Method for manufacturing a rubber-coated member, adhesive sheet, and rubber-coated member

Abstract

To provide a method for manufacturing a member with rubber capable of suppressing generation of burrs of a rubber member, an adhesive sheet, and a member with rubber, in order to solve the problem of the need for a process for removing burrs.SOLUTION: A method for manufacturing a member with rubber comprises a step (S12) of contacting an adhesive sheet having a concave structure on a first surface with an uncrosslinked rubber member, and contacting the adhesive sheet on a second surface of the adhesive sheet with a substrate, and a step (S13) of heating the rubber member to bond the substrate and the rubber member.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a member with rubber, an adhesive sheet, and a member with rubber.

Background Art

[0002] Patent Document 1 describes a method for manufacturing a plate with a seal using a cavity plate having a groove in which a seal portion is formed and a rubber relief groove (side lip). The method for manufacturing a plate with a seal described in Patent Document 1 allows the expansion of the rubber during the crosslinking process of the seal portion to flow into the side lip, so that burrs on the seal portion occur only at a predetermined position.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The method for manufacturing a member with a seal described in Patent Document 1 controls the generation position of burrs and does not suppress the generation of burrs itself. Therefore, there is a problem that a process for removing burrs is required.

Means for Solving the Problems

[0005] A method for manufacturing a member with rubber according to an embodiment includes a step of bringing an adhesive sheet having a concave structure on a first surface into contact with an uncrosslinked rubber member on the first surface and bringing the second surface of the adhesive sheet into contact with a base material, and a step of heating the rubber member to bond the base material and the rubber member.

[0006] In one embodiment of the method for manufacturing a rubber-coated member, the density of the concave structure in the central part of the first surface of the adhesive sheet is made higher than the density of the concave structure at the edge of the first surface of the adhesive sheet.

[0007] One embodiment of the adhesive sheet is an adhesive sheet for bonding a substrate and a rubber member, and has a concave structure on one surface that is bonded to the rubber member.

[0008] One embodiment of the rubber-coated member comprises a base material, a rubber member, and an adhesive sheet positioned between the base material and the rubber member, having a concave structure on one surface that contacts the rubber member. [Effects of the Invention]

[0009] According to the method for manufacturing a rubber-coated member, the adhesive sheet, and the rubber-coated member described herein, the generation of burrs on the rubber member can be suppressed. [Brief explanation of the drawing]

[0010] [Figure 1] This is a flowchart showing an example of a method for manufacturing a rubber-coated member according to this embodiment. [Figure 2] This is a cross-sectional view showing an example of a method for manufacturing a rubber-coated member according to this embodiment. [Figure 3] This is a cross-sectional view showing an example of a separator with a sealing component according to this embodiment. [Figure 4] These are perspective and cross-sectional views showing an example of an adhesive resin sheet according to this embodiment. [Figure 5] These are perspective and cross-sectional views showing an example of an adhesive resin sheet according to this embodiment. [Figure 6] These are perspective and cross-sectional views showing an example of an adhesive resin sheet according to this embodiment. [Modes for carrying out the invention]

[0011] This embodiment Embodiments of this disclosure will be described below with reference to the drawings. In the following disclosure, an example will be described in which the substrate is a separator, the adhesive sheet is an adhesive resin sheet, and the rubber is a sealing component. Such a separator with a sealing component can be applied to a sealing component between cells of a fuel cell.

[0012] Suitable separator materials include metal materials, resin materials, and graphite materials. Suitable adhesive resin sheets are thermoplastic resins. The adhesive resin sheets are provided with stepped grooves or through grooves when viewed in cross-section. Suitable sealing components are rubber gaskets.

[0013] For temporary bonding of the adhesive resin sheet to the separator, thermocompression bonding, ultrasonic bonding, vibration bonding, and laser bonding are preferred. For bonding the separator and the sealing component via the adhesive resin sheet, insert molding, transfer bonding, and lamination bonding are preferred. These methods are as follows:

[0014] Insert molding method • A separator substrate with an adhesive resin sheet is set into the mold. Next, heat and pressure are applied to the uncrosslinked rubber, which is the raw material for the sealing component, and this uncrosslinked rubber is filled into the mold. Next, heat or light is applied to the uncrosslinked rubber in the mold, causing the uncrosslinked rubber, which is the raw material for the sealing component, to crosslink, and at the same time, the sealing component, the adhesive resin sheet, and the separator substrate are bonded together. Then, the seal component, which is integrated with the separator base material, is removed from the mold.

[0015] Transfer method Heat or pressure is applied to the raw material of the sealing member in an uncrosslinked state, and the raw material of the sealing member is filled into a mold. Next, after filling, the mold is opened and the separator with the adhesive resin sheet is placed in the mold. ·Next, heat or light is applied in the mold, causing the seal member to crosslink and the seal component, the adhesive resin sheet, and the separator substrate to adhere to each other. ·Then, the seal component integrated with the separator substrate is demolded from the mold.

