JP2019141887A - Caulking deformation amount setting method and manufacturing method of caulking coupling structure - Google Patents

Abstract

To provide a caulking deformation amount setting method which can further properly set a caulking amount for caulking a caulking part, and a manufacturing method of a caulking coupling structure.SOLUTION: A caulking deformation amount setting method sets a caulking deformation amount D1 of a caulking part 13 for coupling superimposed terminal plates 7 and a band-shaped heat generation member 3. The method includes a simulation caulking process and an evaluation process. In the simulation caulking process, a caulking part sample 13S to which a superimposed terminal plate sample 7s, a band-shaped heat generation member sample 3s and a dummy member sample 8s are attached is plastically deformed by a prescribed simulation caulking deformation amount D2. In the evaluation process, the simulation caulking deformation amount D2 when a surface scratch 41 which does not substantially cause a hang at an acute member 43 even if the acute member 43 is made to pass therethrough is formed at the band-shaped heat generation member sample 3S is set as the caulking deformation amount D1.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a caulking deformation amount setting method and a caulking joint structure manufacturing method.

  For example, a mica heater has a configuration in which a heating wire is wound around a plate-shaped core formed using mica (mica).

  The heating wire is electrically connected to a power source through, for example, a screw member and an electrode. As such a connection structure, the structure which attaches an electrode to the screw member in which the heating wire was crimped can be illustrated. The screw member includes, for example, a heating wire formed at one end of the screw member, a flat terminal plate, and a caulking portion that collectively sandwiches a mica plate that is an insulating member, and a screw shaft portion that extends from the caulking portion. Have. The caulking portion is plastically deformed by the caulking device in a state where the heating wire, the terminal plate, and the mica plate are overlapped with each other, so that the caulking portion sandwiches the heating wire, the terminal plate, and the mica plate. A plate-like electrode is fixed to the screw shaft portion.

  An example of the caulking device is a spin caulking device (see, for example, Patent Document 1). The spin caulking device described in Patent Document 1 includes a main shaft and a processing pin provided below the main shaft. The processing pin is directed obliquely with respect to the rotation axis of the main shaft. The tip end portion of the processing pin is displaced toward the caulking portion side while rotating around the rotation axis of the main shaft in a state of being applied to the caulking portion before being plastically deformed. Thereby, a processing pin crushes a caulking part, and as a result, a caulking part pinches | interposes a heating wire, a terminal board, and a mica plate. In Patent Document 1, the current waveform of the electric motor that rotates the spindle and the machining pin is referred to in determining whether or not the squeezing amount of the caulking portion is appropriate.

Japanese Patent Laying-Open No. 2015-181331

  The above-described appropriate crushing amount of the caulking portion, that is, the appropriate caulking deformation amount has conventionally been set based on the experience of the worker performing the caulking work. For this reason, the amount of caulking varies from worker to worker. Such a variation leads to a variation in the bonding strength between the caulking portion and the heating wire.

  On the other hand, according to the caulking state determination method described in Patent Document 1, the current waveform of the electric motor that rotates the main shaft of the spin caulking device is used as a determination criterion. However, in such a configuration, a result of not actually directly inspecting the caulking portion, which is a current waveform of the electric motor, is used as a criterion. For this reason, there is a possibility that the caulking state cannot be accurately determined.

  A similar problem exists not only in the mica heater but also in an apparatus having a configuration in which a plurality of members are coupled by caulking.

  In view of the above circumstances, an object of the present invention is to provide a caulking deformation amount setting method and a caulking coupling structure manufacturing method capable of more appropriately setting the caulking amount.

  (1) In order to solve the above-described problem, a caulking deformation amount setting method according to an aspect of the present invention sets a caulking deformation amount of a caulking portion that couples a plurality of caulking members superimposed on each other by caulking. A caulking deformation amount setting method for preparing a plurality of caulking member samples as a plurality of caulking member samples and a caulking portion sample as a sample of the caulking portion, and being superimposed on each other A simulated caulking step of simulating the caulking process by attaching a plurality of the caulking member samples to the caulking portion sample before being caulked and deformed, and then plastically deforming the caulking portion sample with a predetermined plastic deformation amount. And an evaluation step for evaluating the result of the simulation caulking step, wherein the predetermined sharp member is The predetermined plastic deformation amount when the surface flaw that does not substantially cause the sharp member to be caught even if it passes is formed on the caulking member sample by the simulated caulking step is set as the caulking deformation amount. .

