JP2004058391A - Thermally caulking structure and method for thermally caulking and connecting - Google Patents
Thermally caulking structure and method for thermally caulking and connecting Download PDFInfo
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- JP2004058391A JP2004058391A JP2002218237A JP2002218237A JP2004058391A JP 2004058391 A JP2004058391 A JP 2004058391A JP 2002218237 A JP2002218237 A JP 2002218237A JP 2002218237 A JP2002218237 A JP 2002218237A JP 2004058391 A JP2004058391 A JP 2004058391A
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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
- B29C65/56—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
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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
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
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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
- B29C65/78—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
- B29C65/782—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined
- B29C65/7823—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint
- B29C65/7829—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint said distance pieces being integral with at least one of the parts to be joined
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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
- B29C66/20—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
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
- B29C66/431—Joining the articles to themselves
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- 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
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
- B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
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- 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
- B29C66/70—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
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- B29C66/80—General aspects of machine operations or constructions and parts thereof
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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
- B29C66/81427—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 ridge, e.g. for making a weakening line; comprising a single tooth
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- 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
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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
- B29C66/80—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
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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
- B29C66/90—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
- B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
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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
- B29C66/90—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
- B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
- B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
- B29C66/91441—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time
- B29C66/91443—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile
- B29C66/91445—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile by steps
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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
- B29C66/90—Measuring or controlling the joining process
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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
- B29C66/90—Measuring or controlling the joining process
- B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
- B29C66/924—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools
- B29C66/9241—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force or the mechanical power
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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
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- B29C66/90—Measuring or controlling the joining process
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B29C66/9292—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges in explicit relation to another variable, e.g. pressure diagrams
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Abstract
Description
【0001】
【発明の属する技術分野】
本発明は、熱可塑性樹脂製の部材と他の部材とを熱かしめ接合により接合された熱かしめ構造体及びその熱かしめ接合方法に関するものである。
【0002】
【従来の技術】
例えば、自動車のエアバックの開閉ドアは、熱可塑性樹脂製の板状の部材に鉄板等の補強部材をかしめて形成された構造となっている。そして、熱可塑性樹脂製の板状の部材は、一方の面が意匠面を形成し、その反対面側に補強部材が接合されている。このように形成されたエアバックの開閉ドアの従来の構成について、図面を参照して説明する。
【0003】
エアバックの開閉ドアの断面図を図9(a)(b)に示す。図9(a)に示すように、エアバックの開閉ドアは、熱可塑性樹脂製の板状の部材(以下、「かしめ部材」という)21に補強部材(以下、「被かしめ部材」という)22から構成されている。具体的には、かしめ部材21は、意匠面21cを有する板状の基板21aと、基板21aと一体成形されたかしめ突起21bとからなる。また、被かしめ部材22は、かしめ部材21のかしめ突起21bに嵌合する嵌合穴22aを有している。そして、かしめ部材21と被かしめ部材22とを熱かしめ接合により接合する。
【0004】
次に、熱かしめ接合方法について説明する。まず、かしめ部材21のかしめ突起21bと被かしめ部材22の嵌合穴22aとを嵌合させ、かしめ部材21の基板21aと被かしめ部材22とを接触させた状態に位置決めする。続いて、超音波加熱器20により所定の加圧力と熱が、かしめ突起21bに付与される。これにより、かしめ突起21bが溶融されて変形する。その後、変形したかしめ突起21bを冷却する。かしめ突起21bの変形後の状態を図9(b)に示す。すなわち、被かしめ部材22は、かしめ部材21の基板21aと変形したかしめ突起21bとによりかしめて接合される。
【0005】
【発明が解決しようとする課題】
