JP2016049549A - Hollow component and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a blade component and a hollow component which can join respective members at a desired joining position with ultrasonic welding even when a hollow structure is formed by joining two resin-molded members.SOLUTION: A horizontal blade has a hollow structure in which a resin-molded body and a lid are joined with ultrasonic welding. A junction of the body and the lid includes a first portion and a second portion different from the first portion. The first portion is a portion joined with contact of a first ultrasonic horn 83. The second portion is a portion joined with contact of a second ultrasonic horn 84 different from the first ultrasonic horn 83.SELECTED DRAWING: Figure 8

Description

  The present invention relates to a blade part and a method for manufacturing a hollow part.

  Conventionally, as disclosed in Patent Document 1 (Japanese Patent Laid-Open No. 1-1963329), there is an ultrasonic welding method as a method of joining two members. When joining using the ultrasonic welding method, it is necessary to abut the ultrasonic horn on the two overlapped members.

  Incidentally, some recent air conditioners include a hollow structure blade component made of resin. Here, the resin-molded member may cause an error in the dimension of the member due to molding variation or shrinkage variation. For this reason, when trying to manufacture a hollow blade component by joining two resin-molded members by ultrasonic welding, it is not possible to join each member at a desired joining position due to the displacement of the position of the ultrasonic horn. Or the ultrasonic horn cannot be brought into contact with each other and the members cannot be joined.

  Therefore, even if the subject of the present invention is a case where a hollow structure is formed by joining two resin-molded members, blade components that can join each member at a desired joining position by ultrasonic welding, And it is providing the manufacturing method of a hollow component.

  A blade component according to a first aspect of the present invention is a hollow blade component in which a resin-molded first member and a second member are joined by ultrasonic welding, and includes a first member and a second member. The joining portion includes a first portion and a second portion different from the first portion. The first part is a part to be joined by contacting the first ultrasonic horn. The second part is a part to be joined by contacting a second ultrasonic horn different from the first ultrasonic horn.

  In the blade component according to the first aspect of the present invention, the first ultrasonic horn is contacted to join the first portion, and the second ultrasonic horn different from the first ultrasonic horn is contacted. Thus, the second part is joined. For this reason, when joining a 1st member and a 2nd member, the position of each ultrasonic horn can be adjusted so that it may suit a desired joining position.

  Thereby, even if it is a case where two resin-molded members are joined and a hollow structure is formed, each member can be joined at a desired joining position by ultrasonic welding.

  A method for manufacturing a hollow part according to a second aspect of the present invention is a method for manufacturing a hollow part in which a resin-molded first member and a second member are joined by ultrasonic welding, and includes an adjustment step and a welding step. And comprising. In the adjustment step, the relative position between the first ultrasonic horn and the second ultrasonic horn is adjusted. The first ultrasonic horn is brought into contact with the first portion of the joint portion between the first member and the second member. The second ultrasonic horn is brought into contact with a second portion different from the first portion in the joint portion. The welding process is performed after the relative positions of the first ultrasonic horn and the second ultrasonic horn are adjusted in the adjustment process. In the welding step, ultrasonic welding is performed by bringing the first ultrasonic horn into contact with the first portion and bringing the second ultrasonic horn into contact with the second portion.

  In the method for manufacturing a hollow part according to the second aspect of the present invention, after the adjusting step for adjusting the relative positions of the first ultrasonic horn and the second ultrasonic horn is performed, a welding step for performing ultrasonic welding is performed. . For this reason, before joining a 1st member and a 2nd member, the position of each ultrasonic horn can be adjusted so that it may suit a desired joining position.

  Thereby, even if it is a case where two resin-molded members are joined and a hollow structure is formed, each member can be joined at a desired joining position by ultrasonic welding.

  The method for manufacturing a hollow part according to a third aspect of the present invention is the method for manufacturing a hollow part according to the second aspect. In the welding step, the first ultrasonic horn and the second ultrasonic horn are the first part and the second part. At the same time. For this reason, compared with the case where a 1st ultrasonic horn and a 2nd ultrasonic horn vibrate each of a 1st part and a 2nd part at a separate timing, joining time can be shortened.

  A method for manufacturing a hollow part according to a fourth aspect of the present invention is the method for manufacturing a hollow part according to the second aspect or the third aspect, wherein the first ultrasonic horn and the second ultrasonic horn vibrate so that the hollow part is excited. Are joined together. In this method for manufacturing a hollow part, the entire outer peripheral edge of the hollow part can be joined by the first ultrasonic horn and the second ultrasonic horn.

  The hollow component manufacturing method according to the fifth aspect of the present invention is the hollow component manufacturing method according to any one of the second to fourth aspects, wherein the dimension of the hollow component in the longitudinal direction is 500 mm or more. In this method for manufacturing a hollow part, a long hollow part having a dimension of 500 mm or more can be manufactured by ultrasonic welding.

  In the blade component according to the first aspect of the present invention, even when two resin-molded members are joined to form a hollow structure, each member can be joined at a desired joining position by ultrasonic welding. it can.

  In the method for manufacturing a hollow part according to the second aspect of the present invention, even when two resin-molded members are joined to form a hollow structure, each member is joined at a desired joining position by ultrasonic welding. can do.

  In the method for manufacturing a hollow part according to the third aspect of the present invention, the joining time can be shortened.

  In the method for manufacturing a hollow part according to the fourth aspect of the present invention, the entire outer peripheral edge of the hollow part can be joined.

  In the method for manufacturing a hollow part according to the fifth aspect of the present invention, a long hollow part having a dimension of 500 mm or more can be manufactured by ultrasonic welding.

The perspective view of the air conditioning apparatus which has a horizontal blade | wing which concerns on one Embodiment of this invention. The top view of the horizontal blade | wing which concerns on one Embodiment of this invention. Sectional drawing of the horizontal blade | wing which concerns on one Embodiment of this invention. Sectional drawing of the horizontal blade | wing which concerns on one Embodiment of this invention. Sectional drawing of the horizontal blade | wing which concerns on one Embodiment of this invention. The enlarged view of a recessed part vicinity. The top view of an ultrasonic welding apparatus. The front view of an ultrasonic welding apparatus. The perspective view of a receiving jig. The perspective view of an ultrasonic horn. The figure which shows a 1st ultrasonic horn. The figure which shows a 2nd ultrasonic horn. The block block diagram of an ultrasonic welding apparatus. The figure which shows the state by which the ultrasonic horn contact | abutted to the main body and the lid | cover. The enlarged view of the protrusion part vicinity at the time of joining. The figure which shows the state by which the ultrasonic horn contact | abutted to the main body and the lid | cover. The figure which shows the state by which the ultrasonic horn contact | abutted to the main body and the lid | cover.

  Hereinafter, a blade part as a hollow part according to an embodiment of the present invention will be described with reference to the drawings. The following embodiments are specific examples of the present invention and do not limit the technical scope of the present invention.

(1) Overall Configuration FIG. 1 is a perspective view of an air conditioner having horizontal blades 10 according to an embodiment of the present invention. FIG. 2 is a plan view of the horizontal blade 10 according to an embodiment of the present invention. An indoor unit 100 of an air conditioner that employs a horizontal blade 10 as a blade component according to an embodiment of the present invention is a wall-mounted indoor unit attached to an indoor wall as shown in FIG. It has a cooling function and a heating function. The indoor unit 100 includes a casing 110 as a casing. The casing 110 is formed with a suction port 111 for taking indoor air into the casing 110 and a blower outlet 112 for blowing the air taken into the casing 110 into the room. In addition, a heat exchanger, a fan, and the like are housed in the casing 110, and the indoor air sucked from the suction port 111 when the fan is driven passes through the heat exchanger and is blown out from the air outlet 112. . When the room air passes through the heat exchanger, heat is exchanged to become cold air or warm air and return to the room.