  According to this configuration, the simulated caulking process is performed in an environment very close to the actual caulking environment. In the evaluation step, the surface flaw of the caulking member sample as a result of actually caulking the samples is directly evaluated. With such an evaluation method, an appropriate amount of caulking deformation can be set more accurately. In addition, since an appropriate amount of caulking deformation is set based on a more objective index, it is not necessary to set a different amount of caulking deformation for each worker who performs caulking work. In addition, in the evaluation step, the amount of plastic deformation when a surface flaw that does not substantially cause the sharp member to be caught even if the sharp member passes is set as the caulking deformation amount. By such a unique evaluation method, it is possible to set a caulking deformation amount that is neither excessive nor excessive. Depending on the above, it is possible to realize a caulking deformation amount setting method that can more appropriately set the amount of caulking.

  (2) In the evaluation step, when it is evaluated that the predetermined plastic deformation amount is inappropriate as the caulking deformation amount, the preparation step, the simulated caulking step, and the evaluation step are repeated again, and n ( In some cases, n is a natural number equal to or greater than 2) and the predetermined plastic deformation amount in the simulated caulking process is reduced or increased as the variable n increases.

  According to this configuration, it is possible to set an appropriate amount of caulking deformation by a simple method of gradually decreasing or increasing the amount of plastic deformation of the caulking portion in the n-th and subsequent simulation caulking steps.

  (3) The plurality of the caulking member samples include a plate-like member sample, and a belt-like member sample formed in a width narrower than the width of the plate-like member sample and overlaid on the plate-like member sample, In the simulated caulking step, the caulking portion sample may be caulked and deformed so as to sandwich the plate-like member sample and the belt-like member sample.

  According to this configuration, it is possible to set an appropriate amount of caulking deformation in the configuration in which the wide plate-like member and the narrow strip-like member are caulked on the caulking portion in a state where they are overlapped with each other.

  (4) The plate-like member sample includes a through-hole portion, and the strip-like member sample extends from the front surface to the back surface of the plate-like member sample through the through-hole portion, and around the through-hole portion. Caulking by the caulking member sample, and the surface flaw may be a flaw formed in a portion of the band-like member sample that overlaps the plate-like member sample at a peripheral edge of the through-hole portion.

  According to this configuration, in the configuration in which the belt-like member at the location that passes through the through-hole portion is fixed to the caulking portion, it is possible to set an appropriate caulking deformation amount based on the location where scratches are likely to occur due to the coupling with the caulking portion.

  (5) The strip member sample may include a resistance heating member sample, and the plate member sample may include a terminal plate sample that receives the resistance heating member sample.

  According to this configuration, it is possible to set an appropriate amount of caulking deformation of the caulking portion in the heater using the belt-shaped member as a heating wire.

  (6) The caulking part sample includes a caulking base part that receives the plurality of caulking member samples, and a plastic deformation part that caulks the caulking member samples in cooperation with the caulking base part by plastic deformation. May be included.

  According to this configuration, the portion that is caulked and deformed in the caulking portion is only one of the caulking base portion and the plastic deformation portion. For this reason, the reproducibility of the mode of plastic deformation in the caulking portion can be further enhanced in each caulking step of the large number of caulking joint structures. As a result, it is possible to more reliably suppress the occurrence of individual differences in the coupling state between the caulking portion and the caulking member.

  (7) In the simulated caulking step, the plastic deformation portion is plastically deformed toward the caulking base portion from a state of being formed in a columnar shape, so that a plurality of the caulking base portions cooperate with each other. In some cases, the caulking member sample may be caulked so as to sandwich the caulking member sample.

  According to this configuration, the caulking member and the caulking portion are coupled by plastically deforming the plastic deformation portion formed in the columnar shape. An appropriate amount of caulking deformation in such a configuration can be set.