しかし、かしめ突起21bを加熱し冷却する結果、図9(b)に示すように、かしめ部材21の基板21aの意匠面21cに凹凸形状が生じる。このことは、意匠面21cの外観品質を低下させることになる。この凹凸形状が生じる原因としては、かしめ突起21bを加熱し冷却することにより生じるヒケやかしめ突起21bを変形させるための加圧力が意匠面21cまで伝わることによるものと考えられる。
【0006】
また、意匠面21cの反対面においては、超音波加熱器20による成形部分の外側にバリ23が生ずる。一般に、変形後のかしめ突起21bにより被かしめ部材22を確実にかしめるため、かしめ突起21bは超音波加熱器20の成形部分の体積より大きな体積を有するようにしている。つまり、超音波加熱器20の成形部分に収納されないかしめ突起21bがバリ23となって現れる。
【0007】
本発明は、このような事情に鑑みてなされたものであり、熱かしめ接合によりかしめ部材と被かしめ部材とを接合する場合に、かしめ部材の意匠面に凹凸形状を生じさせず、意匠面の反対面にバリを生じさせないようにすることにより、外観品質を向上させることができる熱かしめ構造体及び熱かしめ接合方法を提供することを目的とする。
【0008】
【課題を解決するための手段】
そこで、本発明者はこの課題を解決すべく鋭意研究し、試行錯誤を重ねた結果、かしめ部材と被かしめ部材との間に隙間を設けて熱かしめ接合を行うことを思いつき、本発明を完成するに至った。
【0009】
すなわち、本発明の熱かしめ構造体は、かしめ部材と、被かしめ部材とを有する。ここで、かしめ部材は、基板と、基板の一方の面に突設したかしめ突起と、からなる熱可塑性樹脂製の部材である。被かしめ部材は、かしめ突起に嵌合される嵌合穴を有する部材である。そして、かしめ突起に嵌合穴を嵌合させ、かしめ部材の基板と被かしめ部材との間に所定の隙間を設けて位置決めし、かしめ突起を加熱し変形させることによりかしめ部材に被かしめ部材をかしめて形成されることを特徴とする。
【0010】
つまり、かしめ部材と被かしめ部材との間に所定の隙間を設けることで、かしめ突起を加熱し冷却することにより生じるヒケやかしめ突起を変形させるための加圧力が、かしめ部材の基板のかしめ突起を有しない面(以下、「意匠面」という)に伝わらない。その結果、意匠面に凹凸形状が生じることがなく、意匠面の外観品質を向上させることができる。また、成形器の成形部分に収納できないかしめ突起は、かしめ部材の基板と被かしめ部材との間の所定の隙間部分に移動し、意匠面の反対面にバリが生じることがない。つまり、意匠面とその反対面の外観品質を向上させることができる。さらに、意匠面の反対面にバリが生じないため、例えば、エアバッグの展開時等にバリの飛散を防止できる。
【0011】
また、本発明の熱かしめ構造体におけるかしめ部材の基板と被かしめ部材との間に形成された隙間は、かしめ部材の被かしめ部材に対向する面および/または被かしめ部材のかしめ部材に対向する面に形成された複数の隙間保持用突起により形成されるようにしてもよい。これにより、被かしめ部材をかしめ部材の基板との間に所定の隙間を容易に形成することができる。例えば、かしめ部材が隙間保持用突起を有する場合に、かしめ部材と被かしめ部材を位置決めするには、かしめ突起と嵌合穴とを嵌合させ、隙間保持用突起が被かしめ部材に接触する位置に固定すればよい。すなわち、隙間保持用突起の高さ分が、形成される隙間になる。
【0012】
また、本発明の熱かしめ構造体の被かしめ部材は、かしめ部材の基板を補強する補強部材としてもよい。かしめ部材は樹脂製であるため割れやすいという問題がある。そこで、例えば、被かしめ部材として鉄板等を用いることにより、かしめ部材を補強することができる。
【0013】
また、本発明の熱かしめ構造体の被かしめ部材は、基板の延長線上に基板と一体成形され、基板に対して折り曲げて形成される折曲部としてもよい。通常、かしめ部材の基板の板厚が薄いほど基板に割れが生じやすい。そこで、基板の一部を折り曲げた折曲部を被かしめ部材として用いることにより、板厚を増加させることができ、強度を増加させることができる。さらに、被かしめ部材として、かしめ部材の一部を用いているため、補強部品として別部品を使用することもなく、コストダウンにつながる。つまり、部品点数を増加させることなく、かしめ部材の強度を増加させることができる。
【0014】
また、本発明の熱かしめ接合方法は、かしめ部材に被かしめ部材を、かしめ部材のかしめ突起を加熱し変形させることによりかしめて接合する熱かしめ接合方法であって、部材位置決めステップと、かしめ突起変形ステップと、からなることを特徴とする。ここで、かしめ部材は、基板と、基板の一方の面に突設したかしめ突起と、からなる熱可塑性樹脂製の部材である。被かしめ部材は、かしめ部材のかしめ突起に嵌合される嵌合穴を有する部材である。そして、部材位置決めステップは、かしめ突起と嵌合穴とを嵌合させ、基板と被かしめ部材との間に所定の隙間を設けてかしめ部材及び被かしめ部材を位置決めするステップである。かしめ突起変形ステップは、かしめ突起を加熱し変形させるステップである。
【0015】
つまり、かしめ部材と被かしめ部材との間に所定の隙間を設けることで、かしめ突起を加熱し冷却することにより生じるヒケやかしめ突起を変形させるための加圧力が、意匠面に伝わらない。その結果、意匠面に凹凸形状が生じることがなく、意匠面の外観品質を向上させることができる。また、成形器の成形部分に収納できないかしめ突起は、かしめ部材の基板と被かしめ部材との間の所定の隙間部分に移動し、意匠面の反対面にバリが生じることがない。つまり、意匠面とその反対面の外観品質を向上させることができる。さらに、意匠面の反対面にバリが生じないため、例えば、エアバッグの展開時等にバリの飛散を防止できる。
【0016】
【発明の実施の形態】
