Welding method, resin joined body, and square housing

Abstract

The invention relates to a welding method, a resin assembly, and a square housing. Provided are a welding method, a resin joined body, and a square housing, whereby it is possible to reliably perform laser welding while suppressing an increase in size. In a state in which the first resin member (2) and the second resin member (3) are pressurized, the first resin member (2) and the second resin member (3) are welded by irradiation of laser light. The first resin member (2) is a light-absorbing resin member that absorbs laser light, and the second resin member (3) is a light-transmitting resin member that transmits laser light. A lower inclined surface (31) inclined with respect to the pressing direction is formed on the second resin member (3), and an opposing surface (21) that faces the lower inclined surface (31) and contacts the lower inclined surface (31) by pressing is formed on the first resin member (2). In the welding step, the first resin member (2) and the second resin member (3) are welded by irradiating a laser beam through the second resin member (3) from a direction intersecting the pressing direction toward a contact portion (53) between the lower inclined surface (31) and the facing surface (21).

Description

Technical Field

[0001] This invention relates to a welding method for welding multiple resin components, a resin joint, and a square housing. Background Technology

[0002] In the past, resin joints, which consist of multiple resin components joined together by laser welding, were used in various applications.

[0003] The motor described in Patent Document 1 includes a resin housing that houses the rotor and stator, and a resin cover that covers the upper part of the housing. The cover is joined to the housing by laser welding. The cover integrally has a disc-shaped top plate and a cylindrical peripheral wall, the peripheral wall surrounding the outer periphery of the upper cylindrical portion of the housing. A welded portion based on laser welding is continuously formed in a ring shape between the outer peripheral surface of the upper cylindrical portion and the inner peripheral surface of the peripheral wall.

[0004] Patent Document 2 describes an automotive fluid filtration device that uses laser welding to join an upper housing structure component made of laser-transparent resin and a lower housing structure component made of laser-non-transparent resin, thus forming a resin housing for housing a filter element. Laser welding is performed by irradiating a laser beam from above the upper flange of the upper housing structure component toward the lower flange of the lower housing structure component, with the upper flange abutting against the lower flange of the lower housing structure component.

[0005] Patent Document 1: Japanese Patent Application Publication No. 2021-58001

[0006] Patent Document 2: Japanese Patent Application Publication No. 2006-231875

[0007] In the device described in Patent Document 1, laser welding may not be properly performed in the gap created by the difference between the outer diameter of the upper cylindrical portion of the outer casing and the inner diameter of the peripheral wall portion of the cover. In the device described in Patent Document 2, the resin housing may become larger due to the provision of an upper flange portion and a lower flange portion, thereby reducing its vehicle-mountability. Summary of the Invention

[0008] Therefore, the object of the present invention is to provide a welding method, a resin joint, and a square housing that can suppress large-scale growth and reliably perform laser welding.

[0009] To achieve the above objective, the present invention provides a welding method in which, under pressure in a manner that brings a light-transmitting resin component and a light-absorbing resin component into contact, the light-transmitting resin component and the light-absorbing resin component are welded by laser irradiation. One of the light-transmitting resin component and the light-absorbing resin component has an inclined surface that is tilted relative to the pressure direction, and the other component has a opposing surface facing the inclined surface. While the light-transmitting resin component and the light-absorbing resin component are under pressure, causing the inclined surface to contact the opposing surface, the laser is passed through the light-transmitting resin component and irradiated from a direction intersecting the pressure direction toward the contact portion between the inclined surface and the opposing surface, thereby welding the light-transmitting resin component and the light-absorbing resin component.

[0010] In addition, in order to achieve the above-mentioned objective, the present invention provides a resin bond comprising a light-transmitting resin component and a light-absorbing resin component, wherein a portion of each of the light-transmitting resin component and the light-absorbing resin component is melted and bonded by laser irradiation, and the joint portion for bonding the light-transmitting resin component and the light-absorbing resin component is formed at an angle relative to the stacking direction of the light-transmitting resin component and the light-absorbing resin component.

[0011] In addition, in order to achieve the above-mentioned objective, the present invention provides a square shell, which is formed by melting and joining a portion of the light-transmitting resin component and the light-absorbing resin component by laser irradiation. The shell has a square-shaped bottom plate portion and a plurality of side plate portions extending from the bottom plate portion in a direction perpendicular to the bottom plate portion. The joint portion that joins the light-transmitting resin component and the light-absorbing resin component is formed obliquely to the plurality of side plate portions relative to the direction perpendicular to the bottom plate portion.

[0012] According to the welding method, resin joint, and square shell of the present invention, large-scale production can be suppressed and laser welding can be reliably performed. Attached Figure Description

[0013] Figure 1 This is an external view of a battery pack module having a square casing according to the first embodiment.

[0014] Figure 2 It is an exploded 3D view of a square shell.

[0015] Figure 3 This is a cross-sectional view of the battery pack module.

[0016] Figure 4 yes Figure 3 An enlarged view of part A.

[0017] Figure 5 yes Figure 3 An enlarged view of part B.

