JP6953766B2 - Manufacturing method of resin joint and resin joint - Google Patents

Description

The present invention relates to a method for producing a resin bonded body and a resin bonded body.

As a conventional technique for welding resin parts, a spot welding method using ultrasonic waves is known. In this conventional technique, a horn to which ultrasonic vibration is applied is applied to a portion where two types of resin parts overlap, pressure is applied in a direction perpendicular to the member, and a hole is formed in the resin material by a convex portion at the tip of the horn. While melting, the resin materials are welded together. By adhering the resin melted by the horn to both of the two types of resin parts, the welding strength between the resin parts can be maintained and the sealing property can be obtained.

In spot welding, the upper resin (the resin in which the horn is first inserted) is attached to the lower resin while following the horn, instead of being welded while the boundary between the two resin parts is maintained as it is during welding. It penetrates and welds, resulting in the formation of a ring-shaped welded portion.

For example, in Patent Document 1, a recess is formed on one contact surface of two resin plates that are in contact with each other, and a horn that has been ultrasonically vibrated is inserted through the recess from the one resin plate and inserted into the other resin plate. Discloses a technique for increasing joint strength by filling an internal space formed in a recess with a molten resin.

Special Fair 6-53389 Gazette

However, it is difficult to increase the joint strength to the same level as the base metal strength by the prior art such as Patent Document 1. Further, there is a problem that the bonding strength tends to vary depending on the surface condition such as dirt on the contact surface and surface roughness. In particular, the resin filled in Patent Document 1 may not contribute to bonding depending on the surface condition of the resin plate.

Therefore, an object of the present invention is to provide a method for producing a resin bonded body and a resin bonded body capable of increasing the joint strength to the same level as the base metal strength without depending on the surface state of the contact surface.

The method for producing a resin bonded body according to one aspect of the present invention, and the resin bonded body, include a first resin component and a second resin component that are in contact with each other, and a convex portion formed on the contact surface of the first resin component. , A method for manufacturing a resin joint including a concave portion formed on the contact surface of the second resin component and having a convex portion inserted therein, and an enlarged diameter portion in the concave portion having a diameter larger than that of the opening of the concave portion. .. This manufacturing method, the convex portion to the inside and a position of the protrusion while melting the resin material of the first resin component by pressing the horn is ultrasonically vibrated in the state of being inserted into the recess in the first resin component The feature is that the resin material of the first resin part that has been pierced and melted is inserted into the enlarged diameter portion and solidified to form a deformed portion, and the convex portion and the concave portion are engaged with each other via the deformed portion. do.

In the above embodiment, the convex portion and the concave portion engage with each other via the deformed portion, and the deformed portion serves as an anchor for the force that separates the first resin component and the second resin component from each other, thus forming the convex portion. The first resin component and the second resin component can be reliably joined based on the strength of the resin material to be formed and / or the resin material forming the periphery of the recess (shear strength of the resin material). Therefore, it is possible to increase the joint strength between the first resin component and the second resin component to the same level as the strength of the base material, regardless of the surface condition of the contact surface.

FIG. 1 is a schematic view showing an example of the ultrasonic welding and fixing device of the present embodiment. FIG. 2 is a cross-sectional view showing the arrangement of the first resin plate, the second resin plate, and the horn when the resin joint of the first embodiment is manufactured. FIG. 3 is a cross-sectional view when the horn for manufacturing the resin joint of the first embodiment is inserted into the first resin plate. FIG. 4 is a cross-sectional view of the resin bonded body of the first embodiment. FIG. 5 is a cross-sectional view showing the arrangement of the first resin plate, the second resin plate, and the horn when the resin joint of the second embodiment is manufactured. FIG. 6 is a cross-sectional view when the horn for manufacturing the resin joint of the second embodiment is inserted into the first resin plate and the second resin plate. FIG. 7 is a cross-sectional view of the resin bonded body of the second embodiment. FIG. 8 is a cross-sectional view showing the arrangement of the first resin plate, the second resin plate, and the horn when the resin joint of the third embodiment is manufactured. FIG. 9 is a cross-sectional view of the resin bonded body of the third embodiment. FIG. 10 is a cross-sectional view showing the arrangement of the first resin plate, the second resin body, and the horn when the resin bonded body of the fourth embodiment is manufactured. FIG. 11 is a cross-sectional view of the resin bonded body of the fourth embodiment. FIG. 12 is a cross-sectional view showing a positioning range of the horn with respect to the first resin plate and the second resin plate when the resin joint of the fourth embodiment is manufactured. FIG. 13 is a cross-sectional view of the resin bonded body of the fifth embodiment. FIG. 14 is a cross-sectional view of the resin joint of the fifth embodiment when the horn is inserted into the first resin plate. FIG. 15 is a cross-sectional view showing the arrangement of the first resin plate, the second resin plate, and the horn when the resin joint of the sixth embodiment is manufactured. FIG. 16 is a cross-sectional view of the resin bonded body of the sixth embodiment. FIG. 17 is a cross-sectional view showing a manufacturing process (before forcibly pulling out) of the second resin plate of the resin joint of the seventh embodiment. FIG. 18 is a cross-sectional view showing a manufacturing process (after forcibly removing) the second resin plate of the resin joint of the seventh embodiment. FIG. 19 is a cross-sectional view showing a manufacturing process (before forcibly pulling out) of the second resin plate of the resin joint of the eighth embodiment. FIG. 20 is a cross-sectional view showing a manufacturing process (after forcibly removing) the second resin plate of the resin joint of the eighth embodiment. FIG. 21 is a cross-sectional view showing the arrangement of an electronic substrate and an electronic element when the resin bonded body of the ninth embodiment is manufactured. FIG. 22 is a cross-sectional view of the resin bonded body of the ninth embodiment.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[Ultrasonic welding and fixing device]
FIG. 1 is a schematic view showing an example of the ultrasonic welding and fixing device 5 of the present embodiment. In the ultrasonic welding and fixing device 5 of the present embodiment, for example, the first resin plate 1 (first resin component) and the second resin plate 2 (second resin component) are stacked, and these are used as welding objects. The horn 52 is inserted into a predetermined position of the object to be welded while being held, and the object to be welded is welded and fixed.

