil. The pressing surface of the tool horn vibrating ultrasonically in a direction not perpendicular to but along the upper surfaces of the thermoplastic resin members is pressed onto the upper surfaces. The pressing force of the tool horn vibrating ultrasonically is applied to melt the vicinity of the upper surfaces of the thermoplastic resin members. The welded structure part is therefore formed on the unwelded structure part to obtain an overlap structure including the welded structure part arranged on the unwelded structure part.
With this configuration, the ultrasonic welding machines according to the variations of the seventh embodiment provide the following advantages: (1) the same distance is kept between the facing end surfaces before and after the welding; and (2) the anvil-side surface of the thermoplastic resin is neither burned nor discolored before and after the welding; and in addition, (3) the facing surfaces of the pair of thermoplastic resin members are firmly integrated; and (4) even the thinner thermoplastic resin members can be welded.
The fifth embodiment described above is the same in that the two or more thermoplastic resin members are aligned and placed on the anvil and are welded together.
In an eighth embodiment of the present invention, a pair of thermoplastic resin members are butt welded in the following manner. That is, the pair of thermoplastic resin members are placed on an anvil with their end surfaces facing each other. A pressing force of a tool horn vibrating ultrasonically in two opposite directions along the upper surfaces of a region where the end surfaces of the pair of thermoplastic resin members face each other is applied to these upper surfaces, obliquely downward from obliquely above the upper surfaces of the region where the end surfaces of the pair of thermoplastic resin members face each other. The applied ultrasonic vibration energy melts the vicinity of the upper surfaces of the pair of thermoplastic resin members, thereby butt welding the pair of thermoplastic resin members.
Note that the ultrasonic welding machine according to the eighth embodiment of the present invention shown in
The ultrasonic vibration of the pressing surface of the tool horn 35 is applied obliquely, from the upper left to the lower right, to the upper surfaces above the inclined interface between the pair of thermoplastic resin members 10j and 11j. For example, it is understood that the force vector (FVO) of an air press is divided into the horizontal force (FVX) and the vertical force (FVY) to act. Similarly, the pressing force, that is, the vertical force (FVY) applied onto the inclined interface between the pair of thermoplastic resin members 10j and 11j is smaller than the force vector (FVO) of the air press. From the foregoing, if the tool horn is pressed on the surfaces while moving obliquely, it is possible to apply softly a smaller pressing force even with the same ultrasonic welding machine. Particularly in the case of a thinner thermoplastic resin member, the ultrasonic vibration can be applied to the surface of the thinner thermoplastic resin member by softly pressing the surface with a smaller force, which makes it easy to form an overlap structure including a welded structure part (A) arranged on an unwelded structure part (B) at the facing end surfaces of the pair of thinner thermoplastic resin members.
As shown in
In the configuration described in the first variation of the eighth embodiment in
As shown in (a), (b), (c), and (d) of
In the second variation of the eighth embodiment in
As shown in an enlarged view of
The ultrasonic vibration of the tool horn 35b acts as a vibration that presses and hits the “inclined interface” between the pair of thermoplastic resin members 10m and 11m. Accordingly, vibration energy higher than that applied onto the interface perpendicular to the surface of the anvil 70 can be applied, as a strong pressing energy, to the inclined interface between the pair of thermoplastic resin members 10m and 11m. The tool horn 35b has, on the pressing surface, a plurality of projections and recesses. The ultrasonic vibration energy is applied obliquely toward the anvil side of the pair of thermoplastic resin members 10m and 11m to melt the vicinity of the upper surfaces of the pair of thermoplastic resin members. Although the interface is inclined with respect to the surfaces of the pair of thermoplastic resin members 10m and 11m, the ultrasonic vibration is performed so as to leave the unwelded structure part (B).
In the third variation of the eighth embodiment in
As shown in an enlarged view of
As shown in (a), (b), (c), and (d) of
For example, as shown in (a), (b), and (c) of
Although not shown in the figure, the ultrasonic welding machine according to the present invention described above may have the following additional elements to form the welded structure part (A) and the unwelded structure part (B) in any preferred shapes: (1) a tool horn mover that moves the tool horn along the upper surfaces of a pair of thermoplastic resin members or two or more thermoplastic resin members; and (2) a moving speed controller that variably controls the moving speed of the tool horn mover in a predetermined pattern.
