Method for bonding components by using energy ray-curable adhesive

Abstract

A method for bonding components to each other according to this invention bonds, to a plate-shaped member or a shaft, an ultraviolet-curable adhesive cured by irradiation with ultraviolet rays and a wavelength conversion element which emits ultraviolet rays by irradiation with X-rays. The plate-shaped member is brought into contact with the shaft through a bonding layer formed by the ultraviolet-curable adhesive and the wavelength conversion element. The X-rays are transmitted through the plate-shaped member or the shaft to the bonding layer located between the plate-shaped member and the shaft to cure the ultraviolet-curable adhesive.

Claims

1. A method for bonding a first component containing a material incapable of transmitting an energy ray in a first wavelength range to a second component in fabricating an assembly comprising the first component and the second component, wherein the assembly comprises an optical encoder and the first component comprises a slit plate used for the optical encoder, the method comprising: applying, to one component of the first component and the second component, a wavelength conversion element that converts an energy ray in a second wavelength range capable of being transmitted through the first component into an energy ray in the first wavelength range and that emits the energy ray in the first wavelength range, and an energy ray-curable adhesive curable by irradiation with the energy ray in the first wavelength range, the energy ray-curable adhesive being applied on the wavelength conversion element; bringing the other component of the first component and the second component into contact with the energy ray curable adhesive; and transmitting the energy ray in the second wavelength range through the first component to the energy ray-curable adhesive and the wavelength conversion element, thus curing the energy ray-curable adhesive.

2. The method according to claim 1, wherein the energy ray-curable adhesive comprises an ultraviolet-curable adhesive cured by irradiation with light in a range of ultraviolet wavelengths to blue wavelengths, the energy ray in the second wavelength range comprises one of an X-ray and an energy ray having a transmittance higher than a transmittance of the X-ray, and the wavelength conversion element comprises a phosphor which emits light in the range of ultraviolet wavelengths to blue wavelengths in response to one of the X-ray and the energy ray having the transmittance higher than the transmittance of the X-ray.

3. The method according to claim 1, wherein the first component is made of polyetherimide resin.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is an exploded perspective view illustrating an optical rotary encoder to which a bonding method according to the present invention is applicable;

(2) FIG. 2A is a view illustrating a first process step in assembling an optical rotary encoder to which the present invention is applicable;

(3) FIG. 2B is a view illustrating a second process step in assembling the optical rotary encoder to which the present invention is applicable;

(4) FIG. 2C is a view illustrating a third process step in assembling the optical rotary encoder to which the present invention is applicable;

(5) FIG. 2D is a view illustrating a fourth process step in assembling the optical rotary encoder to which the present invention is applicable;

(6) FIG. 3A is a side view illustrating an optical rotary encoder according to the conventional example;

(7) FIG. 3B is a perspective view of the rotary encoder illustrated in FIG. 3A;

(8) FIG. 4A is a side view illustrating a mode in which the rotary encoder illustrated in FIG. 3A is disassembled into two components;

(9) FIG. 4B is a perspective view of the mode illustrated in FIG. 4A; and

(10) FIG. 5 is a perspective view illustrating a mode in which the fit between a shaft portion and a shaft receiving hole in a second plate-shaped member illustrated in FIG. 3B is loosened.

DETAILED DESCRIPTION

(11) An embodiment of the present invention will be described below with reference to the accompanying drawings. The same reference numerals as in the Related Art denote the same components in these drawings. For the sake of a better understanding, these drawings use different scales as appropriate. Although an optical rotary encoder will be taken below as an example of an assembly to which a bonding method according to the present invention is applicable, the present invention is not limited to this.

(12) FIG. 1 is an exploded perspective view illustrating an optical rotary encoder to which a bonding method according to the present invention is applicable.

(13) In the optical rotary encoder, a first plate-shaped member 1 is opposed to a second plate-shaped member 2, as illustrated in FIG. 1. The second plate-shaped member 2 is implemented in a rotational slit plate. A rotational slit plate for an optical encoder is also called a code plate. A plurality of slits (not illustrated) including transparent and nontransparent portions are circumferentially formed on the second plate-shaped member 2. A plurality of slits (not illustrated) are also formed in the surface of the first plate-shaped member 1 opposed to the second plate-shaped member 2, as in the second plate-shaped member 2.

(14) Shaft receiving holes 1a and 2a to receive a shaft 3 are formed at the central portions of the plate-shaped members 1 and 2, respectively. The shaft 3 is free to rotate in the shaft receiving hole 1a of the first plate-shaped member 1. The first plate-shaped member 1 is fixed in position by a fixing mechanism (not illustrated) so as not to rotate integrally with the shaft 3. In contrast to this, the second plate-shaped member 2 is connected to the shaft 3 so as to rotate integrally with the shaft 3.