[0018] Figure 6 It is a cross-sectional view showing a portion of the first resin component and a portion of the second resin component before the first resin component and the second resin component are welded together.

[0019] Figure 7 It is a cross-sectional view showing a state in which the first resin component and the second resin component are in contact with each other and pressurized in the vertical direction.

[0020] Figure 8 It is a cross-sectional view showing a portion of the second resin component and a portion of the third resin component before the second resin component and the third resin component are welded together.

[0021] Figure 9 It is a cross-sectional view showing that the second resin component and the third resin component are in contact with each other and are pressurized in the vertical direction.

[0022] Figure 10 This is an illustration of the welding process in which a second resin component, a first resin component, and a third resin component are welded together by irradiation with a laser.

[0023] Figure 11 This is an explanatory diagram of a variation of the first embodiment, Example 1.

[0024] Figure 12 This is an explanatory diagram of a variation of the first embodiment, Example 2.

[0025] Figure 13 This is an explanatory diagram of variation 3 of the first embodiment.

[0026] Figure 14 This is an explanatory diagram showing the welding process during the manufacturing of the square shell according to the second embodiment.

[0027] Figure 15 It is an enlarged representation Figure 14 A magnified view of a portion of it. Detailed Implementation

[0028] [First Implementation]

[0029] Reference Figures 1-10 The first embodiment of the present invention will be described below. Furthermore, the embodiments described below are shown as preferred examples for carrying out the present invention, wherein some details specifically illustrate various technically preferred aspects, but the scope of the present invention is not limited to these specific embodiments.

[0030] Figure 1This is an external view of the battery pack module 1 having the square housing 10 of the first embodiment. Figure 2 This is an exploded perspective view of the square shell 10. Figure 3 This is a cross-sectional view of battery module 1. Figure 4 yes Figure 3 An enlarged view of part A. Figure 5 yes Figure 3 An enlarged view of part B. Battery module 1 is used, for example, as a power source for a vehicle equipped with an electric motor that serves as a driving source for travel.

[0031] Battery module 1 has a resin square casing 10 and multiple pouch cells 11. Figure 3 (As shown), and a circuit board 12 on which multiple electronic components 121 are mounted. Multiple pouch batteries 11 and the circuit board 12 are housed in a square housing 10. The square housing 10 is one embodiment of the resin bonding body of the present invention. The pouch batteries 11 are rechargeable and dischargeable secondary batteries, and more specifically, are lithium batteries or lithium-ion capacitors with a laminated film as the outer packaging material.

[0032] In this embodiment, four pouch cells 11 are housed in a square casing 10, and the positive and negative electrodes of the pouch cells 11 are connected in series. The circuit board 12 is equipped with multiple electronic components 121, such as ICs, resistors, and capacitors, for monitoring and controlling the charging state, current, and temperature of each pouch cell 11.

[0033] The square housing 10 has a square-shaped base plate portion 100 and a plurality of side plate portions 101 to 104 extending from the base plate portion 100 in a direction perpendicular to the base plate portion 100. In this embodiment, the base plate portion 100 is rectangular. Hereinafter, the direction perpendicular to the base plate portion 100 will be referred to as the vertical direction, and the direction perpendicular to the vertical direction and perpendicular to the thickness direction of each of the side plate portions 101 to 104 will be referred to as the horizontal direction. However, the vertical direction and the horizontal direction may not necessarily correspond to the vertical direction and the horizontal direction when the battery pack module 1 is in use.

[0034] Of the multiple side plate portions 101 to 104, the two side plate portions 101 and 103 extending upward and downward from the long side of the base plate portion 100 have a wider lateral width than the other two side plate portions 102 and 104 extending upward and downward from the short side of the base plate portion 100. Four pouch-type batteries 11 are arranged between the two side plate portions 101 and 103 with the wider lateral width. Figure 3 The image shows a cross-section of the bottom plate portion 100 and the two side plate portions 101 and 103 along the vertical direction.

[0035] In this embodiment, the square housing 10 has a three-piece structure, consisting of first to third resin components 2 to 4. The first to third resin components 2 to 4 are arranged vertically, and a second resin component 3 is disposed between the first resin component 2 and the third resin component 4. A portion of each of the first resin component 2 and the second resin component 3, and the second resin component 3 and the third resin component 4, are hermetically welded together by laser irradiation.

[0036] The base plate 100 and multiple side plates 101-104 of the square housing 10 are formed by a first resin component 2. A second resin component 3 is continuously disposed at the end of the side plates 101-104 of the first resin component 2 on the side opposite to the base plate 100. A third resin component 4 is a rectangle whose length in the long side direction is shorter than that of the base plate 100, and covers the opening on the upper side of the second resin component 3.

[0037] like Figure 2 As shown, the second resin component 3 is provided with a connecting hole 300 that connects the internal space of the first resin component 2 with the internal space of the second resin component 3. The third resin component 4 is provided with a through hole 400, which is sealed by a cap 13. The cap 13 prevents foreign objects from entering the interior of the square housing 10 through the through hole 400. When the pressure difference between the inside and outside of the square housing 10 increases, air flows through the through hole 400, mitigating the pressure difference.

