CN101842038B - 包括表面清洁设备的用具的电阻焊接零件 - Google Patents
包括表面清洁设备的用具的电阻焊接零件 Download PDFInfo
- Publication number
- CN101842038B CN101842038B CN2008801137983A CN200880113798A CN101842038B CN 101842038 B CN101842038 B CN 101842038B CN 2008801137983 A CN2008801137983 A CN 2008801137983A CN 200880113798 A CN200880113798 A CN 200880113798A CN 101842038 B CN101842038 B CN 101842038B
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- welded unit
- welded
- periphery
- unit
- conductive member
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- Y10T428/19—Sheets or webs edge spliced or joined
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24488—Differential nonuniformity at margin
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Filters For Electric Vacuum Cleaners (AREA)
- Cyclones (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Nozzles For Electric Vacuum Cleaners (AREA)
Abstract
本发明公开了一种用具的零件,例如表面清洁设备的零件,以及制造该零件的方法,以及拆卸该零件的方法。该零件至少包含电阻焊接到一起的第一塑料构件和第二塑料构件。在一些实施例中,塑料构件限定了流体流动腔,例如穿过表面清洁设备的气流通路的一部分。
Description
技术领域
本发明涉及例如表面清洁设备、电动工具、园用工具和厨房用具的设备。在一个具体方面,本发明涉及具有电阻焊接构件的零件。
背景技术
表面清洁设备,例如真空清洁器,通常包含污流体入口、净流体出口和在其间延伸的流体流动通路。清洁元件安置在将污垢从流体中分离出来的流体流动通路中。已知的清洁元件包括气旋式清洁元件和过滤构件,例如过滤器和袋囊。流体流动通路中通常具有电动机从而通过污流体入口引入流体并通过净流体出口排出流体。
已知真空清洁器的流体流动通路和外壳可由很多零件组成,其中至少一些零件通常由模制两个或更多个匹配的塑料构件并随后由螺丝、铆钉等将所述匹配构件固定在一起的方式来制造。因此,匹配塑料构件具有通常位于匹配零件周边的螺丝口。
由于螺纹将匹配零件接合在一起,所以施加到由匹配构件构成的零件上的力不均衡地分布并集中在螺丝口周围。这可能导致零件故障,例如在螺丝口附近破裂。为解决该问题,通常这样的匹配塑料构件具有整体肋条,其在螺丝口之间围绕着导管的内部延伸并增强塑料构件。进一步地,可以增加螺丝口附近的零件的厚度。
发明内容
在一个广泛的方面,提供了用于表面清洁设备的零件。该表面清洁设备具有污流体入口、净流体出口和在其间延伸的流体流动通路。该零件至少包含电阻焊接到一起并限定了一个腔的第一可焊接构件和第二可焊接构件。该腔具有至少一个入流端口和至少一个出流端口。该零件形成了流体流动通路的一部分。因此,该零件与流体流动通路可流体连通从而形成部分流体流动通道。
在另一个广泛的方面,提供了用具的零件,该用具例如表面清洁设备。该零件至少包含电阻焊接在一起的第一可焊接构件和第二可焊接构件。第一可焊接构件和第二可焊接构件中的每一个都具有周边(perimeter),并且零件沿该周边联结。至少一个导电构件布置在第一可焊接构件和第二可焊接构件之间,并沿周边从第一位置延伸到第二位置。
因为第一可焊接构件和第二可焊接构件可以密封地联结到一起,所以根据该广泛方面的实施例是有利的。也就是说,由于是电阻焊接,所以可焊接构件之间的联结可以形成流体密封。于是,因为流体流动通路中漏气而产生的压力损失可以最小化或减少。因此,对于给定的电动机强度,该表面清洁设备可以提供更高水平的吸力并更有效率。
在优选实施例中,第一可焊接构件和第二可焊接构件中至少一个或优选地二者都没有螺丝口。因为螺丝口周围应力的高度集中可导致零件破裂,所以这样的实施例可以是有利的。如果零件形成部分流体流动通路,则破裂将使得流体可以流过零件表面。如果流体流动通路处在压力下,例如水的流体通过毛毡抽取器(carpet extractor)抽取,则这可以导致零件渗漏。如果流体流动通路处于真空下,例如空气通过抽吸电动机(suction motor)上游处的真空清洁器的气流通路抽出,则空气可以通过裂缝被吸入流体流动通路内并且减少抽吸和减小流体流动通路入口处的气流速度,因此降低了真空清洁器的清洁效率。
