JP6483718B2 - 電子制御装置、電子制御装置の製造方法 - Google Patents
電子制御装置、電子制御装置の製造方法 Download PDFInfo
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- JP6483718B2 JP6483718B2 JP2016553054A JP2016553054A JP6483718B2 JP 6483718 B2 JP6483718 B2 JP 6483718B2 JP 2016553054 A JP2016553054 A JP 2016553054A JP 2016553054 A JP2016553054 A JP 2016553054A JP 6483718 B2 JP6483718 B2 JP 6483718B2
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- 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
- B29C66/114—Single butt joints
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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
- 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
- B29C66/114—Single butt joints
- B29C66/1142—Single butt to butt joints
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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
- 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
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
- B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
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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
- 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
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
- B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
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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
- 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
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/124—Tongue and groove joints
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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
- 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
- B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
- B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
- B29C66/244—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being non-straight, e.g. forming non-closed contours
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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
- 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
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/53—Joining single elements to tubular articles, hollow articles or bars
- B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
- B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—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
- 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
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—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
- B29C66/72—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 structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—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
- B29C66/72—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 structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
- B29C66/72143—Fibres of discontinuous lengths
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—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
- 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
- B29C66/731—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 intensive physical properties of the material of the parts to be joined
- B29C66/7311—Thermal properties
- B29C66/73115—Melting point
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—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
- 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
- B29C66/731—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 intensive physical properties of the material of the parts to be joined
- B29C66/7311—Thermal properties
- B29C66/73117—Tg, i.e. glass transition temperature
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—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
- 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
- B29C66/731—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 intensive physical properties of the material of the parts to be joined
- B29C66/7316—Surface properties
- B29C66/73161—Roughness or rugosity
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—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
- 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
- B29C66/735—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 extensive physical properties of the parts to be joined
- B29C66/7352—Thickness, e.g. very thin
- B29C66/73521—Thickness, e.g. very thin of different thickness, i.e. the thickness of one of the parts to be joined being different from the thickness of the other part
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—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
- 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
- B29C66/737—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 state of the material of the parts to be joined
- B29C66/7377—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
- B29C66/73771—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous
-
- 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
- B29C66/70—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
- 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
- B29C66/737—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 state of the material of the parts to be joined
