Method for connecting dissimilar materials and connected body of dissimilar materials

Abstract

To eliminate a low-strength direction in which the joint strength between joined dissimilar materials becomes low, to suppress the separation of the dissimilar materials.SOLUTION: A method for joining dissimilar materials includes the steps pf forming a first recess 100 and a second recess 110 by irradiating a surface of a first member 10 with laser light, the first recess 100 and the second recess 110 being cut into the surface obliquely at angles different from each other, and joining the second member 20 to the surface of the first member 10 with a part of the second member 20 engaging with each of the first recess 100 and the second recess 110 by melting the part of the second member 20 lower in melting point than the first member 10 to cause the part of the second member 20 to flow into each of the first recess 100 and the second recess 110 and solidifying the part of the second member 20.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a method for connecting dissimilar materials and a connection body of dissimilar materials. [Background technology]

[0002] Japanese Patent No. 4020957 (Patent Document 1) is a prior art document disclosing a method for processing a metal material having a joint with a dissimilar material using a laser. In the method for processing a metal material having a joint with a dissimilar material using a laser described in Patent Document 1, a joint for joining the dissimilar material is formed by laser scanning the metal surface in a certain scanning direction and another scanning direction that intersects the aforementioned scanning direction. The dissimilar material is joined to the metal surface that has been subjected to laser scanning processing. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 4020957 Summary of the Invention [Problem to be solved by the invention]

[0004] When laser light is irradiated from one direction onto the surface of one of two different types of dissimilar materials to connect the dissimilar materials at the surface irradiated with the laser light, the connection strength of the dissimilar materials to resist the load that pulls the dissimilar materials apart in the weak direction along that one direction is low, and the connected dissimilar materials are likely to detach from each other.

[0005] The present invention has been made to solve the above-mentioned problems, and aims to provide a method for connecting dissimilar materials and a connected body of dissimilar materials that can eliminate the weak direction in which the connection strength of the connected dissimilar materials is reduced, thereby suppressing detachment of the dissimilar materials. [Means for solving the problem]

[0006] A method for connecting dissimilar materials according to the present invention includes the steps of: irradiating the surface of a first member with laser light to form a first recess and a second recess that are engraved obliquely at different angles relative to the surface; and connecting the second member to the surface of the first member by melting and flowing a portion of the second member, which has a lower melting point than the first member, into each of the first recess and the second recess and solidifying it, thereby engaging the portion of the second member with each of the first recess and the second recess.

[0007] By engaging a portion of the second member with each of the first and second recesses, which are carved obliquely at different angles relative to the surface of the first member, it is possible to eliminate a weak direction that reduces the connection strength between the first and second members that are connected to each other, thereby preventing the first and second members from detaching.

[0008] In one embodiment of the present invention, at least one of the first recess and the second recess is formed linearly on the surface.

[0009] This increases the connection strength between the first member and the second member, making it possible to prevent the first member and the second member from becoming detached.

[0010] In one embodiment of the present invention, at least one of the first recess and the second recess is formed in a spot shape.

[0011] This makes it possible to reduce the energy required for laser light irradiation.

[0012] In one embodiment of the present invention, the first member is made of a metal material, and the second member is made of a resin material.

[0013] In this case, the metal material and the resin material can be connected to each other as different materials.

[0014] A connector of dissimilar materials according to the present invention comprises a first member and a second member. The first member has a first recess and a second recess carved obliquely at different angles relative to the surface. The second member has a lower melting point than the first member and is connected to the surface of the first member. A portion of the second member extends into each of the first recess and the second recess and engages with each of the first recess and the second recess.