因此,如果不使用螺丝口,那么可以减少与螺丝口有关的零件中的点应力。在一些实施例中,基本上可以消除由电阻焊接制作的零件中的点应力。因此并不需要使用与螺丝口有关的增强结构。因此,至少在螺丝口附近不需要使用增强肋条和增加材料的厚度。
没有螺丝口和相关结构(例如肋条)的一个优点是显著减少了第一可焊接构件和第二可焊接构件的重量。例如,零件的重量可以减少10-15%,并且有时可以达到25%。因此,和现有技术下的零件相比,零件可以更轻且制造起来更便宜。
没有螺丝口的另一优点是第一可焊接构件和第二可焊接构件中至少一个且优选地二者都可以没有增强肋条。因为可以消除与肋条有关的材料成本和重量,所以这样的实施例是有利的。因此,该用具可以更轻并因此更容易操纵。
在具体优选实施例中,零件包含用具的部分流体流动通路并且也是用具的结构性构件或载重构件,例如表面清洁设备的清洁头。
在一些实施例中,第一零件和第二零件中的每一个都具有周边,材料腹板延伸到周边内,该腹板具有外表面,并且第一零件和第二零件中至少一个被配置成仅沿平行于外表面的方向传递应力。
在一些实施例中,第一零件和第二零件中的每一个都具有周边,并且该零件进一步包含围绕周边从第一位置延伸到第二位置的导电构件,而且第一部分和第二部分由缝隙分隔。因此,应用的电导线优选沿要固定到另一个零件的零件周边连续延伸,但缝隙除外。该缝隙优选地小于0.08英寸,更优选地小于0.04英寸,并且最优选地小于0.02英寸。优选地,缝隙大于0.001英寸并且优选大于0.005英寸。
在可替换实施例中,可能不具有缝隙。可替换地,导线可以由不导电材料涂覆,以便阻止该导线与其自身或另一条导线接触的位置过热,例如该导线与其自身交叉处过热。例如,该导线可以由瓷釉涂覆。可替换地,导线可以由牺牲性材料涂覆,例如热固性塑料。被加热时,热固性塑料将会熔化并在零件之间流动。热固性塑料可以是允许匹配表面粘合的任意塑料。优选地,热固性塑料是化学性质上与将要结合在一起的被焊接零件充分相似的塑料,并且优选地在化学性质上与焊接到一起的零件相同。
可替换地,或此外,垫片可以安置在导线的相邻部分之间。该垫片可在相邻导线之间提供足够的间隔,以使相邻导线部位处的材料不会熔化太多。可以充分认为该垫片仅阻止导线接触,特别在如果导线未被涂覆的情况下。垫片厚度可以是0.001英寸厚或更大,厚度优选地大于0.005英寸。垫片可以由任何会在焊接工艺所产生的高温下熔化的材料制成。它优选地是塑料,并且更优选地是与被焊接到一起的零件相同的塑料。该垫片可以由任何在化学性质上与即将连结到一起的被焊接零件充分相似的热固性塑料制成,并且优选地由在化学性质上与焊接到一起的零件相同的热固性塑料制成。
在一些实施例中,导电构件包含第一末端和第二末端,并且在零件形成后可通达第一末端和第二末端。因为制造商可通达第一和第二末端来拆卸该零件,从而修理部件(例如位于其中的电动机),仅通过对嵌入的导电构件施加电流,所以这样的实施例可以是有利的。可焊接构件随后可以重焊接到一起从而形成修复的零件。
在一些实施例中,多个导电构件围绕周边延伸并且至少两个导电构件由缝隙间隔开。该缝隙优选地小于0.08英寸,更优选地小于0.04英寸,并且最优选地小于0.02英寸。
在一些实施例中,多个导电构件围绕周边延伸,并且在相邻导电构件的相邻末端之间具有缝隙。该缝隙优选地小于0.08英寸,更优选地小于0.04英寸,并且最优选地小于0.02英寸。
在一些实施例中,导电构件包含第一末端和第二末端,并且可通达第一末端和第二末端。
在一些实施例中,该零件包含真空清洁器的结构性构件。
在另一个广泛的方面,提供了制造表面清洁设备的零件的方法。该方法包含(a)向被置于第一可焊接构件和第二可焊接构件之间的导电构件施加电流,从而熔化第一可焊接构件和第二可焊接构件紧邻导电构件的一部分;并且(b)允许熔化的部分在第一可焊接构件和第二可焊接构件互相接触时硬化。
在一些实施例中,该方法进一步包含在施加电流前沿第一构件和第二构件中的一个的周边、在第一位置和第二位置之间安置导电构件,其中第一位置和第二位置由小于0.08英寸的缝隙分隔。
在一些实施例中,第一可焊接构件和第二可焊接构件沿共用边界互相接触,并且该方法进一步包含沿该边界安置多个导电构件,其中至少两个导电构件被隔开小于0.08英寸。
在一些实施例中,步骤(b)之后,导电构件的至少第一部分和第二部分被放置成可被通达。
在一些实施例中,该方法进一步包含构造使得第一可焊接构件和第二可焊接构件中至少一个没有螺丝口。
在一些实施例中,该方法进一步包含构造使得第一可焊接构件和第二可焊接构件中至少一个没有增强肋条。
在一些实施例中,第一零件和第二零件中的每一个都具有周边,材料腹板在周边内延伸,并且该腹板具有外表面。在一些这样的实施例中,该方法进一步包含构造第一零件和第二零件中的至少一个使其仅以在与外表面平行的方向上传递应力。