Specifically, the controller 38 causes the tool horn 35 to perform the ultrasonic vibration and the pressing, that is, causes the tool horn 35 to vibrate ultrasonically in a direction not perpendicular to but along the upper surfaces of the thermoplastic resin member 10n and 11n so that the pressing surface of the tool horn 35 presses the upper surfaces.
At this moment, the mover of the tool horn 35 and the moving speed controller are used to move the pressing surface of the tool horn 35 along the upper surfaces of the pair of thermoplastic resin members 10n and 11n or two or more thermoplastic resin members 10n and 11n at a moving speed variable in the predetermined pattern. The vicinity of the upper surfaces of the pair of thermoplastic resin members 10n and 11n is melted in this manner. If a moving speed per unit length is high while constant ultrasonic vibration energy is emitted from the pressing surface of the tool horn 35, the ultrasonic vibration energy is emitted thinly with respect to the unit length. On the other hand, if a moving speed per unit length is low, the ultrasonic vibration energy is emitted densely with respect to the unit length. In (a), (b), and (c) of
The moving speed of the tool horn mover is controlled variably in the predetermined pattern to form, on an unwelded structure part, a welded structure part in the shape corresponding to the pattern. In this manner, the control is performed to weld the two or more thermoplastic resin members into an overlap structure including the welded structure part arranged on the unwelded structure part. This control allows the formation of the welded structure part (A) and the unwelded structure part (B) in the shapes as shown in (d) and (e) of
Again, the control of the movement of the tool horn 35 in a certain pattern as necessary allows the free setting of the shapes of the welded structure part (A) and the unwelded structure part (B) as shown in (d) and (e) of
In the eighth embodiment and variations described above, the ultrasonic welding method, the structure welded by the ultrasonic welding method, and the ultrasonic welding machine have been described. In the method, a pair of thermoplastic resin members are butt welded as follows. That is, the pair of thermoplastic resin members are placed on the anvil with their end surfaces facing each other. The pressing surface of the tool horn vibrating ultrasonically in a direction not perpendicular to but along the upper surfaces of a region where end surfaces of the pair of thermoplastic resin members face each other is pressed onto the upper surfaces of the region. The pressing force of the tool horn vibrating ultrasonically is applied to melt the vicinity of the upper surfaces of the pair of thermoplastic resin members. The welded structure part is therefore formed on the unwelded structure part to obtain an overlap structure including the welded structure part arranged on the unwelded structure part.
The ultrasonic welding machine according to the eighth embodiment of the present invention provides the following advantages of the present invention: (1) the same distance is kept between the facing end surfaces before and after the welding; and (2) the anvil-side surface of the thermoplastic resin is neither burned nor discolored before and after the welding; and in addition, (3) the facing surfaces of the pair of thermoplastic resin members are firmly integrated; and (4) even the thinner thermoplastic resin members can be welded.
In an ultrasonic welding machine according to a ninth embodiment of the present invention, an air cooling fan 73 as an air cooling device is attached to the outside of an anvil 70 that has a through-hole 74 through which air C passes. The air flows from one end of the thorough-hole 74 to the other to release the heat inside the anvil 70 to the outside of the anvil 70. A temperature sensor 75 is embedded in the anvil 70 to transmit temperature information via a signal line 75a to an ultrasonic vibration controller 38 and performs feedback control of the temperature information on the anvil 70.
The ultrasonic welding machine according to the ninth embodiment of the present invention has almost the same configuration already shown in
In the ninth embodiment, the pair of thermoplastic resin members 10j and 11j are butt welded as follows. That is, the pair of thermoplastic resin members 10j and 11j are placed on the anvil 70 with their end surfaces facing each other. Based on the temperature information on the anvil, a cooler is used to set the temperature of the anvil 70 to be a constant temperature or lower. The pressing force of the tool horn 35 vibrating ultrasonically in two opposite directions along the upper surface of a region where end surfaces of the pair of thermoplastic resin members 10j and 11j face each other is applied to the upper surface. The ultrasonic vibration energy is therefore applied to melt the vicinity of the upper surfaces of the pair of thermoplastic resin members 10j and 11j.