[0038] In this embodiment, the second resin component 3 is a light-transmitting resin component made of a light-transmitting resin that allows laser light to pass through. The first resin component 2 and the third resin component 4 are light-absorbing resin components made of a light-absorbing resin that absorbs laser light. That is, in this embodiment, the square housing 10 is composed of one light-transmitting resin component (the second resin component 3) and two light-absorbing resin components (the first resin component 2 and the third resin component 4). The light-transmitting resin component (the second resin component 3) is sandwiched between the two light-absorbing resin components (the first resin component 2 and the third resin component 4).

[0039] The resin materials of the second resin component 3, the first resin component 2, and the third resin component 4 are preferably highly compatible, and more preferably the same resin. Furthermore, the resin materials of the first to third resin components 2 to 4 preferably possess high strength and low moisture absorption, capable of withstanding vibrations and impacts during vehicle operation. In this embodiment, the second resin component 3 is composed of PBT (polybutylene terephthalate), and the first resin component 2 and the third resin component 4 are composed of PBT containing laser-absorbing materials such as carbon black. However, the resin materials of the first to third resin components 2 to 4 are not limited to PBT; for example, PPS (polyphenylene sulfide) and PP (polypropylene) can also be used.

[0040] Figure 4 The junction 51 between the first resin component 2 and the second resin component 3, as well as its peripheral portion, are shown. The junction 51 is formed by fusing and curing a portion of the first resin component 2 and a portion of the second resin component 3. Figure 4 In the cross-section shown, the joint 51 is an elongated oval shape that is inclined relative to the stacking direction of the first resin component 2 and the second resin component 3, that is, the vertical direction, and is formed in a ring shape throughout the multiple side plate portions 101 to 104.

[0041] Figure 5 The junction 52 between the second resin component 3 and the third resin component 4, as well as its peripheral portion, are shown. The junction 52 is formed by fusing and curing a portion of the second resin component 3 and a portion of the third resin component 4. Figure 5 In the cross-section shown, the joint 52 is an elongated oval shape that is inclined relative to the stacking direction of the second resin component 3 and the third resin component 4, that is, the vertical direction, and is formed in a ring shape along the periphery of the third resin component 4.

[0042] The welding of the first resin component 2 to the second resin component 3, and the welding of the second resin component 3 to the third resin component 4, are performed while the second resin component 3 is clamped between the first resin component 2 and the third resin component 4, and pressure is applied to the first to third resin components 2 to 4 in the vertical direction. The second resin component 3 has a lower welding portion 301 at the end located on the side of the first resin component 2, and an upper welding portion 302 at the end located on the side of the third resin component 4.

[0043] Next, refer to Figures 6-10 The welding methods for the second resin component 3, the first resin component 2, and the third resin component 4 are described in detail.

[0044] Figure 6 This is a cross-sectional view showing a portion of each of the first resin component 2 and the second resin component 3 before they are welded together. Figure 7 It is a cross-sectional view showing that the first resin component 2 and the second resin component 3 are in contact with each other and are pressurized in the vertical direction. Figure 6 as well as Figure 7 A cross-section perpendicular to the transverse direction is shown of the side plate portion 101 of the square housing 10.

[0045] The lower welding portion 301 of the second resin component 3 is provided with a conical lower inclined surface 31 that is inclined relative to the pressure direction during welding. The lower inclined surface 31 is formed in an annular shape corresponding to each of the plurality of side plate portions 101 to 104 and faces towards the inner side of the square housing 10. Figure 6In the example shown, the tilt angle θ1 of the lower inclined surface 31 relative to the pressure direction (vertical direction) is 30°. However, the tilt angle θ1 is not limited to 30°; for example, it can be any angle between 20° and 70°.

[0046] Furthermore, a lower sidewall portion 32 is provided on the lower weld portion 301 of the second resin component 3, which runs parallel to the lower inclined surface 31 in a direction perpendicular to the pressurization direction. A gap 303 is formed between the lower inclined surface 31 and the lower sidewall portion 32. The lower sidewall portion 32 is formed to protrude downward (towards the base plate portion 100) from the upper end of the lower inclined surface 31. A guide surface 321 is formed at the front end of the lower sidewall portion 32, which is inclined relative to the vertical direction and is used to facilitate the introduction of the weld portion 20 of the first resin component 2 (described below) into the gap 303.

[0047] The welding portion 20 of the first resin component 2, which is welded to the lower welding portion 301 of the second resin component 3, has a counter surface 21 opposite to the lower inclined surface 31. The counter surface 21 is a convex shape protruding towards the lower inclined surface 31 of the second resin component 3. More specifically, the counter surface 21 is formed as a convex curved surface. Figure 6 as well as Figure 7 The opposite surface 21 of the cross section shown is arc-shaped.

[0048] When the first resin component 2 and the second resin component 3 are pressurized, the portion of the first resin component 2 in which the opposing surface 21 is formed, namely the welding portion 20, is disposed between the lower inclined surface 31 and the lower side wall portion 32. A portion of the lower inclined surface 31 of the second resin component 3 and a portion of the opposing surface 21 of the first resin component 2 are in linear contact in the contact portion 53.