[0016] Laminating method ·The formed seal component that has completed crosslinking is placed on the separator substrate with the adhesive resin sheet and set in the mold. ·Next, heat and pressure are applied to the seal component, the adhesive resin sheet, and the separator substrate in the mold, causing them to adhere to each other. ·The seal component integrated with the separator substrate is demolded from the mold.

[0017] Next, an example of a method for manufacturing a member with rubber is described. FIG. 1 is a flowchart showing an example of a method for manufacturing a member with rubber according to the present embodiment. FIG. 2 is a cross-sectional view showing an example of a method for manufacturing a member with rubber according to the present embodiment.

[0018] First, in step S11, as shown in FIG. 2A, uncrosslinked rubber 213 is injection-molded into molds 211 and 212, and then the process proceeds to step S12.

[0019] Next, in step S12, as shown in FIG. 2B, a separator 215 with a grooved adhesive resin sheet 214 temporarily fixed is installed in molds 211 and 212, and then the process proceeds to step S13.

[0020] In step S13, as shown in FIG. 2C, the rubber 213 is crosslinked by heating, and the adhesive resin sheet 214 is melted to adhere the rubber 213 and the separator 215, and then the process proceeds to step S14.

[0021] In step S13, the thermal expansion of the rubber 213 is contained within the grooves of the adhesive resin sheet 214. This configuration prevents the thermal expansion of the rubber 213 from flowing out from the edges of the adhesive sheet. Therefore, by using the manufacturing method shown in the flowchart in Figure 1, it is possible to manufacture rubber-coated components while suppressing the generation of burrs on the rubber components.

[0022] In step S14, as shown in Figure 2D, the separators are demolded from the molds 211 and 212. The rubber-coated components are manufactured through the above process.

[0023] Next, we will describe a separator with a sealing component, which is an example of a rubber-coated member. Figure 3 is a cross-sectional view showing an example of a separator with a sealing component according to this embodiment.

[0024] In Figure 3, the separator 301 with a sealing component comprises a base material 311, a resin sheet 312, and a sealing component 313.

[0025] The base material 311 is bonded to the resin sheet 312 at the second surface 315 of the resin sheet 312. The resin sheet 312 has grooves 316-1 to 316-n (where n is any natural number) that penetrate from the first surface 314 to the second surface 315.

[0026] The sealing component 313 is bonded to the resin sheet 312 on its first surface 314. The grooves 316-1 to 316-n are partially filled with the sealing component 313.

[0027] Furthermore, the separator 302 with sealing components comprises a base material 321, a resin sheet 322, and a sealing component 323.

[0028] The base material 321 is bonded to the resin sheet 322 at the second surface 325 of the resin sheet 322. The resin sheet 322 has grooves 326-1 to 326-n (where n is any natural number) on its first surface 324. The grooves 326-1 to 326-n are not through grooves, and the second surface 325 does not have grooves 326-1 to 326-n.

[0029] The sealing component 323 is bonded to the resin sheet 322 on its first surface 324. The grooves 326-1 to 326-n are partially filled with the sealing component 323.

[0030] Next, we will describe the adhesive resin sheet. Figure 4 is a perspective view and a cross-sectional view showing an example of the adhesive resin sheet according to this embodiment.

[0031] In Figure 4, the adhesive resin sheet 401 has grooves 402-1 to 402-n. The grooves 402-1 to 402-n (where n is any natural number) extend perpendicularly to the width direction (X-axis direction) of the sealing component on the first surface 403. As shown in the cross-sectional view at A-A', the grooves 402-1 to 402-n are grooves that penetrate from the first surface 403 to the second surface 404 of the adhesive resin sheet 401.

[0032] Furthermore, the adhesive resin sheet 411 has grooves 412-1 to 412-n. The grooves 412-1 to 412-n (where n is any natural number) extend perpendicularly to the width direction of the sealing component on the first surface 403. As shown in the cross-sectional view at B-B', the grooves 412-1 to 412-n are provided on the first surface 413 of the adhesive resin sheet 411. The grooves 412-1 to 412-n are not through grooves and do not exist on the second surface 414.

[0033] Furthermore, the grooves may extend in a direction parallel to the width direction of the sealing component. Figure 5 is a perspective view and a cross-sectional view showing an example of an adhesive resin sheet according to this embodiment.

[0034] In Figure 5, the adhesive resin sheet 501 has grooves 502-1 to 502-n (where n is any natural number). The grooves 502-1 to 502-n extend parallel to the width direction (X-axis direction) of the sealing component on the first surface 503. As shown in the cross-sectional view at C-C', the grooves 502-1 to 502-n are grooves that penetrate from the first surface 503 to the second surface 504 of the adhesive resin sheet 501.

[0035] Furthermore, the adhesive resin sheet 511 has grooves 512-1 to 512-n (where n is any natural number). The grooves 512-1 to 512-n extend parallel to the width direction of the sealing component on the first surface 513. As shown in the cross-sectional view at D-D', the grooves 512-1 to 512-n are provided on the first surface 513 of the adhesive resin sheet 511. The grooves 512-1 to 512-n are not through grooves and do not exist on the second surface 514.

