CN107530980B - 熔接方法 - Google Patents

熔接方法 Download PDF

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CN107530980B
CN107530980B CN201680025741.2A CN201680025741A CN107530980B CN 107530980 B CN107530980 B CN 107530980B CN 201680025741 A CN201680025741 A CN 201680025741A CN 107530980 B CN107530980 B CN 107530980B
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welding
punch
cover
component
recess
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CN107530980A (zh
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安田笃
河本保典
铃木直人
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Denso Corp
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Denso Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B29C65/7805—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features
    • B29C65/7814—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features in the form of inter-cooperating positioning features, e.g. tenons and mortises
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/137—Beaded-edge joints or bead seals
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B29C66/53461—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01M—LUBRICATING OF MACHINES OR ENGINES IN GENERAL; LUBRICATING INTERNAL COMBUSTION ENGINES; CRANKCASE VENTILATING
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    • F01M11/0004—Oilsumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01M—LUBRICATING OF MACHINES OR ENGINES IN GENERAL; LUBRICATING INTERNAL COMBUSTION ENGINES; CRANKCASE VENTILATING
    • F01M11/00—Component parts, details or accessories, not provided for in, or of interest apart from, groups F01M1/00 - F01M9/00
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    • F01M11/12—Indicating devices; Other safety devices concerning lubricant level
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