As shown in FIG. 1, in the ultrasonic welding fixing device 5, the ultrasonic vibrating unit 51 that supports the horn 52 and applies ultrasonic vibration, the holder 53 that holds the object to be welded, and the holder 53 are moved in the horizontal direction ( It has a first slider 56 for moving in the X direction) and a second slider 57 for moving the first slider 56 in the horizontal direction (Y direction: a direction perpendicular to the X direction).

The ultrasonic vibration unit 51 is supported by a support column (not shown) and can move in the vertical direction. The ultrasonic vibration unit 51 generates ultrasonic vibration and transmits this to the horn 52.

The first slider 56 that moves the holder 53 can move on the rail 561 that is attached to the upper part of the second slider 57 and extends in the X direction. The second slider 57 that moves the first slider 56 can move on the rail 571 that is attached to the base 58 and extends in the Y direction.

According to the ultrasonic welding and fixing device 5 of the present embodiment, the horn 52 can be inserted at an arbitrary position of the welding target to weld the welding target.

[First Embodiment]
FIG. 2 is a cross-sectional view showing the arrangement of the first resin plate 1, the second resin plate 2, and the horn 52 when the resin bonded body 100A of the first embodiment is manufactured. FIG. 3 is a cross-sectional view when the horn 52 for manufacturing the resin bonded body 100A of the first embodiment is inserted into the first resin plate 1. FIG. 4 is a cross-sectional view of the resin bonded body 100A of the first embodiment.

The resin joint 100A (FIG. 4) of the first embodiment has a horn 52 ultrasonically vibrated by a first resin plate 1 (first resin component) and a second resin plate 2 (second resin component). It is joined to each other by deforming a part of the first resin plate 1 using the resin plate 1.

As the material of the first resin plate 1 and the second resin plate 2, a thermoplastic resin is suitable, and for example, acrylic (Acrylic / PMMA), polycarbonate (Polycarbonate), ABS (ABS), polystyrene (Polystyrene), vinyl chloride. (PVC), polyphenylene oxide (PPO / Noyl), polyethersulfone, polycarbonate, and other amorphous resins can be applied. In addition, polypropylene (Polypolyrene), polyethylene (Polyethyrene), polyacetal (POM / Polyetheral), polyamide nylon (Polyamide / Nylon), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyphthalamide (PPA), polyphenylene. Semi-crystalline resins such as sulfide (PPS) and polyetheretherketone (PEEK) can also be applied. For the compatibility of ultrasonic welding, it is necessary to apply the same kind of material to the first resin plate 1 and the second resin plate 2, but if it is an amorphous resin, it is possible to weld different materials. In some cases.

As shown in FIG. 2, a convex portion 12 is formed on the first resin plate 1, and a concave portion 22 is formed on the second resin plate 2. The convex portion 12 is formed on the contact surface 11 of the first resin plate 1 with the second resin plate 2. The recess 22 is provided with an opening 221 on the contact surface 21 of the second resin plate 2 with the first resin plate 1. Further, the inner diameter of the opening 221 is formed so as to be equal to or slightly larger than the outer diameter of the convex portion 12. The convex portion 12 is inserted into the concave portion 22. Therefore, the length of the convex portion 12 and the depth of the concave portion 22 are such that when the contact surface 11 of the first resin plate 1 and the contact surface 21 of the second resin plate 2 are brought into contact with each other, the tip of the convex portion 12 is concave. Designed to contact the bottom of 22.

Further, the recess 22 is formed with a diameter-expanded portion 222 that expands the inner diameter of the recess 22 from an intermediate position in the depth direction. Therefore, as shown in FIG. 2, when the convex portion 12 is inserted into the concave portion 22, a gap 223 is formed between the side surface of the convex portion 12 and the inner side surface of the enlarged diameter portion 222.