  The air outlet 112 is an opening extending in the longitudinal direction of the indoor unit 100 (in the left-right direction in FIG. 1), and is formed at the front lower portion of the casing 110, that is, at the front lower portion of the indoor unit 100 as shown in FIG. Yes. Moreover, the horizontal blade | wing 10 which can cover the blower outlet 112 is arrange | positioned at the blower outlet 112. FIG. The horizontal blade | wing 10 is a plate-shaped member which exhibits rectangular shape. In addition, the dimension of the longitudinal direction of the horizontal blade | wing 10 of this embodiment shall be 500 mm or more. The horizontal blade 10 is provided so as to be rotatable about a rotation shaft 120 extending along the longitudinal direction thereof, and takes a predetermined posture by rotating. And the horizontal blade | wing 10 closes the blower outlet 112 by covering the blower outlet 112 at the time of a driving | operation stop, and adjusts the vertical wind direction of the conditioned air which passes a heat exchanger and blows off from the blower outlet 112 at the time of a driving | operation.

  3 is a cross-sectional view of the horizontal blade 10 cut along III-III in FIG. 4 is a cross-sectional view of the horizontal blade 10 cut along IV-IV in FIG. FIG. 5 is a cross-sectional view of the horizontal blade 10 cut along V-V in FIG. FIG. 6 is a partially enlarged view of the cross section of the front end 10 a of the horizontal blade 10.

  The horizontal blade 10 is made of resin and has a hollow structure. Thereby, the heat insulation performance of the horizontal blade | wing 10 improves. The horizontal blade 10 mainly includes a main body 20 as a first member and a lid 30 as a second member, and is configured by joining the main body 20 and the lid 30 by ultrasonic welding. For this reason, it can be said that the lid 30 is joined to the main body 20 with the hollow portion 60 interposed between the lid 30 and the main body 20.

  Moreover, the horizontal blade | wing 10 of this embodiment is curving smoothly so that the whole front lower part of the indoor unit 100 may become a rounded shape. In addition, the shape of the horizontal blade | wing 10 is not limited to this, The flat shape in which the horizontal blade | wing 10 is not curving may be sufficient. Moreover, although the horizontal blade | wing 10 of this embodiment is exhibiting rectangular shape, if a hollow structure is used, an external shape will not be limited to this.

(2) Detailed configuration (2-1) Main body 20
The main body 20 is a box-shaped member having one opening in a plan view, a rectangular main body side base portion 21 positioned opposite the opening, and a main body side outer peripheral wall erected from the outer peripheral edge of the main body side base portion 21 22. In the main body side base portion 21, a plurality (three in this case) of bearing portions 23 that support the rotating shaft 120 are provided at one end portion of both ends in the short direction that is a direction orthogonal to the longitudinal direction. It has been. For this reason, it can be said that the rotating shaft 120 of the horizontal blade 10 is disposed at the rear end portion 10b, which is one end portion of both ends of the horizontal blade 10 in the short direction. In addition, the surface of the main body side base portion 21 opposite to the surface on which the bearing portion 23 is provided constitutes the outer surface of the horizontal blade 10 that is visually recognized by the user when the operation is stopped. In addition, the bearing part 23 of this embodiment is provided in the center side rather than the right-and-left end part which is the edge part of the longitudinal direction of the main body side base 21. FIG.

  The main body side base 21 includes an inclined portion 24. The inclined portions 24 are located at both ends of the main body side base portion 21 in the short direction, and are inclined toward the direction in which the main body side outer peripheral wall 22 is erected. Further, the main body side base 21 is curved in one direction so that the horizontal blade 10 is curved. Specifically, the main body side base 21 is curved in a direction opposite to the direction in which the main body side outer peripheral wall 22 is erected.

(2-2) Lid 30
The lid | cover 30 is arrange | positioned so that the opening of the main body 20 may be covered, and it is comprised so that it may fit inside the main body 20 in this embodiment. Moreover, the lid | cover 30 comprises the inner surface of the horizontal blade | wing 10 which is not visually recognized by a user at the time of a driving | operation stop. As shown in FIG. 2, the lid 30 has a central portion 31 and an outer peripheral edge portion 32. The central portion 31 includes a rectangular lid-side base 33 and wall portions 34 standing from both ends in the short direction perpendicular to the longitudinal direction of the lid-side base 33 (see FIGS. 3 and 4). The lid side base portion 33 is curved in the same direction as the main body side base portion 21 in a state where the lid 30 is fitted into the main body 20.

  The edge part located in the both ends of the longitudinal direction of the lid | cover 30 among the outer periphery parts 32 consists of the left side edge part 35 and the right side edge part 36. FIG. The left side edge part 35 and the right side edge part 36 extend in a direction intersecting with the direction in which the lid side base part 33 extends (the direction orthogonal here) (see FIGS. 5 and 17). The outer surfaces of the left edge portion 35 and the right edge portion 36 are positioned so as to face the inner surface of the main body side outer peripheral wall 22 positioned at the left and right ends in the longitudinal direction of the main body 20. A communication port 36 a for communicating the inside and the outside of the hollow portion 60 is provided in the vicinity of the end on the side far from the bearing portion 23 in the left edge 35 and / or the right edge 36.

  Edge portions located at both ends in the lateral direction, which is a direction orthogonal to the longitudinal direction of the lid 30, of the outer peripheral edge portion 32 include a front side edge portion 38 and a rear side edge portion 37. As shown in FIG. 4, the front side edge portion 38 is an edge portion on the side farther from the bearing portion 23 than the rear side edge portion 37. The front edge 38 and the rear edge 37 extend from the tip of the wall 34 along the inclined portion 24. The front side edge portion 38 is positioned in the vicinity of the concave portion 50 into which an ultrasonic horn 81 to be described later is inserted. In this embodiment, the front side edge portion 38 constitutes a part of the concave portion 50 as shown in FIG. More specifically, the front edge portion 38 includes a contact surface 38a with which the protrusions 183a and 184a of the ultrasonic horn 81 abut and a facing surface 38b extending in the same direction as the direction in which the contact surface 38a extends. The inclined portion 24 of the main body 20 includes a contact surface 24b that comes into contact with the facing surface 38b. As shown in FIG. 4, a rib 39 is provided on the rear edge 37. In the present embodiment, as shown in FIG. 3, it is assumed that the rear edge 37 is not provided in a portion of the lid 30 located in the vicinity of the bearing portion 23.

  In addition, a molten resin portion 180 is formed on the surface on the lid 30 side in the joint portion between the main body 20 and the lid 30. The molten resin portion 180 is melted by ultrasonic vibration by the ultrasonic horn 81 and welds the inclined portion 24 of the main body 20 and the outer peripheral edge portion 32 of the lid 30. As shown in FIG. 6, the molten resin portion 180 has a triangular cross section.

(3) Production of horizontal blade 10 (3-1) Ultrasonic welding apparatus 80
FIG. 7 is a plan view of the ultrasonic welding apparatus 80 showing a state in which the ultrasonic horn 81 is in contact with the main body 20 and the lid 30. FIG. 8 is a front view of the ultrasonic welding apparatus 80 showing a state in which the ultrasonic horn 81 is in contact with the main body 20 and the lid 30. FIG. 9 is a perspective view of the receiving jig 82. FIG. 10 is a perspective view of the ultrasonic horn 81. FIG. 11A is a front view of the first ultrasonic horn 83. FIG. 11B is a bottom view of the first ultrasonic horn 83. FIG. 11C is a side view of the first ultrasonic horn 83. FIG. 12A is a front view of the second ultrasonic horn 84. FIG. 12B is a bottom view of the second ultrasonic horn 84. FIG. 12C is a side view of the second ultrasonic horn 84. FIG. 13 is a block diagram of the ultrasonic welding apparatus 80. FIG. 14 is a cross-sectional view taken along the line XIV-XIV in FIG. 7 and shows a state where the second ultrasonic horn 84 is in contact with the main body 20 and the lid 30. FIG. 15 is a partially enlarged view of FIG. 14 and shows a portion that becomes the front end 10 a of the horizontal blade 10. FIG. 16 is a cross-sectional view taken along the line XVI-XVI of FIG. 7 and shows a state where the first ultrasonic horn 83 is in contact with the main body 20 and the lid 30. 17A is a cross-sectional view taken along the line XVII (a) -XVII (a) of FIG. 7 and shows a state in which the first ultrasonic horn 83 is in contact with the main body 20 and the lid 30. FIG. FIG. 17B is a cross-sectional view taken along the line XVII (b) -XVII (b) in FIG. 7 and shows a state in which the second ultrasonic horn 84 is in contact with the main body 20 and the lid 30. 7 and 8, the upper part of the ultrasonic welding device 80 from the ultrasonic horn 81 is omitted.