  (8) In the simulated caulking step, the caulking punch pressurizes the caulking portion sample along a predetermined circumferential direction, and plastically deforms the caulking portion sample by moving the caulking punch in a predetermined linear movement direction. Spin caulking is performed, and the predetermined plastic deformation amount may be a movement amount of the caulking punch in the linear movement direction after the caulking punch starts to press the caulking portion sample.

  According to this configuration, the amount of caulking deformation can be expressed by the amount of movement of the caulking punch in the linear movement direction. That is, the amount of caulking deformation can be set as an easily measured value.

  (9) In order to solve the above-described problem, a method for manufacturing a caulking joint structure according to an aspect of the present invention includes a caulking process in which a plurality of caulking members overlapped with each other are joined by caulking processing of caulking portions. The caulking deformation amount set by the caulking deformation amount setting method is set as the caulking deformation amount of the caulking portion in the caulking process.

  According to this configuration, it is possible to realize a caulking joint structure including a caulking portion that is plastically deformed with an appropriate amount of caulking deformation, which is neither excessive nor excessive.

  According to the present invention, the amount of caulking can be set more appropriately.

It is a typical top view of the mica heater as a heating device which has the attachment structure of a plurality of members concerning one embodiment of the present invention. It is a partial sectional view of an attachment structure and shows the state which looked at the attachment structure from the side. It is a perspective view which shows the state by which a part of attachment structure was assembled, and has shown the state seen from the back surface side of the mica plate. It is a figure which shows the state which looked at the attachment structure from the back surface side of the mica plate. It is a schematic diagram of the principal part of a spin crimping machine and a mica heater. It is a figure for demonstrating the assembly of an attachment structure. It is a typical side view of the sample structure before performing the simulated caulking, and a part thereof is shown in cross section. It is a flowchart for demonstrating an example of the flow of a setting of a crimping deformation amount. It is a figure for demonstrating evaluation of a surface flaw, FIG. 9 (A) is a top view which shows the state in which the surface flaw has not arisen, FIG.9 (B) shows the state whose surface flaw is a pass level. FIG. 9C is a cross-sectional view taken along the line IXC-IXC in FIG. 9B and shows a state in which the surface scratch is at an acceptable level, and FIG. FIG. 9E is a cross-sectional view taken along the line IXE-IXE in FIG. 9D, showing that the surface scratch is too deep and not satisfactory. It shows a state at a pass level. It is a figure which shows a modification.

  Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.

  FIG. 1 is a schematic plan view of a mica heater 1 as a heating device having a multi-member mounting structure 4 according to an embodiment of the present invention. Hereinafter, the attachment structure 4 of a plurality of members is also simply referred to as “attachment structure 4”. FIG. 2 is a partial cross-sectional view of the mounting structure 4 and shows the mounting structure 4 as viewed from the side. FIG. 3 is a perspective view showing a state in which a part of the attachment structure 4 is assembled, and shows a state seen from the back surface 2b side of the mica plate 2. FIG. FIG. 4 is a view showing a state in which the mounting structure 4 is viewed from the front surface 2a side of the mica plate 2.

  1 to 4, the mica heater 1 is used to apply heat around the mica heater 1. The mica heater 1 is installed in, for example, a heat treatment apparatus for manufacturing a semiconductor, a heat treatment apparatus for manufacturing a flat panel display, or the like. In the present embodiment, an example in which the mica heater 1 is used in a heat treatment apparatus will be described. Examples of the heat treatment performed in this heat treatment apparatus include a CVD (Chemical Vapor Deposition) process, a diffusion process, an annealing process, a solar cell manufacturing process, a semiconductor device manufacturing process, and the like. The mica heater 1 may be provided in a heat treatment apparatus for performing heat treatment on metal parts such as gears and power transmission shafts. The mica heater 1 is disposed around the heat treatment chamber of the heat treatment apparatus. In addition, the use of the mica heater 1 may be other than the use described above, and the specific use is not limited.

  In this embodiment, the mica heater 1 is formed in a rectangular shape as a whole, and a mica plate 2 around which a belt-like heating member 3 as a resistance heating member is wound is sandwiched between another pair of mica plates (not shown). have. Although a heater using mica will be described as an embodiment of the present invention, the present invention may be applied to a heater using an insulating member other than mica.