在一些实施例中,零件包括金属部件,并且该方法进一步包含在施加电流之前将金属部件安置在第一可焊接构件和第二可焊接构件之间。
在另一个广泛的方面,提供了拆卸表面清洁设备的零件的方法。该零件包含通过电阻焊接沿边界联结在一起的至少两个可焊接构件以及至少部分地嵌入其中的导电构件。该方法包含向导电构件施加电流;以及分隔开实施至少两个可焊接构件。
在一些实施例中,该至少两个可焊接构件形成表面清洁设备的部件的外壳,并且该方法进一步包含维护该部件(例如维修或更换电动机)。该方法可以进一步包含依次将可焊接构件电阻焊接在一起。
在一些实施例中,该方法进一步包含将至少两个可焊接构件沿边界对准,并向导电构件施加电流,借此将零件电阻焊接在一起。
在一些实施例中,该方法进一步包含回收该至少两个可焊接构件。
可以理解该零件可以用于表面清洁设备、厨房用具、电动工具或园用工具。
优选用容纳金属部件的零件来实现该工艺。特别地,该方法可以用来形成容纳组件(例如电动机)的零件。由于部件中的金属也会因焊接操作被加热,所以部件中存在金属会阻止使用感应焊接。然而与此相反,电阻焊接不加热部件的金属,而仅加热与电源电气接触的导电构件,例如导线。
该工艺进一步的优点是,具有复杂几何形状的零件可以容易地焊接,而不需要建立具有匹配几何形状的焊接夹具,而该焊接夹具在使用声波焊接的情况下是必要的。
附图说明
本发明以上的和其它的优点,将连同下面对本发明优选实施例的描述更加完整和具体地被理解,其中:
图1是表面清洁设备的透视图,其包含使用电阻焊接制造的表面清洁头的实施例;
图2是图1的表面清洁头的分解图;
图3是图1的表面清洁头的透视图,其示出该零件制造步骤的实施例;
图4是图3示出的一个可焊接构件的放大图;
图5A和图5B是在向导电构件施加电流之前,沿图1的线5-5截取的剖面图,其中示出了图3中例示的可焊接构件的邻接表面的可替换构造;以及
图6是在向导电构件施加电流之后,沿图1的线5-5截取的剖面图;
图7是手持式表面清洁设备的示意图,其中示出气流通道;
图8是图7所示的手持式表面清洁设备的透视图,其中移除盖子从而示出被提供来允许盖子通过电阻焊接从而部固定到污垢收集仓室的导电构件;以及
图9是图8的区域A的放大图。
具体实施方式
参考图1,示出包含根据本发明的零件的示范性表面清洁设备10。在所示实施例中,表面清洁设备10是具有直立段的立式真空清洁器,该直立段包含表面清洁头12、旋流器14、污垢仓16、过滤器外壳18、电动机外壳20中的电动机。该直立段被安装于主干24,该主干24包括延伸到旋流器14的上气流导管以及把手22。表面清洁头12包含污流体入口26,空气通过该污流体入口26进入表面清洁设备10内。污空气从表面清洁头12进入主干24的上气流导管,并且被引导朝着旋流器14向上移动。在旋流器14中,较大的污垢微粒从空气中分离,并沉积到污垢仓16中。空气离开旋流器14,并经过将较小的污垢微粒从空气中去除的可选过滤器外壳18。然后洁净空气被吸取通过电动机外壳并从净流体出口28排出。因此,在所示实施例中,流体流动通路由表面清洁头12、主干24、旋流器14、过滤器外壳18和电动机外壳20限定。
本发明的实施例涉及真空清洁器的零件。可以理解,本发明的零件可以被包括在各种结构的各类表面清洁设备中。因此,虽然表面清洁设备10是立式真空清洁器,但是本发明的零件可以用于包括罐状真空清洁器、手持式真空清洁器、可携带的带式真空清洁器、棒状真空清洁器、干/湿真空清洁器、毛毡抽取器等的任何类型的表面清洁设备,并且这些设备可以具有任意的设计。
一些具体实施例涉及形成表面清洁设备的流体流动通道的一部分的零件。这样的零件可以包括限定了具有入流端口和出流端口的腔的任何零件。例如清洁头12、旋流器14、过滤器外壳18和电动机外壳20中的一个或更多,或者形成流体流动通路一部分的另一个零件可能是这样的零件,或包含这样的零件。在一些进一步的实施例中,这样的零件可以包括表面清洁设备的结构性零件,例如主干24。为简单起见,将参考表面清洁头12来描述本发明的实施例。然而,可以理解,所描述的方法和设备可改变从而适应具体零件。
参考图1,图中示出本发明的零件11的实施例。在所示实施例中,零件11是表面清洁头12。表面清洁头12包含被限定在第一构件46和第二构件48的内表面之间的腔、入流端口31(即表面清洁头12的污空气入口)以及出流口44,该出流口44是与主干24的上气流导管连接的端口(参看图2)。在所示实施例中,该腔包含前仓室30、后仓室32和多个在其间延伸的气流柱34。气流柱34提供了在前仓室30和后仓室32之间的流体连通。
在可替换实施例中,其中零件11不是表面清洁头,腔可以以不同的方式配置。例如,在实施例中,其中零件11是主干24,腔可以是柱状的。
在所示实施例中,前仓室30包含上部36、下部38和相对的侧面40、42。入流端口31被限定在下部38中,并提供了表面清洁设备的污流体入口。可以在前仓室30中提供可旋转安装的刷子。出流端口44提供了在表面清洁头12和主干24之间的流体连通。