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    • B29L2031/3481—Housings or casings incorporating or embedding electric or electronic elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Level Indicators Using A Float (AREA)
  • Measurement Of Levels Of Liquids Or Fluent Solid Materials (AREA)

Abstract

本发明提供熔接方法，使树脂制的第一部件(110)与树脂制的第二部件(120)抵接，并利用熔接用冲头(210)对抵接部的侧面部进行加热及加压，而对第一部件(110)和第二部件(120)进行熔接。在侧面部中，预先在第一部件(110)设置突出部(112)，而在第一部件(110)与第二部件(120)之间形成台阶(132)，预先在熔接用冲头(210)的末端部形成供熔融部填充的冲头凹部(211)，通过熔接用冲头(210)的加压，而在冲头凹部(211)内将第一部件(110)的突出部(112)向第二部件(120)侧压扁，一边使冲头凹部(211)的外周侧端部(212)陷入第一部件(110)以及第二部件(120)，一边使第一部件(110)的熔融部和第二部件(120)的熔融部填充于冲头凹部(211)内。

Description

熔接方法
相关申请的交叉引用
本申请的公开内容基于通过参照并入本申请的2015年6月3日提出的日本专利申请2015-113417号以及2016年3月31日提出的日本专利申请2016-070305号。
技术领域
本公开例如涉及用于对液面检测装置所使用的树脂制的主体和罩进行熔接的熔接方法。
背景技术
在专利文献1中记载有对积存在容器内的液体的液面高度进行检测的液面检测装置。专利文献1的液面检测装置具备平板状的主体和有底筒状的罩，在由主体和罩形成的收纳室内收纳有浮子、磁铁、以及舌簧开关等。其中，浮子以及磁铁根据液面的变化上下移动，利用舌簧开关检测液面是否变为规定的液面高度。
并且，在专利文献1中，在主体形成卡定孔、并且在罩形成朝向卡定孔延伸的卡定爪，通过使卡定爪卡止于卡定孔，将罩保持于主体。
专利文献1：日本特开2014-235158号公报
根据本公开的发明人的研究，在上述专利文献1中，由于主体与罩被卡定孔与卡定爪保持，因此若在搭载有液面检测装置的搭载对象例如像车辆那样振荡行为大的情况下，则有时不能够获得充分的强度。
为此，想到通过对主体与罩进行熔接而接合，从而强化保持强度的方案。在此，将现有的一般的熔接方法作为比较例示于图16A以及图16B。在该比较例中，如图16A所示，对主体110与罩120的抵接面的侧面部通过末端形成为平坦状的熔接冲头210A进行加热并加压。因此，在该情况下，如图16B所示，存在如下担忧：主体110与罩120的熔融树脂以相对于抵接面相互分离的方式向逃逸方向流动，导致熔接面积变小而得不到充分的熔接强度。
发明内容
鉴于上述问题，本公开的目的在于提供确保熔接面积，来充分获得熔接强度的熔接方法。
在本公开的熔接方法中，使树脂制的第一部件与树脂制的第二部件抵接，并利用熔接用冲头对抵接部的侧面部进行加热及加压，而对第一部件与第二部件进行熔接。
本开示的熔接方法为，(i)在侧面部中，预先在第一部件设置突出部，而在第一部件与第二部件之间形成台阶，(ii)预先在熔接用冲头的前端部形成供熔融部填充的冲头凹部，(iii)通过熔接用冲头的加压，而在冲头凹部内将第一部件的突出部向第二部件侧压扁，(iv)一边使冲头凹部的外周侧端部陷入第一部件以及第二部件，一边使第一部件的熔融部和第二部件的熔融部填充于冲头凹部内。
根据本公开，通过熔接用冲头的加压，而在冲头凹部内将第一部件的突出部向第二部件侧压扁，从而能够在最初的步骤，使第一部件熔接于第二部件，来增加第一部件与第二部件的熔接面积。
进一步加压下去，一边使冲头凹部的外周侧端部陷入第一部件以及第二部件中，一边使第一部件的熔融部和第二部件的熔融部填充于冲头凹部内。由此，犹如注射成形那样，能够使熔融的树脂流入冲头凹部内，对作为熔接对象的第一部件以及第二部件整体适当地进行熔接，从而能够获得充分的熔接强度。
附图说明
关于本公开的上述目的以及其他目的、特征及优点，参照附图并通过下述的详细记述会变得更加明确。
图1是示出安装于油底壳内的液面检测装置的剖视图。
图2是示出液面检测装置的剖视图。