次に、実施形態を挙げ、本発明をより詳しく説明する。本実施形態においては、本発明の熱かしめ構造体として、自動車の助手席用エアバッグの開閉ドアを例にとり説明する。図1に示すように、自動車のフロントガラス側に装備されたインストルメントパネル10の上側内部にエアバッグ装置が配置されている。そして、インストルメントパネル10の補強部材(図示せず)にエアバッグケース11が連結固定されている。このエアバッグケース11に、インストルメントパネル10の頂面10aと略面一となるように配置される開閉ドア12,12が組付けられている。そして、エアバッグ動作時には、フロントガラスに近い側の開閉ドア12はフロントガラス側へ、フロントガラスから遠い側の開閉ドア12はフロントガラスと反対側へ開き、エアバッグケース11内に収納されているエアバッグ(図示せず)が膨張展開する。
【0017】
次に、開閉ドア12について図2を参照して詳細に説明する。図2は、図1に示す開閉ドア12の裏面を示す斜視図である。すなわち、開閉ドア12のうち図1におけるインストルメントパネル10の頂面10aと略面一となる面が図2における裏面の意匠面1cである。この開閉ドア12は、熱可塑性樹脂製の部材(以下、「かしめ部材」という)1に鉄板の補強部材(以下、「被かしめ部材」という)2が熱かしめ接合されている。すなわち、図2においては、8箇所の熱かしめ接合部1eによりかしめ部材1に被かしめ部材2が接合されている。なお、開閉ドア12の被かしめ部材2がエアバッグケース11に連結固定されている。また、本実施形態におけるかしめ部材1は、ポリプロピレン樹脂を用いている。
【0018】
次に、熱かしめ接合される前のかしめ部材1と被かしめ部材2の形状について、図3及び図4を参照して説明する。図3に示すように、かしめ部材1は、基板1aと、かしめ突起1bと、隙間保持用突起1dとが一体成形されている。基板1aは、板厚3.5mmであって、一方の面が意匠面1cを形成している。かしめ突起1bは、基板1aの意匠面1cの反対面に形成されている。図3における近隣する3つのかしめ突起1bは、変形後の図2における熱かしめ接合部1eの1箇所に相当する。このかしめ突起1bは、根元部が約1.7mm×18.0mm、高さが約18mmである。さらに、かしめ突起1bは、先端側が細く形成されている。そして、隙間保持用突起1dは、基板1aの意匠面1cの反対面であって、近隣する3つのかしめ突起1bの周囲に4箇所形成されている。この隙間保持用突起1dの高さは、約1.5mmである。
【0019】
図4に示すように、被かしめ部材2は、板厚約1.3mmであって、嵌合穴2aを有している。この嵌合穴2aは、かしめ部材1のかしめ突起1bと嵌合するように形成されている。すなわち、図4に示す3つの嵌合穴が、図3における3つのかしめ突起1bに嵌合する。この嵌合穴2aの大きさは、約2.3mm×19mmである。
【0020】
続いて、このように形成されたかしめ部材1と被かしめ部材2との熱かしめによる接合方法について図5を参照して説明する。図5(a)は、熱かしめ接合前における開閉ドア12の断面図である。図5(b)は熱かしめ接合された開閉ドア12の断面図である。まず、図5(a)に示すように、かしめ部材1のかしめ突起1bと被かしめ部材2の嵌合穴2aとを嵌合させる。その際、かしめ部材1の隙間保持用突起1dの先端と被かしめ部材2とが接触する位置にかしめ部材1及び被かしめ部材2を位置決めする(部材位置決めステップ)。すなわち、かしめ部材1の基板1aと被かしめ部材2との隙間は、隙間保持用突起1dの高さと同様であるので、1.5mmとなる。そして、かしめ突起変形工程(かしめ突起変形ステップ)を開始する。まず、かしめ突起1bの先端側を超音波加熱器20により加熱しながら加圧する。具体的には、約200℃の温度で加熱しながら、約1.8MPaの加圧力で約4〜7秒間かしめ突起1bを加圧する。これにより、かしめ突起1bが溶融して変形する。その後、超音波加熱器20を約80℃の温度まで下げて、溶融したかしめ突起1bを約4秒間冷却する。
【0021】
かしめ突起1bを変形させて被かしめ部材2をかしめた形状を、図5(b)に示す。すなわち、かしめ部材1の意匠面1cは、凹凸形状が生じていない。これは、かしめ部材1の基板1aと被かしめ部材2との間に隙間を設けたことにより、超音波加熱器20による熱や加圧力が意匠面1cまで伝わらないためであると考えられる。また、変形したかしめ突起1cは、意匠面1cの反対面においては、超音波加熱器20の成形部分を転写した形状に形成されている。すなわち、従来発生していたバリが生じていない。これは、かしめ部材1の基板1aと被かしめ部材2との間の隙間に変形したかしめ突起1bの一部が移動したためであると考えられる。このように、意匠面1c及び意匠面の反対面の外観品質が非常に良好となる。また、かしめ部材1の基板1aと被かしめ部材2との隙間に変形したかしめ突起1cが移動することにより、より強固に被かしめ部材2をかしめることができる。
【0022】
次に、かしめ部材1の基板1aと被かしめ部材2との間の隙間を変更して、熱かしめ接合を行った場合における外観品質について説明する。隙間を0mm、1.0mm、1.5mm、2.0mmとした場合について上述の熱かしめ接合を行った。なお、かしめ部材1及び被かしめ部材2の形状は上記実施形態と同様である。また、超音波加熱器20による加熱温度及び加圧力は、上記実施形態と同様である。また、加圧工程時間及び冷却工程時間も上記実施形態とほぼ同様である。この結果を図6に示す。
【0023】
図6に示すように、隙間が0mmの場合、すなわち、従来の熱かしめ接合方法の場合は、意匠面1cに凹凸形状が生じ、意匠面1cの反対面にはバリが生じるため、外観品質は非常に悪い。隙間が1.0mmの場合には、意匠面1c及び意匠面1cの反対面共にほぼ良好な外観品質を得ることができた。また、隙間が1.5mm及び2.0mmの場合には、意匠面1c及び意匠面1cの反対面共に非常に良好な外観品質を得ることができた。
【0024】
次に、超音波加熱器20による加圧力を変化させて熱かしめ接合を行った。他の条件については、上記実施形態と同様である。この結果を図7に示す。図7より、加圧力が1.3MPaの場合に比べて1.9MPaの場合は、外観品質が良好となることがわかる。すなわち、加圧力が大きい程、外観品質は向上する。なお、加圧力が1.3MPaより小さい場合には、かしめ突起1bが溶融しないため、かしめ接合を行うことができない。さらに、加圧力が1.9MPaより大きい場合には、かしめ突起1bが破断するため、かしめ接合を行うことができない。
