CN101868343B - 熔合体的制造方法 - Google Patents

熔合体的制造方法 Download PDF

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Publication number
CN101868343B
CN101868343B CN2008801084717A CN200880108471A CN101868343B CN 101868343 B CN101868343 B CN 101868343B CN 2008801084717 A CN2008801084717 A CN 2008801084717A CN 200880108471 A CN200880108471 A CN 200880108471A CN 101868343 B CN101868343 B CN 101868343B
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fusion
carbon fiber
reservations
resin
component element
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CN2008801084717A
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CN101868343A (zh
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柴田义范
日高慎介
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Toyota Motor Corp
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Toyota Motor Corp
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    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
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    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809—Fabrics
    • B29K2105/0845—Woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0854—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/10—Cords, strands or rovings, e.g. oriented cords, strands or rovings
    • B29K2105/101—Oriented
    • B29K2105/108—Oriented arranged in parallel planes and crossing at substantial angles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
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Abstract

本发明提供一种熔合体的制造方法，熔合体(100)具有将第一熔合预定部(111)以及第二熔合预定部(121)互相熔合而成的熔合部(101)，所述第一熔合预定部(111)由第一热塑性树脂(NA1)和第一碳纤维(CF1)所构成；所述第二熔合预定部(121)由第二热塑性树脂(NA2)和第二碳纤维(CF2)所构成。该熔合体的制造方法包括熔合工序，在该熔合工序中，使第一熔合预定部和第二熔合预定部抵接并且紧密接触，通过对二者通电以使其发热，而使第一热塑性树脂和第二热塑性树脂互相熔融固化，从而形成熔合部。

Description

熔合体的制造方法
技术领域
本发明涉及一种熔合体的制造方法，该熔合体具有：由热塑性树脂和碳纤维构成的两个以上的融合预定部互相熔合而成的熔合部。 
背景技术
当例如在汽车车身外板中，使用由热塑性树脂和碳纤维构成的树脂复合体时，作为对该树脂复合体之间进行接合的接合方法，包括粘合方法。 
