CN114364515A - 热铆接结合体 - Google Patents

热铆接结合体 Download PDF

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CN114364515A
CN114364515A CN202080063929.2A CN202080063929A CN114364515A CN 114364515 A CN114364515 A CN 114364515A CN 202080063929 A CN202080063929 A CN 202080063929A CN 114364515 A CN114364515 A CN 114364515A
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heat
caulking
excess
mounting hole
recess
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吉永久美子
内田智史
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Hitachi Astemo Ltd
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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
    • 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
    • B29C66/20—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
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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
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30321—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of protrusions belonging to at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • 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
    • B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60—Riveting or staking
    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/322—Providing cavities in the joined article to collect the burr
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • 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
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
    • 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
    • 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
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/843—Machines for making separate joints at the same time in different planes; Machines for making separate joints at the same time mounted in parallel or in series
    • B29C66/8432—Machines for making separate joints at the same time mounted in parallel or in series
    • 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
    • B29C66/71—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 composition of the plastics material of the parts to be joined
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
    • B29L2031/3481—Housings or casings incorporating or embedding electric or electronic elements

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  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

将设置于合成树脂制的盖(4)的铆接销(15)插入设置于金属制的壳体(3)的安装孔(21)，端部通过利用焊嘴(24)热铆接而成型为模塑成型部(17)。以扩大安装孔(21)的开口端部的形式形成过剩吸收凹部(31)，从而吸收过剩树脂。过剩吸收凹部(31)位于模塑成型部(17)的区域内侧。因此在热铆接工序中从焊嘴(24)向外侧溢出的熔融过剩树脂变少。