  The mica heater 1 is electrically and mechanically connected to the pair of electrode portions 5 and 5. The pair of electrode portions 5 and 5 are electrically connected to a power source (not shown) via corresponding covered electric wires 6 and 6.

  Each electrode part 5 is a metal member formed using a crimp terminal or the like. Each electrode portion 5 includes a flat plate portion 5a, and a through hole portion 5b is formed in the flat plate portion 5a. The electrode parts 5 and 5 are also mechanically and electrically connected to the electric wire at one end of the corresponding covered electric wires 6 and 6 by caulking or the like. The wires of each covered wire 6 are electrically connected to a power source (not shown). With the above configuration, the power from the power source is supplied to the mica heater 1.

  The mica heater 1 includes a mica plate 2, a belt-like heat generating member 3, and attachment structures 4 and 4 for attaching the belt-like heat generating member 3 to the electrode portion 5.

  The mica plate 2 is a flat plate member mainly composed of mica (mica), and is provided as a frame portion in the mica heater 1. The mica plate 2 is an example of the “insulating member” of the present invention, and has a property of not conducting electricity. In the present embodiment, the mica plate 2 is formed in a rectangular plate shape having a thickness of about several mm. One end and the other end in the longitudinal direction of the mica plate 2 each include a terminal mounting portion 2c. Each terminal attachment portion 2c is a portion where the attachment structure 4 is provided. Each terminal mounting portion 2c is formed with a through-hole portion 2d. The through hole 2d is formed in a circular shape in the present embodiment. The shape of the through hole 2d may be a shape other than a circle. A band-shaped heating member 3 is wound around the mica plate 2.

  The belt-like heat generating member 3 is a thermoelectric conversion member that converts electric power supplied from a power source through the electrode portions 5 and 5 into heat. Heat generated by the belt-like heat generating member 3 becomes heat generated by the mica heater 1. The belt-like heat generating member 3 is an elongated belt-like plate member, and is configured to generate heat at a predetermined temperature when given power is applied. For example, the belt-like heat generating member 3 has a configuration in which impurities serving as resistance are mixed in metal. The belt-like heat generating member 3 has flexibility. The thickness of the belt-like heating member 3 is, for example, about 1 mm. The width of the belt-like heat generating member 3 is, for example, about several mm, and is formed to be narrower than the width of the terminal plate 7 described later. The belt-like heat generating member 3 is spirally wound around the outer surface of the mica plate 2 and extends from one terminal mounting portion 2c to the other terminal mounting portion 2c. The number of turns by which the belt-like heat generating member 3 is wound around the mica plate 2 is appropriately set according to the shape and performance of the heat treatment apparatus in which the mica plate 2 is installed.

  One end portion 3 a of the belt-like heat generating member 3 is connected to one electrode portion 5 through one attachment structure 4. Similarly, the other end portion 3 b of the belt-like heat generating member 3 is connected to the other electrode portion 5 via the other mounting structure 4. In the following, since one mounting structure 4 and the other mounting structure 4 have the same configuration, one mounting structure 4 provided on the one end 3a side will be described, and the other mounting structure 4 will be described. Detailed description is omitted. The one attachment structure 4 is provided for attaching the one end 3 a of the belt-like heat generating member 3 to the electrode part 5 as described above.

  The attachment structure 4 includes a terminal attachment portion 2c of the mica plate 2, a terminal plate 7 attached to the terminal attachment portion 2c, one end portion 3a along the terminal plate 7 of the belt-like heating member 3, and the belt-like heating member 3 A dummy member 8 disposed adjacent to one end portion 3a of the first end portion 3a and extending along the terminal plate 7, a pair of washers 21 and 22 sandwiching the one end portion 3a and the dummy member 8, one end portion 3a of the belt-like heating member 3, and a dummy member 8, a terminal member 10 for caulking and fixing the electrode part 5 and the washers 21 and 22, the electrode part 5 and a pair of nut members 11 and 12 screwed to the terminal member 10.