As shown in
This configuration provides the following advantages of the present invention: (1) the same distance is kept between the facing end surfaces before and after the welding; and (2) the anvil-side surface of the thermoplastic resin is neither burned nor discolored before and after the welding; and in addition, (3) the facing surfaces of the pair of thermoplastic resin members are firmly integrated; and (4) even the thinner thermoplastic resin members can be welded.
Note that the air cooling fan 73 has been described above as the cooler, a liquid cooler for circulating a liquid refrigerant may be used.
An ultrasonic welding machine according to a tenth embodiment of the present invention controls cooling of an anvil.
In an operation flow of the ultrasonic welding machine according to the ninth embodiment of the present invention shown in
An ultrasonic welding machine according to an eleventh embodiment of the present invention controls a temperature of an anvil within a predetermined temperature range before the start of a welding operation to the end of the welding operation.
Specifically, in another operation flow of the ultrasonic welding machine according to the eleventh embodiment of the present invention shown in
After controlling the temperature of the anvil within the predetermined temperature range, the ultrasonic vibration controller 38 causes the tool horn 35 to descend at a predetermined amount each time Δt. At each time, it is observed whether the temperature (T0) of the anvil 70 is lower than or equal to a predetermined temperature (T1) (step ST14), and whether applied ultrasonic vibration energy E0 is lower than or equal to a predetermined amount (E1) of energy (step ST15). If both the answers are No, the tool horn 35 ascends to avoid an increase of the gap (S) or burning of the surfaces (step ST16), and the welding operation ends (step ST17).
The ultrasonic welding machine according to the tenth embodiment of the present invention cools the anvil after the end of the welding operation. The ultrasonic welding machine according to the eleventh embodiment of the present invention controls the temperature of the anvil within the predetermined temperature range during the welding operation. This control stably reduces an increase in the gap (S) or burning of the surfaces.
As shown in
As shown in (a) and (b) of
In the twelfth embodiment of the present invention, the pair of thermoplastic resin members are butt welded as follows. That is, the pair of thermoplastic resin members are placed on the anvil with their end surfaces facing each other. The tool horn vibrates ultrasonically in parallel to the facing surfaces of the thinner thermoplastic resin members. The pressing force of the tool horn vibrating ultrasonically in two opposite directions along the upper surface of a region where end surfaces of the pair of thermoplastic resin members face each other is applied to the upper surface. The ultrasonic vibration energy is thus applied to melt the vicinity of the upper surfaces of the pair of thermoplastic resin members.
The following steps may be combined for the welding: a step in which the tool horn 36a is pressed obliquely with respect to the surfaces of the pair thinner thermoplastic resin members 10f and 11f as shown in (a) and (b) of
The ultrasonic welding machine according to the twelfth embodiment provides the following advantages: (1) the same distance is kept between the facing end surfaces before and after the welding; and (2) the anvil-side surface of the thermoplastic resin is neither burned nor discolored before and after the welding; and in addition, (3) the facing surfaces of the pair of thermoplastic resin members are firmly integrated; and (4) even the thinner thermoplastic resin members can be welded.
An example has been described with reference to
In the thirteenth embodiment of the present invention, a method of manufacturing a white fitting part 10cw and a red fitting part 11cr as separated parts and welding these parts to the planar part of a white plate 10c and the planar part of a red plate 11c, respectively, will be described.
Specifically, the steps are as follows.
(First Step) The thermoplastic resin member 10c that is the thinner white plate, the white fitting part 10cw, the thermoplastic resin member 11c that is the thinner red plate, and the red fitting part 11cr are formed as separated parts.
(Second Step) The thermoplastic resin member 10c that is the thinner white plate and the white fitting part 10cw are welded together, and the thermoplastic resin member 11c that is the thinner red plate and the red fitting part 11cr are welded together.
(Third Step) The thermoplastic resin member 10c that is the thinner white plate with the white fitting part 10cw and the thermoplastic resin member 11c that is the thinner red plate with the red fitting part 11cr are welded into the brand nameplate 100.
In the first step, a thermoplastic resin plate is cut by a known technique into the thermoplastic resin member 10c that is the thinner white plate, the white fitting part 10cw, the thermoplastic resin member 11c that is the thinner red plate, and the red fitting part 11cr as separate parts.