Description

热铆接结合体
技术领域
本发明涉及通过热铆接结合成例如电子装置的外壳等的热铆接结合体。
背景技术
在例如将金属制的壳体和合成树脂制的盖组合而成的电子装置的外壳中，有时采用热铆接的结合代替螺丝的结合。热铆接是使合成树脂制的铆接销贯通安装孔，并对该铆接销的端部进行加热加压成型为比安装孔扩大的热铆接部的方法。热铆接部的成型使用在前端面凹设与需要的热铆接部的形状对应的杯状的成型用模具面的电热式焊嘴(以下，简称焊嘴)进行。
在这样的热铆接中，在由焊嘴对铆接销前端部加热加压使树脂材料可塑化时，在树脂材料相对于形成杯状的成型用模具面的容积不足的情况下，热铆接部部分破损地成型，不能得到规定的结合强度。因此，通常以稍微产生过剩的树脂材料的方式设计贯通安装孔并突出的铆接销的前端部分的大小和成型用模具面的容积的关系。
因此存在如下问题，在进行热铆接时，过剩的树脂材料从焊嘴的前端面向周围溢出，产生所谓的毛刺。该毛刺经常附着于焊嘴的前端面，其结果是导致必须中断热铆接加工并通过人工作业清理焊嘴的前端。特别地，在焊嘴的前端部具备温度传感器(热电偶)的情况下，在焊嘴的清理时派生出使温度传感器断开等技术问题。
在专利文献1中，已公开了以下技术：为了避免在热铆接时产生的过剩树脂材料引起的毛刺从热铆接部脱离进入机器内，以在安装孔的周围从焊嘴外周部分露出的形式预先形成小孔或者缺口，从而过剩的树脂材料经由这些小孔或者缺口向焊嘴的外侧溢出。
但是，在专利文献1的技术中，经由小孔或者缺口向焊嘴的外侧溢出的熔融树脂材料的一部分附着于焊嘴的前端并固化，从而导致不能充分解决由过剩的树脂材料引起的焊嘴污损的技术问题。
现有技术文献
专利文献
专利文献1：(日本)特开2011-167900号公报
发明内容
本发明的其中一个实施方式为，在通过贯通安装孔的铆接销的端部模塑成型为比安装孔扩大的热铆接部而相互结合而成的热铆接结合体中，在热铆接部扩大并相接的铆接承受面上，在比热铆接部的模塑成型区域更靠内侧设置有供过剩的熔融树脂流入的过剩吸收凹部。
根据本发明，由于过剩的树脂材料流入位于由热铆接部覆盖的区域内的过剩吸收凹部，因此向热铆接部的外侧溢出并变为毛刺的树脂材料变少。因此，在热铆接加工时，焊嘴的污损变少。
附图说明
图1是示出作为本发明的一个实施例的通过热铆接结合的外壳的立体图。
图2是放大示出其主要部位的立体图。
图3是示出热铆接工序前的外壳的立体图。
图4是放大示出其主要部位的立体图。
图5是示出利用焊嘴进行热铆接的状态的外壳的侧视图。
图6是放大示出进行热铆接状态的主要部位的立体图。
图7是沿着图2的A－A线的剖视图。
图8是与焊嘴共同示出的与图7相同的主要部位的剖视图。
图9是沿着热铆接工序前的图4的B－B线的剖视图。
图10是示出热铆接工序前的安装孔以及过剩吸收凹部的俯视图。
图11是示出热铆接工序的工序说明图。
图12是示出将过剩吸收凹部设置为圆弧形的第二实施例的热铆接工序前的主要部位的俯视图。
图13是示出热铆接部的模塑成型部和过剩吸收凹部的尺寸关系的说明图。
图14是示出将过剩吸收凹部的内壁面设置为倾斜面的第三实施例的主要部位的剖视图。
图15是示出将模塑成型部设置为半球状的第四实施例的主要部位的剖视图。
图16是示出将模塑成型部设置为半球状将过剩吸收凹部的内壁面设置为倾斜面的第五实施例的主要部位的剖视图。
图17是示出将过剩吸收凹部设置为独立的槽状的第六实施例的主要部位的剖视图。
图18是示出在铆接承受面上设置突出部的第七实施例的主要部位的剖视图。
具体实施方式
以下，对将该发明适用于自动车用的电子装置的外壳的一个实施例参照附图详细说明。
图1是作为本发明的一个实施例的电子装置1的立体图。该电子装置1例如作为车辆用自动变速机的控制器安装于车辆的适当位置，其具备外壳2、和收纳于该外壳2的内部的未图示的电路基板。外壳2由形成大致矩形的板状的金属制的壳体3、和以覆盖该壳体3的一面(在图1中为下方的面)的方式形成为凸起形状的合成树脂制的盖4构成，安装于未图示的电路基板的一端的连接器5夹持于壳体3和盖4之间。壳体3在四个位置具备用于安装到车体的舌片状的支架部6。
壳体3和盖4通过在四个角上分别设置的总共4个位置的热铆接部11相互结合，从而构成密闭的外壳2。图2是将1个热铆接部11放大示出。如图所示，在壳体3和盖4中分别设置有矩形耳部12、13，其形成沿着彼此的接合面的一个平面分别向外侧伸出并相互对应的大致正方形的外形，这些矩形耳部12、13之间通过热铆接部11结合。
热铆接部11是如后述地将设置于作为合成树脂制盖4的一部分的矩形耳部13的铆接销15(参照图4、图9)的前端部加热软化并压扁而成型为圆盘状的模塑成型部17的结构，在径向扩大的模塑成型部17的周缘部分与壳体3侧的矩形耳部12中的平坦的铆接承受面18相接。由此，壳体3和盖4牢固地结合。在图示例中，模塑成型部17形成为具有与铆接承受面18相接的圆形的大径部17a、和重合在该大径部17a上的圆形的小径部17b的两段形状。
图3示出将热铆接工序前的壳体3和盖4组合而成的外壳2，图4示出作为主要部位的矩形耳部12、13部分的热铆接工序前的状态。如图所示，盖4具有形成为圆锥台形的铆接销15，在壳体3侧贯通形成有供该铆接销15插入的圆形的安装孔21。该安装孔21以能够容易插入铆接销15的方式形成为在与盖4的接合面侧为大径的锥状的孔。在一个示例中，铆接销15的外周面的锥角和安装孔21的内周面的锥角大致相等。在热铆接工序前的状态中，贯通安装孔21的铆接销15的前端部从铆接承受面18突出规定量。