对表面清洁头12的更详细的描述可参考美国专利申请11/953,355(提交于2007年12月10日),该申请的全部内容包括在此以供参考。
参考图2,表面清洁头12由第一构件46和第二构件48制造,其中第一构件46和第二构件48被电阻焊接到一起从而形成表面清洁头12。在所示实施例中,表面清洁头12仅包含两个构件。然而,在可替换实施例中,表面清洁头可以包含可以被电阻焊接到第一构件和第二构件的附加构件,例如第三构件和第四构件。可替换地,第一构件46可包含两个模制零件,这两个模制零件均被电阻焊接到第二构件48。因此,任何数量的零件都可以被电阻焊接到一起。
第一构件46和第二构件48包含任何可焊接成分,例如受热时熔化并且优选是塑料的材料。在优选实施例中,第一构件46和第二构件48是单独模制的并可包含聚氯乙烯(PVC)、聚碳酸酯、聚乙烯、聚丙烯、ABS或任何其它热定型塑料。在优选的实施例中,通过注塑来形成第一构件46和第二构件48。然而,在其它实施例中,通过旋转成型、真空成型等方法来制造第一构件46和第二构件48。
在示出的实施例中,第一可焊接构件46和第二可焊接构件48中的每一个限定了至少一个周边,其中第一可焊接构件46和第二可焊接构件48沿该周边的至少一部分联结。因此,构件的周边是要被联结的表面并且可以是构件的部分或全部周长。在图2示出的示范性实施例中,第一可焊接构件46包含四个周边50a、50b、50c、50d,并且第二可焊接构件48包含四个周边52a、52b、52c、52d。周边50b、50c、52b和52c围绕中间空隙或开孔51b和51c延伸。周边50d和52d部分地围绕中间空隙51d延伸。周边50a和52a部分地围绕基本全部表面清洁头12延伸。周边50a沿其全部长度被联结到周边52a,周边50b沿其全部长度被联结到周边52b,周边50c沿其全部长度联结到周边52c,并且周边50d沿其全部长度联结到周边52d。可以理解,这些周边被电阻焊接到一起时,构件46、48固定到一起从而限定了仅具有为入口31和出口44的开孔的流体导管。因此,可以理解,本文所用术语“周边”是指至少部分地沿或绕部件延伸的边界,并且可以是闭合的或不闭合的。
在所示实施例中,每个周边包含多个边沿54,边沿54连接在一起从而限定了被固定到匹配边沿上的通路。在可替换实施例中,一个或更多周边可以是基本圆形或圆角的,并且可以因此仅包含单个边沿。在所示实施例中,边沿54具有在大约0.5厘米到大约1.5厘米之间的宽度。然而在其它的实施例中,边沿54可以具有其他宽度。
在所示实施例中,构件46和构件48沿每个周边的整体被联结。在可替换实施例中,可焊接构件可以仅沿每个周边的一部分被联结。例如,在零件11是主干24的实施例中,构件46和构件48可以包含末端开口柱体的第一和第二纵向延伸半部(halve)。在这样的实施例中,每个周边可以包含两个直边沿和两个半圆边沿,并且构件可以仅沿直边沿联结,其中直边沿是匹配边沿或要联结的边沿,而且在限定了半圆柱形的一个半部的直边沿之间延伸的材料是形成半圆柱形的材料腹板。
周边被联结时,由在周边之间提供的腹板来限定所形成的腔。例如,在一些实施例中,塑料腹板56a、56b在一些周边内部或一些周边之间延伸,从而限定每个第一可焊接构件46和第二可焊接构件48的内表面58a、58b和外表面60a、60b。在所示实施例中,腹板56从周边50a和52a向内延伸。腹板56a在周边50a和周边50b、50c和50d之间延伸,并且腹板56b在周边52a和周边52b、52c和52d之间延伸。空隙51b-51d也可以在周边50b、50c、50d和52b、52c、52d内延伸。
为形成表面清洁头12,将第一构件46和第二构件48电阻焊接到一起。在所示实施例中,第一构件46和第二构件48沿每个周边50a、50b、50c、50d、52a、52b和52c、52d被电阻焊接到一起。在可替换实施例中,第一构件46和第二构件48可以仅沿一些周边被电阻焊接到一起。电阻焊接第一构件46和第二构件48的方法将参考图3-6在下面描述。
参考图3,在电阻焊接第一可焊接构件46和第二可焊接构件48的第一步骤中,沿要联结的周边或边沿对准第一构件46和第二构件48。在所示实施例中,第一构件46和第二构件48沿周边50a、50b、50c、50d、52a、52b、52c和52d对准。任何被容纳在表面清洁头12内部的部件,例如一个或更多个刷子或轮子138,以及一个或更多个枢轴连接件152,可以在零件对准之前或之后被设置在第一构件46和第二构件48之间。
如上所述,在一些实施例中,真空清洁器的零件可以包含电动机外壳,或容纳金属部件的其它外壳。在这样的实施例中,可以在电阻焊接第一构件46和第二构件48前,将金属部件设置在第一构件46和第二构件48之间。
沿要联结的周边或边沿,将至少一个导电构件(例如导线62)安置在第一可焊接构件46和第二可焊接构件48之间,如图4的放大图所例示。在所示实施例中,第一导线62a设置在周边50a和52a之间,第二导线62b设置在周边50b和52b之间,第三导线62c设置在周边50c和52c之间,第四导线62d设置在周边50d和52d之间。导线62被设置成使得它们沿每个周边50从第一位置64a-d延伸到第二位置66a-d。导线可以被嵌入零件中,或可以设置在上表面或周边上。