[0015] By engaging a portion of the second member with each of the first and second recesses, which are carved obliquely at different angles relative to the surface of the first member, it is possible to eliminate a weak direction that reduces the connection strength between the first and second members that are connected to each other, thereby preventing the first and second members from detaching. [Effects of the Invention]

[0016] According to the present invention, it is possible to prevent the separation of the different materials by eliminating the weak direction in which the connection strength of the different materials connected to each other is reduced. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a perspective view showing the configuration of a connection body made of different materials according to a first embodiment of the present invention. [Figure 2] 2 is a cross-sectional view of the connector of FIG. 1 as seen from the direction of the arrows along line II-II. [Figure 3] 4 is a cross-sectional view showing a state in which a first recess and a second recess are formed by irradiating a first member with laser light in the method for connecting dissimilar materials in accordance with the first embodiment of the present invention. FIG. [Figure 4] FIG. 3 is a cross-sectional view showing the configuration of a connector made of different materials according to a first modified example of the first embodiment of the present invention. [Figure 5] FIG. 10 is a cross-sectional view showing the configuration of a connector made of different materials according to a second modified example of the first embodiment of the present invention. [Figure 6] FIG. 10 is a perspective view showing the configuration of a connector made of different materials according to a second embodiment of the present invention. [Figure 7]10 is a top view showing the configuration of a first member in a connection body of different materials according to embodiment 3 of the present invention. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, a method for connecting dissimilar materials and a connector for connecting dissimilar materials according to each embodiment of the present invention will be described with reference to the drawings. In the following description of the embodiments, the same or corresponding parts in the drawings will be given the same reference numerals, and the description thereof will not be repeated.

[0019] In the drawings, the direction parallel to the surface of the first member is the X direction, the direction perpendicular to the X direction on the surface of the first member is the Y direction, and the direction perpendicular to the surface of the first member is the Z direction.

[0020] (Embodiment 1) Fig. 1 is a perspective view showing the configuration of a connection body made of different materials according to embodiment 1 of the present invention, Fig. 2 is a cross-sectional view of the connection body of Fig. 1 as seen from the direction of the arrows along line II-II.

[0021] As shown in FIGS. 1 and 2, a connection body 1 of different materials according to the first embodiment of the present invention includes a first member 10 and a second member 20. As shown in FIG.

[0022] In this embodiment, the first member 10 has a substantially rectangular parallelepiped shape. However, the shape of the first member 10 is not limited to a rectangular parallelepiped shape.

[0023] The first member 10 is made of a metal material. For example, the first member 10 is made of aluminum. Note that the first member 10 is not limited to aluminum, and may be made of a metal material such as iron or copper. Furthermore, the first member 10 is not limited to a metal material, and may be made of a resin material, ceramics, or the like, as long as it can be laser-processed.

[0024] The first member 10 has a first recess 100 and a second recess 110 that are carved obliquely at different angles relative to the surface. In this embodiment, the first recess 100 and the second recess 110 are formed so that they approach each other as they move away from the surface (XY plane) of the first member 10. That is, the first recess 100 and the second recess 110 are formed so that they are located on opposite sides of each other with respect to an imaginary plane (XZ plane) perpendicular to the surface of the first member 10 and approach each other as they move toward the carved tip. For example, the first recess 100 and the second recess 110 may be formed symmetrically with respect to the imaginary plane (XZ plane).

[0025] In this embodiment, the first recess 100 and the second recess 110 are each formed in an oblique direction intersecting with the surface of the first member 10 at an angle in the range of 60° to 80° when viewed from the X direction. However, the angles at which the first recess 100 and the second recess 110 intersect with the surface of the first member 10 may be different from each other and are not limited to the above-mentioned range of 60° to 80°. In this embodiment, one first recess 100 and one second recess 110 are formed on the surface of the first member 10, but at least one of the first recess 100 and the second recess 110 may be formed multiple times. Furthermore, recesses engraved at an angle different from each of the first recess 100 and the second recess 110 may be formed on the surface of the first member 10.

[0026] At least one of the first recess 100 and the second recess 110 may be formed linearly on the surface of the first member 10. In the present embodiment, each of the first recess 100 and the second recess 110 is formed linearly extending in the X direction on the surface of the first member 10. Note that, although each of the first recess 100 and the second recess 110 is formed linearly on the surface of the first member 10 in the present embodiment, they may be formed curvedly.