在热铆接工序中，使用在前端面凹设有与需要的模塑成型部17的形状对应的杯状的成型用模具面23(图8参照)的棒状的焊嘴24对如上所述地从安装孔21突出的铆接销15的前端部如图5以及图6所示地进行加热加压，形成模塑成型部17。在具体的一个示例中，盖4由热可塑性树脂例如聚对苯二甲酸丁二醇酯树脂组成，通过由加热到300℃左右的温度的电热式焊嘴24加热加压数10秒左右，而成型为热铆接部11即模塑成型部17。值得注意的是，通过使用与四个位置的热铆接部11对应的四个焊嘴24，能够使四个位置的热铆接部11的形成同时进行。
图11是热铆接工序的工序说明图，如工序(a)所示，使在前端具有成型用模具面23的焊嘴24朝向铆接销15的前端沿着轴向下降，进行加热加压。由此，如工序(b)所示，铆接销15的前端软化并沿着成型用模具面23逐渐变形。最后如工序(c)所示，成为焊嘴24与铆接承受面18相接的状态，完成模塑成型部17的成型。之后，在树脂材料一定程度上冷却固化的状态下，如工序(d)所示，使焊嘴24向上方抬起。由此，完成热铆接工序。
在此，在工序(a)中位于铆接承受面18上方的铆接销15的前端部分的材料量(即可塑化的树脂材料量)设定为比焊嘴24的形成为杯状的成型用模具面23的内容积稍大。假设可塑化的树脂材料相对于形成为杯状的成型用模具面23的容积不足时，成为热铆接部11的模塑成型部17部分破损地成型，从而不能得到规定的结合强度。
因此，通过以相对于成型用模具面23的容积产生过剩的树脂材料的方式设定铆接销15的直径和长度，能够避免模塑成型部17的破损。另一方面，通过这样存在过剩的树脂材料，如前所述，会产生以下问题：可塑化的过剩树脂从焊嘴24前端和铆接承受面18之间向周围溢出而变成毛刺。
在本实施例中，为了防止由这样的过剩树脂导致的毛刺，如图7～图9所示，在铆接承受面18中的安装孔21的周围设置有过剩吸收凹部31。图7是沿着图2的A－A线的剖视图，过剩的熔融树脂流入过剩吸收凹部31内并固化成与模塑成型部17连续的过剩树脂部32。图9示出热铆接工序前的过剩吸收凹部31和铆接销15。
该第一实施例的过剩吸收凹部31通过将铆接承受面18中的安装孔21的开口端部向半径方向外侧扩大而形成。在铆接销15的轴向上的过剩吸收凹部31的端部中，使得该端部与铆接销15的外表面之间的间隙变窄，以限制熔融树脂的流入。具体地，过剩吸收凹部31的外周侧的内壁面31a以沿着铆接销15的中心轴线(换言之安装孔21的中心轴线)形成大致圆筒面的方式延伸，在过剩吸收凹部31的端部具备底面31b，在该底面31b与安装孔21的内壁面21a之间形成阶梯。底面31b沿着与铆接销15的中心轴线正交的平面。内壁面31a可以为与铆接销15的中心轴线平行的圆筒面，但在图示的示例中，作为加工时的拔模斜度而稍微倾斜。
即，该实施例的过剩吸收凹部31如图9、图10所示地沿着安装孔21的整周形成为圆环状，在铆接承受面18和底面31b之间具有能够充分吸收过剩树脂的容积。具体地，最好设定为相对设计上的过剩树脂量具有一定过剩的容积。值得注意的是，流入过剩吸收凹部31的熔融过剩树脂的流动最终由底面31b堵塞，因此不会因为模塑成型部17的树脂材料不足导致在模塑成型部17产生破损。
另外，铆接承受面18中的过剩吸收凹部31的外径比模塑成型部17的大径部17a的直径小。即，在通过热铆接工序成型为模塑成型部17后的状态中，在模塑成型部17的模塑成型区域17’(参照图10)的内侧存在过剩吸收凹部31。因此，熔融过剩树脂难以被压出模塑成型部17的半径方向外侧。在图11的工序(b)和工序(c)之间熔融树脂被压向铆接承受面18，因此过剩树脂在焊嘴24的成型用模具面23的内侧流入过剩吸收凹部31，并在此被吸收。值得注意的是，在图11中，为了图的简单化，并未区别过剩吸收凹部31和安装孔21。
图13是用于说明铆接承受面18中的模塑成型部17和过剩吸收凹部31之间优选的尺寸关系的说明图，以铆接承受面18中的铆接销15的外周面的位置为基准，将模塑成型部17(大径部17a)的半径方向尺寸设为L1，过剩吸收凹部31的半径方向尺寸设为L2，优选地具有如下关系:“L1/2＜L2＜L1”。由于“L2＜L1”的关系，过剩吸收凹部31变成位于焊嘴24的成型用模具面23的内侧，过剩树脂难以附着到环状包围成型用模具面23的焊嘴24前端面。另一方面，通过具有“L1/2＜L2”的关系，过剩吸收凹部31开口足够大，因此熔融的过剩树脂不会朝向外周侧而可靠地流入过剩吸收凹部31内。
因此，根据上述实施例，过剩的熔融树脂材料流入位于由模塑成型部17覆盖的区域17’内的过剩吸收凹部31，形成过剩树脂部32，因此向模塑成型部17外侧溢出并变成毛刺的树脂材料变少。因此，在热铆接加工时，焊嘴24的污损变少。
图12示出过剩吸收凹部31的第二实施例。该图12与图10相同，示出热铆接工序前的矩形耳部12中的过剩吸收凹部31。
在该第二实施例中，过剩吸收凹部31未在安装孔21的整周上连续，被分割为四个圆弧形部分。换言之，过剩吸收凹部31在安装孔21周围的四个位置部分形成。在该结构中，作为四个过剩吸收凹部31的和，具有能够充分吸收过剩树脂的容积。