  The ultrasonic welding device 80 is a device that uses the heat generated at the interface by applying ultrasonic vibration and a load to the joint, and a plurality of (here, two) ultrasonic horns. 81 and a receiving jig 82. The ultrasonic welding apparatus 80 of the present embodiment has two ultrasonic horns 81, but the number of ultrasonic horns is optimal according to the size and shape of the workpieces to be joined by ultrasonic welding. What is necessary is just to determine to a proper number. That is, if the ultrasonic welding apparatus 80 has two or more (for example, three, four, five, etc.) ultrasonic horns, the number is not limited.

  The receiving jig 82 is fixed to the pedestal 85 and is disposed so as to face the ultrasonic horn 81. The receiving jig 82 is designed so that it can be installed in a state where the main body 20 and the lid 30 as a workpiece are combined. In the present embodiment, the main body 20 and the lid 30 are installed so that the bearing portion 23 of the main body 20 is positioned on the front side of the receiving jig 82.

  As shown in FIGS. 10 to 12, the ultrasonic horn 81 includes a first ultrasonic horn 83 and a second ultrasonic horn 84. The first ultrasonic horn 83 and the second ultrasonic horn 84 are reciprocated in the vertical direction with respect to the receiving jig 82 by weighting devices 86 and 86 such as air cylinders, for example. Moreover, the 1st ultrasonic horn 83 and the 2nd ultrasonic horn 84 are arrange | positioned along with the horizontal direction (left-right direction in FIG. 8), as shown in FIG. The ultrasonic welding device 80 is configured to move at least one of the first ultrasonic horn 83 and the second ultrasonic horn 84 by a predetermined distance in the horizontal direction (direction orthogonal to the load direction). ing. That is, one ultrasonic horn can be moved back and forth in a direction approaching and moving away from the other ultrasonic horn.

  The 1st ultrasonic horn 83, the 2nd ultrasonic horn 84, and the receiving jig 82 are designed in the shape which can join the whole joining part located in the outer periphery part of each of the main body 20 and the lid | cover 30 at once. In particular, in the rear portions of the lower surfaces 183 and 184 that are contact surfaces with the workpiece in the first ultrasonic horn 83 and the second ultrasonic horn 84, as shown in FIGS. Protrusions 183a and 184a are provided. The outer shape of the protrusions 183a and 184a is formed to be similar to the recess 50. Further, as shown in FIGS. 10 to 12, the front portions of the lower surfaces 183 and 184 have a shape that is recessed on the inside (upper side in FIG. 10) so as to avoid the bearing portion 23. Furthermore, the lower surfaces 183 and 184 have a shape that is recessed inward (upper side shown in FIG. 10) so that portions other than the joint portion of the lid 30 do not contact.

  Ultrasonic transducers 87 and 87 are connected to the first ultrasonic horn 83 and the second ultrasonic horn 84, respectively. A high frequency voltage is applied to the ultrasonic transducers 87 and 87 from an oscillator for a predetermined time in accordance with an instruction from a control device (not shown). As a result, the ultrasonic transducers 87 and 87 oscillate ultrasonic waves. Then, the ultrasonic waves oscillated by the ultrasonic transducers 87 and 87 are mechanically amplified to the optimum amplitude by the boosters 88 and 88, and the first ultrasonic horn 83 and the second ultrasonic horn 84, which are resonance bodies, respectively. Vibrate.

(3-2) Manufacturing Method of Horizontal Blade 10 First, the resin main body 20 and the lid 30 are respectively molded by an existing molding method such as injection molding or extrusion molding. Next, as shown in FIGS. 3 and 4, the inner surface 21 a of the main body side base 21 of the main body 20 and the inner surface 33 a of the lid side base 33 of the lid 30 face each other, and the outer peripheral edge 32 of the lid 30 is on the main body side. The main body 20 and the lid 30 are installed on the receiving jig 82 in a state where the main body 20 and the lid 30 are overlapped so as to be fitted inside the outer peripheral wall 22. At this time, in the portion that becomes the front end portion 10a of the horizontal blade 10, the facing surface 38b of the front edge 38 of the lid 30 and the contact surface 24b of the inclined portion 24 of the main body 20 face each other, as shown in FIG. The main body 20 outer peripheral wall 22 of the main body 20, the wall portion 34 of the lid 30, and the front edge 38 constitute a recess 50 that is recessed toward the inside (main body 20 side).

  The main body 20 and the lid 30 are brought to one end of both ends in the longitudinal direction (left-right direction) of the receiving jig 82 in a state where the main body 20 and the lid 30 are installed. The reference positions of the left and right ends are determined. And as an adjustment process, adjustment of the relative position of the 1st ultrasonic horn 83 and the 2nd ultrasonic horn 84 is performed. Specifically, the horizontal positions of the first ultrasonic horn 83 and the second ultrasonic horn 84 are adjusted so as to match the reference positions of the left and right ends of the main body 20 and the lid 30. For example, in the case where each of the first ultrasonic horn 83 and the second ultrasonic horn 84 is configured to be movable in the horizontal direction, the first ultrasonic horn 83 is adjusted so as to match the horizontal dimension of the main body 20 and the lid 30. And each of the 2nd ultrasonic horn 84 is horizontally moved in the left-right direction. In this way, the first ultrasonic horn 83 and the second ultrasonic horn 84 are positioned.

  Thereafter, each of the first ultrasonic horn 83 and the second ultrasonic horn 84 is moved toward the receiving jig 82 by the weighting devices 86 and 86. As a result, the first ultrasonic horn 83 and the second ultrasonic horn 84 are in a predetermined state with respect to the receiving jig 82 with the overlapping portion of the main body 20 and the lid 30 sandwiched between the receiving jig 82 and the first ultrasonic horn 83 and the second ultrasonic horn 84. Pressed with pressure. At this time, the protrusions 183a and 184a of the lower surfaces 183 and 184 of the first ultrasonic horn 83 and the second ultrasonic horn 84 abut against the surfaces 22a, 34a and 38a constituting the recess 50 (see FIGS. 6 and 15). ). Further, the flat front portions of the lower surfaces 183 and 184 of the first ultrasonic horn 83 and the second ultrasonic horn 84 abut against the front end surface 39a of the rib 39 of the rear edge 37 (see FIG. 14). 3, the flat front portions of the lower surfaces 183 and 184 of the first ultrasonic horn 83 and the second ultrasonic horn 84 are located at the rear portion of the lid-side base 33. It contacts the surface 33f (see FIG. 16). Further, as shown in FIG. 17, the flat left end portion of the lower surface 183 of the first ultrasonic horn 83 abuts on the tip surface 36 f of the right edge portion 36, and the flat right end portion of the lower surface 184 of the second ultrasonic horn 84. Comes into contact with the front end surface 35 f of the left side edge 35. As described above, the first ultrasonic horn 83 and the second ultrasonic horn 83 are formed on the surfaces 22a, 34a, and 38a constituting the recess 50, the front end surface 39a of the rib 39, the rear surface 33f of the lid side base 33, and the front end surfaces 35f and 36f. The lower surfaces 183 and 184 of the ultrasonic horn 84 are brought into contact with each other, and the first ultrasonic horn 83 and the second ultrasonic horn 84 are vibrated, so that the first ultrasonic horn 83 and the second ultrasonic horn 84 are The overlapping portion between the main body 20 and the lid 30 sandwiched between the receiving jigs 82 is joined. Accordingly, the horizontal blade 10 having the hollow portion 60 between the main body 20 and the lid 30 and having substantially the entire outer peripheral edge joined by ultrasonic welding is completed.