The diameter-expanded portion 222 does not have to be formed over the entire circumference on the inner side surface around the bottom of the recess 22, but may be formed at least in a part in the circumferential direction. Therefore, the recess 22 can be formed by using a movable type (not shown). The movable type has, for example, a housing form having the same outer shape as the convex portion 12, and a member that follows the outer shape of the enlarged diameter portion 222 from an intermediate position of the convex portion 12 in the radial direction (direction perpendicular to the insertion direction of the convex portion 12). ) Can be applied in an extended form. Then, resin molding may be performed with the movable mold in the expanded form, and after molding, the movable mold may be placed in the accommodating form and the movable mold may be taken out from the recess 22.

The horn 52 has a boss portion 521 that is inserted into the first resin plate 1 (and the second resin plate 2), and a ring-shaped dome portion 522. At least the tip portion 5211 of the boss portion 521 has a conical shape, and the main body 5212 has a cylindrical shape or a tapered shape in which the outer diameter decreases toward the tip. Then, the tip (apex) of the tip portion 5211 is pressed against the first resin plate 1. The dome portion 522 damps the resin material overflowing from the surface of the first resin plate 1 by inserting the boss portion 521 to form a resin reservoir 31 (FIGS. 3 and 4). The shapes of the boss portion 521 and the dome portion 522 are designed according to the shape of the object to be welded and the form of welding.

As shown in FIGS. 2 and 3, in the manufacturing process of the resin bonded body 100A of the present embodiment, the contact surface 11 of the first resin plate 1 and the contact surface 21 of the second resin plate 2 are brought into contact with each other, and With the convex portion 12 inserted into the concave portion 22, the boss portion 521 (horn 52) ultrasonically vibrated is pressed from a position on the upper surface (back surface) of the first resin plate 1 facing the convex portion 12 ( (See FIG. 2), while melting the resin material of the first resin plate 1 by ultrasonic vibration, the tip of the boss portion 521 is positioned halfway in the length direction of the convex portion 12 (for example, the dome portion 522 is the first resin plate 1). (Position to contact with). At that time, the resin material in which the first resin plate 1 (convex portion 12) is melted extends to the gap 223 and adheres to the inner side surface of the enlarged diameter portion 222, and the remaining resin material is from the surface of the first resin plate 1. It overflows and is dammed by the dome portion 522 to form a resin reservoir 31.

As shown in FIG. 4, by pulling out the horn 52, the melted resin material is solidified to form the resin bonded body 100A of the present embodiment. At this time, the portion from which the boss portion 521 is pulled out remains as a melting hole 32 (cavity in the convex portion 12), and the resin material solidified in the gap 223 (FIG. 2) becomes the deformed portion 4.

In the resin bonded body 100A of the present embodiment, the convex portion 12 is deformed in the radial direction by ultrasonic melting to form the deformed portion 4. The deformed portion 4 has entered the enlarged diameter portion 222 in the recess 22. Therefore, the convex portion 12 and the concave portion 22 have an overhang structure in which the first resin plate 1 and the second resin plate 2 are engaged with each other in the thickness direction by the deformed portion 4 (and the enlarged diameter portion 222). Therefore, in the resin joint 100A, even if a force is applied in the direction in which the first resin plate 1 and the second resin plate 2 are separated from each other, the deformed portion 4 becomes an anchor, and the strength of the resin material of the convex portion 12 is used. The bond can be maintained by the bond strength.

[Effect of the first embodiment]
In the method for producing the resin bonded body 100A according to the present embodiment, the contact surfaces of the first resin plate 1 and the second resin plate 2 and the first resin plate 1 (and either one of the second resin plates 2) that are in contact with each other. A convex portion 12 formed on the 11 and a concave portion 22 formed on the contact surface 21 (of the other) of the (first resin plate 1 and) the second resin plate 2 into which the convex portion 12 is inserted are provided. This is a method for producing the resin bonded body 100A. In this manufacturing method, the horn 52 ultrasonically vibrated with the convex portion 12 inserted in the concave portion 22 is pressed against the first resin plate 1 (and / or the second resin plate 2) to press the convex portion 12 (and / or the second resin plate 2). , And / or the concave portion 22) is deformed in the direction (diameter direction) perpendicular to the insertion direction of the convex portion 12 to form the deformed portion 4, and the convex portion 12 and the concave portion 22 are engaged with each other via the deformed portion 4. It is characterized by matching.

The resin bonded body 100A of the present embodiment realized by the above manufacturing method is formed by a first resin plate 1 and a second resin plate 2 in contact with each other and a first resin plate 1 (and either one of the second resin plates 2). A convex portion 12 formed on the contact surface 11 and a concave portion 22 formed on the contact surface 21 of (the first resin plate 1 and) the second resin plate 2 (whichever is the other) and into which the convex portion 12 is inserted. A deformed portion formed by deforming the resin material (and / or the resin material forming the concave portion 22) forming the convex portion 12 in a direction (diametrical direction) perpendicular to the insertion direction of the convex portion 12 by ultrasonic melting. 4. The convex portion 12 and the concave portion 22 are engaged with each other via the deformed portion 4.