值得注意的是，也可以是以下结构：四个过剩吸收凹部31每个形成为大致四边形，四个过剩吸收凹部31整体呈大致十字形配置。
图14示出过剩吸收凹部31的第三实施例。该图14与图7相同，是在由热铆接工序形成热铆接部11后的状态下的主要部位的剖视图。
在该第三实施例中，过剩吸收凹部31的外周侧的内壁面31a形成为相对于铆接销15的中心轴线(换言之安装孔21的中心轴线)向在铆接承受面18侧扩大的方向倾斜的倾斜面。而且，在过剩吸收凹部31的端部中，由倾斜面形成的外周侧的内壁面31a与安装孔21的内壁面21a不经由阶梯地连续。
值得注意的是，该第三实施例中的过剩吸收凹部31可以为如图10的示例呈圆环状在整周上连续的结构，也可以为如图12的示例分割为多个圆弧状的结构。
接着，图15示出将热铆接部11的模塑成型部17设置为半球状的第四实施例。过剩吸收凹部31是与图7～图9所述的第一实施例的过剩吸收凹部31相同的结构。即，过剩吸收凹部31的外周侧的内壁面31a以沿着铆接销15的中心轴线(换言之安装孔21的中心轴线)形成为大致圆筒面的方式延伸，在过剩吸收凹部31的端部，具备与安装孔21的内壁面21a之间形成阶梯的底面31b。底面31b沿着与铆接销15的中心轴线正交的平面。
值得注意的是，该第四实施例中的过剩吸收凹部31可以为如图8的示例呈圆环状在整周上连续的结构，也可以为如图10的示例分割为多个圆弧状的结构。
接着，图16示出将热铆接部11的模塑成型部17设置为半球状，并且将过剩吸收凹部31的外周侧的内壁面31a设置为倾斜面并与安装孔21的内周面21a不经由阶梯地连续的第五实施例。
即，过剩吸收凹部31构成为与图14示出的第三实施例相同。
值得注意的是，该第五实施例中的过剩吸收凹部31可以为如图10的示例呈圆环状在整周上连续的结构，也可以为如图12的示例分割为多个圆弧状的结构。
接着，图17示出将过剩吸收凹部31与安装孔21独立形成的第六实施例。
在第六实施例中，插入铆接销15的安装孔21作为锥状的孔以贯通壳体3侧的矩形耳部12的方式形成。过剩吸收凹部31在铆接承受面18中形成为包围安装孔21的开口的周围并与该安装孔21独立的槽状。该过剩吸收凹部31位于成为热铆接部11的模塑成型部17的模塑成型区域17’的内侧。
在这样的结构中，在热铆接工序中熔融的过剩树脂也流入过剩吸收凹部31，并作为过剩树脂部32固化。因此，能够抑制熔融过剩树脂从焊嘴24和铆接承受面18之间流出而导致的毛刺的发生。
值得注意的是，也可以将形成与安装孔21独立的槽状的过剩吸收凹部31如图12所分割为多个圆弧形部分而形成。
接着，图18示出在铆接承受面18上设置圆环状的突出部35的第七实施例。突出部35构成为具有与焊嘴24的成型用模具面23的内径对应的外径，并在焊嘴24与铆接承受面18抵接时在与成型用模具面23的内周面以极小的间隙嵌合。过剩吸收凹部31沿着该突出部35的内周形成。图18是铆接销15由焊嘴24加热加压且模塑成型部17已成型的状态下的剖视图。
值得注意的是，作为过剩吸收凹部31本身的结构，也可以为上述实施例的任何一种。例如，与图7～图9所示的第一实施例相同，由形成大致圆筒面的内壁面31a和端部的底面31b形成过剩吸收凹部31。
以上，详细说明了该发明的一个实施例，但该发明不仅限定于上述实施例，可以有各种变更。例如，在上述实施例中铆接销15和安装孔21以及模塑成型部17任何一个可以为圆形，也可以为圆形以外的形状。例如，也可以使用棱柱状的铆接销15或异形的模塑成型部17等。另外，构成上述盖4的合成树脂材料或热铆接工序中的温度条件等仅仅是示例，只要能够产生热铆接，可以为任何树脂材料或温度。另外，本发明不限于上述实施例的电子装置的外壳，能够广泛地适用于由热铆接将两种部件结合的结构。
如上所述，本发明的热铆接结合体包括：第一部件，其具有合成树脂制的铆接销；第二部件，其具有插入上述铆接销的安装孔；并且通过贯通上述安装孔的上述铆接销的端部模塑成型为比上述安装孔扩大的热铆接部而相互结合而成，其中，
在上述热铆接部扩大并相接的上述第二部件的铆接承受面上，在比上述热铆接部的模塑成型区域更靠内侧设置有供过剩的熔融树脂流入的过剩吸收凹部。
在优选的一个实施方式中，上述过剩吸收凹部通过放大上述铆接承受面中的上述安装孔的开口端部而形成，
在上述铆接销的轴向上的上述过剩吸收凹部的端部中，使该端部与上述铆接销的外表面之间的间隙变窄以限制熔融树脂的流入。
在具体的一个示例中，上述过剩吸收凹部的外周侧的内壁面沿着上述铆接销的中心轴线延伸，该过剩吸收凹部在端部具备底面，在该底面与上述安装孔的内壁面之间形成阶梯。
或者，上述过剩吸收凹部的外周侧的内壁面形成为相对于上述铆接销的中心轴线向在上述铆接承受面侧扩大的方向倾斜的倾斜面，
在上述过剩吸收凹部的端部，上述倾斜面与上述安装孔的内壁面连续。
另外，在优选的另一实施方式中，上述过剩吸收凹部形成为在上述铆接承受面包围上述安装孔的周围且与该安装孔独立的槽状。
另外，在优选的一个实施方式中，上述过剩吸收凹部在上述安装孔的周围的多个位置中部分地形成。
在具体的一个示例中，上述第一部件为在周围的多个位置具备上述铆接销的盖，上述第二部件为在周围的多个位置具备上述安装孔的壳体，通过两者的结合构成在内部具有电路基板收纳空间的电子装置的外壳。