【0025】
なお、上記実施形態では、隙間保持用突起1dをかしめ部材1が有しているが、これに限られるものではない。すなわち、被かしめ部材2が隙間保持用突起1dを有するようにしてもよい。この場合には、上記と同様の熱かしめ接合方法により行うことができる。もちろん、かしめ部材1及び被かしめ部材2の双方が隙間保持用突起1dを有するようにしてもよい。また、熱かしめ接合をする際に、かしめ部材1の基板1aと被かしめ部材2との間に所定の隙間を有するようにかしめ部材1及び被かしめ部材2を位置決めすることができれば、かしめ部材1及び被かしめ部材2の双方が隙間保持用突起1dを有しない他の方法でもよい。例えば、熱かしめ接合を行う際に、所定の隙間を確保できる他の部材を挿入しておき、熱かしめ接合終了後に挿入していた他の部材を取り除く方法であってもよい。
【0026】
また、上記実施形態では、かしめ突起1cを溶融するために、超音波加熱器20を使用したが、これに限られるものではない。例えば、熱風加熱、高周波加熱、熱ヒーター加熱や振動溶着等、熱可塑性樹脂製のかしめ部材1のかしめ突起1cを溶融し圧力をかけることができるものであればよい。
【0027】
(他の実施形態)
上記実施形態では、かしめ部材1と被かしめ部材2とを別部材としたが、本実施形態では同一部材としている。本実施形態について、図8(a)(b)(c)を参照して説明する。
【0028】
図8(a)に、熱かしめ接合を行う前の部材5の側面図を示す。この部材5は、熱可塑性樹脂、例えばポリプロピレン樹脂により形成されている。そして、部材5は、基板部5a、折曲部5b、かしめ突起5c、隙間保持用突起5dとからなる。基板部5aは、上記実施形態における基板1aの相当する。かしめ突起5c及び隙間保持用突起5dは、それぞれ上記実施形態におけるかしめ突起1b及び隙間保持用突起1dに相当する。折曲部5bは、かしめ突起5c側へ折り曲げられた場合に、かしめ突起5cに勘合する嵌合穴5eを有している。
【0029】
次に、このような形状からなる部材5の熱かしめ接合について説明する。まず、折曲部5bをかしめ突起5c側へ図8(b)に示すように折り曲げる。個の場合、嵌合穴5eは、かしめ突起5cに嵌合するようになっている。さらに、折曲部5bは、隙間保持用突起5dの先端に接触する位置に固定しておく(部材位置決めステップ)。つまり、折り曲げられた折曲部5bが、上記実施形態における被かしめ部材に相当することになる。続いて、かしめ突起変形工程(かしめ突起変形ステップ)を開始する。まず、かしめ突起5cの先端側を超音波加熱器20により加熱しながら加圧する。具体的には、約200℃の温度で加熱しながら、約1.8MPaの加圧力で約4〜7秒間かしめ突起5cを加圧する。これにより、かしめ突起5cが溶融して変形する。その後、超音波加熱器20を約80℃の温度まで下げて、溶融したかしめ突起5cを約4秒間冷却する。
【0030】
かしめ突起5cを変形させて折曲部5bをかしめた形状を、図8(c)に示す。この場合においても、図8(c)に示すように、上記実施形態と同様の効果を奏することができる。すなわち、意匠面及び意匠面の反対面の外観品質が非常に良好となる。さらに、部材5の一部を用いて熱かしめ接合を行っていることから、上記実施形態のように別部品を使用することなく、一つの部材で補強することができる。つまり、コストダウン化を図ることができると共に、補強することができる。
【0031】
なお、この実施形態における熱かしめ構造体は、例えば、自動車のバンパー等に使用することができる。すなわち、バンパーの端部の強度増加を容易にかつ低コストで行うことができる。
【0032】
また、上記実施形態では、エアバッグの開閉ドアやバンパーを例にとり説明したが、これに限られるものではない。本発明が適用することができる限り、他の部分でもよい。
【0033】
なお、被かしめ部材は、金属、非金属又は樹脂等どのような部材であってもよい。また、上記実施形態では、補強部材と熱かしめ接合を行うことについて説明したが、これに限られるものではなく、例えば、他の部品と一体に接合する場合にも適用することができる。
【0034】
【発明の効果】
本発明の熱かしめ構造体及び熱かしめ接合方法によれば、外観品質を向上させることができる。すなわち、かしめ部材の意匠面に凹凸形状を生じさせることがなく、意匠面の反対面にバリを生じさせることがない。
【図面の簡単な説明】
【図1】自動車のフロントガラス側に装備されたインストルメントパネルを示す斜視図である。
【図2】本発明の熱かしめ構造体を示す斜視図である。
【図3】本発明のかしめ部材を示す斜視図である。
【図4】本発明の被かしめ部材を示す斜視図である。
【図5】本発明の熱かしめ接合方法について説明する断面図である。
【図6】隙間に対する外観品質を示す図である。
【図7】加圧力に対する外観品質を示す図である。
【図8】他の実施形態における熱かしめ接合方法について説明する図である。
【図9】従来の熱かしめ接合方法について説明する断面図である。
【符号の説明】
1 ・・・ かしめ部材
1a ・・・ 基板
1b ・・・ かしめ突起
1c ・・・ 意匠面
1d ・・・ 隙間保持用突起
2 ・・・ 被かしめ部材
2a ・・・ 嵌合穴
5 ・・・ 部材
5a ・・・ 基板部
5b ・・・ 折曲部
5c ・・・ かしめ突起
5d ・・・ 隙間保持用突起
10 ・・・ インストルメントパネル
11 ・・・ エアバッグケース
12 ・・・ 開閉ドア
20 ・・・ 超音波加熱器[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a heat caulking structure in which a member made of a thermoplastic resin and another member are bonded by heat caulking, and a method of heat caulking the same.