虽然在上述的树脂复合体中，通常用粘合剂进行粘合，但是，由于在由热塑性树脂构成的树脂复合体中不存在有助于提高粘合强度的官能团，因而直接粘合时粘合强度较低。因此，例如有必要对接合的接合面实施表面处理，从而需要花费时间或成本。另外，粘合剂的硬化也需要花费时间。 
此外，作为树脂复合体的焊接(熔合)方法，包括利用热板的方法、利用超声波振动的方法，但是，这些方法都很难应用于如车身类的大尺寸零件。 
另外，作为树脂构件的焊接方法，已知有一种利用激光在含有无机填充剂或增强剂的热塑性树脂中对热塑性树脂组合物进行接合(熔合)的技术，该热塑性树脂组合物包括：含有蒽醌染料的胺盐或者单偶氮络合物染料的激光穿透性黑色着色剂(专利文献1)。 
专利文献1：日本特表2004-521972号公报 
发明内容
本发明所要解决的课题 
然而，当要焊接(熔合)的树脂构件没有激光穿透性时，由于不能利用上述的激光焊接进行焊接(熔合)，因而利用激光焊接进行焊接(熔合)的方式被限定于以下的树脂构件，除了含有专利文献1所述的激光穿透性黑色着色剂的树脂构件之外，就是含有穿透激光的着色剂的树脂构件。尤其是，由碳纤维构成的树脂复合体很难使激光穿透。 
本发明是鉴于上述的现状而作出的。其目的在于，提供一种熔合体的制造方法，其能够简便地对于由热塑性树脂和碳纤维构成的熔合预定部之间进行熔合，从而形成熔合体。 
解决课题的方法 
而且，该解决方法为一种熔合体的制造方法，所述熔合体具有将第一熔合预定部以及第二熔合预定部互相熔合而成的熔合部，所述第一熔合预定部由第一热塑性树脂和第一碳纤维所构成；所述第二熔合预定部由第二热塑性树脂和第二碳纤维所构成，其中，所述熔合体的制造方法包括熔合工序，在该熔合工序中，使所述第一熔合预定部和所述第二熔合预定部抵接并且紧密接触，通过对二者通电以使其发热，而使所述第一热塑性树脂和第二热塑性树脂互相熔融固化，从而形成所述熔合部。所述熔合体通过在所述熔合部熔合第一树脂部和第二树脂部而成，所述第一树脂部由至少含有第一热塑性树脂的材质所构成，并包括所述第一熔合预定部；所述第二树脂部由至少含有第二热塑性树脂的材质所构成，并包括所述第二熔合预定部。所述第一熔合预定部中的所述第一碳纤维的含有率，大于所述第一树脂部中的其它部位；所述第二熔合预定部中的所述第二碳纤维的含有率，大于所述第二树脂部中的其它部位。所述第一熔合预定部含有第一正交碳纤维组，所述第一正交碳纤维组被取向在与抵接于所述第二熔合预定部的第一抵接面正交的方向上；所述第二熔合预定部含有第二正交碳纤维组，所述第二正交碳纤维组被取向在与抵接于所述第一熔合预定部的第二抵接面正交的方向上。所述第一正交碳纤维组，由通过平行排列各个碳纤维而呈层状的碳纤维组所形成；所述第二正交碳纤维组，由通过平行排列各个碳纤维而呈层状的碳纤维组所形成。 
本发明的熔合体的制造方法包括熔合工序，在该熔合工序中，使第一熔合预定部和第二熔合预定部抵接并且紧密接触，通过对二者通电以使其发热，从而形成熔合部。由此，能够简便地制造对第一熔合预定部和第二熔合预定部进行熔合的熔合体。 
而且，与其它部位相比，第一熔合预定部含有更多的第一碳纤维。与其它部位相比，第二熔合预定部也含有更多的第二碳纤维。因此，通过对该第一熔合预定部和第二熔合预定部进行通电，能够进一步使大量的电流流动，并能够在此处使其可靠地发热，从而可靠地形成熔合部。另一方面，在其它 部位中，可以根据其它目的(所要求的强度或弹性系数等的特性)设定为，不含有碳纤维或适当的含有率。 
并且，在本发明的一种方式中的熔合体的制造方法为，第一熔合预定部和第二熔合预定部，分别具有第一正交碳纤维组和第二正交碳纤维组。因此，当使第一熔合预定部和第二熔合预定部抵接并且紧密接触，并在与第一抵接面和第二抵接面正交的方向上、即取向方向上进行通电时，由于电流沿着第一正交碳纤维组和第二正交碳纤维组进行流动，因而能够形成低电阻，并能够容易且可靠地使大量的电流流动。因此，能够产生大量的热量，在第一熔合预定部和第二熔合预定部中，能够可靠地使第一热塑性树脂和第二热塑性树脂进行熔融。因而，能够制造使第一熔合预定部和第二熔合预定部可靠地进行熔合的熔合体。 
此外，第一熔合预定部和第二熔合预定部，也可以被包含在相互不同的构件中。即、第一熔合预定部可以被包含在第一构件中，第二熔合预定部可以被包含在与第一构件不同的第二构件中。而且，第一熔合预定部和第二熔合预定部也可以被包含在相同的构件中。即、也可以是，第一熔合预定部和第二熔合预定部构成单一构件中的互不相同的部分。 