- B29C66/7377—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
- B29C66/73775—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being crystalline
-
- 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
- B29C66/70—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
- 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
-
- 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
- B29C66/70—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
- 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
- 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
- B29C66/70—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
- 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
- B29C66/7394—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 thermoset
- B29C66/73941—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 thermoset characterised by the materials of both parts being thermosets
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- 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
- B29C66/70—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
- B29C66/74—Joining plastics material to non-plastics material
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- 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
- B29C66/70—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
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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
- 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
- B29C66/832—Reciprocating joining or pressing tools
- B29C66/8322—Joining or pressing tools reciprocating along one axis
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
- B29C66/959—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 characterised by specific values or ranges of said specific variables
- B29C66/9592—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 characterised by specific values or ranges of said specific variables in explicit relation to another variable, e.g. X-Y diagrams
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
- H05K5/06—Hermetically-sealed casings
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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
- B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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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
- 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
- B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
- B29C66/022—Mechanical pre-treatments, e.g. reshaping
- B29C66/0224—Mechanical pre-treatments, e.g. reshaping with removal of material
- B29C66/02245—Abrading, e.g. grinding, sanding, sandblasting or scraping
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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
- 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
- B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
- B29C66/026—Chemical pre-treatments
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—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
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
- B29C66/7428—Transition metals or their alloys
- B29C66/74283—Iron or alloys of iron, e.g. steel
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
- B29C66/8122—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
- B29C66/8126—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
- B29C66/81266—Optical properties, e.g. transparency, reflectivity
- B29C66/81267—Transparent to electromagnetic radiation, e.g. to visible light
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
- B29L2031/3481—Housings or casings incorporating or embedding electric or electronic elements
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Description
本発明の第2の態様によると、電子回路部を備える電子制御装置の製造方法は、結晶性樹脂および非結晶性樹脂を含有してアロイ化された熱可塑性のポリマーアロイからなる樹脂成形体と、金属からなる金属体とを準備し、非結晶性樹脂のガラス転移温度は、結晶性樹脂の溶融開始温度よりも低く、ポリマーアロイの結晶化速度が結晶性樹脂の結晶化速度よりも低いか、または、ポリマーアロイの再結晶化温度が結晶性樹脂の再結晶化温度よりも低く、少なくとも樹脂成形体における金属体にレーザ接合される部分に、酸素官能基を増大させる処理を施し、樹脂成形体を非結晶性樹脂のガラス転位温度以上の温度まで加熱し、樹脂成形体および金属体を互いに押圧接触させた状態で、樹脂成形体と金属体とをレーザ接合して、電子回路部を収容する収容空間を封止する。
−第1の実施の形態−
図1は本発明の第1の実施の形態に係るレーザ接合構造を有する電子制御装置100の概略を示す斜視図であり、図2は電子制御装置100の概略を示す分解斜視図である。本実施の形態に係る電子制御装置100は、自動車に搭載され、エンジンを電子制御するエンジンコントローラユニット(ECU)である。図2に示すように、電子制御装置100は、エンジン制御用の回路基板5と、樹脂成形体1と、金属ベース4とを備えている。
図4は電子制御装置100を製造する工程を説明するためのフローチャートである。電子制御装置100の製造方法は、樹脂選定工程S110と、射出成形工程S120と、組立準備工程S130と、組立工程S140と、表面改質処理工程S145と、レーザ接合工程S150とを含む。
樹脂選定工程S110では、結晶性樹脂と、アロイ化する非結晶性樹脂とを選定する。選定の際、以下の選定条件を満足するように、結晶性樹脂および非結晶性樹脂をそれぞれ選定する。選定された結晶性樹脂および非結晶性樹脂をアロイ化し、ペレット状のポリマーアロイを形成する。
<選定条件>非結晶性樹脂のガラス転移温度Tg<結晶性樹脂の溶融開始温度Ti
図4に示す射出成形工程S120では、樹脂選定工程S110で得られたペレット状のポリマーアロイを加熱溶融し、射出成形機(不図示)により射出成形することで樹脂成形体1を形成する。例えば、射出成形機のノズルは、カバー1aの中央部に対応する位置に配置される。ノズルの射出口から射出されたポリマーアロイは、中央部から周囲に拡がり、カバー1aおよびコネクタ1bが一体的に成形される。
組立準備工程S130では、樹脂成形体1と、電子部品6が実装された回路基板5と、金属ベース4とを準備する。
組立工程S140では、回路基板5を樹脂成形体1の凹部1cに配置し、コネクタ1bの端子ピンと回路基板5とをスポットフロー(局所半田付け)などによって半田接合し、両者を電気的に接続する。回路基板5を樹脂成形体1に接着剤、熱カシメ、ねじ止めなどにより固定する。接着剤を用いて固定する場合、紫外線硬化接着剤、あるいは、室温で硬化する2液接着剤を用いて固定することで、工程時間の短縮化を図ることができるので好適である。
表面改質処理工程S145では、大気圧プラズマ処理を樹脂成形体1および金属ベース4の接合面に施す。表面改質処理工程S145では、大気圧下でプラズマを発生させ、樹脂成形体1の樹脂接合面1dおよび金属ベース4の金属接合面4dに向けてプラズマを照射する。これにより、樹脂接合面1dに酸素官能基が生成、増大され、表面エネルギーが増大する。また、金属接合面4dに大気圧プラズマ処理を施すと、表面の洗浄や強固な酸化膜の形成によって、表面エネルギーは増大する。なお、表面改質工程は、射出工程の後以降及び接合前であればどの部分で行っても良い。