[0049] An abutment surface 22 is formed in the weld portion 20 of the first resin component 2. This abutment surface 22 is opposite to the lower sidewall portion 32 of the second resin component 3 in the thickness direction and abuts against the lower sidewall portion 32 when the first resin component 2 is elastically deformed under pressure. The lower sidewall portion 32 restricts the warping of the weld portion 20 in the thickness direction caused by the contact between the opposing surface 21 and the lower inclined surface 31 and the pressure applied.

[0050] Figure 8 This is a cross-sectional view showing a portion of each of the second resin component 3 and the third resin component 4 before they are welded together. Figure 9 This is a cross-sectional view showing the state in which the second resin component 3 and the third resin component 4 are in contact with each other and are pressurized in the vertical direction.

[0051] The upper welding portion 302 of the second resin component 3 is provided with a conical upper inclined surface 33 that is inclined relative to the pressure direction (vertical direction) during welding. The upper inclined surface 33 faces the inner side of the square housing 10. Figure 8 In the middle, the tilt angle θ2 of the upper inclined surface 33 relative to the pressure direction is 30°. However, the tilt angle θ2 is not limited to 30°, for example, it can be between 20° and 70°.

[0052] Furthermore, an upper sidewall portion 34 is provided on the upper weld portion 302 of the second resin component 3, parallel to the upper inclined surface 33 in a direction perpendicular to the pressurization direction. A gap 304 is formed between the upper inclined surface 33 and the upper sidewall portion 34. The upper sidewall portion 34 is formed to protrude upward (towards the third resin component 4) from the lower end of the upper inclined surface 33. A guide surface 341 is formed at the front end of the upper sidewall portion 34, which is inclined relative to the vertical direction and is used to facilitate the introduction of the weld portion 40 of the third resin component 4 (described below) into the gap 304.

[0053] The welding portion 40 of the third resin component 4, which is welded to the upper welding portion 302 of the second resin component 3, has a counter surface 41 opposite to the upper inclined surface 33. The counter surface 41 is a convex shape protruding towards the upper inclined surface 33 of the second resin component 3. More specifically, the counter surface 41 is formed as a convex curved surface. Figure 8 as well as Figure 9 The opposite surface 41 of the cross section shown is arc-shaped.

[0054] When the second resin component 3 and the third resin component 4 are pressurized, the portion of the third resin component 4 in which the opposing surface 41 is formed, namely the welding portion 40, is disposed between the upper inclined surface 33 and the upper side wall portion 34. A portion of the upper inclined surface 33 of the second resin component 3 and a portion of the opposing surface 41 of the third resin component 4 are in linear contact in the contact portion 54.

[0055] Furthermore, an abutment surface 42 is formed on the weld portion 40 of the third resin component 4. This abutment surface 42 is opposite to the upper sidewall portion 34 of the second resin component 3 in the thickness direction and abuts against the upper sidewall portion 34 when the third resin component 4 elastically deforms under pressure. The upper sidewall portion 34 restricts warping of the weld portion 40 in the thickness direction caused by pressure due to the contact between the opposing surface 41 and the upper inclined surface 33.

[0056] Figure 10 This diagram illustrates a welding process in which a second resin component 3, a first resin component 2, and a third resin component 4 are welded together by laser irradiation. In this welding process, lasers 610 and 620 are irradiated onto the first to third resin components 2 to 4 from a portion located on the outside of the square housing 10, simultaneously welding the first resin component 2 to the second resin component 3 and the second resin component 3 to the third resin component 4. Furthermore, the first to third resin components 2 to 4 are pre-formed through an injection molding process performed prior to the welding process. Figure 10In the diagram, arrow F1 indicates the pressure direction of the first to third resin components 2 to 4.

[0057] The welding of the first resin component 2 and the second resin component 3 is performed as follows: while the first resin component 2 and the second resin component 3 are pressurized in the vertical direction, and a portion of the lower inclined surface 31 of the second resin component 3 and a portion of the opposing surface 21 of the first resin component 2 are in linear contact in the contact portion 53, a laser 610 is emitted from the first laser head 61 and irradiates the second resin component 3 through the contact portion 53 in a direction intersecting the pressurization direction.

[0058] The welding of the second resin component 3 and the third resin component 4 is performed as follows: while the second resin component 3 and the third resin component 4 are pressurized in the vertical direction, and a portion of the upper inclined surface 33 of the second resin component 3 and a portion of the opposing surface 41 of the third resin component 4 are in linear contact in the contact portion 54, the laser 620 from the second laser head 62 irradiates the second resin component 3 through the contact portion 54 in a direction intersecting the pressurization direction.

[0059] exist Figure 10 In the example shown, although the optical axes 610a and 620a of lasers 610 and 620 are perpendicular to the vertical direction, they are not limited to this. For example, laser 610 can be irradiated from the first laser head 61 in a manner where the optical axis 610a is perpendicular to the lower inclined surface 31 of the second resin component 3, and laser 620 can be irradiated from the second laser head 62 in a manner where the optical axis 620a is perpendicular to the upper inclined surface 33 of the second resin component 3.

