JP3960269B2 - Manufacturing method of resin products - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a resin product.
[0002]
[Prior art]
Conventionally, laser welding is used when manufacturing a resin product composed of a plurality of molded bodies.
For example, Patent Document 1 discloses a method in which two molded bodies are welded by irradiating a laser beam toward a convex portion while pressing a convex portion provided on a laser-transmitting molded body against the laser-absorbing molded body. It is disclosed.
Patent Document 2 discloses a method in which two molded bodies are welded by press-fitting the other molded body into one molded body, butting the surfaces together and irradiating a laser beam toward the butted portion. Yes.
[0003]
[Patent Document 1]
JP 2002-248688 A [Patent Document 2]
Japanese Patent Laid-Open No. 2003-19752
[Problems to be solved by the invention]
However, in the method disclosed in Patent Document 1, a clearance due to a molding error inevitably occurs at the contact interface between the end surface of the convex portion and the pressing surface against which the convex portion is pressed. The presence of this clearance makes it difficult for the heat of the resin melted from the pressing surface upon receiving laser light to be transmitted to the end surface of the convex portion, so that the convex portion is not sufficiently melted, and the welding strength and airtightness are lowered.
[0005]
In the method disclosed in Patent Document 2, when the molded body is formed into a complicated shape, or when the press-fitting allowance is reduced even if the shape of the molded body is simple, a clearance is generated at the butt portion of the molded body. Therefore, the welding strength and the air tightness are lowered. On the other hand, in the method disclosed in Patent Document 2, when the shape of the molded body is simplified to increase the press-fitting allowance, defects such as cracks occur in the molded body.
In view of the above problems, an object of the present invention is to provide a method for manufacturing a resin product that ensures welding strength and airtightness at the welding interfaces of a plurality of molded bodies.
[0006]
[Means for Solving the Problems]
According to the invention of claim 1, since the second molded body is resin-molded on the surface of the first molded body, the second molded body is brought into close contact with the surface of the first molded body without depending on the shape of each molded body. Can do. Due to this adhesion, no clearance is generated at the interface between the first molded body and the second molded body. Therefore, the first molding is performed by irradiating the laser beam along the path from the laser beam transmitting second molded body side through the interface between the first and second molded bodies to the laser beam absorbing first molded body. The heat of the resin melted from the body can be reliably transmitted to the second molded body. Since the second molded body is sufficiently melted by this reliable heat transfer, the welding strength and the air tightness are ensured at the welding interface of the first and second molded bodies.
[0007]
Furthermore, according to the first aspect of the present invention, two first molded bodies selected from a plurality of (two or more) molded first molded bodies are brought into contact with each other as contact molded bodies, respectively. A 2nd molded object is shape | molded in the shape which covers the contact interface of two contact molded objects along the periphery of the interface. And a 2nd molded object is welded to the site | part which pinches | interposes a contact interface in each contact molded object. Since the welding strength is ensured at the welding interface between the second molded body and the portion sandwiching the abutting interface of each abutting molded body, the two abutting molded bodies can be firmly bonded via the second molded body. In addition, airtightness is ensured at the welding interface between the second molded body and the part sandwiching the contact interface of each contact molded body, so that the contact interface whose peripheral edge is covered by the second molded body can be hermetically sealed. It becomes.
[0008]
According to the second aspect of the present invention, since the two contact molded bodies are brought into contact with each other by fitting, the two contact molded bodies can be integrated prior to the molding of the second molded body. This integration facilitates the molding operation of the second molded body.
The selection of the two first molded bodies according to claims 1 and 2 may be one or more. When there are a plurality of selections of the two first molded bodies, the same first molded body may overlap in each selection. Further, when there are a plurality of selections of the two first molded bodies, the contact stage, the secondary molding stage and the welding stage according to claims 1 and 2 are performed according to each selection.
[0009]
Since the invention according to claim 3 is a resin product manufactured by the manufacturing method according to claim 1 or 2 , the welding strength and airtightness at the welding interface of the first and second molded bodies Is a product that is secured.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a plurality of embodiments of the present invention will be described with reference to the drawings.