另外，第一熔合预定部和第二熔合预定部，均由热塑性树脂和碳纤维构成即可。因此，作为上述的第一构件或者单一构件，除了在第一熔合预定部之外的部位中的碳纤维的含有率(重量％)，与第一熔合预定部相同的情况外，还包括与第一熔合预定部不同的情况。另外，作为第二构件或者单一构件，除了在第二熔合预定部之外的部位中的碳纤维的含有率(重量％)，与第二熔合预定部相同的情况外，还包括与第二熔合预定部不同的情况。 
而且，作为上述的第一构件和第二构件，或者作为单一构件，还包括下述构件，即、该构件仅由金属、陶瓷、与第一、第二熔合预定部的树脂不同的树脂所构成，或者仅由碳纤维所构成等，在第一熔合预定部和第二熔合预定部之外的部位中，不包括热塑性树脂或者碳纤维中的一方或双方。 
另外，作为第一碳纤维和第二碳纤维，除了可以使用例如分散在热塑性树脂中的填充物状的碳纤维之外，还可以使用碳纤维的编织布、无纺布形态的碳纤维。尤其是，由于碳纤维编织布的纤维方向一致，因而在碳纤维的延伸方向上进行通电时，能够降低通电电阻，并能够使大量的电流流动，从而在通电时能够使其可靠地产生大量的热量，因而更优选为碳纤维编织布。 
并且，在上述的任意一种熔合体的制造方法中，可以采用以下的熔合体的制造方法，即、所述第一熔合预定部和所述第二熔合预定部均含有60～90重量％的碳纤维。 
由于第一熔合预定部和第二熔合预定部，均含有60～90重量％的碳纤维，因此在使它们抵接并且紧密接触进行通电时，与碳纤维不足60重量％的情况相比，其能够更可靠地对碳纤维进行通电。由于电流流动时，碳纤维将随之发热，因而能够可靠地对于在第一熔合预定部或者第二熔合预定部中的该碳纤维周边的热塑性树脂进行熔融。因此，能够可靠地使第一熔合预定部和第二熔合预定部进行熔合，从而形成熔合体。另一方面，当第一熔合预定部或者第二熔合预定部中的碳纤维的含有率超过90重量％时，则热塑性树脂的量太少而导致难于互相熔合。 
附图说明
图1A为，对第一参考方式的熔合体进行说明的立体图。 
图1B为，图1A的局部放大剖视图(A-A剖面)。 
图2A为，对第一参考方式的第一、第二树脂构件进行说明的立体图。 
图2B为，图2A的放大剖视图(B-B剖面)。 
图3为，对第一参考方式、第一实施方式的第一、第二基材进行说明的图。 
图4为，对第一参考方式的第一、第二树脂构件的制造方法进行说明的图。 
图5A为，对第一参考方式所涉及的熔合工序进行说明的图。 
图5B为，对第一参考方式所涉及的熔合工序之后的熔合体进行说明的图。 
图6A为，第一实施方式的熔合体的立体图。 
图6B为，图6A的局部放大剖视图(C-C剖面)。 
图7A为，对第一实施方式的第一、第二树脂构件进行说明的图。 
图7B为，图7A的放大剖视图(D-D剖面)。 
图8A为，在第一实施方式的第一、第二卷绕基材中的第一、第二单取向截断基材的立体图。 
图8B为，表示第一实施方式的第一、第二卷绕基材的卷绕途中的立体图。 
图8C为，第一实施方式的第一、第二卷绕基材的立体图。 
图9为，对第一实施方式的第一、第二树脂构件的制造方法进行说明的图。 
图10A为，对第一实施方式所涉及的熔合工序进行说明的图。 
图10B为，对第一实施方式所涉及的熔合工序之后的熔合体进行说明的图。 
符号说明： 
100、200熔合体 
101、201熔合部 
110、210第一树脂构件(第一树脂部) 
111、211第一熔合预定部 
113、213第二树脂板部(其它部位) 
120、220第二树脂构件(第二树脂部) 
121、221第二熔合预定部 
123、223第二树脂板部(其它部位) 
212A第一抵接面 
222A第二抵接面 
CF1第一碳纤维 
CF1a第一取向A碳纤维(第一碳纤维、第一正交碳纤维) 
CF1b第一取向B碳纤维(第一碳纤维) 
CF1c第一取向C碳纤维(第一碳纤维) 
CF2第二碳纤维 
CF2a第二取向A碳纤维(第二碳纤维、第二正交碳纤维) 
CF2b第二取向B碳纤维(第二碳纤维) 
CF2c第二取向C碳纤维(第二碳纤维) 
NA1第一树脂(第一热塑性树脂) 
NA2第二树脂(第二热塑性树脂) 
具体实施方式
(第一参考方式) 
参照附图，对本发明的第一参考方式进行说明。 
在图1A和图1B中，表示了本发明第一参考方式所涉及的熔合体100，图1A为立体图，图1B为A-A剖视图。该熔合体100具有第一树脂板部113A、第二树脂板部123A和熔合部101，所述第一树脂板部113A呈矩形板状，并由第一树脂NA1(尼龙66)、以及通过平行排列各个碳纤维而呈层状的多层的第一碳纤维CF1组所构成；所述第二树脂板部123A呈矩形板状，并由第二树脂NA2(尼龙66)、以及通过平行排列各个碳纤维而呈层状的多层的第二碳纤维CF2组所构成；所述熔合部101介于第一树脂板部113A和第二树脂板部123A之间。并且，如后文所述，该熔合体100是通过熔合第一树脂构件110和第二树脂构件120而制造的，所述第一树脂构件110呈矩形板状，并由第一树脂NA1和第一碳纤维CF1所构成；所述第二树脂构件120呈矩形板状，并由第二树脂NA2和第二碳纤维CF2所构成。 