According to the above configuration, the convex portion 12 and the concave portion 22 are engaged with each other via the deformed portion 4, and the deformed portion 4 serves as an anchor against the force for pulling the first resin plate 1 and the second resin plate 2 apart from each other. The first resin plate 1 and the second resin plate 2 are reliably joined based on the strength of the resin material forming the convex portion 12 and / or the resin material forming the periphery of the concave portion 22 (shear strength of the resin material). Can be made to. Therefore, the joint strength can be increased to the same level as the base metal strength without depending on the surface states of the contact surface 11 and the contact surface 21.

Further, in the method for manufacturing the resin bonded body 100A according to the present embodiment, the contact surface 11 of the first resin plate 1 is provided with a convex portion 12, the contact surface 21 of the second resin plate 2 is provided with a concave portion 22, and the concave portion 22 is provided. A position where the horn 52 is pressed against the first resin plate 1 to melt the resin material of the first resin plate 1 and becomes the inside of the convex portion 12. It is characterized in that the resin material of the first resin plate 1 which has been pierced and melted is inserted into the enlarged diameter portion 222 and solidified to form the deformed portion 4.

Therefore, in the resin joint 100A according to the present embodiment, the concave portion 22 is formed with an enlarged diameter portion 222 having an inner diameter larger than that of the opening 221 of the concave portion 22, and the deformed portion 4 extends from the side surface of the convex portion 12. It has entered the enlarged diameter portion 222. As a result, the deformed portion 4 that engages with the recess 22 (diameter-expanded portion 222) can be easily formed.

In the present embodiment, the convex portion 12 is formed on the first resin plate 1 as one of the first resin component and the second resin component, and the concave portion 22 is formed on the second resin plate 2 as the other. 1 A concave portion 22 may be formed in the resin plate 1, a convex portion 12 may be formed in the second resin plate 2, and a horn 52 (boss portion 521) may be inserted from the second resin plate 2 to form the same configuration as in FIG. Further, as long as the structure in which the deformed portion 4 engages with the enlarged diameter portion 222 is maintained, it is not always necessary to completely fill the gap 223 with the resin material.

[Second Embodiment]
FIG. 5 is a cross-sectional view showing the arrangement of the first resin plate 1, the second resin plate 2, and the horn 52 when the resin bonded body 100B of the second embodiment is manufactured. FIG. 6 is a cross-sectional view when the horn 52 (boss portion 521) for manufacturing the resin bonded body 100B of the second embodiment is inserted into the first resin plate 1 and the second resin plate 2. FIG. 7 is a cross-sectional view of the resin bonded body 100B of the second embodiment.

The method for manufacturing the resin bonded body 100B of the second embodiment is characterized in that the horn 52 is penetrated through the convex portion 12 and inserted to an intermediate position in the thickness direction of the second resin plate 2. Therefore, in the resin joint 100B of the second embodiment, the enlarged diameter portion 222 and the deformed portion 4 are formed as in the first embodiment, but the molten hole 32 penetrates the convex portion 12 and is the second resin plate. The bottom is formed at an intermediate position in the depth direction of 2.

In the present embodiment, the length of the boss portion 521 of the horn 52 is designed to be longer than that of the first embodiment. For example, the difference in height between the tip of the boss portion 521 and the lower portion of the dome portion 522 is that of the first resin plate 1. It is designed to be larger than the sum of the thickness and the length of the convex portion 12.

As shown in FIG. 6, by inserting the boss portion 521 until the dome portion 522 comes into contact with the first resin plate 1, the tip of the boss portion 521 penetrates the convex portion 12 and the thickness of the second resin plate 2 is increased. It reaches a position in the middle of the direction. At this time, the resin material forming the convex portion 12 is melted, and the boss portion 521 moves to the portion where the second resin plate 2 is melted.

As shown in FIG. 7, the melting hole 32 is formed by pulling out the boss portion 521. In this embodiment as well, an overhang structure is formed by the deformed portion 4, but the resin material forming the convex portion 12 forms a welded portion 3 ultrasonically welded to the second resin plate 2 at the bottom of the molten hole 32. ..

Since the resin bonded body 100B of the present embodiment has not only the shear strength in the deformed portion 4 similar to the first embodiment but also the welding strength by the welded portion 3, it is possible to obtain a higher bonding strength than in the first embodiment. ..

[Third Embodiment]
FIG. 8 is a cross-sectional view showing the arrangement of the first resin plate 1, the second resin plate 2, and the horn 52 when the resin bonded body 100C of the third embodiment is manufactured. FIG. 9 is a cross-sectional view of the resin bonded body 100C of the third embodiment.

The method for manufacturing the resin bonded body 100C of the third embodiment includes a recess 13 on the contact surface 11 of the first resin plate 1 and a protrusion 14 on the upper surface (the back surface of the contact surface 11) where the recess 13 is hollow. A convex portion 23 is provided on the contact surface 21 of the second resin plate 2. Then, the deformed portion 4 is formed by pressing the horn 52 against the protruding portion 14 and penetrating it from the bottom surface of the concave portion 13 to a position inside the convex portion 23 to expand the diameter of the convex portion 23 and the protruding portion 14. It is characterized by doing.