(Reference embodiment)
FIG. 2 shows a solenoid valve as a resin product manufactured according to the reference embodiment of the present invention. The solenoid valve 10 is used, for example, in a system that sends evaporative fuel generated in a fuel tank of an automobile to an engine, and opens and closes the flow path of the evaporative fuel.
[0011]
Here, the electromagnetic valve 10 will be described in detail.
The passage member 20 is formed of resin, and forms a valve seat 21 and an inflow passage 22 and an outflow passage 23 that form a flow path. The connector member 28 is formed in a cylindrical shape with resin. The connector member 28 is fitted with a connector portion of an external power source.
[0012]
The base member 30 is made of resin, and is welded to the passage member 20 and the connector member 28 at both end portions 30a and 30b. In the present embodiment, the one end 20a of the passage member 20 is covered with the one end 30a of the base member 30 over the entire circumferential direction, and the one end 28a of the connector member 28 is covered with the base member 30 over the entire circumferential direction. The other end 30b is covered. A fixed core 31, a yoke 32, a core plate 33, a resin bobbin 34, a coil 35, and a terminal 36 are embedded in the base member 30. The fixed core 31, the yoke 32 and the core plate 33 are made of a magnetic material, and the yoke 32 and the core plate 33 are fixed to both ends of the fixed core 31. The resin bobbin 34 around which the coil 35 is wound is fixed to the outer peripheral wall of the fixed core 31 having a cylindrical shape. The terminal 36 electrically connected to the terminal of the coil 35 protrudes to the inner peripheral side of the connector member 28. A resin-made regulating member 37 is fixed to the inner peripheral wall of the end portion of the fixed core 31 on the core plate side.
[0013]
The movable core 40 is formed of a magnetic material in a cylindrical shape, and is disposed closer to the valve seat than the fixed core 31. A regulating member 37 enters the inner peripheral side of the movable core 40, and the movable core 40 can reciprocate according to the guidance of the regulating member 37. The outer peripheral portion of the leaf spring 41 is sandwiched between the passage member 20 and the core plate 33. The valve member 42 is made of rubber, and can be brought into contact with the valve seat 21 and the regulating member 37 by being fitted and fixed to the central portion of the leaf spring 41. Both ends of the coil spring 43 are engaged with the valve member 42 and the regulating member 37, and the valve member 42 and the leaf spring 41 are urged toward the valve seat by the coil spring 43. One end of the movable core 40 is joined to the leaf spring 41 around the valve member 42.
[0014]
When the coil 35 is energized through the terminal 36 by an external power source in which the connector portion is fitted to the connector member 28, a magnetic force that attracts the movable core 40 toward the fixed core 31 is generated. Accordingly, the movable core 40 approaches the fixed core 31 while deflecting the leaf spring 41 to the counter valve seat side against the urging force of the coil spring 43, so that the valve member 42 is separated from the valve seat 21. The inflow passage 22 and the outflow passage 23 communicate with each other when the valve member 42 is separated from the valve seat 21. On the other hand, when the coil 35 is not energized, the movable core 40 is separated from the fixed core 31 by bending the leaf spring 41 toward the valve seat by the biasing force of the coil spring 43. Thereby, since the valve member 42 is seated on the valve seat 21, the communication between the inflow passage 22 and the outflow passage 23 is blocked.
[0015]
Next, the manufacturing method of the solenoid valve 10 will be described according to the flowchart shown in FIG.
In step S11, as shown in FIG. 4, the fixed core 31, the yoke 32, the core plate 33, the resin bobbin 34, the coil 35, the terminal 36, the regulating member 37, the movable core 40, the leaf spring 41, the valve member 42, and the coil spring. 43 is integrated to form the insert 50.
[0016]
In step S12, the passage member 20 having laser light absorptivity is resin-molded as shown in FIG. In step S12, the connector member 28 having a laser beam absorptivity is resin-molded as shown in FIG. Here, for the passage member 20 and the connector member 28, the same or different thermoplastic resins are used so that the laser beam transmittance is 5% or less, for example, so that the absorbability with respect to the used laser beam is increased. Mold each one. As the thermoplastic resin to be used, for example, resins such as polyamide and polybutylene terephthalate, or those obtained by blending a colorant such as carbon black and other various additives into those resins can be appropriately selected.