(15) FIGS. 2A, 2B, 2C, and 2D illustrate in sequence, first, second, third, and fourth process steps, respectively, when the second plate-shaped member 2 is bonded to the shaft 3 in assembling the above-mentioned optical rotary encoder. These drawings represent the respective processes in vertical cross-sections of the shaft 3 and the second plate-shaped member 2 depicted as FIGS. 3A and 3B. Upon defining the upward direction of each drawing as the vertical upward direction and the downward direction of each drawing as the vertical downward direction, an embodiment of the present invention will be described hereinafter.

(16) A shaft 3 is provided first, as illustrated in FIG. 2A. The shaft 3 includes a portion having a diameter larger than that of a shaft portion 3a to be inserted into a shaft receiving hole 2a in a second plate-shaped member 2, i.e., a large-diameter portion 3b. The tolerance of fit between the shaft receiving hole 2a and the shaft portion 3a is set as small as possible. For example, the shaft receiving hole 2a and the shaft portion 3a are preferably fitted to each other based on the tolerance of transition fit.

(17) The adoption of such a tolerance of fit allows accurate radial positioning of the second plate-shaped member 2 relative to the center of the shaft portion 3a during an operation of inserting the shaft portion 3a into the shaft receiving hole 2a.

(18) A wavelength conversion element 4 is attached to the upper surface of the large-diameter portion 3b of the shaft 3, as illustrated in FIG. 2B. A phosphor which emits light in the ultraviolet to blue wavelength range by irradiation with X-rays is used as the wavelength conversion element 4 according to this embodiment. In other words, the wavelength conversion element 4 acts as a phosphor which converts a first energy ray in the wavelength range of about 0.01 nm to about 1 nm into a second energy ray in the wavelength range of about 10 nm to about 450 nm to emit the second energy ray.

(19) An ultraviolet-curable adhesive (to be simply referred to as a UV adhesive hereinafter) 5 is attached onto the wavelength conversion element 4, as illustrated in FIG. 2C. The UV adhesive 5 is cured by irradiation with light in the ultraviolet to blue wavelength range (about 10 nm to about 450 nm).

(20) The second plate-shaped member 2 is brought into contact with the upper surface of the large-diameter portion 3b of the shaft 3 while fitting the shaft portion 3a with the shaft receiving hole 2a in the second plate-shaped member 2, as illustrated in FIG. 2D. With this operation, the second plate-shaped member 2 is bonded to the upper surface of the large-diameter portion 3b of the shaft 3 by a bonding layer 6 formed by the wavelength conversion element 4 and the UV adhesive 5.

(21) With this fitting process, since the tolerance of fit between the shaft receiving hole 2a and the shaft portion 3a is set to that of transition fit, the second plate-shaped member 2 is accurately radially positioned relative to the center of the shaft portion 3a.

(22) An ultraviolet non-transmissive material is used as the material of the second plate-shaped member 2 according to this embodiment. Examples of this material may include PEI (Polyetherimide) resin (e.g., Product Name: Ultem (registered trademark)), aluminum, and stainless steel. Applying PEI resin to the material of the second plate-shaped member 2 makes it possible to improve the environmental resistance, impact resistance, heat resistance, and chemical stability of the rotational slit plate.

(23) In the processes illustrated in FIGS. 2B and 2C, although the wavelength conversion element 4 is attached onto the large-diameter portion 3b of the shaft 3 and the UV adhesive 5 is applied onto the wavelength conversion element 4, the present invention is not limited to such processes. For example, a particulate wavelength conversion element 4 may be mixed into the UV adhesive 5 and the obtained mixture may be applied onto the large-diameter portion 3b of the shaft 3. Alternatively, such a mixture or wavelength conversion element 4 may be attached to the lower portion of the second plate-shaped member 2 to be abutted against the upper surface of the large-diameter portion 3b of the shaft 3, instead of attaching it onto the large-diameter portion 3b of the shaft 3.

(24) X-rays 7 are applied from the upper side of the second plate-shaped member 2 to the bonding layer 6 on the large-diameter portion 3b of the shaft 3, as illustrated in FIG. 2D. The X-rays 7 can be transmitted through the second plate-shaped member 2 made of PEI resin and reaches the wavelength conversion element 4 of the bonding layer 6. Upon receiving the X-rays 7, the wavelength conversion element 4 emits light in the ultraviolet to blue wavelength range. The light in the ultraviolet to blue wavelength range then impinges on the entire UV adhesive 5 of the bonding layer 6, which then cures sufficiently. It is, therefore, possible to ensure a given mechanical strength of the bonding portion (a portion forming the bonding layer 6) which bonds the lower surface of the second plate-shaped member 2 to the upper surface of the large-diameter portion 3b of the shaft 3.