[0027] In this embodiment, the second member 20 has a substantially rectangular parallelepiped shape, but the shape of the second member 20 is not limited to a rectangular parallelepiped shape.

[0028] The second member 20 is made of a material having a lower melting point than the first member 10. In this embodiment, the second member 20 is made of a resin material. The second member 20 is made of, for example, polypropylene. Note that the second member 20 is not limited to polypropylene, and may be made of a resin material such as polycarbonate or polyamide. Furthermore, the second member 20 is not limited to a resin material, and may be made of a metal material. The melting point of the second member 20 is lower than the melting point of the first member 10 by, for example, 100°C or more.

[0029] The second member 20 is adjacent to the first member 10 in the Z direction. The second member 20 is connected to the surface of the first member 10.

[0030] A portion of the second member 20 enters the first recess 100 and the second recess 110 and engages with each of the first recess 100 and the second recess 110. Specifically, a first protrusion 120 and a second protrusion 130 are formed on the second member 20. The first protrusion 120 is formed to match the internal shape of the first recess 100 and engages with the first recess 100. The second protrusion 130 is formed to match the internal shape of the second recess 110 and engages with the second recess 110.

[0031] Here, a description will be given of a method for connecting dissimilar materials according to embodiment 1 of the present invention. Fig. 3 is a cross-sectional view showing a state in which a first recess and a second recess are formed by irradiating a first member with laser light in the method for connecting dissimilar materials according to embodiment 1 of the present invention.

[0032] As shown in Figure 3, in the method for connecting dissimilar materials according to embodiment 1 of the present invention, first, a laser beam is irradiated onto the surface of the first component 10 to form a first recess 100 and a second recess 110 that are obliquely engraved at different angles relative to the surface of the first component 10.

[0033] In this embodiment, the first recess 100 and the second recess 110 are each formed by irradiating the surface of the first member 10 with laser light from the laser oscillator 2. The laser light is irradiated from the laser oscillator 2 obliquely onto the surface of the first member 10. The first recess 100 and the second recess 110 may be formed by a single pulse of laser light irradiation, by multiple pulses of laser light irradiation, or by continuous irradiation of laser light. The conditions of the laser oscillator 2, such as the output of the laser light, are adjusted appropriately according to the material properties of the first member 10.

[0034] Next, as shown in Figure 2, a portion of the second member 20 is melted and flowed into each of the first recess 100 and the second recess 110 and solidified, thereby connecting the second member 20 to the surface of the first member 10 while engaging the portion of the second member 20 with each of the first recess 100 and the second recess 110.

[0035] The second member 20 is formed, for example, by injection molding, by melting and flowing a portion of the second member 20 into each of the first recess 100 and the second recess 110, and then solidifying the melted portion. However, the method for melting and flowing the second member 20 is not limited to injection molding, and may be a method in which the second member 20 is heated through the first member 10 to melt a portion of the second member 20 in contact with the first member 10, or the like.

[0036] If the first recess and the second recess are engraved in the same direction, perpendicular or oblique, to the surface of the first member 10, and a load is applied in the direction in which the first recess and the second recess are engraved so as to separate the first member 10 and the second member 20, the first convex portion will easily detach from the first recess, and the second convex portion will easily detach from the second recess, and the connection between the first member and the second member will become significantly weaker. In other words, if the first recess and the second recess are engraved in the same direction, perpendicular or oblique, to the surface of the first member 10, the connection strength against a load that separates the first member and the second member in the weakening direction along that direction will be significantly weaker, and the first member 10 and the second member 20 will become more likely to separate easily.