As described above, the passage member 20 and the connector member 28 each correspond to the first molded body, and step S12 corresponds to the primary molding stage.
[0017]
In step S13, as shown in FIG. 6, the insert member 50 is inserted, and the base member 30 having laser beam transparency is resin-molded on the surfaces of the end portions 20a and 28a of the passage member 20 and the connector member 28. . Here, for the base member 30, a thermoplastic resin is used so that, for example, the laser beam transmittance is 25% or more so that the absorption of the laser beam used is lower than both the passage member 20 and the connector member 28. Use to mold. As a thermoplastic resin to be used, for example, a resin such as polyamide or polybutylene terephthalate, or a combination of these resins with a clarifying agent and other various additives with sufficiently low absorption to the laser beam used is appropriately selected. it can.
[0018]
An example of the forming method of the base member 30 in step S13 is shown in FIG. In this method example, first, the passage member 20, the connector member 28, and the insert product 50 are arranged at predetermined positions of the mold 52 as shown in FIG. With this arrangement, the surfaces of the end portions 20 a and 28 a of the passage member 20 and the connector member 28 are exposed to the cavity 53 of the mold 52. Next, as shown in FIG. 7B, a melt 54 of thermoplastic resin is injected into the cavity 53 and filled. At this time, molding conditions such as molding temperature are set so that the surfaces exposed to the cavities 53 at the end portions 20a and 28a of the members 20 and 28 do not melt, or even if melted, an unmelted portion remains on the exposed surface. Set. When the molten resin 54 filled in the cavity 53 is cooled and solidified, the base member 30 (see FIG. 6) integrated with the passage member 20, the connector member 28, and the insert product 50 is secondarily formed.
As described above, the base member 30 corresponds to the second molded body, and step S13 corresponds to the secondary molding stage.
[0019]
In step S14, as shown in FIG. 1A, the interface member 56 between the passage member 20 and the base member 30 is irradiated with laser light to weld the passage member 20 and the base member 30 together. At this time, a path L1a from the end 30a side of the base member 30 covering the outer periphery of the end 20a of the passage member 20 through the interface 56 to the end 20a is set as an irradiation path. At this time, for example, as shown schematically in FIG. 8, the laser beam is irradiated to the entire circumferential direction of the end portion 20a by sequentially moving the laser beam passage location at the interface 56 in the circumferential direction of the end portion 20a. . Lasers that generate laser light include solid-state lasers such as glass lasers, ruby lasers, YAG lasers, and titanium sapphire lasers, gas lasers such as He—Ne lasers, CO ₂ lasers, rare gas ion lasers, and excimer lasers, semiconductor lasers, etc. Can be selected as appropriate, and is used with an output that takes into account the composition of the forming resin of the members 20 and 30.
[0020]
As schematically shown in FIG. 1A, the laser light irradiated along the path L1a passes through the laser light transmitting end 30a and is absorbed by the laser light absorbing end 20a. The surface forming the interface 56 of the end 20a that has absorbed the laser beam is melted, and the molten resin comes into contact with the surface forming the interface 56 of the end 30a to melt the end 30a by heat transfer. When the molten resin from the end portions 20a and 30a is mixed and cooled and solidified, the passage member 20 and the base member 30 are fixed to each other.
[0021]
In step S14, as shown in FIG. 1B, the laser beam is irradiated to the interface 58 between the connector member 28 and the base member 30 to weld the connector member 28 and the base member 30 together. At this time, a path L1b passing through the interface 58 from the end 30b side of the base member 30 covering the outer periphery of the end 28a of the connector member 28 to the end 28a side is set as an irradiation path, and the circumferential direction of the end 28a The entire area is irradiated with laser light. As schematically shown in FIG. 1B, the laser light irradiated along the path L1b passes through the laser light transmitting end 30b and is absorbed by the laser light absorbing end 28a. The end portions 28a and 30b are melted by the same principle as in the case of laser beam irradiation along the path L1a. The molten resin from the end portions 28a and 30b are mixed and solidified by cooling, whereby the connector member 28 and the base member 30 are fixed to each other.
As described above, step S14 corresponds to the welding stage.