  The electrode portion 5 is an example of the “fastened member” in the present invention. The terminal plate 7, the one end 3a of the belt-like heat generating member 3, the dummy member 8, and the washers 21 and 22 are examples of the “caulking member” of the present invention. The terminal board 7 is an example of the “plate member” in the present invention. The belt-like heating member 3 is an example of “one belt-like member” and “resistance heating member” in the present invention, and the dummy member 8 is an example of “another belt-like member” in the present invention. The nut member 11 is an example of the “fastening member” in the present invention.

  The terminal plate 7 is a stay member for attaching the terminal member 10 to the terminal attachment portion 2 c of the mica plate 2. In this embodiment, the terminal plate 7 is formed using a conductive member such as an aluminum alloy plate. In this embodiment, the terminal board 7 is formed in a rectangular flat plate shape, and is formed in an elongated rectangle. The horizontal width and the vertical width of the terminal board 7 are both set wider than the width of the belt-like heat generating member 3 (the length in the direction perpendicular to the longitudinal direction of the belt-like heat generating member 3) and the width of the dummy member 8. The thickness of the terminal plate 7 may be smaller or larger than the thickness of the terminal attachment portion 2c of the mica plate 2.

  The terminal board 7 runs along the surface 2a of the mica plate 2, for example. The terminal plate 7 covers the through hole 2d of the terminal mounting portion 2c of the mica plate 2. A through hole portion 7a is formed in a portion of the terminal plate 7 that covers the through hole portion 2d of the terminal mounting portion 2c. The through hole portion 7a of the terminal plate 7 is a portion through which the terminal member 10 penetrates, and is a portion through which the one end portion 3a of the belt-like heat generating member 3 and the dummy member 8 pass. The size of the through hole portion 7a of the terminal plate 7 is smaller than the size of the through hole portion 2d of the mica plate 2, and the through hole portion of the mica plate 2 in plan view (as viewed from the axial direction S1 of the terminal member 10). The through-hole part 7a of the terminal board 7 is arrange | positioned in the area | region in which 2d is formed. Fixed piece portions 7 b are formed at, for example, four corners of the terminal board 7.

  The fixed piece 7 b is a piece provided to fix the terminal plate 7 to the terminal mounting portion 2 c of the mica plate 2. Each fixed piece 7b extends from a portion of the terminal board 7 along the front surface 2a of the mica plate 2 to the back surface 2b side of the mica plate 2 and is formed at a corresponding portion of the mica plate 2 2e. And the location along the surface 2a of the mica plate 2 in the terminal plate 7 and the fixed piece portion 7b cooperate to sandwich the terminal mounting portion 2c of the mica plate 2.

  The terminal plate 7 is fixed to the mica plate 2 as an insulating member by the clamping structure described above. Further, as shown in FIG. 4, when the terminal plate 7 is viewed in plan, a plurality of fixing points (fixed) arranged on the virtual straight lines A <b> 1 and A <b> 2 passing through the central axis L <b> 1 of the terminal member 10 with the terminal member 10 interposed therebetween. The terminal plate 7 is fixed to the mica plate 2 at a portion where the piece 7b is provided. In the present embodiment, the virtual straight lines A1 and A2 intersect each other in plan view. Two fixed piece portions 7b are arranged on one virtual straight line A1, and two fixed piece portions 7b are arranged on the other virtual straight line A2. In this way, the fixed piece 7b is fixed at four locations around the central axis L1.

  1 to 4 again, the peripheral edge portion of the through hole portion 7a of the terminal plate 7 is overlapped with the one end portion 3a of the belt-like heat generating member 3 and the dummy member 8.

  The dummy member 8 is a member simulating the one end 3 a of the belt-like heat generating member 3. The dummy member 8 is formed of the same material as the material of the belt-like heat generating member 3 or an insulating material, and has flexibility. The dummy member 8 is a member that is not intended to be energized (heated), and is formed separately from the belt-shaped heat generating member 3 and separated from the belt-shaped heat generating member 3. The thickness and width of the dummy member 8 are set to be the same as those of the belt-like heat generating member 3. The length of the dummy member 8 is, for example, a value less than about 100 mm, and is about the same as the length of the one end portion 3 a of the belt-like heat generating member 3. Note that the width of the dummy member 8 may be larger or smaller than the width of the belt-like heat generating member 3.