[0002]
[Prior art]
For example, an opening / closing door of an airbag of an automobile has a structure formed by caulking a reinforcing member such as an iron plate on a plate-shaped member made of a thermoplastic resin. One surface of the plate-shaped member made of a thermoplastic resin forms a design surface, and a reinforcing member is joined to the opposite surface. The conventional configuration of the airbag opening / closing door thus formed will be described with reference to the drawings.
[0003]
FIGS. 9A and 9B are cross-sectional views of the opening / closing door of the airbag. As shown in FIG. 9 (a), the opening / closing door of the airbag is constituted by a plate-like member (hereinafter, referred to as a “caulking member”) 21 made of a thermoplastic resin and a reinforcing member (hereinafter, referred to as a “caulking member”) 22. It is composed of Specifically, the
[0004]
Next, a heat caulking method will be described. First, the
[0005]
[Problems to be solved by the invention]
However, as a result of heating and cooling the
[0006]
Further, on the surface opposite to the
[0007]
The present invention has been made in view of such circumstances, and when a caulking member and a member to be caulked are joined by heat caulking, the design surface of the caulking member does not have an uneven shape, and the design surface An object of the present invention is to provide a heat caulking structure and a heat caulking method that can improve appearance quality by preventing burrs from being generated on the opposite surface.
[0008]
[Means for Solving the Problems]
The inventor of the present invention has intensively studied to solve this problem, and after repeated trial and error, came up with the idea of performing a heat caulking joint by providing a gap between the caulking member and the member to be caulked, and completed the present invention. I came to.
[0009]
That is, the heat caulking structure of the present invention has a caulking member and a member to be caulked. Here, the caulking member is a member made of a thermoplastic resin including a substrate and a caulking projection protruding from one surface of the substrate. The member to be swaged is a member having a fitting hole fitted into the swage projection. Then, the fitting hole is fitted to the caulking protrusion, a predetermined gap is provided between the substrate of the caulking member and the member to be caulked, the positioning is performed, and the caulking member is heated by the caulking protrusion to deform the caulking member. It is characterized by being formed by caulking.
[0010]
That is, by providing a predetermined gap between the caulking member and the member to be caulked, the pressing force generated by heating and cooling the caulking protrusion and deforming the caulking protrusion, the caulking protrusion of the substrate of the caulking member. (Hereinafter referred to as “design surface”). As a result, there is no unevenness on the design surface, and the appearance quality of the design surface can be improved. In addition, the caulking protrusion that cannot be accommodated in the molding portion of the molding machine moves to a predetermined gap between the substrate of the caulking member and the member to be caulked, and burrs do not occur on the surface opposite to the design surface. That is, the appearance quality of the design surface and the opposite surface can be improved. Furthermore, since burrs do not occur on the surface opposite to the design surface, the burrs can be prevented from scattering when, for example, the airbag is deployed.
[0011]
Further, in the heat caulking structure of the present invention, the gap formed between the substrate of the caulking member and the member to be caulked is opposed to the surface of the caulking member facing the caulking member and / or the surface of the caulking member facing the caulking member. It may be formed by a plurality of gap holding projections formed on the surface. Thus, a predetermined gap can be easily formed between the member to be swaged and the substrate of the member to be swaged. For example, in the case where the caulking member has the gap holding projection, in order to position the caulking member and the member to be swaged, the position where the caulking projection and the fitting hole are fitted to each other, and the gap holding projection contacts the member to be swaged. It should be fixed to. That is, the height of the gap holding projection is the gap to be formed.
[0012]
The member to be caulked of the heat caulking structure of the present invention may be a reinforcing member for reinforcing the substrate of the caulking member. Since the caulking member is made of resin, there is a problem that the caulking member is easily broken. Therefore, for example, by using an iron plate or the like as the member to be swaged, the member to be swaged can be reinforced.
[0013]
Further, the member to be caulked of the heat caulking structure of the present invention may be a bent portion formed integrally with the substrate on an extension of the substrate, and formed by bending the substrate. Usually, as the thickness of the substrate of the caulking member is smaller, the substrate is more likely to crack. Therefore, by using a bent portion obtained by bending a part of the substrate as a caulking member, the plate thickness can be increased, and the strength can be increased. Furthermore, since a part of the caulking member is used as the member to be caulked, there is no need to use another component as a reinforcing component, leading to cost reduction. That is, the strength of the caulking member can be increased without increasing the number of components.