[0022]
According to the manufacturing method of the reference embodiment described above, since the base member 30 is resin-molded on each surface of the passage member 20 and the connector member 28, the base member 30 can be brought into close contact with each surface of the members 20 and 28. it can. Due to this close contact, no clearance is generated at the interface 56 between the passage member 20 and the base member 30 and at the interface 58 between the connector member 28 and the base member 30. Therefore, since the heat of the resin melted from the members 20 and 28 upon receiving the laser beam can be reliably transmitted to the base member 30, the base member 30 is sufficiently melted. Therefore, the welding strength and air tightness at the interfaces 56 and 58 can be secured.
[0023]
(First embodiment)
FIG. 9 shows a solenoid valve as a resin product manufactured according to the first embodiment of the present invention. Components substantially the same as those in the reference embodiment are denoted by the same reference numerals.
In the electromagnetic valve 70 of the first embodiment, the end portion 20a of the passage member 20 is fitted and brought into contact with one end portion 60a of the base member 60 corresponding to the base member 30 of the reference embodiment , and covers the contact interface 72 thereof. A first covering member 74 is welded to each end 20a, 60a. The first covering member 74 is formed of a resin and is welded to a portion sandwiching the interface 72 at each of the end portions 20a and 60a. Thereby, the 1st covering member 74 has covered the interface 72 over the circumferential direction whole area along the outer periphery.
[0024]
Further, in the electromagnetic valve 70 of the first embodiment, the second cover member that covers the contact interface 82 with the end portion 28a of the connector member 28 fitted into the terminal 36 and in contact with the other end portion 60b of the base member 60. 84 is welded to each end 28a, 60b. The second covering member 84 is formed of resin and is welded to a portion sandwiching the interface 82 at each of the end portions 28a and 60b. Thereby, the 2nd covering member 84 has covered the interface 82 over the whole circumferential direction along the outer periphery.
[0025]
Next, a method for manufacturing the electromagnetic valve 70 according to the first embodiment will be described with reference to the flowchart shown in FIG.
In step S21, the insert 50 is formed in the same manner as in step S11 of the reference embodiment .
[0026]
In step S22, similarly to step S12 of the reference embodiment , the passage member 20 and the connector member 28 having laser light absorption are resin-molded. In step S22, as shown in FIG. 11, the insert 50 is inserted, and the base member 60 having laser light absorption is resin-molded. The base member 60 is also molded using the same or different thermoplastic resin as that of the members 20 and 28 so that the absorbability of the used laser beam is increased as in the case of the passage member 20 and the connector member 28.
As described above, the passage member 20, the connector member 28, and the base member 60 each correspond to the first molded body, and step S21 corresponds to the primary molding stage.
[0027]
In step S23, the end portion 20a of the passage member 20 is fitted into the end portion 60a of the base member 60 as shown in FIG. 12A, and the end portion 20a is turned into the end portion 60a as shown in FIG. Make contact. In step S23, the end portion 28a of the connector member 28 is fitted to the terminal 36 embedded in the base member 60 as shown in FIG. 12A, and the end portion 28a is used as the base as shown in FIG. It is made to contact | abut to the edge part 60b of the member 60. FIG.
As described above, it can be considered that the passage member 20 and the base member 60 correspond to two contact molded bodies that are the two selected first molded bodies, and the connector member 28 and the base member 60 are separately selected. It can be considered that the two first molded bodies correspond to the two contact molded bodies, and therefore step S23 corresponds to the contact stage.
[0028]
In step S24, as shown in FIG. 13, the first covering member 74 having laser light transmittance is provided on the outer surface of the portion sandwiching the contact interface 72 at each of the end portions 20a and 60a of the passage member 20 and the base member 60. Resin molding. Further, in step S24, as shown in FIG. 13, a second covering member 84 having a laser beam transmissivity is provided on the outer surface of the portion sandwiching the contact interface 82 at each of the end portions 28a and 60b of the connector member 28 and the base member 60. The resin is molded. Here, the first and second cover members 74 and 84 are molded using a thermoplastic resin so that the laser beam absorbability is lower than that of any of the passage member 20, the connector member 28, and the base member 60. .