  The dummy member 8 and the belt-like heat generating member 3 extend from the front surface 7c to the back surface 7d of the terminal plate 7 through the through hole portion 7a of the terminal plate 7, and the terminal member 10 is caulked as described later around the through hole portion 7a. It is caulked by part 13. In the present embodiment, in the circumferential direction of the through-hole portion 7a of the terminal plate 7 (that is, the circumferential direction C1 of the terminal member 10), the one end portion 3a of the belt-like heat generating member 3 and the dummy member 8 are arranged apart from each other. . The one end portion 3a of the belt-like heat generating member 3 and the dummy member 8 are arranged at a pitch of 180 degrees in the circumferential direction C1, for example. Thus, the one end part 3a and the dummy member 8 of the strip | belt-shaped heat generating member 3 as a some strip | belt-shaped member are arrange | positioned in the multiple places of the circumferential direction of the through-hole part 7a. Note that a plurality of dummy members 8 may be provided, and the one end portion 3a of the belt-like heat generating member 3 and the plurality of dummy members 8 may be spaced apart from each other in the circumferential direction C1 at an equal pitch or an unequal pitch in the circumferential direction C1.

  In the present embodiment, the dummy member 8 runs along the front surface 7 c, the back surface 7 d of the terminal board 7, and the back surface 2 b of the mica plate 2. Similarly, one end portion 3 a of the belt-like heat generating member 3 extends along the front surface 7 c, the back surface 7 d of the terminal plate 7, and the back surface 2 b of the mica plate 2. The one end 3 a and the dummy member 8 of the belt-like heat generating member 3 are electrically and mechanically connected to the electrode portion 5 through the terminal member 10.

  The terminal member 10 is caulked with the one end portion 3a of the belt-like heat generating member 3 and the dummy member 8, and is connected with the electrode portion 5 by a fastening mechanism by screw fastening. The terminal member 10 is a screw shaft-like member, and penetrates the through hole portion 2 d of the terminal mounting portion 2 c of the mica plate 2 and the through hole portion 7 a of the terminal plate 7. In the present embodiment, the terminal member 10 is an integrally molded product formed using a metal member. The terminal member 10 may be formed by combining a plurality of members. In the present embodiment, the terminal member 10 sandwiches the terminal plate 7, but is disposed away from the mica plate 2. That is, the caulking portion 13 described later of the terminal member 10 is disposed away from the mica plate 2 as an insulating member. As viewed in the axial direction S1 (which is also the axial direction of the through hole portion 2d), the entire terminal member 10 including the caulking portion 13 described later is disposed in the through hole portion 2d of the mica plate 2.

  The terminal member 10 includes a caulking portion 13, a screw shaft portion 14 that is integrally formed with the caulking portion 13 and to which the electrode portion 5 is attached, and a tool attachment portion to which an attachment tool 100 that receives torque acting on the screw shaft portion 14 is attached. 15.

  The caulking portion 13 is provided in order to couple the one end portion 3a of the belt-like heat generating member 3 and the dummy members 8 as caulking members by caulking. The caulking portion 13 is formed at the proximal end portion of the terminal member 10. In the present embodiment, the caulking portion 13 is formed over the entire area in the circumferential direction C1 of the terminal member 10, but may be formed in a part of the circumferential direction C1.

  The caulking portion 13 includes a main body portion 16, a base portion 17, and a plastic deformation portion 18.

  The main body portion 16 is a shaft portion of the caulking portion 13 and is a shaft portion passing on the central axis L <b> 1 of the terminal member 10.

  The base portion 17 is provided to receive a portion of the one end portion 3 a of the belt-like heat generating member 3 and the dummy member 8 that is disposed on the back surface 7 d side of the terminal board 7. The base portion 17 is a portion formed in an annular shape, and has an annular surface extending in a direction orthogonal to the axial direction S1 of the terminal member 10. The base portion 17 receives the one end portion 3 a of the belt-like heat generating member 3 and the dummy member 8 through the washer 22. The washer 22 is formed using a conductive member such as metal. The washer 22 is disposed, for example, in the through hole portion 2d of the mica plate 2 and faces the peripheral edge portion of the through hole portion 7a of the terminal plate 7 in the axial direction S1. A plastic deformation portion 18 is disposed so as to face the base portion 17 in the axial direction S1.