[0036] The adhesive resin sheets 501 and 511 shown in Figure 5 are provided with grooves parallel to the width direction of the sealing component, which allows them to accommodate differences in expansion due to differences in rubber shape in the depth direction of the sealing component.

[0037] Furthermore, depending on the groove arrangement according to the cross-sectional shape of the sealing component, grooves parallel to the width direction and grooves parallel to the depth direction may be mixed in a mesh-like or dot-like pattern. Figure 6 is a perspective view and a cross-sectional view showing an example of an adhesive resin sheet according to this embodiment.

[0038] In Figure 6, the adhesive resin sheet 601 has grooves 602-1 to 602-n and grooves 603-1 to 603-m (where n and m are arbitrary natural numbers). Grooves 602-1 to 602-n extend parallel to the depth direction (Y-axis direction) of the sealing component on the first surface 604. Grooves 603-1 to 603-m extend parallel to the width direction (X-axis direction) of the sealing component on the first surface 604.

[0039] Furthermore, in Figure 6, the adhesive resin sheet 611 has perforated structures 612-1 to 612-n (where n is any natural number). The perforated structures 612-1 to 612-n are scattered on the first surface 613 of the adhesive resin sheet 611. The perforated structures 612-1 to 612-n are arranged parallel to at least one of the width direction and depth direction of the sealing component.

[0040] The adhesive resin sheets 601 and 611 can accommodate differences in thermal expansion due to differences in the shape of the sealing components.

[0041] As described above, according to the manufacturing method of the rubber-coated member, the adhesive resin sheet, and the rubber-coated member of this embodiment, the expansion of the rubber member is contained in the recessed structure of the adhesive sheet, thus suppressing the generation of burrs on the rubber member.

[0042] Furthermore, according to the manufacturing method of the rubber-coated member, the adhesive resin sheet, and the rubber-coated member of this embodiment, by providing stepped grooves and through holes in the adhesive resin sheet, the surface pressure on the separator when the sealing component is compressed is made uniform.

[0043] Furthermore, according to the manufacturing method of the rubber-coated member, the adhesive resin sheet, and the rubber-coated member of this embodiment, by providing stepped grooves or through holes in the adhesive resin sheet, the expanded excess rubber volume during the transfer process escapes to the adhesive resin sheet side, thereby increasing the design flexibility of the separator.

[0044] It should be noted that the present invention is not limited to the embodiments described above, and can be modified as appropriate without departing from the spirit of the invention. For example, through grooves and stepped grooves may be mixed together to match the shape of the rubber. Also, the shape of the grooves when viewed from above may be a dotted line. That is, the grooves may be intermittently located on a straight line. Furthermore, the density of the grooves per predetermined area may have a density distribution, such as being denser towards the center and sparser at both ends in the width direction of the sealing component.

[0045] Furthermore, for example, if the cross-sectional shape of the rubber is trapezoidal or mountain-shaped, with the width narrowing from the separator bonding surface to the apex, the volume of rubber expansion will be greater in the center when the rubber expands due to heat. By adjusting the groove depth (through-holes, steps) and groove density, it is possible to accommodate differences in the amount of expansion in different parts of the rubber. [Explanation of Symbols]

[0046] 211 molds 213 Rubber 214, 401, 411, 501, 511, 601, 611 Adhesive resin sheets 215, 301, 302 Separators 311, 321 Base material 312, 322 Resin sheet 313, 323 Seal parts

Claims

1. A step of bringing an adhesive sheet having a concave structure on its first surface into contact with an uncrosslinked rubber member on the first surface, and bringing the adhesive sheet into contact with a substrate on its second surface, The process includes heating the rubber member to bond the base material and the rubber member, The rubber member has a vertex positioned at the center of the adhesive surface with the adhesive sheet, and its cross-sectional shape narrows from the adhesive surface to the vertex. A method for manufacturing a rubber-coated member, wherein the density of the concave structure in the central part of the first surface of the adhesive sheet is higher than the density of the concave structure at the edge of the first surface of the adhesive sheet.

2. An adhesive sheet for bonding a base material and a rubber member, wherein the first surface that adheres to the rubber member has a concave structure, The rubber member has a vertex positioned at the center of the adhesive surface with the adhesive sheet, and its cross-sectional shape narrows from the adhesive surface to the vertex. An adhesive sheet in which the density of the concave structure in the central part of the first surface is higher than the density of the concave structure at the edge of the first surface.

3. Substrate and Rubber material and The adhesive sheet is located between the substrate and the rubber member and has a concave structure on a first surface which is in contact with the rubber member, The rubber member has a vertex positioned at the center of the adhesive surface with the adhesive sheet, and its cross-sectional shape narrows from the adhesive surface to the vertex. The rubber-coated member wherein the density of the concave structure in the central part of the first surface of the adhesive sheet is higher than the density of the concave structure at the edge of the first surface of the adhesive sheet.

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