  Here, in this embodiment, when the main body 20 and the lid 30 are joined, the first ultrasonic horn 83 and the second ultrasonic horn 84 are in contact with different parts. For this reason, the part joined by the first ultrasonic horn 83 contacting (hereinafter referred to as the first part) and the second ultrasonic horn 84 are brought into contact with the joint between the main body 20 and the lid 30. It can be said that there is a part (hereinafter referred to as a second part) that is different from the first part to be joined. In the present embodiment, the first portion is a portion including the right end portion 10d of the horizontal blade 10 and the right end portions of the front end portion 10a and the rear end portion 10b in the joint portion. The second portion is a portion including the left end portion 10c of the horizontal blade 10 and the left end portions of the front end portion 10a and the rear end portion 10b in the joint portion. Then, the first ultrasonic horn 83 and the second ultrasonic horn 84 vibrate the first portion and the second portion at the same timing, so that the first portion and the second portion are joined simultaneously.

(4) Features (4-1)
Here, an error may occur in the dimension of the member molded by the resin due to molding variation or shrinkage variation. For this reason, when trying to manufacture one product by superposing resin-molded members and joining them by ultrasonic welding, the position of the ultrasonic horn is shifted from the desired joining position, and each member is joined to the desired joining position. In some cases, the members cannot be joined at the position, or the ultrasonic horn cannot be brought into contact with each other and the respective members cannot be joined.

  In the present embodiment, the first ultrasonic horn 83 is brought into contact with and joined to the first portion of the joint, and the second ultrasonic horn different from the first ultrasonic horn 83 is joined to the second portion of the joint. 84 is abutted and joined. For this reason, when joining the main body 20 and the lid | cover 30, the position of the 1st ultrasonic horn 83 is adjusted according to a 1st part, and the position of the 2nd ultrasonic horn 84 is adjusted according to a 2nd part. be able to.

  In the present embodiment, when the main body 20 and the lid 30 are joined, after the relative positions of the first ultrasonic horn 83 and the second ultrasonic horn 84 are adjusted, the main body 20 and the lid 30 are joined. The For this reason, before joining the main body 20 and the lid | cover 30, the position of the 1st ultrasonic horn 83 is adjusted according to a 1st part, and the position of the 2nd ultrasonic horn 84 is adjusted according to a 2nd part. be able to.

  Thereby, even when two resin-molded members are joined to form a hollow structure product, each member can be joined at a desired joining position by ultrasonic welding.

(4-2)
In the present embodiment, the first ultrasonic horn 83 and the second ultrasonic horn 84 vibrate the first portion and the second portion at the same timing. For this reason, the manufacturing time can be shortened compared with the case where the 1st ultrasonic horn 83 and the 2nd ultrasonic horn 84 vibrate each of the 1st part and the 2nd part at different timing.

(4-3)
In the present embodiment, the entire outer peripheral edge of the horizontal blade 10 is joined by the first ultrasonic horn 83 and the second ultrasonic horn 84 being vibrated. That is, the entire outer peripheral edge of the hollow horizontal blade 10 can be joined by the two ultrasonic horns 81.

(4-4)
The horizontal blade 10 of the present embodiment has a longitudinal dimension of 500 mm or more. That is, by the manufacturing method of this embodiment, the long horizontal blade | wing 10 whose dimension is 500 mm or more can be manufactured by ultrasonic welding.

(4-5)
In the first ultrasonic horn 83 and the second ultrasonic horn 84 of the present embodiment, the protruding portions 183a and 184a along the longitudinal direction of the ultrasonic horns 83 and 84 are provided only at the rear portions of the ultrasonic horns 83 and 84, respectively. Is provided.

  Here, in the configuration of the main body 20 and the lid 30 of the present embodiment, the main body 20 outer peripheral wall 22 and the wall portion 34 and the rear edge 37 of the lid 30 are recessed toward the inside (the main body 20 side). As shown in FIG. 14, the first ultrasonic horn 83 and the second ultrasonic horn 84 do not come into contact with the inner surface of the depression. That is, in this embodiment, the recessed part 50 into which the protrusions 183a and 184a of the first ultrasonic horn 83 and the second ultrasonic horn 84 are inserted is the rear end where the rotary shaft 120 is disposed in the horizontal blade 10. It is formed only at the front end 10a opposite to 10b. For this reason, at the time of joining, the contact position of the ultrasonic horn 81 can be adjusted at the joint located at the rear end 10b of the horizontal blade 10. That is, even if there is a dimensional variation in the front-rear direction of the main body 20 and the lid 30, the protrusions 183 a and 184 a of the ultrasonic horns 83 and 84 are inserted into the recesses 50 positioned on the front side, and the surfaces 22 a that constitute the recesses 50. The protruding portions 183a and 184a of the ultrasonic horns 83 and 84 can be easily brought into contact with 34a and 38a. Thereby, the possibility that the main body 20 and the lid 30 cannot be joined can be reduced.

  Moreover, the recessed part 50 is located in the front side edge part 10a on the horizontal blade | wing 10 opposite to the rear side edge part 10b in which the rotating shaft 120 is arrange | positioned. For this reason, it is possible to improve the positioning accuracy of the joint portion at the front end portion 10a that is easily visible to the user during operation, and it is possible to make this less noticeable even if the molten resin protrudes during ultrasonic welding.

  As a result, it is possible to suppress a decrease in appearance quality.

(5) Modification (5-1) Modification A
In the said embodiment, although the horizontal blade | wing 10 used for the wall-hanging type indoor unit 100 is demonstrated, the blade | wing components of this invention are not limited to this. That is, it may be a blade component having a hollow structure included in the air conditioner, and may be, for example, a horizontal blade 10 used for a ceiling-mounted indoor unit or a propeller fan used for an outdoor unit.

  Moreover, this invention is not restricted to a blade | wing component, It can use as a manufacturing method at the time of manufacturing the product of a hollow structure, ie, a hollow part. In particular, by using the manufacturing method of the present invention, it is possible to manufacture a long part having a hollow structure using ultrasonic welding.

(5-2) Modification B
In the above embodiment, the first ultrasonic horn 83 and the second ultrasonic horn 84 vibrate the first portion and the second portion at the same timing, but the present invention is not limited to this, and the first ultrasonic horn 83 is not limited thereto. The second ultrasonic horn 84 may be designed to vibrate the first part and the second part at different timings.

  In the present invention, two members molded with resin can be joined to each other at a desired joining position by ultrasonic welding, and application to a hollow part is effective.

10 Horizontal blades (blade parts)
20 Main body (first member)
30 Lid (second member)
83 1st ultrasonic horn 84 2nd ultrasonic horn

JP-A-1-196329

The present invention relates to a hollow part and a manufacturing method thereof .

  Conventionally, as disclosed in Patent Document 1 (Japanese Patent Laid-Open No. 1-1963329), there is an ultrasonic welding method as a method of joining two members. When joining using the ultrasonic welding method, it is necessary to abut the ultrasonic horn on the two overlapped members.