图3是在从图2的III方向观察的情况下的向视图。
图4是在从图3的IV方向观察的情况下的向视图。
图5是示出第一实施方式中的熔接的前步骤的剖视图。
图6是示出在第一实施方式中主体的突出部被压扁的步骤的剖视图。
图7是示出在第一实施方式中熔接完成的步骤的剖视图。
图8是示出第二实施方式中的熔接的前步骤的剖视图。
图9是示出在第二实施方式中主体的突出部被压扁的步骤的剖视图。
图10是示出在第二实施方式中熔接完成的步骤的剖视图。
图11是示出第三实施方式中的主体和罩的立体图。
图12是示出图11中的凹部以及凸部的立体图。
图13是示出图11中的熔接突起部的位置错开的情况的立体图。
图14A是示出错位的熔接突起部与熔接冲头的位置关系的说明图。
图14B是示出错位的熔接突起部与熔接冲头的位置关系的说明图。
图15是示出第三实施方式的变形例中的凹部和凸部的立体图。
图16A是示出比较例的剖视图。
图16B是示出比较例的剖视图。
具体实施方式
下面，参照附图说明用于实施本公开的多个实施方式。在各实施方式中，存在与先说明的实施方式中的事项对应的部分标记相同的附图标记并省略重复说明的情况。在各实施方式中仅说明结构的一部分的情况下，结构的其他部分可以适用先说明的其他实施方式。在各实施方式中，对于部分彼此的组合，除了已明确具体说明能够组合的之外，只要不存在特别的组合障碍，即便没有明确说明，也能够进行部分性地组合。
(第一实施方式)
在图1～图7中示出第一实施方式的熔接方法。第一实施方式的熔接装置200是对熔接的对象即液面检测装置100中的主体110与罩120进行熔接的装置。
首先，对液面检测装置100简单地进行说明。液面检测装置100是对存积在规定的容器内的液体的液面高度进行检测的装置，例如对设置于车辆发动机的下部的油底壳10内的发动机油的液面进行检测。如图1所示，在油底壳10的内部设置有沿水平方向伸出的托架11，液面检测装置100利用螺栓12固定于托架11。液面检测装置100在油底壳10内的发动机油变为规定液面高度以下时生成检测信号，并向例如控制车辆的组合仪表的动作的控制部输出。
如图2～图4所示，液面检测装置100具备主体110、罩120、浮子140、磁铁150、以及舌簧开关160等。在本实施方式的液面检测装置100中，在主体110的下侧配置罩120来使用。
主体110例如是形成菱形的树脂制的板部件，其形成针对托架11的固定部，并且封堵后述的罩120的开口部。在树脂材料内含有用于使材料强度、耐热性等特性提高的例如玻璃纤维。主体110的板面以朝向水平方向的方式配置。
主体110的中心部是组装罩120的部位。在该中心部形成有互为反向地以三角形状延伸的两个臂部，主体110的整体形状如上述那样形成为菱形。在两个臂部分别形成有供螺栓12插通的安装孔111。主体110与本公开的第一部件对应。
罩120是形成有底筒状的树脂制的部件，其配置在主体110的下侧。罩120的开口侧的端部以与主体110的中心部抵接的方式通过后述的熔接而接合。在树脂材料内与上述主体110同样地也含有用于使材料强度、耐热性等特性提高的例如玻璃纤维。
罩120的底的部分形成底部121，并且筒状的周面形成侧壁部122。罩120的内部成为收纳室131，后述的浮子140、磁铁150、以及舌簧开关160等被收纳在该收纳室131内。并且，在侧壁部122形成有使收纳室131的内部与外部连通的连通孔122a。罩120与本公开的第二部件对应。
在此，如图3所示，与主体110的臂部所延伸的方向错开90度的部位(图3中的上部以及下部)以比罩120的外形稍大的方式形成，该部位成为突出部112。由此，如图4所示，主体110的侧面部相对于罩120的侧壁部122突出，在主体110与罩120之间形成有台阶132。换言之，在主体110(第一部件)的侧面部设置突出部112，在主体110的侧面部与罩120(第二部件)的侧面部之间形成台阶132。在形成有这样的台阶132的区域形成有多个熔接部133。在本实施方式中，熔接部133的数量为四个。
浮子140呈扁平的圆筒状，由比重比发动机油小的树脂材料形成。浮子140被收纳在收纳室131内，能够根据从连通孔122a流入收纳室131内的发动机油的液面而上下移动。
磁铁150在浮子140的内周侧安装于浮子140的轴向中间部的位置。磁铁150与浮子140一同根据发动机油的液面而上下移动。磁铁150对后述的舌簧开关160形成磁场。