In the second step, as shown in
In the third step, the thermoplastic resin member 10c that is the thinner white plate with the white fitting part 10cw and the thermoplastic resin member 11c that is the thinner red plate with the red fitting part 11cr are welded together to obtain the brand nameplate 100.
In the procedure described above, the individual parts are welded ultrasonically to produce the brand nameplate 100.
An example has been described above in which two or more thermoplastic resin members are aligned and placed on the anvil and the end surfaces of the two or more thermoplastic resin members are butt welded. Alternatively, the present invention is also applicable to welding of two or more thermoplastic resin members stacked on an anvil.
In the following fourteenth to sixteenth embodiments, an ultrasonic welding method, the structure welded by the ultrasonic welding method, and an ultrasonic welding machine will be described. In the method, two or more thermoplastic resin members are welded as follows. That is, the two or more thermoplastic resin members are stacked one on another on an anvil. The pressing surface of a tool horn vibrating ultrasonically in a direction not perpendicular to but along the upper surfaces of the thermoplastic resin members is pressed on the upper surfaces. The pressing force of the tool horn vibrating ultrasonically is applied to melt the vicinity of the upper surfaces of the thermoplastic resin members. A welded structure part is therefore formed on an unwelded structure part to obtain an overlap structure including the welded structure part arranged on the unwelded structure part.
In an ultrasonic welding machine according to the fourteenth embodiment of the present invention, a heat-resistant film and a heat-resistant ring are welded together.
Super engineering plastics such as liquid crystal polymer (LCP) were tried as the material of the heat-resistant film 84 and the heat-resistant ring 85. As a result, the heat-resistant film 84 was beautifully welded to the heat-resistant ring 85 without causing any thermal deformation. In particular, a significantly thin heat-resistant film 84 with a thickness of several tens of μm was welded beautifully, and the technique can thus be utilized in wider technical fields including precision parts.
In a case in which the heat-resistant ring 85 that is a molded article with a higher heat resistance and the heat-resistant film 84 made of the same material are welded by an ultrasonic welder, a welding method using vertical vibration, that is, a welding method applying vertical vibration to the upper surfaces of the thermoplastic resin members causes thermal deformation of only the heat-resistant ring 85 on the welding interface, and it is therefore extremely difficult to provide a sufficient welding strength. On the other hand, horizontal vibration, that is, vibration parallel to the upper surfaces of the thermoplastic resin members provides better heat generation efficiency as compared to the vertical vibration. In the horizontal vibration, a distance that needs to be melted to provide a required strength is significantly short, and no thermal deformation of the heat-resistant ring 85 occurs. Even in a case in which the heat-resistant ring 85 and the heat-resistant film 84 are welded at an extremely smaller width that is too small to ensure strength in welding by the vertical vibration, the ring and the film are welded to each other at a low pressure by the horizontal vibration and not deformed by the pressure.
According to the experiment in the fourteenth embodiment of the present invention, it is possible to weld a thin resin having a higher thermal deformation temperature. Even welding at a small width can ensure sufficient strength. Such welding is advantageous in reducing the sinking amount of the melted resin and reduce welding burrs.
An example has been described in the fourteenth embodiment in which the heat-resistant ring 85 and the heat-resistant film 84 are welded together. An ultrasonic welding machine according to a fifteenth embodiment welds, instead of the heat-resistant film 84, a heat-resistant lattice-like filter 94 to a heat-resistant thin ring 95.
In particular, in
Both the heat-resistant filter 94 and the heat-resistant ring 95 have high melting point temperatures and thus hardly melt. However, when the pressing surface of a tool horn 35c vibrating ultrasonically in the direction along the surfaces of the heat-resistant ring 95 and the heat-resistant filter 94 is pressed onto the surfaces, a welded structure part (A) is formed on an unwelded structure part (B) as shown in (c) of
According to the fifteenth embodiment of the present invention, too, it is possible to weld a thin resin having a higher thermal deformation temperature. Even welding at a small width can ensure sufficient strength. Such welding is advantageous in reducing the sinking amount of the melted resin and reduce welding burrs.
The pair of thermoplastic resin members that are objects to be welded are not only the planes such as flat plates or sheets but also three-dimensional objects such as polyhedrons or spheres including helmets or containers. An example will be described as a sixteenth embodiment of the present invention in which a heat-resistant film is welded to the bottom of a round plate-like plastic container.