如图1B的剖视图所示，在该熔合体100中，第一树脂板部113A中的各个第一碳纤维CF1、以及第二树脂板部123A中的各个第二碳纤维CF2被取向在与板厚度方向DA(图1B中的上下方向)垂直的方向(图中的水平方向)上，各个第一碳纤维CF1层和各个第二碳纤维CF2层被平行配置。 
另外，在熔合部101中，第一树脂NA1和第二树脂NA2一起进行熔融固化，从而形成为一体。在该熔合部101中的第一碳纤维CF1和第二碳纤维CF2的含有率(重量％)，要高于在熔合体100中的其它部位(第一树脂板部113A和第二树脂板部123A)。具体而言，熔合部101中的第一碳纤维CF1组或者第二碳纤维CF2组在第一方向DA上被配置成多层，其层数多于第一树脂板部113A和第二树脂板部123A。 
接下来，对第一参考方式所涉及的熔合体100的制造方法进行说明。 
如上所述，第一参考方式所涉及的熔合体100是通过熔合第一树脂构件110和第二树脂构件120而制成的。在此，首先，对第一树脂构件110进行说明。在图2A和图2B中，表示了该第一树脂构件110的立体图和放大剖视图。 
第一树脂构件110为，由第一树脂NA1和第一碳纤维CF1组所构成的矩形板的树脂复合体。如图2B所示，该第一碳纤维CF1组在第一树脂构件 110中为层状，且被取向在与板厚度方向DA(图2B中的上下方向)大致垂直的方向上，第一碳纤维CF1的层与层之间被配置为大致相互平行。 
在该第一树脂构件110中的一个端部为，与第二树脂构件120进行熔合的第一熔合预定部111。在该第一熔合预定部111中的第一碳纤维CF1的含有率，大于第一树脂构件110中的其它部位113。具体而言，在第一熔合预定部111中的层状的第一碳纤维CF1组，其层数多于该其它部位113。在第一熔合预定部111中的第一碳纤维CF1的含有率被设为65重量％。 
另外，在第一树脂构件110的第一主表面112中，将包含在第一熔合预定部111中的部位(与第二树脂构件120抵接的部位)作为第一抵接面112A。 
接下来，对第二树脂构件120进行说明。该第二树脂构件120为，由第二树脂NA2和第二碳纤维CF2组所构成的矩形板状的树脂复合体。如图2B所示，与第一树脂构件110同样，该第二碳纤维CF2组在第二树脂构件120中为层状，且被取向在与板厚度方向DA(图2B中的上下方向)大致垂直的方向上，第二碳纤维CF2的层与层之间被配置为大致相互平行。 
在该第二树脂构件120中的一个端部为，与第一树脂构件110进行熔合的第二熔合预定部121。在该第二熔合预定部121中的第二碳纤维CF2的含有率，大于第二树脂构件120中的其它部位123。具体而言，在第二熔合预定部121中的层状的第二碳纤维CF2组，其层数多于该其它部位123。在第二熔合预定部121中的第二碳纤维CF2的含有率被设为65重量％。 
另外，在第二树脂构件120的第二主表面122中，将包含在第二熔合预定部121中的部位(与第一树脂构件110抵接的部位)作为第二抵接面122A。 
接下来，参照图3和图4，对第一树脂构件110的制造方法进行说明。 
如图3所示，将尼龙66的第一树脂无纺布NA1b、以及由同方向排列(取向)的第一碳纤维CF1组构成的层交替层压，从而形成第一基材115。作为该第一碳纤维CF1层，使用了三种碳纤维的延伸方向(取向)各不相同的层状的碳纤维组，具体而言，该第一碳纤维CF1层使用了第一取向A碳纤维CF1a(取向0°)组、第一取向B碳纤维CF1b(取向60°)组和第一取向C碳纤维CF1c(取向-60°)组。并且，按照第一取向A碳纤维CF1a组、第一取向B碳纤维CF1b组和第一取向C碳纤维CF1c组的顺序，将它们进行层压。 
切断上述的第一基材115，从而形成宽度为W1、长度为L1的第一长基材115L以及宽度为W1、长度为L2(L2＜L1)的第一短基材115S(参照图4的上段部分)。而且，将两个第一长基材115L彼此层压在一起，进而从其上下方向分别层压两个第一短基材115S，以便夹持其端部115La。另一方面，在两层的第一长基材115L中的未层压第一短基材115S的部位上，重叠放置了由尼龙66构成的树脂无纺布140。 