  The plastic deformation portion 18 is provided to receive a portion of the one end portion 3a of the belt-like heat generating member 3 and the dummy member 8 that is disposed on the surface 7c side of the terminal plate 7. The plastic deformation portion 18 is disposed at the proximal end portion of the terminal member 10. The plastic deformation portion 18 is a portion formed in an annular shape, and is an annular portion that extends in the radial direction R <b> 1 of the terminal member 10. The plastic deformation portion 18 is formed in a shape extending in the radial direction R1 by being plastically deformed by a caulking punch 33 described later. The plastic deformation portion 18 has a shape before being plastically deformed by the caulking punch 33, for example, a cylindrical shape (columnar shape). A recess 18 a is formed in the plastic deformation portion 18 on the proximal end side of the terminal member 10.

  The plastic deformation portion 18 receives the one end portion 3 a of the belt-like heat generating member 3 and the dummy member 8 via the washer 21. The washer 21 is formed in the same shape as the washer 22 using the same material as the washer 22. The washer 21 faces the peripheral edge of the through hole 7a of the terminal plate 7 in the axial direction S1. With the above configuration, the washer 21, the one end 3a and the dummy member 8, the terminal plate 7, and the washer 22 between the base portion 17 and the plastic deformation portion 18 are firmly formed by caulking. It is sandwiched between.

  That is, the caulking portion 13 is caulked and deformed so as to sandwich the terminal plate 7, the one end portion 3 a of the belt-like heating member 3, the dummy member 8, and the washers 21 and 22. A tool mounting portion 15 is disposed adjacent to the caulking portion 13 having the above-described configuration.

  The tool attachment portion 15 is a portion with which an attachment tool 100 such as a spanner or a wrench is engaged. In the present embodiment, the tool attachment portion 15 is continuous with the main body portion 16 and the base portion 17 of the caulking portion 13, and one end portion of the tool attachment portion 15 is formed integrally with the base portion 17. Note that the tool attachment portion 15 and the caulking portion 13 may be arranged apart from each other in the axial direction S1. The tool attachment portion 15 is formed in a polygonal shape (in this embodiment, a hexagonal shape) in cross-section perpendicular to the axial direction S1. The length of the tool attachment portion 15 in the axial direction S <b> 1 is preferably equal to or greater than the thickness of the portion of the attachment tool 100 that engages with the tool attachment portion 15. In the present embodiment, the thickness of the tool attachment portion 15 is set larger than the thickness of the caulking portion 13 (the length in the axial direction S1).

  The outer peripheral portion of the tool attachment portion 15 has a two-surface width portion 15a. The two-surface width portion 15a is formed side by side with the screw shaft portion 14 in the axial direction S1. The two-sided width portion 15a has a pair of parallel planes extending along the axial direction S1. In this embodiment, since the tool attachment portion 15 is formed in a hexagonal cross section, three sets of two-surface width portions 15a are formed. Note that it is sufficient that at least one pair of the two-surface width portions 15a is provided, and the cross-sectional shape of the tool attachment portion 15 may be a polygonal shape other than a hexagonal shape or a shape including a curve. The mounting tool 100 receives torque (load around the circumferential direction C1) acting on the terminal member 10 by engaging with at least one of the three sets of two-surface width portions 15a. A screw shaft portion 14 is provided adjacent to the tool mounting portion 15 having the above-described configuration in the axial direction S1.

  As described above, the screw shaft portion 14 is a portion to which the electrode portion 5 is attached. A male screw is formed on the outer peripheral portion of the screw shaft portion 14. The outer diameter of the screw shaft portion 14 is set to be less than the outer diameter (maximum outer diameter) of the tool mounting portion 15. A washer 23, a flat plate-like part 5 a of the electrode part 5, and a washer 24 are passed through the screw shaft part 14. Washers 23 and 24 are formed using a conductive member such as metal. Washers 23 and 24 sandwich the flat plate-like portion 5 a of the electrode portion 5. A pair of nut members 11 and 12 are disposed adjacent to the washer 24 disposed on the distal end side of the screw shaft portion 14 of the washers 23 and 24.

