JP3866732B2 - 樹脂構造物のレーザー接合方法 - Google Patents

樹脂構造物のレーザー接合方法 Download PDF

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JP3866732B2
JP3866732B2 JP2004127963A JP2004127963A JP3866732B2 JP 3866732 B2 JP3866732 B2 JP 3866732B2 JP 2004127963 A JP2004127963 A JP 2004127963A JP 2004127963 A JP2004127963 A JP 2004127963A JP 3866732 B2 JP3866732 B2 JP 3866732B2
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laser beam
region
contact surface
laser
resin
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JP2005178351A (ja
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ジー−ウェイ，チェン
アンドレーアス，デンツァー
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ライスター プロセス テクノロジーズ
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1674—Laser beams characterised by the way of heating the interface making use of laser diodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
    • B23K26/066—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms by using masks
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B29C65/1638—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding focusing the laser beam on the interface
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/16—Laser beams
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    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B29C66/712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1687—Laser beams making use of light guides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1696—Laser beams making use of masks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/733—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7332—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being coloured
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    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
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Description

本発明は樹脂製の異なった加工部材あるいは樹脂製の加工部材を異なった材料に接合するレーザー接合方法に関するもので、上部のレーザー光源に面している加工部材はレーザー光線に対して透明な素材で構成し、もう一方の加工部材はレーザー光線を吸収する素材で構成しており、互いの加工部材が接する接触面が熔融し、それに続く冷却時に加圧により互いに接合する。
このような方法として例えば特許文献１に記載の技術が知られている。ここでは、カーテン状のレーザー光線を加工部材に照射し、加熱しない部分はマスクで覆うようにしている。組立てたり、組立て前の加工部材が知られた方法によりに接合される。２つの加工部材は互いの接触面でのみ溶接する必要があるので、それに相当するマスクを用いる。
レーザー光線による樹脂の溶接では投与する熱エネルギーを制御する必要がある。エネルギーの投与量はエネルギー密度と照射時間に依存し、樹脂の昇温速度及び最高到達温度が決まる。
上記のマスク溶接の原理により、加工部材に対応して所望する平面的な溶接構造を得ることができる。その際、溶接面に線を形成するカーテン状のレーザー光線により所望する平面が処理され、レーザー出力及び走査速度によりエネルギー投与量を制御する。カーテン状の光線の伝播方向におけるエネルギー密度は殆ど変化しないので、空間への熱エネルギー供給はマスクに依存する。従って、部材の異なった高さ部分及び照射すべきでない部分はマスクで覆う必要がある。当然ながら上記のことは平面を高速で走査する点状のレーザー光線についても当てはまる。
欧州特許出願公開第０，９９７，２６１−Ａ１号明細書
上記のマスクを用いる従来の方法はマスクの調整が必要であり、そのため生産性が低くなるという短所がある。
従って、本発明の課題は上記のレーザー光線を照射する溶接法により高い生産性を有する組立て加工部材の接合を実現する可能性を提案することにある。
上記課題は主請求項に記載の特徴を有する方法により解決できる。従属請求項に本発明の発展形態を記載している。
本発明による方法においては、光学系によりレーザー光線を集光するので、接触面域におけるエネルギー密度が最大となる。接触面域の断面の大小に応じて対応するレンズを選択する。この設定により、接触面及下方に構成した表面領域にレーザー光線が照射されるが、第２の加工部材の接触面部分のみが熔融すようになる。そのため、加工部材は接触面域においてのみ熔融し、互いに接合する。結果として、マスクを用いなくても接触面の組立て溶接が可能となる。レーザー光線に関しては、エネルギー高密度領域が２つの加工部材を溶接するのに十分となるように、レーザー光源から光線の伝播方向に該高密度流域を配置することが重要である。所望の溶接をするには、構造物の高さｄが最高エネルギー密度の領域の高さｈよりも遥かに大きいことが重要である。従って、例えばエネルギー高密度の領域が低い場合には、それに相応して少なくともレーザー光線に不透明な第２の加工部材の構造が小さいものを選んでも、エネルギー密度が不十分なので下方に構成した構造物が軟化することはない。更には、エネルギー最大密度領域はほんの表面に在ることが好ましい。
高いエネルギー密度を上記の選ばれた領域に相当する狭い領域のみ適用するので、高いエネルギー密度を有する光線域に絞ったレーザー光線を用いることが好ましい。レーザー光線に不透明な第２の加工部材の溶接すべき領域に応じて、絞られた光線域の高さｈ及び幅ｂを設定することが好ましい。
更に、本発明では、円柱レンズを用いてレーザー光線を生成する方法も提案している。直線状のレーザー光線は円柱の集光レンズによりレンズの集光面にのみ結像する。このことは、伝播方向に沿ったレーザー光線のエネルギー密度はレーザー光源からの距離に依存することを意味する。最高エネルギー密度は絞られた光線域内に在る。絞られた光線域（高さｈ、幅ｂ）の形状は開口度及びレンズの焦点距離に依存する。集光角度が大きいほど及び焦点距離が短いほど、絞られた光線域は狭くなる。絞られた光線域の厚さは、鮮明な像を結ぶ領域の厚さとも称する。
構造用加工部材においては、構造の高さの差が絞られた光線域よりも明らかに大きければ、溶接継目の形状は焦点面における平面構造のみで決まる。
以下、図面を用いて本発明の実施例を詳細に説明する。
図１には円柱レンズ２へと向かうレーザー光線１を拡大して示している。円柱レンズ２はレーザー光線１をレーザー光線３へと変換し、光線の伝播方向のエネルギー密度を変化させている。これにより縦方向に沿ったレーザー光線の幅あるいは径は同じでなくなり、高いエネルギー密度の領域でのレーザー光線の幅あるいは径は、低いエネルギー密度の領域に比し狭くなる。実施例では上記のようにレーザー光線３へと変換され、絞られた光線域４を生成する。図２では絞られた光線域４においてレーザー光線３が再び広がることを示している。図に示す、絞られた光線域４の幅ｂ及び高さｈは対応する光学的手段の影響を受ける。ここではｂをレーザー光線３の最小幅と定義する。高さｈは最小幅ｂを有する領域の長さと定義する。
図１にはレーザー光線に対して透明な第１の加工部材５及びその下のレーザー光線に対して不透明な第２の加工部材６も図示している。図では説明上、加工部材５は透明な物体として図示しているが、この部材が着色してないわけではない。加工部材６は接触面７よりも下方に構成したレーザー光線３では軟化しない表面領域８を伴った構造を有している。透明な加工部材５は図１に示すものとは異なる従来の技術のようなものでもよい。その場合は、不適切な加熱となるので、上部の加工部材５が下部の加工部材６の表面を覆わないようにする。図１で明らかなように、絞られた光線域４の周りのエネルギー密度が高い領域は接触面７の領域にある。変換したレーザー光線３の表面領域８におけるエネルギー密度は表面領域を溶解する程ではない。その結果、接触面が軟化するのみで、既知の技術および方法によってこの領域において加工部材５、６を接合できる。従来技術とは異なり、レーザー光線を下方に構成した表面領域へも照射できれば問題はない。その結果マスクは不要となる。接触面７を有する加工部材５、６を絞られた光線域４に配置することが重要である。高さｈ及び幅ｂを変えることによって、レーザー光線を加工部材５、６における構造の形状に適合することができる。
図３には標準のレーザーダイオード９の模式的構成を示し、円錐状のレーザー光線１が円柱レンズ２へと導かれる。図１と同様に、レーザー光線１は円柱レンズ２によりレーザー光線３へと変換され、下方の表面域８は対象外として、溶接すべき表面域１０上を動く。溶接すべき表面域１０は加工部材の全表面と同一ではないことに留意すべきである。加工部材５、６とレーザー光線３との相対的な動きが重要であることも明かである。実施例では加工部材５、６が動くようになっている。
図４の実施例では、光導波路１１からの円錐状レーザー光線１２は球面集光レンズ１３を介して円柱レンズ２へと導かれる。
実施例では線状のレーザー光線と加工部材とが相対的に動くようになっている。線状のレーザー光線に代わりに点状のレーザー光線を表面に照射してもよい。
２つの樹脂加工部材の溶接原理を示す斜視図 絞られた光線域を示す拡大斜視図 標準レーザーダイオードによる溶接の基本構成を示す斜視図 光導波路からのレーザー光線による溶接の基本構成を示す斜視図
符号の説明
１ レーザー光線
２ 円柱レンズ
３ 変換されたレーザー光線
４ 絞られた光線域
５、６ 加工部材
７ 接触面
８ 表面領域
９ レーザーダイオード
１０ 表面領域
１１ 光導波路
１２ 円錐状レーザー光線
１３ 球面レンズ