Claims (7)

1.一种热铆接结合体，其包括：第一部件，其具有合成树脂制的铆接销；第二部件，其具有插入上述铆接销的安装孔；并且通过贯通上述安装孔的上述铆接销的端部模塑成型为比上述安装孔扩大的热铆接部而相互结合而成，其中，
在上述热铆接部扩大并相接的上述第二部件的铆接承受面上，在比上述热铆接部的模塑成型区域更靠内侧设置有供过剩的熔融树脂流入的过剩吸收凹部。
2.如权利要求1所述的热铆接结合体，其中，
上述过剩吸收凹部通过放大上述铆接承受面中的上述安装孔的开口端部而形成，
在上述铆接销的轴向上的上述过剩吸收凹部的端部中，使该端部与上述铆接销的外表面之间的间隙变窄以限制熔融树脂的流入。
3.如权利要求2所述的热铆接结合体，其中，
上述过剩吸收凹部的外周侧的内壁面沿着上述铆接销的中心轴线延伸，该过剩吸收凹部在端部具备底面，在该底面与上述安装孔的内壁面之间形成阶梯。
4.如权利要求2所述的热铆接结合体，其中，
上述过剩吸收凹部的外周侧的内壁面形成为相对于上述铆接销的中心轴线向在上述铆接承受面侧扩大的方向倾斜的倾斜面，
在上述过剩吸收凹部的端部，上述倾斜面与上述安装孔的内壁面连续。
5.如权利要求1所述的热铆接结合体，其中，
上述过剩吸收凹部形成为在上述铆接承受面包围上述安装孔的周围且与该安装孔独立的槽状。
6.如权利要求1至5中任一项所述的热铆接结合体，其中，
上述过剩吸收凹部在上述安装孔的周围的多个位置中部分地形成。
7.如权利要求1至6中任一项所述的热铆接结合体，其中，
上述第一部件为在周围的多个位置具备上述铆接销的盖，上述第二部件为在周围的多个位置具备上述安装孔的壳体，通过两者的结合构成在内部具有电路基板收纳空间的电子装置的外壳。
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JPH08156101A (ja) * 1994-12-12 1996-06-18 Rohm Co Ltd 回路基板に対する合成樹脂製部品の取付け装置
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JP2018083329A (ja) * 2016-11-22 2018-05-31 アイシン精機株式会社 熱カシメ構造体
JP2018135909A (ja) * 2017-02-20 2018-08-30 本田技研工業株式会社 接合部材、接合方法および回転電機

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US20220332056A1 (en) 2022-10-20

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