[0037] On the other hand, in the present embodiment, even if a load is applied so as to separate the first member 10 and the second member 20 along the engraved direction of the first recess 100, the second protrusion 130 does not easily detach from the second recess 110, which is engraved at a different angle from the first recess 100, and the connection strength between the first member 10 and the second member 20 can be increased. Furthermore, even if a load is applied so as to separate the first member 10 and the second member 20 along the engraved direction of the second recess 110, the first protrusion 120 does not easily detach from the first recess 100, which is engraved at a different angle from the second recess 110, and the connection strength between the first member 10 and the second member 20 can be increased. In this way, in the present embodiment, the weak direction in which the connection strength between the first member 10 and the second member 20 connected to each other is reduced is eliminated, and detachment between the first member 10 and the second member 20 can be suppressed.

[0038] In the method for connecting dissimilar materials and the connecting body 1 of dissimilar materials according to embodiment 1 of the present invention, by engaging a portion of the second member 20 with each of the first recess 100 and the second recess 110 which are carved obliquely at different angles relative to the surface of the first member 10, it is possible to eliminate the weak direction that reduces the connection strength of the connected dissimilar materials and suppress detachment of the dissimilar materials.

[0039] In the method for connecting dissimilar materials and the connecting body 1 of dissimilar materials according to embodiment 1 of the present invention, at least one of the first recess 100 and the second recess 110 is formed linearly on the surface of the first member 10, thereby increasing the connection strength between the first member 10 and the second member 20 and preventing the first member 10 and the second member 20 from detaching.

[0040] In the method for connecting dissimilar materials and the connecting body 1 for dissimilar materials according to embodiment 1 of the present invention, the first member 10 is formed from a metal material and the second member 20 is formed from a resin material, so that the metal material and the resin material can be connected to each other as dissimilar materials.

[0041] A method for connecting dissimilar materials and a connector of dissimilar materials according to a modification of the first embodiment of the present invention will be described below with reference to the drawings. The method for connecting dissimilar materials and the connector of dissimilar materials according to this modification differ from the method for connecting dissimilar materials and the connector of dissimilar materials 1 according to the first embodiment of the present invention in the configuration of the first recess and the second recess, and therefore, the description of the configuration that is the same as the method for connecting dissimilar materials and the connector of dissimilar materials 1 according to the first embodiment of the present invention will not be repeated.

[0042] Fig. 4 is a cross-sectional view showing the configuration of a dissimilar material connection body according to a first modified example of embodiment 1 of the present invention. As shown in Fig. 4, a dissimilar material connection body 1A according to the first modified example of embodiment 1 of the present invention includes a first member 10A and a second member 20A.

[0043] The first member 10A has a first recess 101 and a second recess 111 that are carved obliquely at different angles relative to the surface of the first member 10A. In this modification, a connecting portion 141 is formed at the carved tip of the first recess 101 and the second recess 111. The connecting portion 141 connects the first recess 101 and the second recess 111.

[0044] A portion of the second member 20A enters the first recess 101 and the second recess 111 and engages with the first recess 101 and the second recess 111, respectively. Specifically, a first protrusion 121 and a second protrusion 131 are formed on the second member 20A. The first protrusion 121 engages with the first recess 101, and the second protrusion 131 engages with the second recess 111. The first protrusion 121 and the second protrusion 131 are connected to each other at a connecting portion 141.

[0045] In the method for connecting dissimilar materials and the connected body 1A of dissimilar materials according to the first variant of embodiment 1 of the present invention, the first convex portion 121 and the second convex portion 131, which are part of the second member 20A, are connected to each other at the connecting portion 141, and a part of the second member 20A is engaged with each of the first recess 101 and the second recess 111. This makes it possible to increase the connection strength of the dissimilar materials while eliminating the weak direction that reduces the connection strength of the connected dissimilar materials, thereby further suppressing detachment of the dissimilar materials.

[0046] Fig. 5 is a cross-sectional view showing the configuration of a dissimilar material connection body according to a second modified example of embodiment 1 of the present invention. As shown in Fig. 5, a dissimilar material connection body 1B according to the second modified example of embodiment 1 of the present invention includes a first member 10B and a second member 20B.