(25) In an assembly formed by the above-mentioned processes, most of the UV adhesive 5 illustrated in FIG. 2D is sandwiched between the lower surface of the second plate-shaped member 2 and the upper surface of the large-diameter portion 3b of the shaft 3. Only one edge portion of the bonding layer 6 is exposed in the bonding layer 6. The use of an ultraviolet non-transmissive material to fabricate the second plate-shaped member 2 makes it difficult to irradiate the entire UV adhesive 5 with ultraviolet rays.

(26) To overcome this difficulty, X-rays 7 having a transmittance higher than that of ultraviolet rays are transmitted through the second plate-shaped member 2 to the wavelength conversion element 4 of the bonding layer 6, as described earlier. With this operation, the wavelength conversion element 4 emits light in the ultraviolet to blue wavelength range so that the UV adhesive 5 receives the light in the ultraviolet to blue wavelength range and thereby cures. Thus, although most of the UV adhesive 5 is covered with an ultraviolet non-transmissive member, the bonding method that uses the above-mentioned phosphor forming the wavelength conversion element 4 can satisfactorily cure the UV adhesive 5.

(27) PEI resin can be employed not only as the material of the second plate-shaped member 2 but also for the first plate-shaped member 1 (see FIG. 1) opposed to the second plate-shaped member 2.

(28) In each process step of this embodiment, the shaft 3 is placed to make the shaft portion 3a face vertically upward, as illustrated in FIGS. 2A to 2D. When the shaft 3 is bonded to the second plate-shaped member 2 upon fixing of the orientation of the shaft 3 in the above-mentioned manner, the operations in all the process steps illustrated in FIGS. 2A to 2D can be performed commonly from the upper side, thus facilitating automation. This bonding method also facilitates control of the amounts of a UV adhesive 5 and a wavelength conversion element 4 attached onto the large-diameter portion 3b of the shaft 3.

(29) Other embodiments of the present invention will be described below.

(30) In the above-mentioned embodiment, the UV adhesive 5 cured by irradiation with light in the ultraviolet to blue wavelength range is employed as an adhesive which bonds the second plate-shaped member 2 and the shaft 3 to each other. However, the adhesive applicable to the present invention is not limited to such a UV adhesive 5. In other words, the adhesive used may be an energy ray-curable resin cured by irradiation with light in a wavelength range other than the ultraviolet to blue wavelength range, such as light of, e.g., blue-green or green.

(31) When an energy ray-curable resin cured by irradiation with ultraviolet, violet, blue, blue-green, or green light is used as such an adhesive, a phosphor which emits ultraviolet, violet, blue, blue-green, or green light by irradiation with X-rays is preferably used as the wavelength conversion element 4. Table 1 illustrates such an X-ray phosphor.

(32) TABLE-US-00001 TABLE 1 Emission Spectrum Emission Peak Wavelength Phosphor Color [nm] BaSO.sub.4:Eu Violet 380 BaFCl:Eu Violet 385 BaFBr:Eu Violet 390 CaWO.sub.4 Blue 425 Gd.sub.2O.sub.2S:Tb Green 545 LaOBr:Tm Blue 360, 460 YTaO.sub.4:Nb Blue 410 YTaO.sub.4 Ultraviolet 340 YTaO.sub.4:Tm Blue 360, 460 ZnS:Ag Blue 450 (Zn, Cd)S:Ag Green 530 Bi.sub.4Ge.sub.3O.sub.12 Blue 480 CdWO.sub.4 Blue-green 480 Gd.sub.2O.sub.2S:Pr Green 515 CsI:Na Blue 420 CsI:Tl Green 540

(33) When an energy ray-curable adhesive cured by irradiation with ultraviolet, violet, blue, blue-green, or green light is used as an adhesive which bonds the second plate-shaped member 2 and the shaft 3 to each other, it suffices to select any X-ray phosphor illustrated in Table 1, in accordance with the emission color preferably used for the curing.

(34) As can be seen from Table 1, when an adhesive cured by ultraviolet light is used, an X-ray phosphor made of YTaO.sub.4 (yttrium tantalate) is preferably used for the wavelength conversion element 4. Further, although not illustrated in Table 1, examples of an X-ray phosphor which emits ultraviolet light may include solid phosphors such as diamonds and AlN (aluminum nitride).

(35) When an adhesive cured by violet light is used, an X-ray phosphor containing, e.g., BaSO.sub.4:Eu (barium sulfate doped with europium), BaFCl:Eu (barium chloride fluoride doped with europium), or BaFBr:Eu (barium fluorobromide doped with europium) is preferably employed for the wavelength conversion element 4.