レーザ接合工程S150において、レーザ光10を照射する際、金属ベース4の表面で反射した反射光がレーザ光源に照射されると、レーザ光源が劣化してしまうおそれがある。このため、レーザ光10の反射光がレーザ光源に照射されないように、斜めにレーザ光10を照射する。そのため、2工程でレーザ照射する場合を以下に示す。
第1加圧工程S152では、図6(a)および図7に示すように、押圧治具190の縁部が矩形状の金属ベース4の一辺に沿うレーザ照射面11の近傍に位置するように、押圧治具190を位置決めし、押圧治具190を上方から金属ベース4に当て、金属ベース4を下方に向けて押圧する。これにより、金属ベース4の金属接合面4dと、樹脂成形体1の樹脂接合面1dとが互いに押圧接触される。なお、金属接合面4dおよび樹脂接合面1dには、それぞれ微小な凹凸が形成されているため、「金属接合面4dと樹脂接合面1dとが互いに押圧接触される」とは、樹脂接合面1dと金属接合面4dとが全領域に亘って押圧接触されることを意味するものではなく、一部に隙間が形成されていることを含む。金属ベース4に対する押圧治具190の接触面積を大きくするほど、金属ベース4の反りや、金属ベース4と樹脂成形体1との密着性の低下を抑制できる。
第1レーザ照射工程S154は、押圧治具190により樹脂成形体1と金属ベース4とが互いに押圧接触された状態で行われる。第1レーザ照射工程S154では、図6(a)および図7に示すように、矩形状の金属ベース4の一辺に沿うレーザ照射面11にレーザ光10を照射し、図6(a)において破線で模式的に示すように、始点(A点)から終点(B点)まで一直線状にレーザ光10を走査し、金属接合面4dと樹脂接合面1dとを接合する。
第2加圧工程S156では、図6(b)および図7に示すように、押圧治具190の縁部が矩形状の金属ベース4の三辺に沿うレーザ照射面11の近傍に位置するように、押圧治具190を位置決めし、押圧治具190を上方から金属ベース4に当て、金属ベース4を下方に向けて押圧する。これにより、金属ベース4の金属接合面4dと、樹脂成形体1の樹脂接合面1dとが互いに押圧接触される。
第2レーザ照射工程S158は、押圧治具190により樹脂成形体1と金属ベース4とが互いに押圧接触された状態で行われる。第2レーザ照射工程S158では、図6(b)および図7に示すように、矩形状の金属ベース4の三辺に沿うレーザ照射面11にレーザ光10を照射し、図6(b)において破線で模式的に示すように、始点(A点)から終点(B点)まで略コ字状にレーザ光10を走査し、金属接合面4dと樹脂接合面1dとを接合する。
自動車に搭載される電子制御装置100のように、振動や衝撃が作用する電子制御装置では、樹脂成形体1と金属ベース4との接合強度を高くすることが重要である。ところで、特許文献1には、PBT樹脂に、ポリカーボネート樹脂、アクリロニトリルスチレン共重合体、ポリフェニレンオキシド、スチレン樹脂、アクリル樹脂、ポリエーテルスルホン、ポリアリレート、ポリエチレンテレフタレート樹脂の中から選ばれる少なくとも1種を混合物として用いることが、成形性、靭性、成形体低反り性などの必要特性から実用上好適であるということが記載されている(特許文献1の段落[0104]参照)。
[比較用樹脂片]
樹脂片TPpが、PBT樹脂により成形されている。PBT樹脂には、ガラスファイバーが約30重量%添加されている。
[第1樹脂片]
樹脂片TPpが、PBT樹脂を母材として、ポリスチレン(以下、PSと記す)樹脂をアロイ材としたポリマーアロイにより成形されている。ポリマーアロイに含有されるPBT樹脂とPS樹脂の配合比率は、PBT樹脂が70%程度、PS樹脂が30%程度とされている。ポリマーアロイには、ガラスファイバーが約30重量%添加されている。
樹脂片TPpが、PBT樹脂を母材として、アクリロニトリルスチレン(以下、ASと記す)樹脂をアロイ材としたポリマーアロイにより成形されている。ポリマーアロイに含有されるPBT樹脂とAS樹脂の配合比率は、PBT樹脂が80%程度、AS樹脂が20%程度とされている。ポリマーアロイには、ガラスファイバーが約30重量%添加されている。
樹脂片TPpが、PBT樹脂を母材として、ポリカーボネート(以下、PCと記す)樹脂をアロイ材としたポリマーアロイにより成形されている。ポリマーアロイに含有されるPBT樹脂とPC樹脂の配合比率は、PBT樹脂が80%程度、PC樹脂が20%程度とされている。ポリマーアロイには、ガラスファイバーが約40重量%添加されている。
樹脂片TPpが、PBT樹脂を母材として、ポリエチレンテレフタレート(以下、PETと記す)樹脂をアロイ材としたポリマーアロイにより成形されている。ポリマーアロイに含有されるPBT樹脂とPET樹脂の配合比率は、PBT樹脂が70%程度、PET樹脂が30%程度とされている。ポリマーアロイには、ガラスファイバーが約30重量%添加されている。
図9は、強度評価結果を示す図である。図9に示す強度評価結果は、レーザ接合前にプラズマ処理を施した比較用樹脂片と、接合面の平均粗さをRa0.3μmとした金属片TPmとからなるレーザ接合体における接合強度を1(すなわち基準値)としたときの値(すなわち相対値)により、各レーザ接合体の接合強度を表している。なお、比較用樹脂片、第1、第2および第4樹脂片におけるガラスファイバーの添加量が約30重量%であるのに対し、第3樹脂片におけるガラスファイバーの添加量は約40重量%であるが、このガラスファイバーの添加量の差がレーザ接合強度に与える影響はわずかである。
図9に示すように、比較用樹脂片、第1〜第4樹脂片のそれぞれと、接合面の平均粗さRaが0.3μmの金属片TPmとをレーザ接合したレーザ接合体は、いずれも室温に戻ると界面で剥離してしまう、もしくは、レーザ光10を照射しても接合しないことが判明した。
金属片TPmの接合面の平均粗さRaが0.3μmの場合は、第1〜第4樹脂片を用いたレーザ接合体は、いずれも比較用樹脂片を用いたレーザ接合体に比べて接合強度が向上した。特に、第3樹脂片を用いたレーザ接合体の接合強度の向上効果が顕著であり、凝集破壊の割合がその他の場合に比べて多くなっていた。