如同可以意识到的,周边50a和52a以及周边50d和52d不形成闭环。因此,第一位置64a、64d和第二位置66a、66d可以并且优选位于每个周边的末端。然而,周边50b和52b,以及周边50c和52c限定了闭环。在这种情形中,第一位置64b、64c和第二位置66b、66c优选地间隔开从而限定了在第一位置64和第二位置66处导线62的部分之间的缝隙65。缝隙65可以用来防止在位置64和位置66处导线的部分之间产生短路。可替换地或另外,可以涂覆导线和/或用垫片分离导线。
在一些实施例中,缝隙65的尺寸被设定成使得在电流经过导线60时,第一可焊接构件46和第二可焊接构件48中至少一个在缝隙65中的部分将会充分熔化,以便在缝隙65中产生流体密封。缝隙65优选小于0.08英寸,更优选小于0.04英寸并且最优选小于0.02英寸。如果没有缝隙,或者如果位置64、66靠得太近,那么在焊接工艺中会有过多的塑料熔化,从而导致形成不完全的密封(即,可能不是流体密封),或者可能在位置64、66处形成结构缺陷。提供缝隙65的优点是不在该区域内提供过度加热。例如,如果在位置64、66处导线末端邻接,则将会向邻近的末端提供额外热量,以便该区域中过多塑料可能熔化到如下程度,即塑料可以流动,并且可能在某个位置提供的塑料不足以提供气密密封或流体密封。因此,如果导线形成环路,如图8所例示,则周边上的导线末端优选地被隔开足够量,以便在其间的塑料熔化足够的量,从而在电流通过导线62时提供完全密封。
在所示实施例中,单个导电构件设置在要被联结到一起的每个周边或边沿之间。然而,在可替换实施例中,一个以上的导电构件可以设置在要被联结到一起的每个周边之间。在这样的实施例中,导电构件可以被设置成使得它们大致互相平行,并且它们分隔开大约小于0.08英寸,优选小于0.04英寸,并且更优选小于0.02英寸。
在所示实施例中,导线62被设置成使得当第一构件46和第二构件48被联结时可通达邻近位置64的导线62的第一部分70和邻近位置66的导线62的第二部分72。例如,如图4所例示,第一部分70和第二部分72在焊接工艺完成后可以延伸出构件46、48的周边。可以理解,在可替换实施例中,部分70、部分72可以凹入到焊接零件内部,并且可以通过从零件的外表面延伸到导线末端的端口来通达部分70、72。
在已经放置了导线60后,第一构件46和第二构件48被设置成沿着将要焊接的共用边界互相接触。在所示实施例中,共用边界沿周边50a、50b、50c、50d、52a、52b、52c和52d延伸。然而,如上所述,该共用边界可以仅包含周边的单个边沿。在一些实施例中,虎钳或其它夹持装置可用来将第一构件46和第二构件48固定地保持就位。可以应用合适的压力。
在一些实施例中,如图5A所示,每个周边的边沿可以是基本平坦的,以便导线60基本夹在构件46和构件48之间。在其它实施例中,如图5B所示,可以在构件46和构件48中的一个的边沿54上提供凹槽74,并且可以在构件46和构件48的另一个的边沿上提供轨76,以便将导线60夹在凹槽74中。因为可以增加构件46、48与导线接触的表面积,所以这样的实施例可以是有利的。
然后向每条导线62的两端施加电压,例如通过将暴露部分70、72连接到电源。在一些实施例中,电源可以是具有直流或交流输出(优选具有直流输出)的可变电压变压器。由于被施加电压,所以导线62将开始升温。随着导线升温,邻近每条导线62的塑料将开始熔化。而且,位于可选缝隙65的塑料将开始熔化。因此,构件46和48可以沿其周边(包括在缝隙65处)连续地联结,并且可以在构件46和48之间提供气密密封。可以理解,施加电流可以与使得构件46和48彼此接触同时进行,或在此之前或在此之后进行。
在一段时间之后,例如大约2到20秒之间,优选大约5秒之后,可以停止施加电压。在已经停止施加电压时,可焊接构件可以被保持成互相接触并且允许硬化。也就是说,可焊接构件将开始冷却,并且熔化部分78将会硬化并焊接到一起,且导线62嵌入其中,如图6所示。
在一些实施例中,在已经电阻焊接了第一构件46和第二构件48之后,用户可以修剪或切割导线62,以使暴露部分70和72在焊接工艺完成后不暴露在零件11中。然而,在优选实施例中,暴露部分70和72在最终产品中保持可被通达。也就是说,暴露部分70和72可不被修剪或切割,而是将它们盘绕。可替换地,零件46和48中的一个或两者可以包括在外表面60上的凹槽或槽口,部分70和72可以被塞入其中,或可以将它们设置在端口中。这样的实施例可以允许方便地修理零件。
然后可以将表面清洁头12与表面清洁设备10的剩余零件装配在一起。由于使用了表面清洁设备10,各种力和压力将会被施加到表面清洁头12上。例如,在使用中,表面清洁头可能接触或撞击一个或更多个壁。然而,因为构件46和48可以在没有辅助机械紧固件的情况下沿其周边连续地联结,所以应力将沿周边基本平均地分布。因此,表面清洁头12将倾向于作为单片零件工作并且不需要具有支撑肋条来辅助力的分布。因此,不受理论限制,可以理解施加到表面清洁头12上的应力将会沿与外表面60a、60b大致平行的方向传递,而不是向内朝支撑肋条传递。