舌簧开关160是对发动机油的液面高度进行检测的开关机构，并配置在浮子140以及磁铁150的内侧。舌簧开关160在发动机油的液面位置处于规定的液面位置以下时，通过与磁铁150的位置对应的磁场的作用而生成检测信号。生成的检测信号经由导线161、以及连接器162输出到组合仪表的控制部。
接下来，对熔接装置200进行说明。熔接装置200是对上述主体110和罩120进行熔接的装置，具备熔接冲头210(熔接用冲头)、加热机构、以及加压机构等。
如图5所示，熔接冲头210例如是剖面呈长圆形状那样的棒状的部件。熔接冲头210被加热机构加热到用于使树脂材料熔融的规定的温度，并且通过加压机构而相对于熔接部133滑动，对熔接部133进行加压。熔接冲头210与本公开的熔接用冲头对应。
在熔接冲头210的靠熔接部133侧的末端部形成有凹部，凹陷的最深的部位形成底部211a。以下，将该凹部称作冲头凹部211。底部211a为平坦的面。并且，冲头凹部211的外周部相对于底部211a形成相对地向熔接部133侧突出的外周侧端部212。
接下来，对利用熔接装置200对主体110与罩120的熔接方法进行说明。
首先，在罩120内收纳浮子140、磁铁150、以及舌簧开关160等。接着，通过规定的定位夹具、或者设置于主体110以及罩120的定位部等，临时固定主体110和罩120，而作为液面检测装置的组装体。然后，如图5所示，将组装体设置于熔接装置200。
接下来，将熔接冲头210加热到规定温度，如图6所示，使其朝向主体110与罩120所抵接的抵接部的、主体110的侧面部以及罩120的侧面部滑动，进行加压。主体110的侧面部为板状的主体110的周面(突出部112)。并且，罩120的侧面部是侧壁部122。此时，首先作为第一步骤，通过熔接冲头210，将主体110的突出部112向侧壁部122侧压扁。被压扁的部位是用图6中的标记133a示出的部位。
接着，如图7所示，使熔接冲头210进一步朝向主体110、以及罩120的侧面部滑动来加压下去。此时，熔接冲头210的外周侧端部212陷入主体110以及罩120中。进一步，主体110以及罩120的被熔融的材料以向熔接冲头210的冲头凹部211内填充的方式流动，该被填充的部位成为熔接部133。然后，使熔接冲头210后退来从组装体分离，从而完成熔接作业。
在本实施方式中，预先在主体110设置突出部112，而在主体110与罩120之间形成台阶132。并且，预先将在内部填充主体110的熔融部和罩120的熔融部的冲头凹部211形成在熔接冲头210的末端部。
由此，通过熔接冲头210的加压，在冲头凹部211内将主体110的突出部112向罩120侧压扁，从而能够在最初的步骤，使主体110熔接于罩120，增加主体110与罩120的熔接面积。
进一步加压下去，使冲头凹部211的外周侧端部212陷入主体110以及罩120中，使主体110以及罩120的熔融部填充在冲头凹部211内。由此，犹如注射成形那样，能够使熔融的树脂流入冲头凹部211内，来对熔接对象即主体110以及罩120整体适当地进行熔接，从而能够获得充分的熔接强度。
在本实施方式中，在主体110以及罩120的树脂材料中加入强化用的玻璃纤维。由此，在将熔融部填充在冲头凹部211内时，各个玻璃纤维能够互相缠绕，因此能够有效地提高熔接强度。
(第二实施方式)
在图8～图10中示出第二实施方式的熔接方法。在第二实施方式中，预先将主体110的侧面部形成为凸缘状的凸缘部113，并预先形成罩120的侧面部作为凸缘状的凸缘部123。也就是说，在主体110的侧面部以及罩120的侧面部，分别预先设置凸缘状的凸缘部113、123。然后，各凸缘部113、123的相对的表面相互抵接，形成液面检测装置。
如图8所示，从主体110起的凸缘部113的突出量比从罩120起的凸缘部123的突出量稍大。凸缘部113中的、比凸缘部123更加突出的部位是突出部112。由此，凸缘部113相对于凸缘部123突出，在各凸缘部113、123之间形成有台阶132。此外，关于熔接装置200的结构，设为与上述第一实施方式的情况相同。
另外，将凸缘部113的厚度尺寸与凸缘部123的厚度尺寸合在一起的尺寸，被设定为比熔接冲头210中的冲头凹部211的尺寸小。也就是说，抵接时的两凸缘部113、123能够有宽裕地进入冲头凹部211内。
在本实施方式中，如图9所示，将熔接冲头210加热到规定温度，并使其朝向凸缘部113与凸缘部123所抵接的抵接部的周面(侧面部)滑动，进行加压。此时，各凸缘部113、123进入熔接冲头210的冲头凹部211内，首先，作为第一步骤，通过熔接冲头210，将凸缘部113的突出部112向凸缘部123侧压扁(图9中的符号133a的部位)。