[0029]
An example of the molding method of the first and second covering members 74 and 84 in step S24 is shown in FIG. In this method example, first, as shown in FIG. 14A, an integrated object 90 in which the passage member 20 and the connector member 28 are fitted to the base member 60 is arranged at a predetermined position of the mold 92. With this arrangement, the outer surfaces of the portions sandwiching the interface 72 at the end portions 20 a and 60 a of the passage member 20 and the base member 60 are exposed to the cavity 93 of the mold 92, and the end portions 28 a of the connector member 28 and the base member 60. 60b, the outer surface of the part sandwiching the interface 82 is exposed to the cavity 94 of the mold 92. Next, as shown in FIG. 14B, a melt of a thermoplastic resin is injected into the cavities 93 and 94 and filled. At this time, the surfaces exposed to the cavities 93 and 94 at the end portions 20a, 28a, 60a, and 60b of the members 20, 28, and 60 are not melted, or even if melted, the unmelted portion remains on the exposed surface. Next, molding conditions such as molding temperature are set. First and second covering members 74 and 84 (see FIG. 5) covering the contact interfaces 72 and 82 between the passage member 20 and the connector member 28 and the base member 60 by the molten resin filled in the cavities 93 and 94 being cooled and solidified. 13) is secondarily formed separately from each other.
As described above, the first covering member 74 and the second covering member 84 each correspond to the second molded body, and step S24 corresponds to the secondary molding stage.
[0030]
In step S25, as shown in FIG. 15 (A), the passage member 20, the base member 60, and the interface 76 between the first covering member 74 are irradiated with laser light, and the passage member 20 and the base member 60 are first covered. The member 74 is welded. At this time, a path L2a that passes through the interface 76 from the first covering member 74 side and reaches the end portions 20a, 60a side of the passage member 20 and the base member 60 is set as an irradiation path, and the circumferential direction of the end portions 20a, 60a is set. The entire area is irradiated with laser light. As schematically shown in FIG. 15A, the laser light irradiated along the path L2a passes through the laser light-transmitting first covering member 74 and is absorbed by the laser light-absorbing end portions 20a and 60a. Is done. The surface that forms the interface 76 of each end 20a, 60a that has absorbed the laser light is melted, and the molten resin contacts the surface that forms the interface 76 of the first covering member 74 to melt the first covering member 74 by heat transfer. Let The molten resin from the end portions 20 a and 60 a and the first covering member 74 is mixed and solidified by cooling, whereby the first covering member 74 is fixed to the passage member 20 and the base member 60.
[0031]
In step S25, as shown in FIG. 15B, the interface 86 between the connector member 28 and the base member 60 and the second cover member 84 is irradiated with laser light, so that the connector member 28 and the base member 60 are secondly exposed. The covering member 84 is welded. At this time, a path L2b that passes through the interface 86 from the second covering member 84 side and reaches the end portions 28a and 60b of the connector member 28 and the base member 60 is set as an irradiation path, and the circumferential direction of the end portions 28a and 60b. The entire area is irradiated with laser light. As schematically shown in FIG. 15B, the laser light irradiated along the path L2b is transmitted through the laser light transmitting second covering member 84 and absorbed by the laser light absorbing end portions 28a and 60b. Therefore, the end portions 28a and 60b and the second covering member 84 are melted by the same principle as that in the case of laser beam irradiation along the path L2a. The molten resin from the end portions 28 a and 60 b and the second covering member 84 is mixed and solidified by cooling, whereby the second covering member 84 is fixed to the connector member 28 and the base member 60.
[0032]
According to the manufacturing method of the first embodiment described above, since the covering members 74 and 84 are resin-molded on the surfaces of the passage member 20, the connector member 28 and the base member 60, the surfaces of these members 20, 28 and 60 are covered. The members 74 and 84 can be brought into close contact with each other. Due to this close contact, no clearance is generated at the interface 76 between the first covering member 74 and the members 20 and 60 and the interface 86 between the second covering member 84 and the members 28 and 60. Therefore, since the heat of the resin melted from the members 20, 28, 60 upon receiving the laser beam can be reliably transmitted to the covering members 74, 84, the covering members 74, 84 are sufficiently melted. Accordingly, since the welding strength can be secured at the interfaces 76 and 86, the passage member 20 and the base member 60 are firmly coupled via the first covering member 74, and the connector member 28 is coupled via the second covering member 84. The base member 60 is firmly coupled. Further, since airtightness can be secured at the interfaces 76 and 86, the contact surfaces 72 of the members 20 and 60 whose peripheral edges are covered by the first covering member 74 and the contacts 28 and 60 whose peripheral edges are covered by the second covering member 84 are secured. The contact interface 82 is hermetically sealed.