而且，通过上部加热板PU和下部加热板PL对由第一长基材115L、第一短基材115S和树脂无纺布140所构成的层压体进行夹持、加压并加热(图4的中段部分)。具体而言，将平板的上部加热板PU和下部加热板PL加热至300℃的同时，对层压体进行加压，并将层压体在300℃的温度下保持20分钟。保持之后，缓慢地冷却至200℃为止，再拆下加热板。 
根据以上方法，从而制成第一树脂构件110(图4的下段部分)。 
关于第二树脂构件120的制造方法，与第一树脂构件110相同，将具有三个不同取向的层状的碳纤维组(第二取向A碳纤维CF2a(取向0°)组、第二取向B碳纤维CF2b(取向60°)组和第二取向C碳纤维CF2c(取向-60°)组)，分别夹持在第二树脂无纺布NA2b之间，从而形成第二基材125。 
切断上述的第二基材125，从而形成宽度为W1、长度为L1的第二长基材125L以及宽度为W1、长度为L2(L2＜L1)的第二短基材125S(参照图4的上段部分)。而且，将两个第二长基材125L彼此层压在一起，进而从其上下方向分别层压两个第二短基材125S，以便夹持其端部125La。另一方面，在两层第二长基材125L中的未层压第二短基材125S的部位上，重叠放置了由尼龙66构成的树脂无纺布140。 
而且，通过上部加热板PU和下部加热板PL对由第二长基材125L、第二短基材125S和树脂无纺布140所构成的层压体进行夹持、加压并加热(图4的中段部分)。具体而言，将平板的上部加热板PU和下部加热板PL加热至300℃的同时，对层压体进行加压，并将层压体在300℃的温度下保持20分钟。保持之后，缓慢地冷却至200℃为止，再拆下加热板。 
根据以上方法，从而制成第二树脂构件120(图4的下段部分)。 
接下来，参照图5A和图5B，对本发明第一参考方式的第一树脂构件110和第二树脂构件120的熔合工序进行说明。 
作为熔合工序，首先使上述第一树脂构件110的第一抵接面112A、与第二树脂构件120的第二抵接面122A互相抵接并且紧密接触。通过这种方式，第一熔合预定部111和第二熔合预定部121将会沿板厚度方向DA(图5B中的上下方向)重叠在一起(图5A)。然后，在前端设为半球状的大致圆柱形状的电极(正极PP和负极NP)的前端之间，夹持并加压第一熔合预定部111和第二熔合预定部121。 
而且，在受到夹持并加压的第一熔合预定部111和第二熔合预定部121之间，通过电极PP、NP施加电压，而使电流流动。具体而言，在对第一熔合预定部111和第二熔合预定部121进行夹持并加压的正极PP和负极NP之间施加电压，在2.8秒的时间以内使10万安培(A)的电流通过。这是由于第一熔合预定部111和第二熔合预定部121中，电流主要流过第一碳纤维CF1和第二碳纤维CF2，从而在整体上形成低电阻，而使电流易于流动。 
通过这种通电方式，由于第一碳纤维CF1、第二碳纤维CF2等将会发热，因而使第一树脂构件110的第一熔合预定部111中的第一树脂NA1、以及第二树脂构件120的第二熔合预定部121中的第二树脂NA2熔融，并且互相熔合之后被固化，从而形成熔合部101。 
根据以上方式，从而制成熔合了第一树脂构件110和第二树脂构件120的熔合体100(图5B)。 
本发明第一参考方式所涉及的熔合体100的制造方法包括熔合工序，在该熔合工序中，使第一熔合预定部111和第二熔合预定部121抵接并且紧密接触，并对二者通电以使其发热，从而形成熔合部101。由此，能够简便地制造使第一熔合预定部111和第二熔合预定部121熔合而成的熔合体100。 
另外，在本发明的第一参考方式中，与其它部位113相比，第一树脂构件110中的第一熔合预定部111含有更多的第一碳纤维CF1。同样，与其它部位123相比，第二树脂构件120中的第二熔合预定部121含有更多的第二碳纤维CF2。因此，当通过对该第一熔合预定部111和第二熔合预定部121进行通电时，就能使更大的电流流动，并使第一、第二熔合预定部111、121可靠地发热，从而能够可靠地形成熔合部101。另一方面，在其它部位113、123中，可以根据其它目的(所要求的强度或弹性系数等特性)，来设定适当的碳纤维CF1、CF2的含有率(在本发明的第一参考方式中，例如为40重量％)。 
而且，由于第一熔合预定部111和第二熔合预定部121，均含有60～90重量％(具体为65重量％)的第一碳纤维CF1和第二碳纤维CF2，因而，当使它们抵接并且紧密接触进行通电时，能够可靠地通过第一碳纤维CF1和第二碳纤维CF2进行通电。而且，由于通过电流流动，而使第一碳纤维CF1和第二碳纤维CF2发热，因而，能够可靠地使第一熔合预定部111或者第二熔合预定部121中的第一树脂NA1和第二树脂NA2进行熔融。因此，通过可靠地使第一熔合预定部111和第二熔合预定部121进行熔合，从而能够形成熔合体100。 