Claims (2)

  1. レーザー光線（３）に対して透明でありレーザー光源に面している上部の加工部材（５）及びレーザー光線（３）を吸収する第２の加工部材（６）が互いに接する接触面（７）が熔融し、それに続く冷却時に加圧下で互いに接合し、少なくとも第２の加工部材（６）は加工部材（５）に面して接触面（７）よりも下方に形成した表面領域（８）を有し、前記加工部材（５、６）を樹脂同志あるいは樹脂と他の素材で構成して接合する方法であって、レーザー光線（３）と加工部材（５、６）は互いに相対的に動き、接触面（７）の領域においてエネルギー密度が最大となり且つ第２の加工部材（６）は接触面（７）においてのみ熔融するように光学系によってレーザー光線（３）を集光し、加工部材（５、６）は接触面（７）の領域においてのみ接合することを特徴とする樹脂構造物のレーザー接合方法。
  2. レーザー光線は、集光によって生じた、絞られた光線域（４）の高さ（ｈ）及び幅（ｂ）を接合すべき加工部材（５、６）の構造に応じて設定することを特徴とする請求項１記載の樹脂構造物のレーザー接合方法。
JP2004127963A 2003-05-22 2004-04-23 樹脂構造物のレーザー接合方法 Expired - Fee Related JP3866732B2 (ja)

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