Therefore, in the resin joint 100C of the third embodiment, the protruding portion 14 is formed on the back surface of the contact surface 11 of the first resin plate 1, and the recess 13 forms a cavity in the protruding portion 14 of the first resin plate 1. The convex portion 23 is formed on the second resin plate 2 so as to communicate with the protruding portion 14 and the convex portion 23, and a melt hole 32 having a bottom portion is formed at an intermediate position of the convex portion 23. Then, the deformed portion 4 engages the convex portion 23 and the concave portion 13 with each other by expanding the diameter of the convex portion 23, the concave portion 13, and the protruding portion 14 in the radial direction.

As shown in FIG. 8, the height of the convex portion 23 and the depth of the concave portion 13 are convex when the contact surface 11 of the first resin plate 1 and the contact surface 21 of the second resin plate 2 are brought into contact with each other. The tip of the 23 is designed to come into contact with the bottom surface of the recess 13.

It is desirable that the protruding portion 14 has a thin hollow structure with the recess 13 so as to facilitate the formation of the deformed portion 4. Further, it is preferable that the inner diameter of the concave portion 13 is designed to be equal to or slightly smaller than the outer diameter of the convex portion 23. It is preferable that the convex portion 23 also has a size slightly larger than the outer diameter of the boss portion 521 so as to facilitate the formation of the deformed portion 4, and is designed to be thinned by inserting the boss portion 521.

As shown in FIG. 9, in the resin joint 100C, a molten hole 32 is formed in which the protruding portion 14 and the convex portion 23 are communicated with each other and a bottom portion is formed at an intermediate position of the convex portion 23, and the inner wall of the molten hole 32 is the protruding portion 14. The resin material of is an welded portion 3 which is ultrasonically welded to the convex portion 23. The deformed portion 4 is formed by expanding the diameter of the convex portion 23, the concave portion 13, and the protruding portion 14 in the radial direction.

In the present embodiment, the boss portion 521 stops piercing up to an intermediate position in the height direction of the convex portion 23 (for example, a position reaching the root of the protruding portion 14 in the height direction), so that the protruding portion 14 The outer diameter of the root position does not change before and after the boss portion 521 is inserted. Therefore, the convex portion 23 and the protruding portion 14 form a tapered deformed portion 4 whose diameter increases toward the tip, and the deformed portion 4 has an overhang structure, and the first resin plate 1 and the second resin plate 2 It is an anchor for the force that separates the two from each other.

In the present embodiment, the bonding strength between the first resin plate 1 and the second resin plate 2 is obtained by the shear strength of the resin material in the deformed portion 4 (convex portion 23, the protruding portion 14) and the welding strength by the welding portion 3. The joint strength is ensured regardless of the surface conditions of the contact surface 11 and the contact surface 21. Further, since the protruding portion 14, the concave portion 13, and the convex portion 23 can be formed without using the movable mold, the manufacturing cost can be reduced.

[Fourth Embodiment]
FIG. 10 is a cross-sectional view showing the arrangement of the first resin plate 1, the second resin plate 2, and the horn 52 (boss portion 521) when the resin bonded body 100D of the fourth embodiment is manufactured. FIG. 11 is a cross-sectional view of the resin bonded body 100D of the fourth embodiment.

The method for manufacturing the resin bonded body 100D of the fourth embodiment is characterized in that the outer diameter of the horn 52 (boss portion 521) is made larger than the outer diameter of the convex portion 23. Therefore, in the resin bonded body 100D of the fourth embodiment, the deformed portion 4 has an overhang structure in which the convex portion 23, the concave portion 13, and the protruding portion 14 are expanded in the radial direction. Further, unlike the third embodiment, the protruding portion 14 has a thick hollow structure.

As shown in FIG. 11, the boss portion 521 is inserted in the same manner as in the third embodiment. In the present embodiment, it is sufficient to insert only the tip portion 5211 of the boss portion 521, but the main body 5212 of the boss portion 521 may be inserted. As a result, the tips of the protruding portion 14 and the convex portion 23 have a conical shape following the taper angle of the tip portion 5211, and the deformed portion 4 in which the protruding portion 14 and the convex portion 23 have an enlarged diameter in the radial direction is formed. Further, the convex portion 23 has a dish-shaped shape in which a tapered outer side surface whose outer diameter increases toward the tip and a tapered inner side surface whose inner diameter increases toward the tip are integrated on the front and back sides. On the inner side surface, a welded portion 3 in which the resin material of the protruding portion 14 is ultrasonically welded is formed.

Similar to the third embodiment, the present embodiment has the shear strength of the resin material of the deformed portion 4 (convex portion 23, the protruding portion 14) and the bonding strength due to the welding strength of the welded portion 3, but the third embodiment. Since the deformed portion 4 can be deformed more in the radial direction than in the third embodiment, the joint strength related to the shear strength of the resin material can be made higher than in the third embodiment. Further, since the protruding portion 14 can be formed to be thick, the rigidity of the joint portion can be increased.