接着，如图10所示，使熔接冲头210进一步朝向各凸缘部113、123的周面滑动来加压下去。此时，熔接冲头210的外周侧端部212陷入主体110以及罩120中。进一步，各凸缘部113、123的已熔融的材料(各凸缘部113、123的熔融部)以向熔接冲头210的冲头凹部211内填充的方式流动，该被填充的部位成为熔接部133。然后，使熔接冲头210后退来从液面检测装置的组装体分离，从而完成熔接作业。
如上所述，在本实施方式中，能够进行与上述第一实施方式同样的熔接，从而能够获得充分的熔接强度。
并且，在本实施方式中，分别对主体110以及罩120设置凸缘部113、123来作为侧面部，并对各凸缘部113、123的周面进行熔接。进一步，各凸缘部113、123进入熔接冲头210的冲头凹部211内，因此熔接时的熔接冲头210的定位变得容易，从而能够进行稳定的熔接。
(第三实施方式)
在图11～图14中示出第三实施方式的熔接方法。在第三实施方式中，预先将主体110以及罩120的成为熔接部的侧面部形成为熔接突起部115、125。换言之。预先将主体110的侧面部形成为熔接用的熔接突起部115(第一突起部)，并预先将罩120的侧面部形成为熔接用的熔接突起部125(第二突起部)。进一步，在主体110设置引导部114以及凹部116，并且在罩120设置凸部126。
熔接突起部115(第一突起部)是从主体110的靠罩120侧的板面朝向外侧突出的熔接用的突起部。形成熔接突起部115的位置，例如为在上述第一实施方式中进行说明的熔接部133(图3)所形成的位置。熔接突起部115(熔接部133)例如形成于四处。
并且，熔接突起部125(第二突起部)是从罩120的靠主体110侧的端部朝向罩120的径向外侧突出的熔接用的突起部。熔接突起部125所形成的位置与上述熔接突起部115的位置对应。因此，熔接突起部125例如形成于四处。
熔接突起部125的突出尺寸形成为比熔接突起部115的突出尺寸稍大。由此，在对主体110和罩120进行临时固定时，在两熔接突起部115、125形成台阶132(图13)。其中，也可以将两熔接突起部115、125中的、突出尺寸大的一侧作为熔接突起部115侧。换言之，也可以是熔接突起部115的突出尺寸比熔接突起部125的突出尺寸稍大。
引导部114是在主体110的中心部呈环状地向罩120侧突出的凸部。引导部114的外周面与罩120的内周面(凹部)抵接，或者与罩120的内周面之间形成微小间隙，而嵌合于罩120。
凹部116是设置于主体110以及罩120中的一方的凹陷部，并且凸部126是设置于主体110以及罩120中的另一方的突出部。在本实施方式中，凹部116预先设置在主体110的周向的规定位置。主体110的周向的规定位置例如指与熔接突起部115相邻的位置。并且，凸部126在罩120的靠主体110侧的端部被预先设置在与凹部116对应的位置。
凹部116以及凸部126的宽度方向(图12)的尺寸在制作上的公差范围内，以凹部116的宽度尺寸比凸部126的宽度尺寸大的方式设定，也就是说，设定为在凹部116与凸部126的嵌合中，在凹部116与凸部126之间形成有微小间隙的间隙配合。
在本实施方式中，在形成液面检测装置100时，在对主体110和罩120进行临时固定时，引导部114的外周面嵌合于罩120的内周面124(凹部)侧，来对罩120在主体110的板面方向(板面上的二维方向)上的位置进行限制。在此基础上，凸部126嵌合于凹部116内，罩120的周向的位置相对于主体110被限制。伴随于此，两熔接突起部115、125的周向的位置变得一致，即防止了两熔接突起部115、125的错位。
然后，通过在上述第一实施方式中说明的熔接冲头210的熔接方法，在两熔接突起部115、125进行熔接。
此处，可以想到：在不设置凹部116以及凸部126而将作为熔接的对象部位的侧面部如上述那样作为熔接突起部115、125的情况下，在对主体110和罩120进行临时固定时，产生图13所示那样的错位，从而得不到充分的熔接强度。
即，如图14A所示，若错位大，而两熔接突起部115、125的一部分从熔接冲头210的外周侧端部212露出，则两熔接突起部115、125的接触面积减少的同时，两熔接突起部115、125与外周侧端部212的间隙变大。由此，在外周侧端部212内(冲头凹部211内)，已熔融的树脂材料无法充分地填充，材料不被施加充分的压力，因此导致熔接强度下降。