另外，第一树脂构件110对应于第一树脂部，第二树脂构件120对应于第二树脂部，第一树脂板部113和第二树脂板部123分别对应于其它部位，第一树脂NA1对应于第一热塑性树脂，第二树脂NA2对应于第二热塑性树脂。 
(第一实施方式) 
接下来，参照图3、图6A～图10B，对本发明的第一实施方式进行说明。 
在本发明第一实施方式的熔合体中，该熔合部中的碳纤维的取向方向与上述第一参考方式不同，但除此以外都相同。 
于是，在以不同点为中心进行说明的同时，省略或简化对相同部分的说明，但是相同的部分将产生相同的作用效果。另外，对相同内容的部分，标记相同的符号进行说明。 
在图6A和图6B中，表示了本发明第一实施方式所涉及的熔合体200。图6A为立体图，图6B为C-C剖视图。与第一参考方式的熔合体100相同，该熔合体200也具有第一树脂板部213A、第二树脂板部223A以及熔合部201，所述第一树脂板部213A呈矩形板状，并由第一树脂NA1(尼龙66)和第一碳纤维CF1组所构成；所述第二树脂板部223A呈矩形板状，并由第二树脂NA2(尼龙66)和第二碳纤维CF2组所构成；所述熔合部201介于第一树脂板部213A与第二树脂板部223A之间。并且，如后文所述，该熔合体200是通过熔合第一树脂构件210和第二树脂构件220而制造的，所述第一树脂构件210呈矩形板状，并由第一树脂NA1和第一碳纤维CF1所构成；所述第二树脂构件220呈矩形板状，并由第二树脂NA2和第二碳纤维CF2所构成。 
与第一参考方式相同，在该熔合体200中的第一树脂板部213A的第一碳纤维CF1，被取向在与板厚度方向DA垂直的方向上。同样，在第二树脂板部223A中，第二碳纤维CF2也被取向在与板厚度方向DA垂直的方向上。 
另外，与第一参考方式相同，在该熔合体200的熔合部201中，第一树脂NA1和第二树脂NA2也一起进行熔融固化，从而形成为一体。但是，如图6B所示，与第一参考方式不同，在该熔合部201中，第一碳纤维CF1组中的一部分和第二碳纤维CF2组中的一部分，均被取向在与板厚度方向DA(图6B中的上下方向)平行的方向上。即、各个第一碳纤维CF1组中的一部分和各个第二碳纤维CF2组中的一部分被平行取向。 
接下来，对第一实施方式所涉及的熔合体200的制造方法进行说明。 
如上所述，第一实施方式所涉及的熔合体200是通过熔合第一树脂构件210和第二树脂构件220而制成的。在此，首先对第一树脂构件210进行说明。在图7A和图7B中，表示了该第一树脂构件210的立体图和放大剖视图。 
第一树脂构件210为，由第一树脂NA1和第一碳纤维CF1组所构成的矩形板状的树脂复合体。如图7B所示，该第一碳纤维CF1组与第一参考方式相同，除了具有被取向在与板厚度方向DA(在图7B是上下方向)垂直方向上的部位之外，还具有含有被取向在与板厚度方向DA平行方向上的碳纤维组的部位。具体而言，在第一碳纤维CF1组中，第一树脂构件210中作为一个端部的第一熔合预定部211，含有被取向在板厚度方向DA上的碳纤维组，在其它部位213中，任意一个碳纤维分别被取向在与板厚度方向DA正交的方向上。 
另外，在第一树脂构件210的第一主表面212中，将包含在第一熔合预定部211中的部位(与第二树脂构件220抵接的部位)作为第一抵接面212A。于是，也可以认为，第一熔合预定部211含有被取向在与第一抵接面212A正交方向上的第一碳纤维CF1(CF1a)组。 
另外，第一熔合预定部211中的第一碳纤维CF1的含有率，大于其它部位213中的含有率，具体而言，其被设为60重量％。 
而且，第二树脂构件220与第一树脂构件210相同，也是由第二树脂NA2和第二碳纤维CF2组所构成的矩形板状的树脂复合体。其中，第二碳纤维CF2组在作为第二树脂构件220的一个端部的第二熔合预定部221中，含有 被取向在板厚度方向DA上的碳纤维组，在其它部位223中，任意一个碳纤维分别被取向在与板厚度方向DA正交的方向上。 
另外，在第二树脂构件220的第二主表面222中，将包含在第二熔合预定部221中的部位(与第一树脂构件210抵接的部位)作为第二抵接面222A。于是，也可以认为，第二熔合预定部221含有被取向在与第二抵接面222A正交方向上的第二碳纤维CF2(CF2a)组。 
而且，第二熔合预定部221中的第二碳纤维CF2的含有率，大于其它部位223的含有率，具体而言，其被设为60重量％。 