  Incidentally, some recent air conditioners include a hollow structure blade component made of resin. Here, the resin-molded member may cause an error in the dimension of the member due to molding variation or shrinkage variation. For this reason, when trying to manufacture a hollow blade component by joining two resin-molded members by ultrasonic welding, it is not possible to join each member at a desired joining position due to the displacement of the position of the ultrasonic horn. Or the ultrasonic horn cannot be brought into contact with each other and the members cannot be joined.

Therefore, the object of the present invention is to provide a hollow part capable of joining each member at a desired joining position by ultrasonic welding, even when two members molded with resin are joined to form a hollow structure. It is in providing the manufacturing method.

Hollow component according to the first aspect of the present invention includes a first member and a second member which is a resin molding a hollow component which are joined by ultrasonic welding, the joint between the first member and the second member , A first portion and a second portion different from the first portion. The first part is a part to be joined by contacting the first ultrasonic horn. The second part is a part to be joined by contacting a second ultrasonic horn different from the first ultrasonic horn.

In the hollow component according to the first aspect of the present invention, the first ultrasonic horn is brought into contact with the first part, and the second ultrasonic horn different from the first ultrasonic horn is brought into contact. Thus, the second part is joined. For this reason, when joining a 1st member and a 2nd member, the position of each ultrasonic horn can be adjusted so that it may suit a desired joining position.

  Thereby, even if it is a case where two resin-molded members are joined and a hollow structure is formed, each member can be joined at a desired joining position by ultrasonic welding.

  A method for manufacturing a hollow part according to a second aspect of the present invention is a method for manufacturing a hollow part in which a resin-molded first member and a second member are joined by ultrasonic welding, and includes an adjustment step and a welding step. And comprising. In the adjustment step, the relative position between the first ultrasonic horn and the second ultrasonic horn is adjusted. The first ultrasonic horn is brought into contact with the first portion of the joint portion between the first member and the second member. The second ultrasonic horn is brought into contact with a second portion different from the first portion in the joint portion. The welding process is performed after the relative positions of the first ultrasonic horn and the second ultrasonic horn are adjusted in the adjustment process. In the welding step, ultrasonic welding is performed by bringing the first ultrasonic horn into contact with the first portion and bringing the second ultrasonic horn into contact with the second portion.

  In the method for manufacturing a hollow part according to the second aspect of the present invention, after the adjusting step for adjusting the relative positions of the first ultrasonic horn and the second ultrasonic horn is performed, a welding step for performing ultrasonic welding is performed. . For this reason, before joining a 1st member and a 2nd member, the position of each ultrasonic horn can be adjusted so that it may suit a desired joining position.

  Thereby, even if it is a case where two resin-molded members are joined and a hollow structure is formed, each member can be joined at a desired joining position by ultrasonic welding.

  The method for manufacturing a hollow part according to a third aspect of the present invention is the method for manufacturing a hollow part according to the second aspect. In the welding step, the first ultrasonic horn and the second ultrasonic horn are the first part and the second part. At the same time. For this reason, compared with the case where a 1st ultrasonic horn and a 2nd ultrasonic horn vibrate each of a 1st part and a 2nd part at a separate timing, joining time can be shortened.

  A method for manufacturing a hollow part according to a fourth aspect of the present invention is the method for manufacturing a hollow part according to the second aspect or the third aspect, wherein the first ultrasonic horn and the second ultrasonic horn vibrate so that the hollow part is excited. Are joined together. In this method for manufacturing a hollow part, the entire outer peripheral edge of the hollow part can be joined by the first ultrasonic horn and the second ultrasonic horn.

  The hollow component manufacturing method according to the fifth aspect of the present invention is the hollow component manufacturing method according to any one of the second to fourth aspects, wherein the dimension of the hollow component in the longitudinal direction is 500 mm or more. In this method for manufacturing a hollow part, a long hollow part having a dimension of 500 mm or more can be manufactured by ultrasonic welding.

In the hollow part according to the first aspect of the present invention, even when two resin-molded members are joined to form a hollow structure, each member can be joined at a desired joining position by ultrasonic welding. it can.

  In the method for manufacturing a hollow part according to the second aspect of the present invention, even when two resin-molded members are joined to form a hollow structure, each member is joined at a desired joining position by ultrasonic welding. can do.

  In the method for manufacturing a hollow part according to the third aspect of the present invention, the joining time can be shortened.

  In the method for manufacturing a hollow part according to the fourth aspect of the present invention, the entire outer peripheral edge of the hollow part can be joined.

  In the method for manufacturing a hollow part according to the fifth aspect of the present invention, a long hollow part having a dimension of 500 mm or more can be manufactured by ultrasonic welding.

The perspective view of the air conditioning apparatus which has a horizontal blade | wing which concerns on one Embodiment of this invention. The top view of the horizontal blade | wing which concerns on one Embodiment of this invention. Sectional drawing of the horizontal blade | wing which concerns on one Embodiment of this invention. Sectional drawing of the horizontal blade | wing which concerns on one Embodiment of this invention. Sectional drawing of the horizontal blade | wing which concerns on one Embodiment of this invention. The enlarged view of a recessed part vicinity. The top view of an ultrasonic welding apparatus. The front view of an ultrasonic welding apparatus. The perspective view of a receiving jig. The perspective view of an ultrasonic horn. The figure which shows a 1st ultrasonic horn. The figure which shows a 2nd ultrasonic horn. The block block diagram of an ultrasonic welding apparatus. The figure which shows the state by which the ultrasonic horn contact | abutted to the main body and the lid | cover. The enlarged view of the protrusion part vicinity at the time of joining. The figure which shows the state by which the ultrasonic horn contact | abutted to the main body and the lid | cover. The figure which shows the state by which the ultrasonic horn contact | abutted to the main body and the lid | cover.

  Hereinafter, a blade part as a hollow part according to an embodiment of the present invention will be described with reference to the drawings. The following embodiments are specific examples of the present invention and do not limit the technical scope of the present invention.

(1) Overall Configuration FIG. 1 is a perspective view of an air conditioner having horizontal blades 10 according to an embodiment of the present invention. FIG. 2 is a plan view of the horizontal blade 10 according to an embodiment of the present invention. An indoor unit 100 of an air conditioner that employs a horizontal blade 10 as a blade component according to an embodiment of the present invention is a wall-mounted indoor unit attached to an indoor wall as shown in FIG. It has a cooling function and a heating function. The indoor unit 100 includes a casing 110 as a casing. The casing 110 is formed with a suction port 111 for taking indoor air into the casing 110 and a blower outlet 112 for blowing the air taken into the casing 110 into the room. In addition, a heat exchanger, a fan, and the like are housed in the casing 110, and the indoor air sucked from the suction port 111 when the fan is driven passes through the heat exchanger and is blown out from the air outlet 112. . When the room air passes through the heat exchanger, heat is exchanged to become cold air or warm air and return to the room.

  The air outlet 112 is an opening extending in the longitudinal direction of the indoor unit 100 (in the left-right direction in FIG. 1), and is formed at the front lower portion of the casing 110, that is, at the front lower portion of the indoor unit 100 as shown in FIG. Yes. Moreover, the horizontal blade | wing 10 which can cover the blower outlet 112 is arrange | positioned at the blower outlet 112. FIG. The horizontal blade | wing 10 is a plate-shaped member which exhibits rectangular shape. In addition, the dimension of the longitudinal direction of the horizontal blade | wing 10 of this embodiment shall be 500 mm or more. The horizontal blade 10 is provided so as to be rotatable about a rotation shaft 120 extending along the longitudinal direction thereof, and takes a predetermined posture by rotating. And the horizontal blade | wing 10 closes the blower outlet 112 by covering the blower outlet 112 at the time of a driving | operation stop, and adjusts the vertical wind direction of the conditioned air which passes a heat exchanger and blows off from the blower outlet 112 at the time of a driving | operation.