接合強度の評価は、上述の樹脂片TPpと金属片TPmとを接合したレーザ接合体だけでなく、電子制御装置100でも実施した。本実施の形態に係る電子制御装置100において、樹脂成形体1を構成するポリマーアロイは、PBT樹脂を母材として、PC樹脂を20%程度含有してアロイ化し、ガラスファイバーを約40重量%添加したものを採用した。
比較例に係る電子制御装置の樹脂成形体1と金属ベース4とを引きはがすように外部から力を加えたところ、樹脂成形体1と金属ベース4との界面で破壊され、樹脂成形体1自体での破壊は確認されなかった。これに対して、本実施の形態に係る電子制御装置100の樹脂成形体1と金属ベース4とを引きはがすように外部から力を加えたところ、樹脂成形体1自体が破壊され、樹脂成形体1と金属ベース4との界面での破壊は確認されなかった。なお、破壊試験において、本実施の形態の電子制御装置を破壊させるために必要な力は、比較例の電子制御装置を破壊させるために必要な力よりも大きかった。つまり、本実施の形態では、レーザ接合強度が比較例に比べて向上していることが確認できた。なお、その時の最大隙間量は40μmほどであったため、アロイ系を用いると、接合強度の向上効果が非常に大きいと言える。
比較例に係る電子制御装置を水没させ、樹脂成形体1に孔を形成して、その孔から収容空間内に0.3MPa程度の圧力をかけたところ、レーザ接合部11aからの気泡漏れが確認できた。これに対して、本実施の形態に係る電子制御装置100を水没させ、樹脂成形体1に孔を形成して、その孔から収容空間内に0.3MPa程度の圧力をかけたところ、レーザ接合部11aからの気泡漏れは確認できなかった。つまり、本実施の形態では、レーザ接合部11aによる収容空間内の気密性が比較例に比べて向上していることが確認できた。
(1)結晶性樹脂および非結晶性樹脂を含有してアロイ化された熱可塑性のポリマーアロイからなる樹脂成形体1と、金属からなる金属ベース4とをレーザ接合し、電子制御装置100を形成した。結晶性樹脂および非結晶性樹脂は、非結晶性樹脂のガラス転移温度Tgが結晶性樹脂の溶融開始温度Tiよりも低くなるように選定した。このため、レーザ走査領域の全体における樹脂接合面1dと金属接合面4dとの隙間量にばらつきがある場合でも、レーザ照射時の樹脂成形体1の温度上昇による軟化(弾性率の低下)により、樹脂接合面1dと金属接合面4dとの隙間量が効果的に低減されるので、十分な接合強度を確保することができる。このように、本実施の形態によれば、アロイ化されていない結晶性樹脂により樹脂成形体1を形成した場合に比べて、レーザ接合強度を向上できる。その結果、電子制御装置100の耐振動性および耐衝撃性を向上できる。
同様に、ポリマーアロイの結晶化速度が母材となる結晶性樹脂の結晶化速度よりも低くなるように、母材となる結晶性樹脂と、アロイ材となる結晶性樹脂(たとえば、PET樹脂)とを選定し、両者を含有させたポリマーアロイを形成することで、レーザ照射後、溶融状態の樹脂が再び結晶化するまでの時間を、アロイ化されていない結晶性樹脂に比べて、長くすることができる。これにより、本実施の形態(たとえば、第4樹脂片と金属片とのレーザ接合体)によれば、アロイ化されていない結晶性樹脂からなる樹脂成形体と金属体とのレーザ接合体に比べて、レーザ接合強度を向上できる。
図11を参照して、第2の実施の形態に係る電子制御装置について説明する。図11は、第2の実施の形態に係る電子制御装置のカバー201aおよびコネクタ201bを示す斜視図である。図中、第1の実施の形態と同一もしくは相当部分には同一符号を付し、説明を省略する。以下、第1の実施の形態との相違点について詳しく説明する。
(9)カバー201aとコネクタ201bとが別体(別部品)であるため、カバー201aとコネクタ201bの材料を別にすることができる。たとえば、難燃性の要求(グレードや環境規制)の高いコネクタ201bについては、カバー201aに比べて難燃剤が多く配合された材料を採用できる。これにより、カバーとコネクタとを一体成形として、難燃性の要求を満足させる場合に比べて、材料費を低減できる。
上述した実施の形態では、金属ベース4の中央部に押圧治具190を配置し、加圧する例について説明したが、本発明はこれに限定されない。たとえば、図12に示すように、金属ベース4の外側端部、すなわちレーザ照射面11よりも外側に押圧治具290を配置し、加圧してもよい。
上述した実施の形態では、第1レーザ照射工程S154で一直線状にレーザ光10を走査し、第2レーザ照射工程S158でコ字状にレーザ光10を走査することで、金属ベース4の外縁を1周走査するようにした(図6参照)。すなわち、金属ベース4のレーザ照射面11を全周に亘って走査する工程を2手順に分けた例について説明したが、本発明はこれに限定されない。1手順で、レーザ光10を全周走査するようにしてもよい。
図13(a)に示すように、金属ベース4の大きさを、樹脂成形体1のカバー1aの大きさよりも一回り小さくしてもよい。この場合、レーザ光10がレーザ照射面11に照射され、金属ベース4を介して樹脂成形体1が熱せられることで、急激な弾性率の低下が起こるため(図10参照)、樹脂成形体1の融点Tmに達する前に樹脂成形体1と金属ベース4との隙間量を低減させ、両者を十分に密着させることができる。さらに、樹脂成形体1の融点Tm以上になると、図13(b)に示すように、樹脂成形体1に金属ベース4の外周部が埋め込まれる。なお、埋め込み深さは、金属ベース4の厚みの1/2以上とすることが好ましい。これにより、リークパスが長くなり、防水性、防塵性、防錆性をさらに向上できる。
図14(a)に示すように、金属ベース4の外周部に樹脂成形体1に向かって突出する凸部21を設け、凸部21の頂面を樹脂成形体1に押し付けるようにしてもよい。これにより、押圧治具290に必要な加圧力を低減させることができ、図14(b)に示すように、容易に必要な埋め込み量を確保することができる。また、加圧工程の際に発生する樹脂バリが外方に飛び出すことを防止できる。