在表面清洁设备10的工作寿命中,可能需要修理、更换或维护表面清洁设备10的各种零件。例如,它可能需要修理表面清洁头的刷子,或更换电动机。可替换地,在表面清洁设备10的工作寿命结束时,可能要回收表面清洁设备10的各种零件,包括表面清洁头12。本发明的实施例提供了拆卸表面清洁设备的零件的办法,例如,以便可以修理或更换零件或零件的组件,或以便回收表面清洁设备的一个或更多个部件。拆卸本发明的零件的方法将参考表面清洁头12在下面描述。然而,该方法可以用于拆卸被电阻焊接到一起设备的任何零件。
在拆卸表面清洁头12的第一步中,如有需要,用户可以将导线62的部分70、部分72移动到暴露位置。例如,用户可以从凹槽移除或取出导线62,以便使部分70和72暴露。一旦导线暴露,或如果在将导线的末端70、72凹入到零件11内时可通达末端70、末端72,则可以经由部分70和72向导线62施加电压。当施加电压时,导线62将开始升温。当导线升温,在联结边沿处的塑料将开始熔化。此外,根据导线62的配置,位于任意缝隙65处的塑料可以开始熔化。由于塑料熔化,用户可应用单独的构件46和构件48。
在构件分离时,可以通达到被保持或容纳在零件11中的任意部件。可以修理、更换或维护部件。可替换地,可以回收或为回收而发送一个或更多个部件,包括第一可焊接构件和第二可焊接构件。
在零件的部件被修理或更换的实施例中,在修理或更换部件后可以再次装配零件11。为了再次装配零件11,沿要被联结的周边再次对准至少两个可焊接构件46、48,在其中提供了在可焊接构件46、48之间的任何部件,可焊接构件46、48之间的任何导电构件62可以沿周边被放置,并且向导电构件施加电流从而将构件电阻焊接到一起。
可以理解,导电构件62不必是导线,其可以是能够由于电流流过而加热塑料的任何构件。导电构件62可以被嵌入到构件46、48中,或可以是在焊接操作之前位于匹配构件46、38之间的单独元件。
根据另一实施例,图7示出手持式清洁设备200,其中例示出通过电阻焊接被装配的两个零件。手持式清洁设备200具有把手218和on/off开关220从而致动第二外壳222内的抽吸电动机。在使用中,抽吸电动机通过由实箭头示出的通路汲取空气,其中污空气进入表面清洁管口226的污空气入口224,经过第一外壳204内部的旋流器208,进入旋流器208内部的涡流探测器(vortex finder)228,并最终在从净空气出口230离开之前经过第二外壳222内的过滤器和抽吸电动机。进入旋流器208的空气内夹带的污垢在旋流器208的顶部从气流中分离出来,由虚箭头示出,并沉积在收集仓室206的地板232上。
如图8和图9所例示,该手持式表面清洁设备200的至少两个构件通过电阻焊接来装配。在该实施例中,盖子202封闭了提供沿第一外壳204的顶表面210的流体密封的第一外壳204,并电阻焊接到其上。因此沿顶表面210提供了导电构件,例如具有在部分70、72上的末端214和216的导线62,该顶表面210限定了要联结到盖子202的周边上的外壳204的周边。优选地,在顶表面210中的凹槽中提供导线62,如图5B所例示。根据这样的实施例,导线62的顶部优选与顶表面210齐平或在其之下。可替换地,导线62的一部分可以从顶表面210向上延伸,并且可以被接收在要被固定到顶表面210上的零件内的凹槽中。
为了将零件(例如盖子202和第一外壳204)固定在一起,可以在端子214和216连接到电源(优选直流电)且施加足够时间的电流以便将盖子202和第一外壳204焊接到一起之前或之后,使零件接触。可以理解,随着施加电流通过导线62,导线62将升温,因此使周围的塑料熔化。这允许在盖子202和第一外壳204之间形成完全的气密密封或流体密封。
电阻焊接的其它细节和实施例,其组成、优点和用途,例如导电构件缝隙和设备拆卸、修理和回收与参考图1到图6的描述基本相同。
可以理解,为清晰起见而在独立实施例或独立方面中描述的本发明的某些特征,也可以结合在单个实施例中提供。相反地,为简单起见而在单个实施例或方面中描述的本发明的多个特征,也可以独立提供或在任何合适子组合中提供。
尽管已经结合特定实施例描述了本发明,但显而易见,很多替换、改进或变化对本领域技术人员来说将是明显的。因此,本发明包括权利要求的精神和范畴内的所有这些替换、改进或变化。另外,任何参考文献的引用或识别不能解释为这样的参考文献可用作本发明的现有技术。
Claims (29)
1.一种用具的零件,其包含:
(a)至少第一可焊接构件和第二可焊接构件,其具有周边并沿所述周边被电阻焊接到一起并且具有公接合构件和母接合构件;以及
(b)至少一个导电构件,其被布置在所述第一可焊接构件和所述第二可焊接构件之间,并沿所述周边从第一位置延伸到第二位置。