[0060] When laser 610, irradiated from the first laser head 61, irradiates the contact portion 53 and its periphery, a portion of the first resin component 2 melts into molten resin, and a portion of the second resin component 3 melts due to the heat of the molten resin and fuses with a portion of the first resin component 2. The portion formed by the fusion of the first resin component 2 and the second resin component 3 gradually extends from the contact portion 53 along the lower inclined surface 31 according to the irradiation time or number of irradiations of the laser 610, and then cools and solidifies, thereby forming the joint portion 51 of the first resin component 2 and the second resin component 3.

[0061] Furthermore, by irradiating the contact portion 54 and its periphery with the laser 620 irradiated from the second laser head 62, a portion of the third resin component 4 is melted into molten resin, and a portion of the second resin component 3 is melted by the heat of the molten resin and fused with a portion of the third resin component 4. The portion formed by the fusion of the second resin component 3 and the third resin component 4 gradually extends from the contact portion 54 along the upper inclined surface 33 according to the irradiation time or number of irradiations of the laser 620, and then cools and solidifies, thereby forming the joint portion 52 of the second resin component 3 and the third resin component 4.

[0062] In the welding process, the first to third resin components 2 to 4 are clamped vertically by a pressure clamp, and pressure is applied to the first resin component 2 and the second resin component 3, and also to the second resin component 3 and the third resin component 4. Furthermore, in the welding process, while irradiating with lasers 610 and 620, the first and second laser heads 61 and 62 and the first to third resin components 2 to 4 are rotated relative to each other about the central axis C of the square housing 10. During this relative rotation, the distance between the first and second laser heads 61 and 62 and the first to third resin components 2 to 4 is adjusted so that the distance between them corresponds to an appropriate distance for the focal length of the lasers 610 and 620. Alternatively, for example, the focal length of the lasers 610 and 620 can be adjusted by adjusting the position of the lenses within the first and second laser heads 61 and 62. Moreover, it is preferable that the intensity distribution of the lasers 610 and 620 is flat-topped rather than Gaussian.

[0063] By rotating the first and second laser heads 61 and 62 relative to the first to third resin components 2 to 4, the first and second laser heads 61 and 62 make at least one circumference around the first to third resin components 2 to 4. If the molten resin melted by the irradiation of lasers 610 and 620 solidifies, the welding process ends.

[0064] According to the first embodiment described above, when the first to third resin components 2 to 4 are pressurized in the vertical direction and irradiated with lasers 610 and 620, welding can be performed while the lower inclined surface 31 of the second resin component 3 is in reliable contact with the opposing surface 21 of the first resin component 2, and the upper inclined surface 33 of the second resin component 3 is in reliable contact with the opposing surface 41 of the third resin component 4. That is, for example, even if the first to third resin components 2 to 4 are warped or have irregular shapes during the injection molding process, the pressure during pressurization can be used to elastically deform the first to third resin components 2 to 4 by contacting the lower inclined surface 31 and the upper inclined surface 33 with the opposing surfaces 21 and 41, and then irradiating the contact portions 53 and 54 where the surfaces are in contact with each other with lasers 610 and 620, welding can be performed reliably. In addition, as described in Patent Document 2, for example, there is no need to provide a flange portion for welding, so the square housing 10 can be miniaturized.

[0065] [Variation Example 1]

[0066] Next, refer to Figure 11 A variation of the first embodiment, example 1, will be described. In the first embodiment, although the case where the opposing surface 21 of the welding portion 20 of the first resin component 2 is formed into a convex curved surface was described, however… Figure 11 In the modified example 1 shown, the opposing surfaces 21 of the welding portion 20 of the first resin component 2 are composed of a pair of inclined surfaces 21a and 21b, and the corner between the pair of inclined surfaces 21a and 21b contacts the lower inclined surface 31. The inclined surface 21a, located inside the gap 303, has an inclination angle relative to the vertical direction that is greater than the inclination angle θ1 of the lower inclined surface 31 (see reference). Figure 6 The other inclined surface 21b has a smaller angle of inclination relative to the vertical direction than the angle θ1 of the lower inclined surface 31. The angle θ3 formed by the pair of inclined surfaces 21a and 21b is an obtuse angle, for example, between 120° and 170°.

[0067] Furthermore, although the case where the opposing surface 41 of the welding portion 40 of the third resin component 4 is formed into a convex curved surface was described in the first embodiment, Figure 11 In the modified example 1 shown, the opposing surfaces 41 of the welding portion 40 of the third resin component 4 are composed of a pair of inclined surfaces 41a and 41b, and the corner between the pair of inclined surfaces 41a and 41b contacts the upper inclined surface 33. The inclined surface 41a, located inside the gap 304, has an inclination angle relative to the vertical direction that is greater than the inclination angle θ2 of the upper inclined surface 33 (see reference). Figure 8The other inclined surface 41b has a smaller angle of inclination relative to the vertical direction than the angle θ2 of the upper inclined surface 33. The angle θ4 formed by the pair of inclined surfaces 41a and 41b is an obtuse angle, for example, between 120° and 170°.