[0014]
Further, the heat caulking method according to the present invention is a heat caulking method in which a member to be caulked to a caulking member is caulked and joined by heating and deforming a caulking projection of the caulking member. And a transformation step. Here, the caulking member is a member made of a thermoplastic resin including a substrate and a caulking projection protruding from one surface of the substrate. The member to be caulked is a member having a fitting hole to be fitted to a caulking projection of the caulking member. Then, the member positioning step is a step of fitting the caulking projection and the fitting hole, and providing a predetermined gap between the substrate and the member to be caulked to position the caulking member and the member to be caulked. The caulking protrusion deformation step is a step of heating and deforming the caulking protrusion.
[0015]
In other words, by providing a predetermined gap between the caulking member and the member to be caulked, the pressing force generated by heating and cooling the caulking protrusion and the pressing force for deforming the caulking protrusion are not transmitted to the design surface. As a result, there is no unevenness on the design surface, and the appearance quality of the design surface can be improved. In addition, the caulking protrusion that cannot be accommodated in the molding portion of the molding machine moves to a predetermined gap between the substrate of the caulking member and the member to be caulked, and burrs do not occur on the surface opposite to the design surface. That is, the appearance quality of the design surface and the opposite surface can be improved. Furthermore, since burrs do not occur on the surface opposite to the design surface, the burrs can be prevented from scattering when, for example, the airbag is deployed.
[0016]
BEST MODE FOR CARRYING OUT THE INVENTION
Next, the present invention will be described in more detail with reference to embodiments. In the present embodiment, an opening / closing door of an airbag for a passenger seat of an automobile will be described as an example of the heat caulking structure of the present invention. As shown in FIG. 1, an airbag device is arranged inside an upper part of an
[0017]
Next, the opening and closing
[0018]
Next, the shapes of the
[0019]
As shown in FIG. 4, the member to be caulked 2 has a plate thickness of about 1.3 mm and has a
[0020]
Next, a method of joining the
[0021]
FIG. 5B shows a shape in which the
[0022]
Next, the appearance quality in the case where the gap between the
[0023]
As shown in FIG. 6, in the case where the gap is 0 mm, that is, in the case of the conventional heat caulking method, irregularities are formed on the
[0024]
Next, heat caulking was performed by changing the pressure applied by the
[0025]
In the above embodiment, the
[0026]
Further, in the above-described embodiment, the
[0027]
(Other embodiments)
In the above embodiment, the swaging
[0028]
FIG. 8A shows a side view of the
[0029]
Next, the heat caulking of the
[0030]
FIG. 8C shows a shape in which the
[0031]
The heat caulking structure according to this embodiment can be used, for example, for a bumper of an automobile. That is, the strength of the end of the bumper can be easily increased at low cost.
[0032]
Further, in the above-described embodiment, the opening / closing door and the bumper of the airbag have been described as examples, but the invention is not limited thereto. Other parts may be used as long as the present invention can be applied.
[0033]
The member to be swaged may be any member such as a metal, a non-metal or a resin. Further, in the above-described embodiment, the description has been given of the case where the heat caulking is performed with the reinforcing member. However, the present invention is not limited to this.
[0034]
【The invention's effect】
According to the heat caulking structure and the heat caulking method of the present invention, the appearance quality can be improved. That is, no irregularities are formed on the design surface of the caulking member, and no burr is generated on the surface opposite to the design surface.
[Brief description of the drawings]
FIG. 1 is a perspective view showing an instrument panel mounted on a windshield side of an automobile.
FIG. 2 is a perspective view showing a heat caulking structure of the present invention.
FIG. 3 is a perspective view showing a caulking member of the present invention.
FIG. 4 is a perspective view showing a caulking member of the present invention.
FIG. 5 is a cross-sectional view illustrating a heat caulking method according to the present invention.
FIG. 6 is a view showing appearance quality with respect to a gap.
FIG. 7 is a view showing appearance quality with respect to a pressing force.
FIG. 8 is a view for explaining a heat caulking method in another embodiment.
FIG. 9 is a cross-sectional view illustrating a conventional heat swaging method.