(36) When an adhesive cured by blue light is used, an X-ray phosphor containing, e.g., CaWO.sub.4 (calcium tungstate), LaOBr:Tm (lanthanum oxybromide doped with thulium), YTaO.sub.4:Nb (yttrium tantalate doped with niobium), YTaO.sub.4:Tm (yttrium tantalate doped with thulium), ZnS:Ag (zinc sulfide doped with silver), Bi.sub.4Ge.sub.3O.sub.12 (single-crystal bismuth germinate), or CsI:Na (cesium iodide doped with sodium) is preferably employed for the wavelength conversion element 4. Although not illustrated in Table 1, NaI(Tl) (sodium iodide doped with thallium) or KI (potassium iodide), for example, is also available as an X-ray phosphor which emits blue light.

(37) When an adhesive cured by blue-green light is used, an X-ray phosphor containing CdWO.sub.4 (cadmium tungstate) is preferably employed for the wavelength conversion element 4.

(38) When an adhesive cured by green light is used, an X-ray phosphor containing, e.g., Cd.sub.2O.sub.2S:Tb (cadmium oxysulfide doped with terbium), (Zn, Cd)S:Ag (zinc sulfide or cadmium sulfide doped with silver), Cd.sub.2O.sub.2S:Pr (cadmium oxysulfide doped with praseodymium), or CsI:Tl (cesium iodide doped with thallium) is preferably employed for the wavelength conversion element 4.

(39) For example, in the above-described embodiment, when, as illustrated in FIG. 2D, the X-rays 7 are transmitted through the second plate-shaped member 2 to the wavelength conversion element 4 containing YTaO.sub.4 (yttrium tantalate), ultraviolet rays are emitted by the wavelength conversion element 4, thus satisfactorily curing the UV adhesive 5.

(40) Not only an X-ray phosphor containing an inorganic substance, as represented in Table 1, but also an X-ray phosphor containing an organic substance can be employed for the wavelength conversion element 4. Examples of an organic phosphor which emits light in the violet to blue wavelength range by irradiation with X-rays may include an anthracene crystal and organic solids such as polystyrene and polyvinyl toluene. An anthracene crystal has a peak emission wavelength of 440 nm and polystyrene and polyvinyl toluene have a peak emission wavelength of 450 nm.

(41) The above-mentioned phosphors such as NaI(Tl) and CsI:Tl exhibit high emission efficiency for -rays. Therefore, although the X-rays 7 are used in the above-described embodiment, -rays may be selected in accordance with the type of phosphor used. In other words, an energy ray for enabling a phosphor serving as the wavelength conversion element 4 to emit light is not limited to the X-rays 7, and an energy ray in a wavelength range capable of being transmitted through the materials of components to be bonded to each other, such as -, -, or -rays may also be used.

(42) An energy ray capable of being transmitted through the materials of components to be bonded to each other may be implemented in a microwave when these materials use no metal. However, the wavelength conversion element 4 used for a microwave is preferred to be an element converting a microwave into a voltage and emits light in the ultraviolet to blue wavelength range by the voltage. An ultraviolet LED is applicable as such a wavelength conversion element 4.

(43) Although the present invention has been described by taking an optical rotary encoder as an example in the above-mentioned embodiment, an assembly to which the present invention is applicable is not limited to an optical rotary encoder. In other words, the present invention is applicable to any type of assembly as long as the assembly includes a bonding portion which bonds arbitrary surfaces of a first component and a second component to each other by using an energy ray-curable adhesive. In particular, the present invention is applicable to an assembly including at least one of first and second components, which is made of a material incapable of transmitting an energy ray preferably used to cure an energy ray-curable adhesive.

Advantageous Effects of Invention

(44) According to the first aspect of the present invention, when the first component is bonded to the second component by using an energy ray-curable adhesive cured by irradiation with an energy ray in the first wavelength range, a wavelength conversion element is added to the energy ray-curable adhesive. The wavelength conversion element emits an energy ray in the first wavelength range by irradiation with an energy ray in the second wavelength range capable of being transmitted through the first component.

(45) An energy ray in the first wavelength range capable of curing the energy ray-curable adhesive is emitted by the wavelength conversion element by transmitting an energy ray in the second wavelength range through the first component to irradiate the energy ray-curable adhesive and the wavelength conversion element. This satisfactorily cures the energy ray-curable adhesive. Therefore, the first component can be made of a material incapable of transmitting the energy ray in the first wavelength range. No configuration for guiding the energy ray in the first wavelength range to the adhesive may be provided to an assembly including the first and second components.

(46) According to the second aspect of the present invention, the method for bonding components to each other in the first aspect can be satisfactorily practiced.

(47) According to the third aspect of the present invention, since the first component is made of polyetherimide resin, environmental resistance, impact resistance, heat resistance, and chemical stability of the first component can be improved.

(48) According to the fourth aspect of the present invention, an optical encoder including a slit plate possessing high environmental resistance, impact resistance, heat resistance, and chemical stability can be provided.

(49) Although typical embodiments have been described above, the present invention is not limited to the above-described embodiments, which can be changed into, e.g., various forms, structures, and materials without departing from the principle of the present invention.