In
A pressing force of the tool horn 30 vibrating ultrasonically in two opposite directions along the upper surfaces of the pair of thermoplastic resin members 61 and 62 is applied to the upper surfaces, while the slide table 65 from the right to the left in
The ultrasonic vibration energy flows along the upper surfaces of the pair of thermoplastic resin members 61 and 62 and does not flow along the thickness of the pair of thermoplastic resin members 61 and 62. This means that an unwelded structure part is left on the anvil-side of the pair of thermoplastic resin members 61 and 62, and that a welded structure part is formed on the unwelded structure part. As a result, the pair of thermoplastic resin members 61 and 62 are welded together in an overlap structure including the welded structure part arranged on the unwelded structure part.
It is understood from the above description that the “tool horn vibrating ultrasonically in two opposite directions along the upper surfaces of the pair of thermoplastic resin members” includes not only (1) the tool horn, described in the first to seventh embodiments, which vibrates ultrasonically along a plane parallel to the upper surfaces of the pair of thermoplastic resin members, but also (2) the tool horn, described in the eighth embodiment, which vibrates ultrasonically along a plane intersecting obliquely with the upper surfaces of the pair of thermoplastic resin members, and (3) the tool horn which vibrates ultrasonically along a plane parallel to the upper surfaces of the thermoplastic resin members, even if the upper surfaces of the pair of thermoplastic resin members are curved.
It is understood from the above description that the directions in which “a pressing force of the tool horn vibrating ultrasonically is applied to the upper surfaces of the pair of thermoplastic resin members” includes not only (1) a direction, described in the first to seventh embodiments, which is perpendicular to the upper surfaces of the pair of thermoplastic resin members, but also (2) a direction, described in the eighth embodiment, which intersects obliquely with the upper surfaces of the pair of thermoplastic resin members.
Note that those skilled in the art of ultrasonic welding machines or ultrasonic welders may refer to applying ultrasonic vibration perpendicularly to the surfaces of thermoplastic resin members as “applying vertical vibration,” and applying ultrasonic vibration in parallel to the surfaces of thermoplastic resin members as “applying horizontal vibration.” The fourteenth embodiment has been described using the terms of the “vertical vibration” and the “horizontal vibration.” According to this usage of the terms, the expressions “vibration in a direction not perpendicular to but along the upper surface(s)” defined as a feature of the present invention may be replaced with the expression—vibration that is not a vertical vibration but a vibration along the upper surface(s)—.
Important features of the present invention further include: a pressing force of a tool horn vibrating ultrasonically is applied to melt the vicinity of upper surfaces of a pair of thermoplastic resin members and form a welded structure part on an unwelded structure part, thereby welding the pair of thermoplastic resin members together in an overlap structure including a welded structure part arranged on an unwelded structure part.
The unwelded structure part is a structure part that is not welded, and its surface remains as it is before the welding operation, which means that the distance between facing surfaces does not increase. The distance and positional relationship between so-called end surfaces do not change. Moreover, the temperature of the surfaces does not increase to a high temperature, and burning does not occur on the surfaces.
The operations in the flowchart or the cooler for cooling the anvil described above are used so that when the vicinity of the upper surfaces of the pair of thermoplastic resin members is welded, the welded structure part is formed on the unwelded structure part to obtain the overlap structure including the welded structure part arranged on the unwelded structure part.
The present invention is widely applicable to an ultrasonic welding method and an ultrasonic welding machine in which: a pair of thermoplastic resin members are arranged so that end surfaces face each other or layered on each other; and a tool horn vibrating ultrasonically is pressed directly onto a surface or surfaces of the pair of thermoplastic resin members, or indirectly through another thermoplastic resin member interposed therebetween, thereby welding the thermoplastic resin members, such as a case in which: a pair of thermoplastic resin members are arranged so that end surfaces face each other; and a tool horn vibrating ultrasonically is pressed directly onto the facing end surfaces, or indirectly through another thermoplastic resin member layered on the pair of thermoplastic resin members, thereby melting the interface between the pair thermoplastic resin members and the other thermoplastic resin member
| Number | Date | Country | Kind |
|---|---|---|---|
| 2018-078022 | Apr 2018 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2019/015975 | 4/12/2019 | WO | 00 |