[Explanation of symbols]
DESCRIPTION OF
Claims (5)
該かしめ突起に嵌合される嵌合穴を有する被かしめ部材とからなり、
該かしめ突起に該嵌合穴を嵌合させ、該かしめ突起を加熱し変形させることにより該かしめ部材に該被かしめ部材をかしめて形成される熱かしめ構造体であって、
前記基板と前記被かしめ部材との間に所定の隙間を形成したことを特徴とする熱かしめ構造体。A caulking member made of a thermoplastic resin composed of a substrate and a caulking projection protruding from one surface of the substrate,
A caulked member having a fitting hole fitted to the caulking projection,
A heat caulking structure formed by caulking the caulking member to the caulking member by fitting the fitting hole into the caulking protrusion and heating and deforming the caulking protrusion;
A heat caulking structure, wherein a predetermined gap is formed between the substrate and the member to be caulked.
前記かしめ突起と前記嵌合穴とを嵌合させ前記基板と前記被かしめ部材との間に所定の隙間を設けて前記かしめ部材及び前記被かしめ部材を位置決めする部材位置決めステップと、
前記かしめ突起を加熱し変形させるかしめ突起変形ステップと、
からなることを特徴とする熱かしめ接合方法。A caulking member made of a thermoplastic resin consisting of a substrate and a caulking protrusion protruding from one surface of the substrate, a member to be caulked having a fitting hole fitted into the caulking protrusion, and the caulking protrusion is heated. A heat caulking method of joining by caulking by deforming,
A member positioning step of positioning the caulking member and the caulking member by providing a predetermined gap between the substrate and the caulking member by fitting the caulking protrusion and the fitting hole,
A caulking protrusion deformation step of heating and deforming the caulking protrusion,
A heat caulking method characterized by comprising:
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JP2002218237A JP2004058391A (en) | 2002-07-26 | 2002-07-26 | Thermally caulking structure and method for thermally caulking and connecting |
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JP2002218237A JP2004058391A (en) | 2002-07-26 | 2002-07-26 | Thermally caulking structure and method for thermally caulking and connecting |
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Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2005035534A (en) * | 2003-06-25 | 2005-02-10 | Calsonic Kansei Corp | Welded part structure of vehicular air bag device |
JP2008044242A (en) * | 2006-08-17 | 2008-02-28 | Mazda Motor Corp | Method for joining resin members and resultant joint structure |
JP2012139893A (en) * | 2010-12-28 | 2012-07-26 | Kawakami Sangyo Co Ltd | Laminated sheet |
FR2982791A1 (en) * | 2011-11-17 | 2013-05-24 | Renault Sa | Method for realizing thermoplastic material part i.e. tailgate, of car, involves providing housing having set of riveting rods and set of reference ribs, and positioning structural insert on another housing |
CN105818358A (en) * | 2016-05-18 | 2016-08-03 | 惠州市壹品科技有限公司 | Encompassing type heating component and heating method |
CN105820403A (en) * | 2015-01-28 | 2016-08-03 | 通用汽车环球科技运作有限责任公司 | Composition for forming a component structure and method of making and using the same |
CN105946221A (en) * | 2016-05-18 | 2016-09-21 | 惠州市壹品科技有限公司 | Ultrasonic hot melting device and method |
-
2002
- 2002-07-26 JP JP2002218237A patent/JP2004058391A/en active Pending
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2005035534A (en) * | 2003-06-25 | 2005-02-10 | Calsonic Kansei Corp | Welded part structure of vehicular air bag device |
JP4498834B2 (en) * | 2003-06-25 | 2010-07-07 | カルソニックカンセイ株式会社 | Manufacturing method for welded portion structure of air bag apparatus for vehicle |
JP2008044242A (en) * | 2006-08-17 | 2008-02-28 | Mazda Motor Corp | Method for joining resin members and resultant joint structure |
JP2012139893A (en) * | 2010-12-28 | 2012-07-26 | Kawakami Sangyo Co Ltd | Laminated sheet |
FR2982791A1 (en) * | 2011-11-17 | 2013-05-24 | Renault Sa | Method for realizing thermoplastic material part i.e. tailgate, of car, involves providing housing having set of riveting rods and set of reference ribs, and positioning structural insert on another housing |
CN105820403A (en) * | 2015-01-28 | 2016-08-03 | 通用汽车环球科技运作有限责任公司 | Composition for forming a component structure and method of making and using the same |
CN105818358A (en) * | 2016-05-18 | 2016-08-03 | 惠州市壹品科技有限公司 | Encompassing type heating component and heating method |
CN105946221A (en) * | 2016-05-18 | 2016-09-21 | 惠州市壹品科技有限公司 | Ultrasonic hot melting device and method |
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