接下来，参照图8A～图8C和图9，对第一树脂构件210的制造方法进行说明。 
在图8C中，表示了第一树脂构件210的基材中的圆柱形状的第一卷绕基材116M。该第一卷绕基材116M，通过将带状的第一单取向截断基材116C(图8A)，卷绕在与第一取向A碳纤维CF1a的取向方向平行的轴心AX而成(参照图8B)，所述第一单取向截断基材116C使用于所述第一基材115，其通过用第一树脂无纺布NA1b夹持第一取向A碳纤维CF1a而形成。通过这种方式制成的第一卷绕基材116M内的第一取向A碳纤维CF1a(取向0°)组，分别被取向为与轴心AX平行。 
利用上述的第一卷绕基材116M和所述的第一长基材115L，来制造第一树脂构件210。具体而言，在层压的两个第一长基材115L的一个端面115Ld一侧，将多个第一卷绕基材116M配置成格子状。此时，可配置成，第一卷绕基材116M的轴心AX均与第一长基材115L的层压方向DE(图9中的上下方向)平行。并且，通过这种方式，第一卷绕基材116M中的第一取向A碳纤维CF1a组被配置成与层压方向DE平行。 
而且，在两层的第一长基材115L上，从层压方向DE的上下方向重叠放置了由尼龙66构成的树脂无纺布240，并使该结构体的层压方向DE的高度与第一卷绕基材116M的高度HM大致相等。而且，在相邻的第一卷绕基材116M之间、或者在第一长基材115L和第一卷绕基材116M之间的间隙中，配置由尼龙66构成的块状的树脂无纺布模塑块250A、250B、250C。这样，形成了矩形板状的结构体，该结构体由第一卷绕基材116M、第一长基材115L、树脂无纺布240和树脂无纺布模塑块250A、250B、250C所构成。 
与第一参考方式相同，当通过上部加热板PU和下部加热板PL夹持加压该结构体并对其进行加热(图9的中段部分)时，从而制成第一树脂构件210(图9的下段部分)。 
关于第二树脂构件220的制造方法，也与第一树脂构件210相同。圆柱形状的第二卷绕基材126M，通过将带状的第二截断基材126C(图8A)卷绕在与第二取向A碳纤维CF2a的取向方向平行的轴心AX而成(参照图8B)，所述第二截断基材126C使用于所述第二基材125，其通过用第二树脂无纺布NA2b夹持第二取向A碳纤维CF2a而形成。通过这种方式制成的第二卷绕基材126M内的第二取向A碳纤维CF2a(取向0°)组，分别被取向为与轴心AX平行。 
利用上述的第二卷绕基材126M和第二长基材125L，来制造第二树脂构件220。具体而言，在层压的两个第二长基材125L的一个端面125Ld一侧，将多个第二卷绕基材126M配置成格子状。此时，将第二卷绕基材126M的轴心AX均配置成与第二长基材125L的层压方向DE平行。并且，通过这种方式，第二卷绕基材126M中的第二取向A碳纤维CF2a组被配置成与层压方向DE平行。 
而且，与第一树脂构件210相同，形成矩形形状的结构体，所述结构体由第二卷绕基材126M、第二长基材125L、树脂无纺布240和树脂无纺布模塑块250A、250B、250C所构成。 
与第一参考方式相同，通过上部加热板PU和下部加热板PL夹持、加压该结构体并对其进行加热(图9的中段部分)，从而制成第二树脂构件220(图9的下段部分)。 
接下来，参照图10A和图10B，对本发明第一实施方式的第一树脂构件210和第二树脂构件220的熔合工序进行说明。 
作为熔合工序，首先使上述第一树脂构件210的第一抵接面212A、与第二树脂构件220的第二抵接面222A互相抵接并且紧密接触。由此，第一熔合预定部211和第二熔合预定部221将沿着板厚度方向DA(在图10B中的上下方向)重叠在一起(图10A)。然后，在前端设为半球状的大致圆柱形状的电极(正极PP和负极NP)的前端之间，夹持并加压第一熔合预定部211和第二熔合预定部221。 
而且，在受到夹持并加压的第一熔合预定部211和第二熔合预定部221之间，通过电极PP、NP施加电压，而使电流流动。于是，在第一熔合预定部211和第二熔合预定部221中，电流将会通过第一取向A碳纤维CF1a组以及第二取向A碳纤维CF2a组而进行流动，所述第一取向A碳纤维CF1a组被取向在与第一抵接面212A正交的方向上；所述第二取向A碳纤维CF2a组被取向在与第二抵接面222A正交的方向上。 
这样，能够使大量的电流流过第一取向A碳纤维CF1a组和第二取向A碳纤维CF2a组，并能够使它们发热。因此，第一树脂构件210的第一熔合预定部211中的第一树脂NA1、以及第二树脂构件220的第二熔合预定部221中的第二树脂NA2将会熔融，互相熔合后进行固化，从而形成熔合部201。 