[0068] In Modified Example 1, when the second resin component 3 is welded to the first resin component 2 and the third resin component 4, the same as in the first embodiment, while the first to third resin components 2 to 4 are pressurized in the vertical direction, the laser is simultaneously irradiated toward the contact portion 53 between the lower inclined surface 31 of the second resin component 3 and the opposing surface 21 of the first resin component 2, and the contact portion 54 between the upper inclined surface 33 of the second resin component 3 and the opposing surface 41 of the third resin component 4, to perform laser welding.

[0069] According to this variation 1, the same effect as the first embodiment can also be obtained.

[0070] [Modification Example 2]

[0071] Next, refer to Figure 12 A variation 2 of the first embodiment will be described. In the first embodiment, a lower inclined surface 31 inclined at a constant angle θ1 relative to the vertical direction is formed on the lower welding portion 301 of the second resin component 3, and the opposing surface 21 of the welding portion 20 of the first resin component 2, which is formed in a convex curved surface, is in contact with the lower inclined surface 31. In the variation 2, an inclined surface 23 inclined at a constant angle θ5 relative to the vertical direction is formed on the welding portion 20 of the first resin component 2, and an opposing surface 35 formed in a convex curved surface and in contact with the inclined surface 23 is formed on the lower welding portion 301 of the second resin component 3.

[0072] Furthermore, in the first embodiment, although it was described that an upper inclined surface 33 is formed on the upper welding portion 302 of the second resin component 3, which is inclined at a constant angle θ2 relative to the vertical direction, and the opposing surface 41 of the welding portion 40 of the third resin component 4, which is formed in a convex curved surface, is in contact with the upper inclined surface 33, in the modified example 2, an inclined surface 43 is formed on the welding portion 40 of the third resin component 4, which is inclined at a constant angle θ6 relative to the vertical direction, and an opposing surface 36 formed in a convex curved surface and in contact with the inclined surface 43 is formed on the upper welding portion 302 of the second resin component 3.

[0073] When welding the second resin component 3 of Modified Example 2 to the first resin component 2 and the third resin component 4, while the first to third resin components 2 to 4 are pressurized in the vertical direction, a laser is simultaneously irradiated toward the contact portion 55 between the inclined surface 23 of the first resin component 2 and the opposing surface 35 of the second resin component 3, and the contact portion 56 between the inclined surface 43 of the third resin component 4 and the opposing surface 36 of the second resin component 3, to perform laser welding.

[0074] According to this modified example 2, the same effect as the first embodiment can also be obtained.

[0075] [Modification Example 3]

[0076] Next, refer to Figure 13 Modification 3 of the first embodiment will be described. In Modification 3, a light-shielding part 24 is provided in the welding portion 20 of the first resin component 2 to block light leakage from the laser irradiated during the welding process. Additionally, a light-shielding part 44 is provided in the welding portion 40 of the third resin component 4 to block light leakage from the laser irradiated during the welding process. Other structures are the same as in the first embodiment.

[0077] The light-shielding portion 24 of the first resin component 2 is formed protruding upward toward the inner side of the opposing surface 21 of the welding portion 20, closer to the gap 303. The light-shielding portion 44 of the third resin component 4 is formed protruding downward toward the inner side of the opposing surface 41 of the welding portion 40, closer to the gap 304. The light-shielding portions 24 and 44 block the leakage of laser light emanating from the joint portions 51 and 52 with the second resin component 3, thereby suppressing the laser from irradiating components inside the second resin component 3 (e.g., wiring components such as busbars connected to the positive or negative electrode of the pouch cell 11).

[0078] According to this Modification 3, in addition to the effects of the first embodiment, it is also possible to suppress the situation where the components inside the second resin component 3 are heated by laser irradiation. Furthermore, the structure of Modification 3 (light-shielding parts 24, 44) can be added to the structure of Modification 1 or Modification 2.

[0079] [Second Implementation]

[0080] Next, refer to Figure 14 as well as Figure 15 The second embodiment of the present invention will be described. Figure 14 This is an explanatory diagram showing the welding process during the manufacturing of the square housing 10A of the second embodiment. Figure 15 It is an enlarged representation Figure 14 A magnified view of a portion of it.

[0081] In the first embodiment, the case where the second resin component 3 is a light-transmitting resin component and the first resin component 2 and the third resin component 4 are light-absorbing resin components was described. In the second embodiment, the second resin component 8 is a light-absorbing resin component, and the first resin component 7 and the third resin component 9 are light-transmitting resin components. That is, in this embodiment, the square housing 10A is constructed by one light-absorbing resin component (the second resin component 8) and two light-transmitting resin components (the first resin component 7 and the third resin component 9). The light-absorbing resin component (the second resin component 8) is sandwiched between the two light-transmitting resin components (the first resin component 7 and the third resin component 9).