  3 is a cross-sectional view of the horizontal blade 10 cut along III-III in FIG. 4 is a cross-sectional view of the horizontal blade 10 cut along IV-IV in FIG. FIG. 5 is a cross-sectional view of the horizontal blade 10 cut along V-V in FIG. FIG. 6 is a partially enlarged view of the cross section of the front end 10 a of the horizontal blade 10.

  The horizontal blade 10 is made of resin and has a hollow structure. Thereby, the heat insulation performance of the horizontal blade | wing 10 improves. The horizontal blade 10 mainly includes a main body 20 as a first member and a lid 30 as a second member, and is configured by joining the main body 20 and the lid 30 by ultrasonic welding. For this reason, it can be said that the lid 30 is joined to the main body 20 with the hollow portion 60 interposed between the lid 30 and the main body 20.

  Moreover, the horizontal blade | wing 10 of this embodiment is curving smoothly so that the whole front lower part of the indoor unit 100 may become a rounded shape. In addition, the shape of the horizontal blade | wing 10 is not limited to this, The flat shape in which the horizontal blade | wing 10 is not curving may be sufficient. Moreover, although the horizontal blade | wing 10 of this embodiment is exhibiting rectangular shape, if a hollow structure is used, an external shape will not be limited to this.

(2) Detailed configuration (2-1) Main body 20
The main body 20 is a box-shaped member having one opening in a plan view, a rectangular main body side base portion 21 positioned opposite the opening, and a main body side outer peripheral wall erected from the outer peripheral edge of the main body side base portion 21 22. In the main body side base portion 21, a plurality (three in this case) of bearing portions 23 that support the rotating shaft 120 are provided at one end portion of both ends in the short direction that is a direction orthogonal to the longitudinal direction. It has been. For this reason, it can be said that the rotating shaft 120 of the horizontal blade 10 is disposed at the rear end portion 10b, which is one end portion of both ends of the horizontal blade 10 in the short direction. In addition, the surface of the main body side base portion 21 opposite to the surface on which the bearing portion 23 is provided constitutes the outer surface of the horizontal blade 10 that is visually recognized by the user when the operation is stopped. In addition, the bearing part 23 of this embodiment is provided in the center side rather than the right-and-left end part which is the edge part of the longitudinal direction of the main body side base 21. FIG.

  The main body side base 21 includes an inclined portion 24. The inclined portions 24 are located at both ends of the main body side base portion 21 in the short direction, and are inclined toward the direction in which the main body side outer peripheral wall 22 is erected. Further, the main body side base 21 is curved in one direction so that the horizontal blade 10 is curved. Specifically, the main body side base 21 is curved in a direction opposite to the direction in which the main body side outer peripheral wall 22 is erected.

(2-2) Lid 30
The lid | cover 30 is arrange | positioned so that the opening of the main body 20 may be covered, and it is comprised so that it may fit inside the main body 20 in this embodiment. Moreover, the lid | cover 30 comprises the inner surface of the horizontal blade | wing 10 which is not visually recognized by a user at the time of a driving | operation stop. As shown in FIG. 2, the lid 30 has a central portion 31 and an outer peripheral edge portion 32. The central portion 31 includes a rectangular lid-side base 33 and wall portions 34 standing from both ends in the short direction perpendicular to the longitudinal direction of the lid-side base 33 (see FIGS. 3 and 4). The lid side base portion 33 is curved in the same direction as the main body side base portion 21 in a state where the lid 30 is fitted into the main body 20.

  The edge part located in the both ends of the longitudinal direction of the lid | cover 30 among the outer periphery parts 32 consists of the left side edge part 35 and the right side edge part 36. FIG. The left side edge part 35 and the right side edge part 36 extend in a direction intersecting with the direction in which the lid side base part 33 extends (the direction orthogonal here) (see FIGS. 5 and 17). The outer surfaces of the left edge portion 35 and the right edge portion 36 are positioned so as to face the inner surface of the main body side outer peripheral wall 22 positioned at the left and right ends in the longitudinal direction of the main body 20. A communication port 36 a for communicating the inside and the outside of the hollow portion 60 is provided in the vicinity of the end on the side far from the bearing portion 23 in the left edge 35 and / or the right edge 36.

  Edge portions located at both ends in the lateral direction, which is a direction orthogonal to the longitudinal direction of the lid 30, of the outer peripheral edge portion 32 include a front side edge portion 38 and a rear side edge portion 37. As shown in FIG. 4, the front side edge portion 38 is an edge portion on the side farther from the bearing portion 23 than the rear side edge portion 37. The front edge 38 and the rear edge 37 extend from the tip of the wall 34 along the inclined portion 24. The front side edge portion 38 is positioned in the vicinity of the concave portion 50 into which an ultrasonic horn 81 to be described later is inserted. In this embodiment, the front side edge portion 38 constitutes a part of the concave portion 50 as shown in FIG. More specifically, the front edge portion 38 includes a contact surface 38a with which the protrusions 183a and 184a of the ultrasonic horn 81 abut and a facing surface 38b extending in the same direction as the direction in which the contact surface 38a extends. The inclined portion 24 of the main body 20 includes a contact surface 24b that comes into contact with the facing surface 38b. As shown in FIG. 4, a rib 39 is provided on the rear edge 37. In the present embodiment, as shown in FIG. 3, it is assumed that the rear edge 37 is not provided in a portion of the lid 30 located in the vicinity of the bearing portion 23.

  In addition, a molten resin portion 180 is formed on the surface on the lid 30 side in the joint portion between the main body 20 and the lid 30. The molten resin portion 180 is melted by ultrasonic vibration by the ultrasonic horn 81 and welds the inclined portion 24 of the main body 20 and the outer peripheral edge portion 32 of the lid 30. As shown in FIG. 6, the molten resin portion 180 has a triangular cross section.

(3) Production of horizontal blade 10 (3-1) Ultrasonic welding apparatus 80
FIG. 7 is a plan view of the ultrasonic welding apparatus 80 showing a state in which the ultrasonic horn 81 is in contact with the main body 20 and the lid 30. FIG. 8 is a front view of the ultrasonic welding apparatus 80 showing a state in which the ultrasonic horn 81 is in contact with the main body 20 and the lid 30. FIG. 9 is a perspective view of the receiving jig 82. FIG. 10 is a perspective view of the ultrasonic horn 81. FIG. 11A is a front view of the first ultrasonic horn 83. FIG. 11B is a bottom view of the first ultrasonic horn 83. FIG. 11C is a side view of the first ultrasonic horn 83. FIG. 12A is a front view of the second ultrasonic horn 84. FIG. 12B is a bottom view of the second ultrasonic horn 84. FIG. 12C is a side view of the second ultrasonic horn 84. FIG. 13 is a block diagram of the ultrasonic welding apparatus 80. FIG. 14 is a cross-sectional view taken along the line XIV-XIV in FIG. 7 and shows a state where the second ultrasonic horn 84 is in contact with the main body 20 and the lid 30. FIG. 15 is a partially enlarged view of FIG. 14 and shows a portion that becomes the front end 10 a of the horizontal blade 10. FIG. 16 is a cross-sectional view taken along the line XVI-XVI of FIG. 7 and shows a state where the first ultrasonic horn 83 is in contact with the main body 20 and the lid 30. 17A is a cross-sectional view taken along the line XVII (a) -XVII (a) of FIG. 7 and shows a state in which the first ultrasonic horn 83 is in contact with the main body 20 and the lid 30. FIG. FIG. 17B is a cross-sectional view taken along the line XVII (b) -XVII (b) in FIG. 7 and shows a state in which the second ultrasonic horn 84 is in contact with the main body 20 and the lid 30. 7 and 8, the upper part of the ultrasonic welding device 80 from the ultrasonic horn 81 is omitted.