根据以上方式，从而制成熔合了第一树脂构件210和第二树脂构件220的熔合体200(图10B)。 
在本发明的第一实施方式中，在第一取向A碳纤维CF1a和第二取向A碳纤维CF2a的取向方向上进行通电。于是，由于电流沿着第一取向A碳纤维CF1a组和第二取向A碳纤维CF2a组进行流动，因而形成比第一参考方式更低的电阻，并能够容易且可靠地使大量的电流流动。因此，能够产生大量的热量，在第一熔合预定部211和第二熔合预定部221中，能够可靠地使第一树脂NA1和第二树脂NA2进行熔融。因此，能够制造可靠地熔合了第一熔合预定部211和第二熔合预定部221的熔合体200。 
在以上内容中，根据第一参考方式和第一实施方式对本发明进行了说明，但本发明并不限于上述第一参考方式和第一实施方式，在不超出其要点的范围内，当然还能够进行适当变更来应用本发明。 
例如，在上述的第一参考方式、第一实施方式中，分别说明了第一熔合预定部111、211被包含在第一树脂构件110、210中；第二熔合预定部121、221被包含在与第一树脂构件不同的第二树脂构件120、220中的示例。但是，这些第一熔合预定部和第二熔合预定部也可以是单一构件中的互不相同的部分。 
另外，在第一参考方式、第一实施方式中，说明了在第一树脂构件110、210的第一熔合预定部111、211中的碳纤维的含有率(重量％)，与其它部位113、213中的碳纤维的含有率不同的示例。然而，也可以将它们的碳纤维的含有率设为相同。关于第二树脂构件120、220的第二熔合预定部121、221， 同样也可以设为第二熔合预定部121、221中的碳纤维的含有率，与第二树脂构件120、220中的其它部位123、223的碳纤维含有率相同。 
相反，在第一参考方式、第一实施方式中，除了第一熔合预定部111、211之外的其它部位113、213，也使用了与第一熔合预定部111、211相同的由第一碳纤维CF1和第一树脂NA1所构成的第一树脂构件110、210。然而，作为其它部位113、213，可以仅由金属、陶瓷、第一树脂NA1或与其不同的树脂所构成，或者仅由碳纤维所构成，并且不含有热塑性的第一树脂NA1或者碳纤维CF1的一方或双方。关于除了第二熔合预定部121、221之外的其它部位123、223，也可具有同样的结构。作为其它部位123、223可以仅由金属、陶瓷、第二树脂NA2或与其不同的树脂所构成，或者仅由碳纤维所构成，并且不含有热塑性的第二树脂NA2或者碳纤维CF2中的一方或双方。 
而且，在第一参考方式中，也可以将第一熔合预定部111、211和第二熔合预定部121、221中的碳纤维CF1、CF2的含有率都设定为相同的65重量％，在第一实施方式中，虽然都设定为相同的60重量％，但是也可以在60～90重量％的范围内设定不同的含有率。 

Claims (2)

1.一种熔合体的制造方法，所述熔合体具有将第一熔合预定部以及第二熔合预定部互相熔合而成的熔合部，所述第一熔合预定部由第一热塑性树脂和第一碳纤维所构成；所述第二熔合预定部由第二热塑性树脂和第二碳纤维所构成，其中，
所述熔合体的制造方法包括熔合工序，在该熔合工序中，使所述第一熔合预定部和所述第二熔合预定部抵接并且紧密接触，通过对二者通电以使其发热，而使所述第一热塑性树脂和第二热塑性树脂互相熔融固化，从而形成所述熔合部，
所述熔合体通过在所述熔合部熔合第一树脂部和第二树脂部而成，所述第一树脂部由至少含有第一热塑性树脂的材质所构成，并包括所述第一熔合预定部；所述第二树脂部由至少含有第二热塑性树脂的材质所构成，并包括所述第二熔合预定部，
所述第一熔合预定部中的所述第一碳纤维的含有率，大于所述第一树脂部中的其它部位；
所述第二熔合预定部中的所述第二碳纤维的含有率，大于所述第二树脂部中的其它部位，
所述第一熔合预定部含有第一正交碳纤维组，所述第一正交碳纤维组被取向在与抵接于所述第二熔合预定部的第一抵接面正交的方向上；
所述第二熔合预定部含有第二正交碳纤维组，所述第二正交碳纤维组被取向在与抵接于所述第一熔合预定部的第二抵接面正交的方向上，
所述第一正交碳纤维组，由通过平行排列各个碳纤维而呈层状的碳纤维组所形成；
所述第二正交碳纤维组，由通过平行排列各个碳纤维而呈层状的碳纤维组所形成。
2.如权利要求1所述的熔合体的制造方法，其中，
所述第一熔合预定部和所述第二熔合预定部，均含有60～90重量％的碳纤维。
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