[0082] The square housing 10A is the same as the square housing 10 of the first embodiment, having a square-shaped base plate portion 100 and multiple side plate portions 101 to 104. The second resin component 8 has a lower weld portion 801 at its end on the side of the first resin component 7 and an upper weld portion 802 at its end on the side of the third resin component 9. The first resin component 7 has a weld portion 70 welded to the lower weld portion 801 of the second resin component 8. The third resin component 9 has a weld portion 90 welded to the upper weld portion 802 of the second resin component 8. The first to third resin components 7 to 9 are the same as in the first embodiment, and are welded by irradiation with lasers 610 and 620 while under pressure in the vertical direction.

[0083] The welding portion 70 of the first resin component 7 is provided with an inclined surface 71 that is inclined relative to the pressure direction (vertical direction) and a wall portion 72 that is parallel to the inclined surface 71 in a direction perpendicular to the pressure direction. The lower welding portion 801 of the second resin component 8 is disposed in the gap 701 between the inclined surface 71 and the wall portion 72. The lower welding portion 801 of the second resin component 8 has a counter surface 81 that is opposite to the inclined surface 71, and the inclined surface 71 and the counter surface 81 come into contact by pressure.

[0084] The opposing surface 81 is a convex shape that protrudes toward the inclined surface 71. When the first resin component 7 and the second resin component 8 are pressed in a direction that brings them closer together, a portion of the inclined surface 71 and the opposing surface 81 respectively come into linear contact. The wall portion 72 restricts the warping in the thickness direction of the lower weld portion 801 caused by the pressure due to the contact between the opposing surface 81 and the inclined surface 71.

[0085] The welding portion 90 of the third resin component 9 is provided with an inclined surface 91 that is inclined relative to the pressure direction, and a wall portion 92 that is parallel to the inclined surface 91 in a direction perpendicular to the pressure direction. The upper welding portion 802 of the second resin component 8 is disposed in the gap 901 between the inclined surface 91 and the wall portion 92. The upper welding portion 802 of the second resin component 8 has a counter surface 82 that is opposite to the inclined surface 91, and the inclined surface 91 and the counter surface 82 come into contact by pressure.

[0086] The opposing surface 82 is a convex shape that protrudes toward the inclined surface 91. When the second resin component 8 and the third resin component 9 are pressed in a direction that brings them closer together, a portion of the inclined surface 91 and the opposing surface 82 respectively come into linear contact. The wall portion 92 restricts the warping in the thickness direction of the upper weld portion 802 caused by the pressure due to the contact between the opposing surface 82 and the inclined surface 91.

[0087] In the welding process of welding the first to third resin components 7 to 9, lasers 610 and 620 are irradiated onto the first to third resin components 7 to 9 from the part located on the outside of the square housing 10A, and the first and second laser heads 61 and 62 and the first to third resin components 7 to 9 are rotated relative to each other about the central axis C of the square housing 10A, while welding the first resin component 7 to the second resin component 8 and welding the second resin component 8 to the third resin component 9 are performed simultaneously.

[0088] The first laser head 61 directs a laser 610 from a direction intersecting the pressurization direction toward the contact portion 57 between the inclined surface 71 of the first resin component 7 and the opposing surface 81 of the second resin component 8. The laser 610 passes through the first resin component 7 and irradiates the opposing surface 81 of the lower welding portion 801 of the second resin component 8. As a result, a portion of the second resin component 8 melts into molten resin, and a portion of the first resin component 7 melts due to the heat of the molten resin, thus fusing portions of the first resin component 7 and the second resin component 8 together.

[0089] The second laser head 62 directs a laser 620 from a direction intersecting the pressurization direction toward the contact portion 58 between the inclined surface 91 of the third resin component 9 and the opposing surface 82 of the second resin component 8. The laser 620 passes through the third resin component 9 and irradiates the opposing surface 82 of the upper welding portion 802 of the second resin component 8. As a result, a portion of the second resin component 8 melts into molten resin, and a portion of the third resin component 9 melts due to the heat of the molten resin, thus fusing a portion of the third resin component 9 and a portion of the second resin component 8 together.

[0090] According to this second embodiment, the same effects as those of the first embodiment can also be obtained. Furthermore, the structures of variations 1 to 3 of the first embodiment can also be applied to the second embodiment.

[0091] (Postscript)

[0092] While the present invention has been described above based on the first and second embodiments and modifications, these embodiments and modifications do not limit the scope of the invention. Furthermore, it should be noted that all combinations of features described in the embodiments and modifications are not necessarily means to solve the problems of the invention. Additionally, the present invention can be implemented by omitting parts of the structure or adding or replacing structures, and by appropriate modifications, without departing from its spirit. Furthermore, parts of the structures of the above-described multiple embodiments can be combined with each other, and modifications can be made, for example, as described below.

[0093] In the above embodiments, although the structure and welding method of the square housings 10 and 10A were described as an example of a resin bond, the welding method of the present invention is not limited to the square housings 10 and 10A and can be used as a manufacturing method for various resin products. Furthermore, although the above embodiments described a three-piece structure of the square housings 10 and 10A, the invention is not limited thereto; it can also be applied to the manufacture of a two-piece resin bond formed by welding a light-transmitting resin component and a light-absorbing resin component. Additionally, the invention can also be applied to the manufacture of a resin bond formed by welding multiple alternately arranged light-transmitting resin components and multiple light-absorbing resin components.