  The ultrasonic welding device 80 is a device that uses the heat generated at the interface by applying ultrasonic vibration and a load to the joint, and a plurality of (here, two) ultrasonic horns. 81 and a receiving jig 82. The ultrasonic welding apparatus 80 of the present embodiment has two ultrasonic horns 81, but the number of ultrasonic horns is optimal according to the size and shape of the workpieces to be joined by ultrasonic welding. What is necessary is just to determine to a proper number. That is, if the ultrasonic welding apparatus 80 has two or more (for example, three, four, five, etc.) ultrasonic horns, the number is not limited.

  The receiving jig 82 is fixed to the pedestal 85 and is disposed so as to face the ultrasonic horn 81. The receiving jig 82 is designed so that it can be installed in a state where the main body 20 and the lid 30 as a workpiece are combined. In the present embodiment, the main body 20 and the lid 30 are installed so that the bearing portion 23 of the main body 20 is positioned on the front side of the receiving jig 82.

  As shown in FIGS. 10 to 12, the ultrasonic horn 81 includes a first ultrasonic horn 83 and a second ultrasonic horn 84. The first ultrasonic horn 83 and the second ultrasonic horn 84 are reciprocated in the vertical direction with respect to the receiving jig 82 by weighting devices 86 and 86 such as air cylinders, for example. Moreover, the 1st ultrasonic horn 83 and the 2nd ultrasonic horn 84 are arrange | positioned along with the horizontal direction (left-right direction in FIG. 8), as shown in FIG. The ultrasonic welding device 80 is configured to move at least one of the first ultrasonic horn 83 and the second ultrasonic horn 84 by a predetermined distance in the horizontal direction (direction orthogonal to the load direction). ing. That is, one ultrasonic horn can be moved back and forth in a direction approaching and moving away from the other ultrasonic horn.

  The 1st ultrasonic horn 83, the 2nd ultrasonic horn 84, and the receiving jig 82 are designed in the shape which can join the whole joining part located in the outer periphery part of each of the main body 20 and the lid | cover 30 at once. In particular, in the rear portions of the lower surfaces 183 and 184 that are contact surfaces with the workpiece in the first ultrasonic horn 83 and the second ultrasonic horn 84, as shown in FIGS. Protrusions 183a and 184a are provided. The outer shape of the protrusions 183a and 184a is formed to be similar to the recess 50. Further, as shown in FIGS. 10 to 12, the front portions of the lower surfaces 183 and 184 have a shape that is recessed on the inside (upper side in FIG. 10) so as to avoid the bearing portion 23. Furthermore, the lower surfaces 183 and 184 have a shape that is recessed inward (upper side shown in FIG. 10) so that portions other than the joint portion of the lid 30 do not contact.

  Ultrasonic transducers 87 and 87 are connected to the first ultrasonic horn 83 and the second ultrasonic horn 84, respectively. A high frequency voltage is applied to the ultrasonic transducers 87 and 87 from an oscillator for a predetermined time in accordance with an instruction from a control device (not shown). As a result, the ultrasonic transducers 87 and 87 oscillate ultrasonic waves. Then, the ultrasonic waves oscillated by the ultrasonic transducers 87 and 87 are mechanically amplified to the optimum amplitude by the boosters 88 and 88, and the first ultrasonic horn 83 and the second ultrasonic horn 84, which are resonance bodies, respectively. Vibrate.

(3-2) Manufacturing Method of Horizontal Blade 10 First, the resin main body 20 and the lid 30 are respectively molded by an existing molding method such as injection molding or extrusion molding. Next, as shown in FIGS. 3 and 4, the inner surface 21 a of the main body side base 21 of the main body 20 and the inner surface 33 a of the lid side base 33 of the lid 30 face each other, and the outer peripheral edge 32 of the lid 30 is on the main body side. The main body 20 and the lid 30 are installed on the receiving jig 82 in a state where the main body 20 and the lid 30 are overlapped so as to be fitted inside the outer peripheral wall 22. At this time, in the portion that becomes the front end portion 10a of the horizontal blade 10, the facing surface 38b of the front edge 38 of the lid 30 and the contact surface 24b of the inclined portion 24 of the main body 20 face each other, as shown in FIG. The main body 20 outer peripheral wall 22 of the main body 20, the wall portion 34 of the lid 30, and the front edge 38 constitute a recess 50 that is recessed toward the inside (main body 20 side).

  The main body 20 and the lid 30 are brought to one end of both ends in the longitudinal direction (left-right direction) of the receiving jig 82 in a state where the main body 20 and the lid 30 are installed. The reference positions of the left and right ends are determined. And as an adjustment process, adjustment of the relative position of the 1st ultrasonic horn 83 and the 2nd ultrasonic horn 84 is performed. Specifically, the horizontal positions of the first ultrasonic horn 83 and the second ultrasonic horn 84 are adjusted so as to match the reference positions of the left and right ends of the main body 20 and the lid 30. For example, in the case where each of the first ultrasonic horn 83 and the second ultrasonic horn 84 is configured to be movable in the horizontal direction, the first ultrasonic horn 83 is adjusted so as to match the horizontal dimension of the main body 20 and the lid 30. And each of the 2nd ultrasonic horn 84 is horizontally moved in the left-right direction. In this way, the first ultrasonic horn 83 and the second ultrasonic horn 84 are positioned.

  Thereafter, each of the first ultrasonic horn 83 and the second ultrasonic horn 84 is moved toward the receiving jig 82 by the weighting devices 86 and 86. As a result, the first ultrasonic horn 83 and the second ultrasonic horn 84 are in a predetermined state with respect to the receiving jig 82 with the overlapping portion of the main body 20 and the lid 30 sandwiched between the receiving jig 82 and the first ultrasonic horn 83 and the second ultrasonic horn 84. Pressed with pressure. At this time, the protrusions 183a and 184a of the lower surfaces 183 and 184 of the first ultrasonic horn 83 and the second ultrasonic horn 84 abut against the surfaces 22a, 34a and 38a constituting the recess 50 (see FIGS. 6 and 15). ). Further, the flat front portions of the lower surfaces 183 and 184 of the first ultrasonic horn 83 and the second ultrasonic horn 84 abut against the front end surface 39a of the rib 39 of the rear edge 37 (see FIG. 14). 3, the flat front portions of the lower surfaces 183 and 184 of the first ultrasonic horn 83 and the second ultrasonic horn 84 are located at the rear portion of the lid-side base 33. It contacts the surface 33f (see FIG. 16). Further, as shown in FIG. 17, the flat left end portion of the lower surface 183 of the first ultrasonic horn 83 abuts on the tip surface 36 f of the right edge portion 36, and the flat right end portion of the lower surface 184 of the second ultrasonic horn 84. Comes into contact with the front end surface 35 f of the left side edge 35. As described above, the first ultrasonic horn 83 and the second ultrasonic horn 83 are formed on the surfaces 22a, 34a, and 38a constituting the recess 50, the front end surface 39a of the rib 39, the rear surface 33f of the lid side base 33, and the front end surfaces 35f and 36f. The lower surfaces 183 and 184 of the ultrasonic horn 84 are brought into contact with each other, and the first ultrasonic horn 83 and the second ultrasonic horn 84 are vibrated, so that the first ultrasonic horn 83 and the second ultrasonic horn 84 are The overlapping portion between the main body 20 and the lid 30 sandwiched between the receiving jigs 82 is joined. Accordingly, the horizontal blade 10 having the hollow portion 60 between the main body 20 and the lid 30 and having substantially the entire outer peripheral edge joined by ultrasonic welding is completed.