2.根据权利要求1所述的零件,其中一个导电构件沿所述周边延伸,所述第一位置和所述第二位置由小于0.08英寸的缝隙分隔。
3.根据权利要求1所述的零件,其中多个导电构件围绕所述周边延伸,且至少两个所述导电构件由小于0.08英寸的缝隙隔开。
4.根据权利要求1所述的零件,其中所述导电构件包含第一末端和第二末端,且其中在所述零件已经形成时可通达到所述第一末端和所述第二末端。
5.根据权利要求1所述的零件,其中所述零件包含真空清洁器的结构性构件。
6.根据权利要求1所述的零件,其中所述导电构件具有不导电涂层。
7.根据权利要求1所述的零件,其中所述第一可焊接构件和所述第二可焊接构件中至少一个没有螺丝口。
8.根据权利要求1所述的零件,其中所述第一可焊接构件和所述第二可焊接构件中至少一个没有增强肋条。
9.根据权利要求1所述的零件,其中所述第一可焊接构件和所述第二可焊接构件中的每一个都具有周边,材料腹板在所述周边之间延伸,所述腹板具有外表面,且所述第一可焊接构件和所述第二可焊接构件中至少一个被配置成仅在与所述外表面平行的方向上传递应力。
10.根据权利要求1所述的零件,其中所述用具是表面清洁设备、厨房用具、电动工具或园用工具。
11.根据权利要求1所述的零件,其中所述公接合构件包括轨,并且所述母接合构件包括凹槽,并且导电构件被置于所述凹槽中。
12.根据权利要求1所述的零件,其中所述第一可焊接构件和所述第二可焊接构件是塑料,并且所述公接合构件和所述母接合构件在所述周边处交界。
13.一种制造用具的零件的方法,其包含:
(a)使得包括公接合构件和母接合构件的第一可焊接构件和第二可焊接构件相互接合并且向被置于所述第一可焊接构件和所述第二可焊接构件之间的导电构件施加电流,从而熔化所述第一可焊接构件和所述第二可焊接构件中至少一个的接近所述导电构件的一部分;以及
(b)允许熔化部分在所述第一可焊接构件和所述第二可焊接构件互相接触时硬化。
14.根据权利要求13所述的方法,进一步包含在施加电流之前,沿所述第一可焊接构件和所述第二可焊接构件中的一个的周边、在第一位置和第二位置之间安置所述导电构件,其中所述第一位置和所述第二位置由小于0.08英寸的缝隙隔开。
15.根据权利要求13所述的方法,其中所述第一可焊接构件和所述第二可焊接构件沿共用边界互相接触,并且所述方法进一步包含沿所述边界安置多个导电构件,其中至少两个所述导电构件由小于0.08英寸的缝隙隔开。
16.根据权利要求13所述的方法,其中在所述步骤(b)之后,所述导电构件的至少第一部分和第二部分被安置成可被通达。
17.根据权利要求13所述的方法,进一步包含提供具有不导电涂层的导电构件。
18.根据权利要求13所述的方法,进一步包含将所述第一可焊接构件和所述第二可焊接构件中至少一个构建成没有螺丝口。
19.根据权利要求13所述的方法,进一步包含将所述第一可焊接构件和所述第二可焊接构件中至少一个构建成没有增强肋条。
20.根据权利要求13所述的方法,其中所述第一可焊接构件和所述第二可焊接构件中的每一个都具有周边,材料腹板在所述周边之间延伸,且所述腹板具有外表面,并且所述方法进一步包含将所述第一可焊接构件和所述第二可焊接构件中的至少一个构建成仅在与所述外表面平行的方向上传递应力。
21.根据权利要求13所述的方法,其中所述零件包括金属部件,并且所述方法进一步包含在施加电流前将所述金属部件安置在所述第一可焊接构件和所述第二可焊接构件之间。
22.根据权利要求13所述的方法,其中所述零件是所述用具中流体流动通路的一部分,并且所述方法进一步包含使所述零件与所述流体流动通路的附加构件以流体连通的方式连接。
23.根据权利要求22所述的方法,进一步包含使所述零件与表面清洁设备的抽吸电动机以流体连通的方式连接。
24.根据权利要求13所述的方法,进一步包含在所述导电构件的相邻部分之间提供垫片。
25.一种拆卸零件的方法,所述零件包含通过电阻焊接沿边界联结到一起的包括公接合构件和母接合构件的至少两个可焊接构件,其中导电构件至少部分嵌入到其中,且所述方法包含:
(a)向所述导电构件施加电流;以及
(b)分离所述至少两个可焊接构件。
26.根据权利要求25所述的方法,其中所述至少两个可焊接构件形成用具的部件的外壳,并且所述方法进一步包含维护所述部件。
27.根据权利要求26所述的方法,其中所述部件包含电动机,并且所述方法进一步包括更换或修理所述电动机。
28.根据权利要求25所述的方法,进一步包含依次将所述可焊接构件电阻焊接到一起。
29.根据权利要求25所述的方法,进一步包含回收所述至少两个可焊接构件。
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CA2,599,303 | 2007-08-29 | ||
CA002599303A CA2599303A1 (en) | 2007-08-29 | 2007-08-29 | Surface cleaning apparatus |