或者如图14B所示，即使是错位小的情况、且两熔接突起部115、125均被收纳在熔接冲头210的外周侧端部212内的情况下，由于两熔接突起部115、125的错位，也存在如下担忧：已熔融的树脂材料的流动产生偏差，导致熔接强度的下降。
相对于此，在本实施方式中，通过设置凹部116和凸部126，利用凹部116与凸部126的嵌合，而在对主体110和罩120进行临时固定时，不产生两熔接突起部115、125的错位。由此，能够充分得到两熔接突起部115、125的熔接强度。
并且，在凹部116与凸部126的嵌合中，使它们成为间隙配合，从而能够无需过度的力量地顺利地进行临时固定。
此外，在凹部116以及凸部126的设定时，也可以将凹部116设置于罩120侧，将凸部126设置于主体110侧。
(第三实施方式的变形例)
针对上述第三实施方式，如图15所示，也可以将凹部116与凸部126的嵌合设为轻压配合即过渡配合。
在与凹部116的宽度方向交叉并相互对置的面，分别设置有轻压入用的突起部116a。突起部116a的剖面形状例如呈三角状，并在供凸部126嵌入的方向上延伸设置。
通过设置突起部116a，在制作上的公差范围内，以两个突起部116a间的尺寸比凸部126的宽度尺寸小、或者比凸部126的宽度尺寸大的方式设定。由此，设定为在凹部116与凸部126的嵌合中，在凹部116与凸部126之间包含没有形成间隙的情况和形成微小间隙的情况的过渡配合(轻压配合)。
在本变形例中，在将凹部116嵌入凸部126时，能够提高两熔接突起部115、125的位置精度，从而能够更加提高熔接强度。
(其他实施方式)
以上对本公开的优选实施方式进行了说明，但本公开并不限于上述实施方式，在不脱离本公开的主旨的范围内能够进行各种变形。上述实施方式的构造不过是例示，并没有将本公开的范围限定于上述记载的范围。本公开的范围包含与本公开的记载等同的意思以及范围内的所有变更。
在上述第一、第二实施方式中，在主体110侧设置突出部112，来设置与罩120侧的台阶132，但突出部112也可以设置于罩120侧。
并且，作为本熔接装置200的熔接对象，设为液面检测装置100(主体110和罩120)，但并不限于此，只要是对树脂制的两个部件进行熔接即可，因此能够广泛应用。

Claims (5)

1.一种熔接方法，
使树脂制的第一部件(110)与树脂制的第二部件(120)抵接，并利用熔接用冲头(210)对抵接部的侧面部进行加热及加压，而对所述第一部件(110)和所述第二部件(120)进行熔接，
其中，
在所述侧面部中，预先在所述第一部件(110)设置突出部(112)，而在所述第一部件(110)与所述第二部件(120)之间形成台阶(132)，
预先在所述熔接用冲头(210)的末端部形成供熔融部填充的冲头凹部(211)，
通过所述熔接用冲头(210)的加压，而在所述冲头凹部(211)内将所述第一部件(110)的所述突出部(112)向所述第二部件(120)侧压扁，
一边使所述冲头凹部(211)的外周侧端部(212)陷入所述第一部件(110)以及所述第二部件(120)中，一边使所述第一部件(110)的熔融部和所述第二部件(120)的熔融部填充于所述冲头凹部(211)内。
2.根据权利要求1所述的熔接方法，其中，
将所述第一部件(110)的所述侧面部形成为凸缘状的凸缘部(113)，
将所述第二部件(120)的所述侧面部形成为凸缘状的凸缘部(123)。
3.根据权利要求1所述的熔接方法，其中，
预先将所述第一部件(110)的所述侧面部形成为熔接用的第一突起部(115)，
预先将所述第二部件(120)的所述侧面部形成为熔接用的第二突起部(125)，
预先在所述第一部件(110)以及所述第二部件(120)中的一方形成凹部(116)，
并预先在所述第一部件(110)以及所述第二部件(120)中的另一方形成凸部(126)，
在使所述第一部件(110)与所述第二部件(120)抵接时，使所述凹部(116)与所述凸部(126)嵌合，来防止所述第一突起部(115)与所述第二突起部(125)的错位。
4.根据权利要求3所述的熔接方法，其中，
所述凹部(116)与所述凸部(126)的嵌合为间隙配合。
5.根据权利要求3所述的熔接方法，其中，
所述凹部(116)与所述凸部(126)的嵌合为过渡配合。
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