FIG. 12 is a cross-sectional view showing a positioning range of the horn 52 with respect to the first resin plate 1 and the second resin plate 2 when the resin bonded body 100D of the fourth embodiment is manufactured. In the present embodiment, the effective range for positioning the boss portion 521 is a range in which the tip end of the boss portion 521 and the upper end portion of the convex portion 23 overlap in a plan view. As long as the boss portion 521 is arranged in the range, a structure equivalent to the overhang structure shown in FIG. 11 can be formed. Therefore, as in this embodiment. By making the outer diameter of the boss portion 521 larger than the outer diameter of the convex portion 23, the range of positioning between the boss portion 521 and the welding object can be widened.

[Fifth Embodiment]
FIG. 13 is a cross-sectional view showing the arrangement of the first resin plate 1, the second resin plate 2, and the horn 52 (dome portion 522) when the resin bonded body 100E of the fifth embodiment is manufactured. FIG. 14 is a cross-sectional view of the resin bonded body 100E of the fifth embodiment.

In the method for manufacturing the resin bonded body 100E of the fifth embodiment, the contact surface 11 of the first resin plate 1 is provided with a concave portion 15, the contact surface 21 of the second resin plate 2 is provided with a convex portion 24, and the convex portion 24 is provided. , It is a tapered shape that expands in diameter toward the tip. The horn 52 (dome portion 522) has a ring shape having an inner diameter larger than the inner diameter of the recess 15. Then, the horn 52 is ultrasonically vibrated and pressed against the first resin plate 1 so that the concave portion 15 is inside in a plan view, and the resin material around the concave portion 15 of the first resin plate 1 is melted to melt the convex portion 24. It is characterized in that the deformed portion 4 is formed by being brought into close contact with the side surface of the surface and solidified.

Therefore, in the resin joint 100E of the fifth embodiment, the concave portion 15 is formed on the first resin plate 1, the convex portion 24 is formed on the second resin plate 2, and the diameter increases toward the tip. It has a tapered shape. The deformed portion 4 is formed by ultrasonically melting the resin material around the concave portion 15 of the first resin plate 1 so as to be in close contact with the convex portion 24, and engages the convex portion 24 and the concave portion 15 with each other. ..

In the present embodiment, the horn 52 does not have the boss portion 521 (FIG. 2) and is formed only by the dome portion 522. The convex portion 24 formed on the second resin plate 2 has a tapered shape whose diameter increases toward the tip, but it does not have to have a tapered shape on the entire circumference of the side surface. Therefore, the convex portion 24 can be formed by using a movable mold.

The cross-sectional shape of the convex portion 24 is preferably circular, but triangles, quadrangles, and other polygons can also be applied as cross-sectional shapes other than circular. The height of the convex portion 24 is formed so as to have the same dimension as the depth of the concave portion 15 or a dimension slightly smaller than the depth of the concave portion 15, and even if the convex portion 24 is inserted into the concave portion 15, the first resin plate 1 The contact surface 11 of the above and the contact surface 21 of the second resin plate 2 are in contact with each other.

As shown in FIG. 13, when the convex portion 24 is inserted into the concave portion 15, a gap 151 is formed between the inner side surface of the concave portion 15 and the side surface of the convex portion 24. Then, as shown in FIG. 14, when the dome portion 522 is pressed against the upper surface of the first resin plate 1, the resin material around the concave portion 15 of the first resin plate 1 melts and moves to the gap 151 to move to the gap 151 of the convex portion 24. Adhere to the side. When the horn 52 is pulled out in this state, the molten resin material is solidified, and the concave portion 15 has a deformed portion 4 whose inner side surface is formed so as to follow the side shape of the convex portion 24. When the horn 52 is pulled out, a ring-shaped groove 16 that follows the outer shape of the dome portion 522 is formed on the back surface of the first resin plate 1.

In the resin bonded body 100E of the present embodiment, the convex portion 24 has a tapered shape whose diameter increases toward the tip, and has an overhang structure in which the deformed portion 4 engages with the convex portion 24. Reference numeral 24 denotes an anchor for the force that separates the first resin plate 1 and the second resin plate 2 from each other. Therefore, also in this embodiment, the first resin plate 1 and the second resin plate 2 can be reliably joined regardless of the surface conditions of the contact surface 11 and the contact surface 21.

[Sixth Embodiment]
FIG. 15 is a cross-sectional view showing the arrangement of the first resin plate 1, the second resin plate 2, and the horn 52 (boss portion 521) when the resin bonded body 100F of the sixth embodiment is manufactured. FIG. 16 is a cross-sectional view of the resin bonded body 100F of the sixth embodiment.

The method for manufacturing the resin joint body 100F of the sixth embodiment uses the resin joint body 100E of the fifth embodiment, and after forming the deformed portion 4, the horn 52 having a larger outer diameter than the convex portion 24 ( The second horn and the boss portion 521) are inserted from a position facing the convex portion 24 of the first resin plate 1 to deform the convex portion 24 and the concave portion 15 in a direction (diameter direction) perpendicular to the insertion direction of the convex portion 24. It is characterized by.