図14に示すように、金属ベース4の冷却フィン7とレーザ照射面11の間に溝部22を設けておいてもよい。このような構造にしておくと、レーザ照射時に発生した熱の接合部以外への逃げが悪化するため、低エネルギーでレーザ接合が可能となる。ただし、剛性の悪化によって、金属ベース4が反る可能性があるため、溝部22の深さは剛性を考慮して設計する必要がある。
加圧工程(S152,S156)において、押圧治具190,290をヒータ等で加熱し、加熱した状態で金属ベース4を加圧してもよい。この場合、樹脂成形体1をアロイ材のガラス転移温度Tg以上の温度まで加熱することで、加熱しない場合に比べて埋め込み量を増加できる。また、ポリマーアロイの再結晶化温度以上であってポリマーアロイの溶融開始温度以下の温度に樹脂成形体1を加熱した状態でレーザ接合することが好ましい。これにより、レーザ接合後も結晶化が遅く進み、接合後の急冷をも抑制できるため、熱応力も低減できる。さらに、レーザ接合に必要なレーザエネルギーを大幅に低減できるメリットもある。
押圧治具190,290に、レーザ光10を透過する耐熱性および透過率の高いガラス板を設け、レーザ光10をガラス板を介してレーザ照射面11に照射してもよい。
上述した実施の形態では、金属ベース4にレーザ照射面11を設けて、金属ベース4にレーザ光10を照射する例について説明したが、本発明はこれに限定されない。樹脂成形体1の透過率が高い場合、樹脂成形体1にレーザ光10を照射して、レーザ接合してもよい。
上述した実施の形態では、金属ベース4は、上述したアルミダイキャストやJISA5052、亜鉛メッキ鋼板の他、ステンレススチール等の種々の金属により形成することもできる。
上述した実施の形態では、樹脂側の酸素官能基を生成、増大させる処理および金属側の表面洗浄、強固な酸化膜形成する処理として、大気圧プラズマ処理の例について説明したが、本発明はこれに限定されない。大気圧プラズマ処理に代えて、減圧プラズマ処理を施してもよい。なお、大気圧プラズマ処理は、生産性の点で減圧プラズマ処理に比べて有効であり、減圧プラズマ処理は、様々な気体を付与できる点で有効である。その他、プラズマ処理に代えて、たとえば、UVオゾン、エキシマレーザ、短パルス照射などのドライ処理を施してもよい。
表面改質処理は、少なくとも樹脂成形体1の樹脂接合面1dに施すことが好ましく、さらに金属ベース4の金属接合面4dに施すことがより好ましい。樹脂側もしくは金属側の一方のみでも効果は大きい。
上述した実施の形態では、ポリマーアロイに含有される非結晶性樹脂の含有率が20〜30%程度の樹脂片TPpを用いたレーザ接合体に対する強度評価について説明したが、本発明はこれに限定されない。なお、ポリマーアロイに含有される非結晶性樹脂の含有率が5%未満であると、接合強度の向上効果が小さいため、ポリマーアロイに含有される非結晶性樹脂の含有率は5%以上とすることが好ましい。
上述した実施の形態では、ポリマーアロイにガラスファイバーが約30〜40重量%程度添加された樹脂片TPpを用いたレーザ接合体に対する強度評価について説明したが、本発明はこれに限定されない。なお、ポリマーアロイに添加されるガラスファイバーが20重量%未満であると、剛性の向上効果が小さいため、添加するガラスファイバーは20重量%以上とすることが好ましい。また、ポリマーアロイに添加されるガラスファイバーが50重量%を超えると、成形性が悪化する場合があるので、添加するガラスファイバーは50重量%以下とすることが好ましい。
上述した実施の形態では、ガラスファイバーをポリマーアロイに添加する例について説明したが本発明はこれに限定されない。ポリマーアロイの剛性を向上させるために、無機物からなる種々の無機フィラーを添加することができる。たとえば、ガラスファイバーに代えて、ガラスフレークや特殊形状のガラスなどを添加してもよい。また、ガラスファイバーに代えて、カーボンファイバーを添加することもできる。これにより、剛性の向上に加え、電磁波シールド性を向上することができる。電磁波シールド性を向上できる無機フィラーとして、導電カーボン(たとえば、ケッチェンブラック、アセチレンブラック、カーボンビーズ、黒鉛等)を採用することもできる。なお、無機フィラーをポリマーアロイに添加しない場合も本発明の範囲内である。
上述した実施の形態では、金属片TPmにおける樹脂片TPpとの接合面の表面粗さRaが0.3μmのものと、2.0μmのものを用いたレーザ接合体に対する強度評価について説明したが、本発明はこれに限定されない。なお、金属片TPmの接合面における表面粗さRaが0.1μm未満であると、接合強度の向上効果が小さく、剥離するおそれがあるため、金属片TPmの接合面における表面粗さRaは0.1μm以上とすることが好ましい。なお、表面粗さRaが0.1μm未満であっても、レーザ接合前にプラズマ処理を施すことで、樹脂片TPpと金属片TPmとを接合させることができる。
樹脂成形体1の材料であるポリマーアロイには、各種添加剤、たとえば、酸化防止剤、紫外線吸収剤、熱安定剤、帯電防止剤等の安定剤や結晶核剤、可塑剤、潤滑剤などを添加してもよい。添加剤の含有量は、接合強度の向上効果を阻害しない程度に設定することが好ましい。
上述した実施の形態では、金属ベース4が矩形平板状に形成され、樹脂成形体1に凹部1cが形成されている例について説明したが、本発明はこれに限定されない。たとえば、金属ベース4に回路基板5を収容する凹部を設け、樹脂成形体1を平板状としてもよい。
第2の実施の形態では、カバー201aとコネクタ201bとを溶着等で結合する例について説明したが、本発明はこれに限定されない。カバー201aとコネクタ201bとは結合しなくてもよい。この場合、カバー201aおよびコネクタ201bのそれぞれを金属ベース4にレーザ接合する。なお、カバー201aおよびコネクタ201bのいずれか一方を金属ベース4にレーザ接合し、他方を接着剤等で金属ベース4に結合させてもよい。レーザ接合と接着剤とを併用する場合であっても、各部品の全てを接着剤で結合する場合に比べて接着剤の使用量を低減することができる。