[0047] The first member 10B has a first recess 102 and a second recess 112 that are carved obliquely at different angles relative to the surface of the first member 10B. In this modification, the first recess 102 and the second recess 112 intersect with each other, and a connecting portion 142 is formed at the intersection. The connecting portion 142 connects the first recess 102 and the second recess 112.

[0048] A portion of the second member 20B enters the first recess 102 and the second recess 112 and engages with the first recess 102 and the second recess 112, respectively. Specifically, a first protrusion 122 and a second protrusion 132 are formed on the second member 20B. The first protrusion 122 engages with the first recess 102, and the second protrusion 132 engages with the second recess 112. The first protrusion 122 and the second protrusion 132 are connected to each other at a connecting portion 142.

[0049] In the method for connecting dissimilar materials and the connected body 1B of dissimilar materials according to the second variant of the first embodiment of the present invention, the first convex portion 122 and the second convex portion 132, which are part of the second member 20B, are connected to each other at the connecting portion 142, and a part of the second member 20B is engaged with each of the first recess 102 and the second recess 112, thereby eliminating the weak direction that reduces the connection strength of the connected dissimilar materials, while increasing the connection strength of the dissimilar materials and further suppressing detachment of the dissimilar materials.

[0050] (Embodiment 2) A method for connecting dissimilar materials and a connector of dissimilar materials according to a second embodiment of the present invention will be described below with reference to the drawings. The method for connecting dissimilar materials and a connector of dissimilar materials according to the second embodiment of the present invention differ from the method for connecting dissimilar materials and connector of dissimilar materials 1 according to the first embodiment of the present invention in the configuration of the first recess and the second recess, and therefore, the description of the configuration that is the same as that of the method for connecting dissimilar materials and connector of dissimilar materials 1 according to the first embodiment of the present invention will not be repeated.

[0051] Fig. 6 is a perspective view showing the configuration of a dissimilar material connected body according to embodiment 2 of the present invention. As shown in Fig. 6, a dissimilar material connected body 1C according to embodiment 2 of the present invention includes a first member 10C and a second member 20C.

[0052] The first member 10C has first recesses 200 and second recesses 210 that are carved obliquely at different angles relative to the surface of the first member 10C. At least one of the first recesses 200 and the second recesses 210 is formed in a spot shape. In this embodiment, each of the first recesses 200 and the second recesses 210 is formed in a spot shape. A plurality of the first recesses 200 and the second recesses 210 are arranged side by side along the X direction.

[0053] A portion of the second member 20C enters the first recess 200 and the second recess 210 and engages with each of the first recess 200 and the second recess 210. Specifically, the second member 20C is formed with a first protrusion 220 and a second protrusion 230. The first protrusion 220 engages with the first recess 200, and the second protrusion 230 engages with the second recess 210.

[0054] In the method for connecting dissimilar materials and the connecting body 1C of dissimilar materials according to the second embodiment of the present invention, at least one of the first recess 200 and the second recess 210 is formed in a spot shape, thereby reducing the energy required for irradiating the laser light compared to when each of the first recess and the second recess is formed in a linear shape.

[0055] (Embodiment 3) Hereinafter, a method for connecting dissimilar materials and a joint of dissimilar materials according to a third embodiment of the present invention will be described with reference to the drawings. The method for connecting dissimilar materials and a joint of dissimilar materials according to the third embodiment of the present invention differ from the method for connecting dissimilar materials and the joint of dissimilar materials 1 according to the first embodiment of the present invention mainly in the configuration of the first member, and therefore, the description of the configuration that is the same as the method for connecting dissimilar materials and the joint of dissimilar materials 1 according to the first embodiment of the present invention will not be repeated.

