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レーザ加工 | 樹脂溶着
レーザ光により溶着界面で熱エネルギーを発生させ、非接触で溶融させる加工方法で、高出力半導体レーザの普及により注目を浴びています。代表的な接合方法としては、「レーザ透過溶着法」と「レーザ浸透溶着法（ACW®法）」があります。高速・高強度・防水性の高い接合を可能とし、自動車産業や電子産業などで使用されている新しい加工方法です。
樹脂溶着のメリット
工程の効率化
- Oリングレス、接着剤レスによる部品点数の削減
- レーザ照射のみで接合・防水するため、工程の簡略化を実現
- 高速接合
- 摩耗物、消耗品がなく、工程の安定化を実現
- 全自動化が容易
製品の高付加価値化
- 高強度の接合が可能なため、母材強度並の接合強度を実現
- 振動レス、局所加熱による内部への影響低減
- 界面のみを溶融することで外観の向上が可能
加工実例
浸透溶着法
・突合わせ溶着が可能
・隙間に対する余裕度が高い溶着法
・同一材料の溶着が可能で、金型コストダウン
※サンプルご提供：旭化成ケミカルズ株式会社様
透過溶着法
・再生可能資源原料（バイオプラスチック）でも溶着可能
・環境負荷の少ない（低消費電力、溶剤レス）接合方法
※サンプルご提供：デュポン株式会社様
再生可能資源原料使用 ソロナ®
・パステルカラー材の溶着が可能
・レーザ吸収材を塗布することにより、色合わせが簡単
※サンプルご提供：オリヱント化学工業株式会社様
素早く効率的な加工条件の設定方法
レーザ樹脂溶着で良好な加工結果を得るためには、レーザ出力と加工速度の最適なバランスを見つけることが重要ですが、それらを導くためには様々な条件で膨大なデータを取得する必要があるため、非常に多くの工数が発生します。しかしながら、加工点の温度を測定しながらレーザ樹脂溶着することで、最適な条件を容易に導き出すことが可能です。近年、需要が高まっている難燃性樹脂のうち、変性PPEを用いた実例をご紹介します。
＊この実例は、旭化成株式会社様よりご提供いただいた 変性PPE樹脂 ザイロン™ を使用しています。
旭化成株式会社様のレーザー溶着に適した樹脂材料は こちら からご確認いただけます。
この事例で使用した製品
加工温度をリアルタイムで計測する機能を備えたレーザ加熱システムです。
需要が高まる難燃性樹脂
近年、電気自動車やドローンなどの普及にともない、2次電池やモーターの需要が増加しています。さらに軽量化の要求により、部品の樹脂化も進んでいます。このような製品では難燃性が非常に重要な要素となり今後需要が増加していくものと考えられます。難燃性樹脂のひとつである変性PPEには以下のような特長があります。
変性PPEの特長
- 難燃性
- エンジニアリングプラスチックの中では最軽量
- 広い温度範囲で機械特性が安定している
- 電気特性に優れる
- 寸法精度が良い
- 耐薬品性
- 無毒
温度測定による加工条件導出のメリット
難燃性樹脂の溶着強度とレーザ出力の関係を、様々な加工速度で測定してグラフ化しても一貫性がありません。このように、レーザ樹脂溶着の最適な加工条件を導くことは困難でした。
各加工速度におけるレーザ出力と引張強度の関係
一方、溶着強度と加工点温度の関係をグラフ化すると、加工速度によって最適な温度帯は異なりますが一定の関係性があることが分かります。
各加工速度における加工点温度と引張強度の関係
加工点温度はレーザ出力と比例するため、加工速度ごとに最適な加工点温度が計測できれば必要なレーザ出力を算出することが可能です。
各加工速度におけるレーザ出力と加工点温度の関係
レーザ出力を上げていくと一定の比率で加工点温度も上昇していきますが、どの加工速度においても一定のレーザ出力を超えると、加工点温度の上昇比率が変化するのと同時に溶着強度が大きく低下します。この加工点温度の上昇比率が変化するレーザ出力が、溶着強度が最大になる加工条件となります。
このように加工点温度に基づいて溶着強度を検証することで、少ない実験回数で最適な条件を予測することができます。さまざまな条件で大量のデータを測定する必要がなくなるため、加工条件を簡単に導くことができます。さらに、これらの結果を積み重ねることで機械学習的に加工条件を予測することも期待されています。
加工速度 10 mm/sec における
加工点温度の上昇比率と引張強度の関係
加工速度 30 mm/sec における
加工点温度の上昇比率と引張強度の関係
加工速度 50 mm/sec における
加工点温度の上昇比率と引張強度の関係
各工法特性比較表
| レーザ溶着 | 超音波溶着 | 熱板溶着 | 振動溶着 | 接着剤 | |
|---|---|---|---|---|---|
| 接着強度・信頼性 | ◎ | △ | ◎ | ◎ | △ |
| 内部への影響 | ◎ | × | △ | × | △ |
| 意匠性 | ◎ | △ | △ | △ | △ |
| 設計の自由度 | ○ | × | △ | △ | ○ |
| 生産性 | ○ | ○ | △ | ○ | △ |
| 安定性 | ◎ | △ | ○ | △ | △ |
おすすめ製品
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