Therefore, in the resin bonded body 100F of the sixth embodiment, the concave portion 15 is formed on the first resin plate 1, the convex portion 24 is formed on the second resin plate 2, and the diameter increases toward the tip. It has a tapered shape. The deformed portion 4 is formed so that the resin material around the concave portion 15 of the first resin plate 1 is ultrasonically melted and brought into close contact with the convex portion 24.

In the present embodiment, the convex portion 24 has a shape in which a tapered outer side surface whose outer diameter increases toward the tip and a tapered inner side surface whose inner diameter increases toward the tip are integrated on the front and back sides. On the inner side surface, a welded portion 3 in which the resin material of the first resin plate 1 is ultrasonically welded is formed.

In the resin bonded body 100F of the present embodiment, as compared with the resin bonded body 100E of the fifth embodiment, not only the deformed portion 4 is further expanded in the radial direction (the taper angle of the convex portion 24 is increased), but also. The structure is such that the resin material of the first resin plate 1 has a welded portion 3 ultrasonically welded on the upper surface of the convex portion 24. Therefore, the bonding strength related to the shear strength of the resin material is higher than that of the fifth embodiment, and the welding strength by the welding portion 3 is also added, so that the bonding strength can be higher than that of the fifth embodiment. ..

[7th and 8th embodiments]
FIG. 17 is a cross-sectional view showing a manufacturing process (before forcibly pulling out) of the second resin plate 2 of the resin bonded body of the seventh embodiment. FIG. 18 is a cross-sectional view showing a manufacturing process (after forcibly removing) the second resin plate 2 of the resin joint of the seventh embodiment. FIG. 19 is a cross-sectional view showing a manufacturing process (before forcibly pulling out) of the second resin plate 2 of the resin bonded body of the eighth embodiment. FIG. 20 is a cross-sectional view showing a manufacturing process (after forcibly removing) the second resin plate 2 of the resin joint of the eighth embodiment.

The seventh embodiment and the eighth embodiment are modifications of the first embodiment or the second embodiment, and represent a case where the second resin plate 2 can be formed by the fixed mold 6. By taking such a form, the manufacturing cost can be reduced.

The recess 22 of the second resin plate 2 constituting the resin joint of the seventh embodiment has a diameter-expanded portion 222 having a so-called bulge shape, and the fixed mold 6 has the recess 22 and the diameter-expanded portion 222. A bulge-shaped protrusion 61 formed following the outer shape is formed. The recess 22 of the second resin plate 2 constituting the resin joint of the eighth embodiment has a tapered diameter-expanded portion 222 whose inner diameter increases toward the bottom of the recess 22, and the fixed mold 6 has a tapered portion 222. , A tapered protrusion 61 formed following the outer shape of the recess 22 and the enlarged diameter portion 222 is formed. In any of the embodiments, since the resin material of the second resin plate 2 has flexibility, the opening 221 of the recess 22 of the second resin plate 2 is widened after the resin molding of the second resin plate 2. The second resin plate 2 can be taken out from the fixed mold 6 by forcibly pulling out the protrusion 61 from the recess 22 while deforming it.

[9th Embodiment]
FIG. 21 is a cross-sectional view showing the arrangement of the electronic substrate 1A and the electronic element 2A when the resin bonded body 100G of the ninth embodiment is manufactured. FIG. 22 is a cross-sectional view of the resin bonded body 100G of the ninth embodiment. The resin bonded body 100G of the ninth embodiment is an application of the resin bonded body of the seventh embodiment, and is an electronic substrate 1A (first resin component) and an electronic element 2A (second) mounted on the electronic substrate 1A. It has a device structure equipped with (resin parts).

The resin joint 100G of the present embodiment is preferably applied to an inverter mounted on an electric vehicle or the like. The electronic element 2A is, for example, a capacitor in which the periphery of an electrolytic capacitor is covered with resin, and a plurality of recesses 22 are formed on the contact surface 21 (mounting surface) thereof, and the recesses 22 have a bulge-shaped enlarged diameter portion 222. Is formed. On the other hand, a convex portion 12 is formed at a position facing the concave portion 22 of the electronic substrate 1A (inverter case), and the electronic element 2A is mounted on the electronic substrate 1A so that the convex portion 12 is inserted into the concave portion 22.

Although not shown, connection electrodes and wiring that electrically connect to the electronic element 2A are arranged on the contact surface 11 (mounting surface) of the electronic substrate 1A (inverter case). Further, outside the electronic element 2A, an external electrode for electrically connecting the internal electrolytic capacitor and the connection electrode arranged in the electronic element 2A is arranged, and the connection electrode and the external electrode are wire or the like. Is connected by.