  Here, in this embodiment, when the main body 20 and the lid 30 are joined, the first ultrasonic horn 83 and the second ultrasonic horn 84 are in contact with different parts. For this reason, the part joined by the first ultrasonic horn 83 contacting (hereinafter referred to as the first part) and the second ultrasonic horn 84 are brought into contact with the joint between the main body 20 and the lid 30. It can be said that there is a part (hereinafter referred to as a second part) that is different from the first part to be joined. In the present embodiment, the first portion is a portion including the right end portion 10d of the horizontal blade 10 and the right end portions of the front end portion 10a and the rear end portion 10b in the joint portion. The second portion is a portion including the left end portion 10c of the horizontal blade 10 and the left end portions of the front end portion 10a and the rear end portion 10b in the joint portion. Then, the first ultrasonic horn 83 and the second ultrasonic horn 84 vibrate the first portion and the second portion at the same timing, so that the first portion and the second portion are joined simultaneously.

(4) Features (4-1)
Here, an error may occur in the dimension of the member molded by the resin due to molding variation or shrinkage variation. For this reason, when trying to manufacture one product by superimposing resin molded members and joining them by ultrasonic welding, the position of the ultrasonic horn is shifted from the desired joining position, and each member is joined to the desired joining. In some cases, the members cannot be joined at the position, or the ultrasonic horn cannot be brought into contact with each other and the respective members cannot be joined.

  In the present embodiment, the first ultrasonic horn 83 is brought into contact with and joined to the first portion of the joint, and the second ultrasonic horn different from the first ultrasonic horn 83 is joined to the second portion of the joint. 84 is abutted and joined. For this reason, when joining the main body 20 and the lid | cover 30, the position of the 1st ultrasonic horn 83 is adjusted according to a 1st part, and the position of the 2nd ultrasonic horn 84 is adjusted according to a 2nd part. be able to.

  In the present embodiment, when the main body 20 and the lid 30 are joined, after the relative positions of the first ultrasonic horn 83 and the second ultrasonic horn 84 are adjusted, the main body 20 and the lid 30 are joined. The For this reason, before joining the main body 20 and the lid | cover 30, the position of the 1st ultrasonic horn 83 is adjusted according to a 1st part, and the position of the 2nd ultrasonic horn 84 is adjusted according to a 2nd part. be able to.

  Thereby, even when two resin-molded members are joined to form a hollow structure product, each member can be joined at a desired joining position by ultrasonic welding.

(4-2)
In the present embodiment, the first ultrasonic horn 83 and the second ultrasonic horn 84 vibrate the first portion and the second portion at the same timing. For this reason, the manufacturing time can be shortened compared with the case where the 1st ultrasonic horn 83 and the 2nd ultrasonic horn 84 vibrate each of the 1st part and the 2nd part at different timing.

(4-3)
In the present embodiment, the entire outer peripheral edge of the horizontal blade 10 is joined by the first ultrasonic horn 83 and the second ultrasonic horn 84 being vibrated. That is, the entire outer peripheral edge of the hollow horizontal blade 10 can be joined by the two ultrasonic horns 81.

(4-4)
The horizontal blade 10 of the present embodiment has a longitudinal dimension of 500 mm or more. That is, by the manufacturing method of this embodiment, the long horizontal blade | wing 10 whose dimension is 500 mm or more can be manufactured by ultrasonic welding.

(4-5)
In the first ultrasonic horn 83 and the second ultrasonic horn 84 of the present embodiment, the protruding portions 183a and 184a along the longitudinal direction of the ultrasonic horns 83 and 84 are provided only at the rear portions of the ultrasonic horns 83 and 84, respectively. Is provided.

  Here, in the configuration of the main body 20 and the lid 30 of the present embodiment, the main body 20 outer peripheral wall 22 and the wall portion 34 and the rear edge 37 of the lid 30 are recessed toward the inside (the main body 20 side). As shown in FIG. 14, the first ultrasonic horn 83 and the second ultrasonic horn 84 do not come into contact with the inner surface of the depression. That is, in this embodiment, the recessed part 50 into which the protrusions 183a and 184a of the first ultrasonic horn 83 and the second ultrasonic horn 84 are inserted is the rear end where the rotary shaft 120 is disposed in the horizontal blade 10. It is formed only at the front end 10a opposite to 10b. For this reason, at the time of joining, the contact position of the ultrasonic horn 81 can be adjusted at the joint located at the rear end 10b of the horizontal blade 10. That is, even if there is a dimensional variation in the front-rear direction of the main body 20 and the lid 30, the protrusions 183 a and 184 a of the ultrasonic horns 83 and 84 are inserted into the recesses 50 positioned on the front side, and the surfaces 22 a that constitute the recesses 50. The protruding portions 183a and 184a of the ultrasonic horns 83 and 84 can be easily brought into contact with 34a and 38a. Thereby, the possibility that the main body 20 and the lid 30 cannot be joined can be reduced.

  Moreover, the recessed part 50 is located in the front side edge part 10a on the horizontal blade | wing 10 opposite to the rear side edge part 10b in which the rotating shaft 120 is arrange | positioned. For this reason, it is possible to improve the positioning accuracy of the joining portion in the front end portion 10a that is easily visible to the user during operation, and it is possible to make this less noticeable even if the molten resin protrudes during ultrasonic welding.

  As a result, it is possible to suppress a decrease in appearance quality.

(5) Modification (5-1) Modification A
In the said embodiment, although the horizontal blade | wing 10 used for the wall-hanging type indoor unit 100 is demonstrated, the blade | wing components of this invention are not limited to this. That is, it may be a blade component having a hollow structure included in the air conditioner, and may be, for example, a horizontal blade 10 used for a ceiling-mounted indoor unit or a propeller fan used for an outdoor unit.

  Moreover, this invention is not restricted to a blade | wing component, It can use as a manufacturing method at the time of manufacturing the product of a hollow structure, ie, a hollow part. In particular, by using the manufacturing method of the present invention, it is possible to manufacture a long part having a hollow structure using ultrasonic welding.

(5-2) Modification B
In the above embodiment, the first ultrasonic horn 83 and the second ultrasonic horn 84 vibrate the first portion and the second portion at the same timing, but the present invention is not limited to this, and the first ultrasonic horn 83 is not limited thereto. The second ultrasonic horn 84 may be designed to vibrate the first part and the second part at different timings.

  In the present invention, two members molded with resin can be joined to each other at a desired joining position by ultrasonic welding, and application to a hollow part is effective.

10 Horizontal blades (blade parts)
20 Main body (first member)
30 Lid (second member)
83 1st ultrasonic horn 84 2nd ultrasonic horn

JP-A-1-196329

Claims (5)

A hollow structure blade component in which a resin-molded first member (20) and a second member (30) are joined by ultrasonic welding,
The joint portion between the first member and the second member includes a first portion and a second portion different from the first portion,
The first part is joined by contacting the first ultrasonic horn (83),
The second portion is joined by contacting a second ultrasonic horn (84) different from the first ultrasonic horn,
Blade component (10). A method for producing a hollow part in which a resin-molded first member (20) and a second member (30) are joined by ultrasonic welding,
A first ultrasonic horn (83) that is in contact with a first portion of the joint portion between the first member and the second member, and a second separate from the first portion of the joint portion. An adjustment step of adjusting the relative position of the second ultrasonic horn (84) that is in contact with the portion;
After the relative positions of the first ultrasonic horn and the second ultrasonic horn are adjusted in the adjustment step, the first ultrasonic horn is brought into contact with the first portion, and the second ultrasonic horn A welding step in which ultrasonic welding is performed by contacting the second portion;
Comprising
Manufacturing method of hollow parts. In the welding step, the first ultrasonic horn and the second ultrasonic horn simultaneously vibrate the first part and the second part.
The method for manufacturing a hollow part according to claim 2. By vibrating the first ultrasonic horn and the second ultrasonic horn, the entire outer peripheral edge of the hollow part is joined.
The method for manufacturing a hollow part according to claim 2 or 3. The longitudinal dimension of the hollow part is 500 mm or more,
The manufacturing method of the hollow components of any one of Claim 2 to 4.

Images