上述した実施の形態では、自動車に搭載されるエンジンコントローラとしての電子制御装置100に本発明を適用した例について説明したが、本発明はこれに限定されない。樹脂成形体と金属体とをレーザ接合する種々の部品、装置に本発明を適用することができる。
アロイ化する樹脂は、少なくともレーザ接合部11aに対応する部分だけであればよい。たとえば、第1の実施の形態において、カバー1aの外周部だけをアロイ化した樹脂からなる成形体で構成し、カバー1aの中央部はアロイ化していない樹脂からなる成形体で構成し、両者を溶着で結合することもできる。
上述した電子制御装置100の製造方法は、あくまでも一例であって、種々の製造方法により電子制御装置100を製造することができる。たとえば、上述した実施の形態では、組立工程S140において、回路基板5を樹脂成形体1の凹部1cに配置、固定してから、金属ベース4を樹脂成形体1に接合する例について説明したが、本発明はこれに限定されない。回路基板5を金属ベース4に配置、固定してから、樹脂成形体1を金属ベース4に接合してもよい。
上述した実施の形態では、樹脂片TPpと金属片TPmとの最大隙間量は20μm程度の例について説明したが、本発明はこれに限定されない。なお、樹脂片TPpと金属片TPmとの隙間量が大きくなるほど接合強度が低下するので、隙間量はできるだけ低減することが望ましい。隙間量が100μmを超えると、樹脂片TPpと金属片TPmとを接合できない。このため、隙間量は100μm以下とする必要がある。ただし、隙間量が50μmよりも大きく100μm以下の場合は、樹脂片TPpの熱分解によって、レーザ接合部11aにボイドが多く残存することになるので、接合強度を長期的に維持することが難しい。このため、樹脂片TPpと金属片TPmとを加圧した状態で、できる限り隙間量を小さくしておくことが好ましく、50μm以下とすることが好ましい。
日本国特許出願2014年第209352号(2014年10月10日出願)
Claims (13)
- 金属体と樹脂成形体とにより画成される収容空間に収容された電子回路部を備える電子制御装置であって、
前記樹脂成形体と前記金属体とがレーザ接合されることにより、前記収容空間が封止されており、
前記樹脂成形体は、結晶性樹脂に他の樹脂を含有してアロイ化された熱可塑性のポリマーアロイからなり、
前記ポリマーアロイの結晶化速度が前記結晶性樹脂の結晶化速度よりも低い、または、前記ポリマーアロイの再結晶化温度が前記結晶性樹脂の再結晶化温度よりも低い、
電子制御装置。 - 請求項1に記載の電子制御装置において、
前記他の樹脂は、非結晶性樹脂であり、
前記非結晶性樹脂のガラス転移温度は、前記結晶性樹脂の溶融開始温度よりも低い、
電子制御装置。 - 請求項1または2に記載の電子制御装置において、
前記ポリマーアロイの弾性率が、所定温度よりも低い低温度領域では前記結晶性樹脂の弾性率よりも高く、前記所定温度よりも高い高温度領域では前記結晶性樹脂の弾性率よりも低い、
電子制御装置。 - 請求項1乃至3のいずれか一項に記載の電子制御装置において、
前記樹脂成形体における前記金属体との接合面および前記金属体における前記樹脂成形体との接合面には、プラズマ処理が施されている、
電子制御装置。 - 請求項1乃至4のいずれか一項に記載の電子制御装置において、
前記ポリマーアロイには、前記結晶性樹脂の共重合体が含有されている、
電子制御装置。 - 請求項2に記載の電子制御装置において、
前記ポリマーアロイに含有される前記非結晶性樹脂の含有率は、5〜40%である、
電子制御装置。 - 請求項1乃至6のいずれか一項に記載の電子制御装置において、
前記ポリマーアロイには、無機フィラーが添加されている、
電子制御装置。 - 請求項1乃至7のいずれか一項に記載の電子制御装置において、
前記金属体における前記樹脂成形体との接合面の表面粗さがRa0.1μm〜5.0μmとされている、
電子制御装置。 - 請求項1乃至8のいずれか一項に記載の電子制御装置において、
少なくとも前記金属体の一部が前記樹脂成形体に埋め込まれている、
電子制御装置。 - 請求項9に記載の電子制御装置において、
前記樹脂成形体は、前記電子回路部を覆うカバーと前記電子回路部に電気的に接続される端子を保持するコネクタとが一体成形された一体成形体である、
電子制御装置。 - 請求項9に記載の電子制御装置において、
前記電子回路部を覆うカバーと、前記カバーとは別体とされ、前記電子回路部に電気的に接続される端子を保持するコネクタとを備え、
前記カバーおよび前記コネクタは、それぞれ前記樹脂成形体であり、互いに結合されている、
電子制御装置。 - 電子回路部を備える電子制御装置の製造方法であって、
結晶性樹脂および非結晶性樹脂を含有してアロイ化された熱可塑性のポリマーアロイからなる樹脂成形体と、金属からなる金属体とを準備し、
前記非結晶性樹脂のガラス転移温度は、前記結晶性樹脂の溶融開始温度よりも低く、
前記ポリマーアロイの結晶化速度が前記結晶性樹脂の結晶化速度よりも低いか、または、前記ポリマーアロイの再結晶化温度が前記結晶性樹脂の再結晶化温度よりも低く、
少なくとも前記樹脂成形体における前記金属体にレーザ接合される部分に、酸素官能基を増大させる処理を施し、
前記樹脂成形体を前記非結晶性樹脂のガラス転位温度以上の温度まで加熱し、
前記樹脂成形体および前記金属体を互いに押圧接触させた状態で、前記樹脂成形体と前記金属体とをレーザ接合して、前記電子回路部を収容する収容空間を封止する、
電子制御装置の製造方法。 - 請求項12に記載の電子制御装置の製造方法において、
前記樹脂成形体と前記金属体とは、前記ポリマーアロイの再結晶化温度以上であって前記ポリマーアロイの溶融開始温度以下の温度に前記樹脂成形体を加熱した状態でレーザ接合される、
電子制御装置の製造方法。
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