In the present embodiment, the boss portion 521 (FIG. 2) of the horn 52 ultrasonically vibrated from a position facing the convex portion 12 on the back surface of the electronic substrate 1A is inserted, and the boss portion 521 is inserted in the length direction of the convex portion 12. Insert it to the middle position. As a result, the resin material of the convex portion 12 melts and enters the enlarged diameter portion 222 to adhere to the convex portion 12. Then, the molten hole 32 is formed by pulling out the boss portion 521, and the resin material in which the molten resin material solidifies and enters the diameter-expanded portion 222 becomes the deformed portion 4. As a result, the electronic substrate 1A having the convex portion 12 and the electronic element 2A having the concave portion 22 are engaged with each other via the deformed portion 4, and the deformed portion 4 separates the electronic substrate 1A and the electronic element 2A from each other. It becomes an anchor against force. Therefore, the electronic element 2A can be reliably mounted on the electronic substrate 1A regardless of the surface states of the contact surface 11 and the contact surface 21.

As the device for forming the resin joint of the present embodiment, the ultrasonic welding and fixing device 5 shown in FIG. 1 has been mentioned, but the present invention is not limited to this, and for example, a hand portion having a mechanism capable of freely rotating is used. Any equipment can be configured as long as it can be formed as described above, such as a robot arm or an operating / rotary table.

Although the embodiments of the present invention have been described above, the above embodiments are only a part of the application examples of the present invention, and the technical scope of the present invention is limited to the specific configurations of the above embodiments. No.

100A Resin joint 1 1st resin plate 11 Contact surface 12 Convex part 2 2nd resin plate 21 Contact surface 22 Concave part 221 Opening part 222 Diameter enlarged part 4 Deformed part

Claims (9)

The first resin part and the second resin part that come into contact with each other,
The convex portion formed on the contact surface of the first resin component and
A concave portion formed on the contact surface of the second resin component and into which the convex portion is inserted,
A method for manufacturing a resin joint, comprising: the recess has a diameter-expanded portion that is larger than the opening of the recess.
A horn that has been ultrasonically vibrated with the convex portion inserted into the concave portion is pressed against the first resin component to melt the resin material of the first resin component to a position inside the convex portion. The resin material of the first resin part, which has been pierced and melted, is inserted into the enlarged diameter portion and solidified to form a deformed portion.
A method for producing a resin bonded body, which comprises engaging the convex portion and the concave portion with each other via the deformed portion. The resin joint according to claim 1, wherein the enlarged diameter portion has a bulge shape that expands in diameter at a depth position in the middle of the recess, or a tapered shape that expands in diameter toward the bottom of the recess. Manufacturing method. The method for producing a resin bonded body according to claim 1, wherein the horn is penetrated through the convex portion and inserted into the second resin component at an intermediate position in the thickness direction. The first resin part and the second resin part that come into contact with each other,
A recess formed on the contact surface of the first resin component and
A protruding portion in which the recess is hollow on the back surface of the contact surface of the first resin component,
A method for manufacturing a resin joint including a convex portion formed on a contact surface of the second resin component.
A horn ultrasonically vibrated with the convex portion inserted into the concave portion is pressed against the first resin component, penetrated from the bottom surface of the concave portion, and inserted to a position inside the convex portion. A deformed portion is formed by expanding the diameter of the convex portion and the protruding portion.
A method for producing a resin bonded body, which comprises engaging the convex portion and the concave portion with each other via the deformed portion. The method for manufacturing a resin bonded body according to claim 4, wherein the outer diameter of the horn is made larger than the outer diameter of the convex portion. The first resin part and the second resin part that come into contact with each other,
A recess formed on the contact surface of the first resin component and
A method for manufacturing a resin joint having a convex portion formed on the contact surface of the second resin component and having a tapered shape in which the convex portion expands in diameter toward the tip.
The first horn that is ultrasonically vibrated with the convex portion inserted into the concave portion and has a ring-shaped inner diameter larger than the inner diameter of the concave portion so that the concave portion is inside in a plan view. The deformed portion is formed by pressing against the resin component of the first resin component, melting the resin material around the concave portion of the first resin component, and bringing the resin material into close contact with the side surface of the convex portion to solidify.
A method for producing a resin bonded body, which comprises engaging the convex portion and the concave portion with each other via the deformed portion. After forming the deformed portion, a second horn having an outer diameter larger than that of the convex portion is inserted from a position facing the convex portion of the first resin component, and the convex portion and the concave portion are inserted into the convex portion. The method for producing a resin bonded body according to claim 6, wherein the resin bonded body is deformed in a direction perpendicular to the direction. The method for manufacturing a resin bonded body according to any one of claims 1 to 7, wherein the first resin component constitutes an electronic substrate, and the second resin component constitutes an electronic device. .. The first resin part and the second resin part that come into contact with each other,
A convex portion formed on the contact surface of either the first resin component or the second resin component, and
A concave portion formed on the contact surface of any one of the first resin component and the second resin component and into which the convex portion is inserted is provided.
The recess is formed with an enlarged diameter portion that expands the inner diameter of the recess from an intermediate position in the depth direction of the recess.
The convex portion is formed with a deformed portion that is deformed in a direction perpendicular to the insertion direction of the convex portion and enters the enlarged diameter portion, and has a cavity in the convex portion.
A resin joint body in which the convex portion and the concave portion are engaged with each other via the deformed portion and the enlarged diameter portion.

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