[0033]
Furthermore, according to the manufacturing method of the first embodiment, the passage member 20 and the connector member 28 can be fitted and integrated with the base member 60 and the terminal 36 embedded therein before the covering members 74 and 84 are formed. . Therefore, for example, when the covering members 74 and 84 are formed as shown in FIG. 14, the members 20, 28 and 60 can be arranged at accurate positions by a single arrangement operation. Thereby, the molding time of the covering members 74 and 84 is shortened.
[0034]
In the above-described embodiments, the example in which the present invention is applied to the manufacture of the electromagnetic valve 10 including a plurality of molded bodies has been described. However, the present invention is applicable to the manufacture of various resin products including a plurality of molded bodies. Applicable.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a method of manufacturing a solenoid valve according to a reference embodiment of the present invention.
FIG. 2 is a cross-sectional view showing a solenoid valve manufactured according to a reference embodiment of the present invention.
FIG. 3 is a flowchart showing a flow of a method for manufacturing a solenoid valve according to a reference embodiment of the present invention.
FIG. 4 is a cross-sectional view for explaining a method of manufacturing a solenoid valve according to a reference embodiment of the present invention.
FIG. 5 is a cross-sectional view for explaining a method of manufacturing a solenoid valve according to a reference embodiment of the present invention.
FIG. 6 is a cross-sectional view for explaining a method of manufacturing a solenoid valve according to a reference embodiment of the present invention.
FIG. 7 is a cross-sectional view for explaining a method of manufacturing a solenoid valve according to a reference embodiment of the present invention.
FIG. 8 is a plan view for explaining a method of manufacturing a solenoid valve according to a reference embodiment of the present invention.
FIG. 9 is a cross-sectional view showing a solenoid valve manufactured according to the first embodiment of the present invention.
FIG. 10 is a flowchart showing a flow of a method for manufacturing a solenoid valve according to the first embodiment of the present invention.
FIG. 11 is a cross-sectional view for explaining the method for manufacturing the electromagnetic valve according to the first embodiment of the present invention.
FIG. 12 is a cross-sectional view for explaining the method for manufacturing the electromagnetic valve according to the first embodiment of the present invention.
FIG. 13 is a cross-sectional view for explaining the method for manufacturing the electromagnetic valve according to the first embodiment of the present invention.
FIG. 14 is a cross-sectional view for explaining the method for manufacturing the electromagnetic valve according to the first embodiment of the present invention.
FIG. 15 is a sectional view for explaining the method for manufacturing the electromagnetic valve according to the first embodiment of the present invention.
[Explanation of symbols]
10, 70 Solenoid valve 20 passage member (first molded body)
28 Connector member (first molded body)
30 Base member (second molded body)
36 Terminal 50 Insert 52, 92 Mold 56, 58, 76, 86 Interface 60 Base member (first molded body)
72, 82 Contact interface 74 First covering member (second molded body)
84 Second covering member (second molded body)
90 integrated products

Claims (3)

A primary molding step of resin-molding a first molded body having laser light absorption;
A secondary molding step of resin-molding a second molded body having laser light transmittance on the surface of the first molded body;
By irradiating a laser beam along a path from the second molded body side through the interface between the first molded body and the second molded body to the first molded body, the first molded body and the A welding stage for welding the second molded body;
Including
A contact step of bringing two selected first molded bodies out of the plurality of first molded bodies molded in the primary molding stage into contact with each other as contact molded bodies;
In the secondary molding step, the second molded body is molded into a shape that covers the contact interface of the two contact molded bodies along the peripheral edge of the interface,
Wherein in the welding step, the manufacturing method of the tree butter products you characterized by welding the said second shaped body portion sandwiching the contact surface at each said contact molded body. The method for producing a resin product according to claim 1 , wherein, in the contact step, the two contact molded bodies are brought into contact with each other by fitting. A resin product produced by the production method according to claim 1 .

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