PCT/CA2008/001529 WO2009026708A1 (en) | 2007-08-29 | 2008-08-28 | Resistively welded part for an appliance including a surface cleaning apparatus |
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CN2008801137983A Active CN101842038B (zh) | 2007-08-29 | 2008-08-28 | 包括表面清洁设备的用具的电阻焊接零件 |
CN200880113799.8A Active CN101842040B (zh) | 2007-08-29 | 2008-08-28 | 具有外部设置的污垢仓室的气旋式表面清洁设备 |
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2007
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2008
- 2008-08-27 US US12/675,636 patent/US20110146024A1/en not_active Abandoned
- 2008-08-27 WO PCT/CA2008/001519 patent/WO2009026700A1/en active Application Filing
- 2008-08-28 US US12/675,590 patent/US8349428B2/en active Active
- 2008-08-28 CA CA2731776A patent/CA2731776C/en active Active
- 2008-08-28 WO PCT/CA2008/001531 patent/WO2009026710A1/en active Application Filing
- 2008-08-28 CN CN200880113797A patent/CN101842039A/zh active Pending
- 2008-08-28 US US12/675,558 patent/US8590102B2/en active Active
- 2008-08-28 US US12/675,611 patent/US8677558B2/en active Active
- 2008-08-28 CA CA2731649A patent/CA2731649A1/en not_active Abandoned
- 2008-08-28 US US12/675,512 patent/US20100299865A1/en not_active Abandoned
- 2008-08-28 CN CN2008801137983A patent/CN101842038B/zh active Active
- 2008-08-28 CN CN200880113799.8A patent/CN101842040B/zh active Active
- 2008-08-28 WO PCT/CA2008/001530 patent/WO2009026709A1/en active Application Filing
- 2008-08-28 CA CA2894369A patent/CA2894369C/en active Active
- 2008-08-28 WO PCT/CA2008/001535 patent/WO2009026714A1/en active Application Filing
- 2008-08-28 CA CA2731777A patent/CA2731777A1/en not_active Abandoned
- 2008-08-28 WO PCT/CA2008/001533 patent/WO2009026712A1/en active Application Filing
- 2008-08-28 WO PCT/CA2008/001529 patent/WO2009026708A1/en active Application Filing
- 2008-08-28 WO PCT/CA2008/001534 patent/WO2009026713A1/en active Application Filing
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- 2008-08-28 US US12/675,540 patent/US9027201B2/en active Active
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2013
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2014
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