[0094] Furthermore, in the first embodiment described above, although the lower inclined surface 31 and the upper inclined surface 33 are described as being inclined at a constant angle relative to the vertical direction, this is not a limitation. For example, the lower inclined surface 31 and the upper inclined surface 33 may also be curved surfaces with a curvature smaller than that of the opposing surfaces 21 and 41. Similarly, as in the second embodiment, the inclined surfaces 71 and 91 may also be curved surfaces with a curvature smaller than that of the opposing surfaces 81 and 82.

[0095] Explanation of reference numerals in the attached figures

[0096] 10, 10A… Square shell (resin joint)

[0097] 100…base plate

[0098] 101~104…Side panel section

[0099] 2, 7… First resin component

[0100] 21… Opposite surfaces

[0101] 23… Inclined surface

[0102] 24…Light shielding part

[0103] 3, 8… Second resin component

[0104] 31…lower inclined surface

[0105] 32…lower side wall portion

[0106] 33… Upper inclined surface

[0107] 34… Upper sidewall

[0108] 35… Opposite surfaces

[0109] 36… Opposite surfaces

[0110] 4, 9… Third resin component

[0111] 41… Opposite surfaces

[0112] 43… Inclined surface

[0113] 44…Light shielding part

[0114] 51, 52… Joint

[0115] 53~58…Contact part

[0116] 610, 620… lasers

[0117] 71… Inclined surface

[0118] 72…wall section

[0119] 81, 82... Opposite surfaces

[0120] 91… Inclined surface

[0121] 92…wall section.

Claims

1. A welding method comprising welding a light-transmitting resin component and a light-absorbing resin component together by laser irradiation while the latter is under pressure in a manner that brings them into contact, wherein... In one of the aforementioned light-transmitting resin components and the aforementioned light-absorbing resin components, an inclined surface is formed relative to the aforementioned pressurization direction, and a opposing surface is formed opposite to the aforementioned inclined surface in the other component. With the light-transmitting resin component and the light-absorbing resin component under pressure so that the inclined surface is in contact with the opposing surface, the laser is passed through the light-transmitting resin component and irradiated towards the contact portion between the inclined surface and the opposing surface from a direction intersecting the pressure direction, thereby welding the light-transmitting resin component and the light-absorbing resin component.

2. The welding method according to claim 1, wherein, The aforementioned opposing surface is a convex shape that protrudes towards the aforementioned inclined surface. When the light-transmitting resin component and the light-absorbing resin component are pressurized, a portion of each of the inclined surface and the opposing surface comes into linear contact.

3. The welding method according to claim 2, wherein, The aforementioned opposing surfaces are formed into convex curved surfaces.

4. The welding method according to claim 1, wherein, One of the aforementioned components is provided with a wall portion that runs parallel to the inclined surface in a direction perpendicular to the aforementioned pressurization direction. When the light-transmitting resin component and the light-absorbing resin component are brought into contact under pressure, the portion of the other component having the opposing surface is disposed between the inclined surface and the wall portion.

5. The welding method according to claim 1, wherein, The light-absorbing resin component is provided with a light-shielding part to block the leakage of the laser light escaping from the joint with the light-transmitting resin component.

6. A welding method comprising welding one of the aforementioned light-transmitting resin components and two of the aforementioned light-absorbing resin components clamping the one of the aforementioned light-transmitting resin components, wherein, The welding method according to any one of claims 1 to 5 is performed simultaneously: welding one of the two light-absorbing resin components to one of the light-transmitting resin components, and welding the other of the two light-absorbing resin components to one of the light-transmitting resin components.

7. A welding method comprising welding one of the aforementioned light-absorbing resin components and two of the aforementioned light-transmitting resin components clamping the one of the aforementioned light-absorbing resin components, wherein, The welding method according to any one of claims 1 to 5 is performed simultaneously for: welding one of the two light-transmitting resin components to one of the light-absorbing resin components, and welding the other of the two light-transmitting resin components to one of the light-absorbing resin components.

8. A resin bond comprising a light-transmitting resin component and a light-absorbing resin component, wherein a portion of each of the light-transmitting resin component and the light-absorbing resin component is melted and bonded together by laser irradiation, wherein... The joint where the light-transmitting resin component and the light-absorbing resin component are joined is formed at an angle relative to the stacking direction of the light-transmitting resin component and the light-absorbing resin component.

9. A square housing comprising a light-transmitting resin component and a light-absorbing resin component, wherein a portion of each of the light-transmitting resin component and the light-absorbing resin component is melted and joined together by laser irradiation, wherein... It has a square-shaped base plate and multiple side plate portions extending from the base plate in a direction perpendicular to the base plate. The joint where the light-transmitting resin component and the light-absorbing resin component are joined is formed obliquely on the plurality of side plates relative to the direction perpendicular to the base plate.

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