[0056] Fig. 7 is a top view showing the configuration of a first member in a connection body of different materials according to embodiment 3 of the present invention. In Fig. 7, the second member is shown in a see-through manner for ease of understanding.

[0057] As shown in FIG. 7, a connection body 1D of different materials according to the third embodiment of the present invention includes a first member 10D and a second member.

[0058] The first component 10D has a first recess 300, a second recess 310, and a third recess 320 carved obliquely at different angles relative to the surface of the first component 10D. The first recess 300, the second recess 310, and the third recess 320 each extend linearly on the XY plane, intersecting at approximately 60° angles with each other. As a result, multiple triangles are formed on the surface of the first component 10D, surrounded by the first recess 300, the second recess 310, and the third recess 320. The carved tips of the first recess 300, the second recess 310, and the third recess 320 are located inside the triangles when viewed from the Z direction. In other words, the first recess 300, the second recess 310, and the third recess 320 are each formed to follow the circumferential surface of a triangular pyramid.

[0059] In this embodiment, the first recess 300, the second recess 310, and the third recess 320 are configured so as to form multiple triangular shapes on the surface of the first member 10D, but this is not limited to this, and four or more types of recesses may be formed that are carved obliquely at different angles relative to the surface of the first member 10D so as to form polygonal shapes having four or more sides on the surface of the first member 10D.

[0060] In the method for connecting dissimilar materials and the connected body 1D of dissimilar materials according to the third embodiment of the present invention, a polygonal shape is formed on the surface of the first member 10D by a plurality of recesses carved obliquely at different angles relative to the surface of the first member 10D. This eliminates the weak direction that reduces the connection strength of the connected dissimilar materials, and by forming a part of the second member so as to surround the entire circumference of the polygonal truncated pyramid, the connection strength of the dissimilar materials can be increased and detachment of the dissimilar materials can be further suppressed.

[0061] It should be noted that the above-described embodiments disclosed herein are illustrative in all respects and are not intended to be limiting. Therefore, the technical scope of the present disclosure should not be interpreted solely by the above-described embodiments. Furthermore, all modifications within the scope and meaning equivalent to the claims are included. In the description of the above-described embodiments, combinable configurations may be combined with each other. [Explanation of symbols]

[0062] 1, 1A, 1B, 1C, 1D: connecting body; 10, 10A, 10B, 10C, 10D: first member; 20, 20A, 20B, 20C: second member; 100, 101, 102, 200, 300: first recess; 110, 111, 112, 210, 310: second recess.

Claims

1. a step of irradiating a surface of a first member with a laser beam to form a first recess, a second recess, and a third recess that are engraved obliquely at different angles relative to the surface; a step of melting and flowing a portion of a second member having a melting point lower than that of the first member into each of the first recess, the second recess, and the third recess, and solidifying the portion of the second member to connect the second member to the surface of the first member while engaging the portion of the second member with each of the first recess, the second recess, and the third recess; a connecting portion that connects the first recess, the second recess, and the third recess to each other, and forms a triangle surrounded by the first recess, the second recess, and the third recess on the surface of the first member, and the first recess, the second recess, and the third recess are each formed so as to follow the peripheral surface of a triangular pyramid that includes the triangle.

2. 2. The method for connecting dissimilar materials according to claim 1, wherein the first member is made of a metal material, and the second member is made of a resin material.

3. a first member having a first recess, a second recess, and a third recess formed therein, the first recess, and the first recess being carved obliquely at different angles relative to the surface; a second member having a lower melting point than the first member and connected to the surface of the first member; a portion of the second member extends into each of the first recess, the second recess, and the third recess and engages with each of the first recess, the second recess, and the third recess; The first member has a connecting portion formed therein, which connects the first recess, the second recess, and the third recess, a triangle surrounded by the first recess, the second recess, and the third recess is formed on the surface of the first member, A connector of dissimilar materials, wherein each of the first recess, the second recess, and the third recess is formed along the peripheral surface of a triangular pyramid including the triangle.

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