  The nut members 11 and 12 are provided in order to fasten the electrode portion 5 as a member to be fastened to the terminal member 10 by screwing to the screw shaft portion 14. The nut members 11 and 12 are, for example, hexagon nuts. When one nut member 11 is screwed to the screw shaft portion 14, the nut member 11 and the tool mounting portion 15 cooperate to fasten the electrode portion 5 to the terminal member 10. The other nut member 12 is fastened to the one nut member 11 with a predetermined torque, thereby preventing the one nut member 11 from loosening. The nut member 12 may be omitted.

  The above is the schematic configuration of the mica heater 1.

  Next, with reference to FIG. 5, the structure of the spin caulking machine 30 for caulking the caulking part 13 will be described. FIG. 5 is a schematic diagram of the main parts of the spin caulking machine 30 and the mica heater 1.

  In the present embodiment, an example in which spin caulking is employed for caulking of the caulking portion 13 will be described as an example, but this need not be the case. The caulking process of the caulking part 13 may be performed by a caulking process other than spin caulking, such as caulking process using a chisel.

  The spin crimping machine 30 includes a drive motor 31 that is an electric motor, a main shaft 32 that is arranged in a vertical posture and is rotationally driven by the drive motor 31, a caulking punch 33 that is fixed to the main shaft 32 as a caulking tool, and a drive motor 31. , A moving mechanism 34 for linearly moving the main shaft 32 and the caulking punch 33 in a vertical direction, and a control unit 35 for controlling the drive motor 31 and the moving mechanism 34.

  The moving mechanism 34 has, for example, a hydraulic mechanism or a ball screw mechanism, and supports the housing of the drive motor 31. With this configuration, a pressing force that pressurizes the end face 18 b of the plastic deformation portion 18 of the caulking portion 13 acts on the caulking punch 33 during caulking.

  The caulking punch 33 is attached to one end of the main shaft 32. The caulking punch 33 is formed in a pin shape having a central axis L3 that extends with an inclination with respect to the rotation axis L2 of the main shaft 32.

  The control unit 35 has a configuration for outputting a predetermined output signal based on a predetermined input signal, and can be formed using, for example, a safety programmable controller. The safe programmable controller refers to a publicly certified programmable controller having a safety function of SIL2 or SIL3 of JIS (Japanese Industrial Standard) C 0508-1. The control unit 35 may be formed using a computer including a CPU (Central Processing Unit), a RAM (Random Access Memory), and a ROM (Read Only Memory).

  FIG. 6 is a view for explaining assembly of the mounting structure 4. Referring to FIGS. 5 and 6, when assembling mounting structure 4 having the above configuration, an operator first fixes terminal plate 7 to terminal mounting portion 2 c of mica plate 2. Next, the worker passes the one end portion 3 a of the belt-like heat generating member 3 and the dummy member 8 through the through hole portion 7 a of the terminal plate 7. Thereafter, the worker sandwiches the one end portion 3 a of the belt-like heat generating member 3, the dummy member 8 and the terminal plate 7 with the washers 21 and 22. Next, the operator passes the plastic deformation portion 18 before the plastic deformation in the caulking portion 13 of the terminal member 10 through the through hole portions of the washers 21 and 22 and the through hole portion 7a of the terminal plate 7. Thereafter, the worker plastically deforms the plastic deformation portion 18 using the spin crimping machine 30, so that the washers 21 and 22, the one end portion 3 a of the belt-like heating member 3, the dummy member are formed on the plastic deformation portion 18 and the base portion 17. 8 and the terminal board 7 are clamped.

  Thereafter, as shown in FIG. 2, the worker passes the washer 23, the flat plate-like part 5 a of the electrode part 5, and the washer 24 through the screw shaft part 14. Next, the worker screw-couples the nut members 11 and 12 to the screw shaft portion 14 with the attachment tool 100 engaged with the tool attachment portion 15.

  Referring to FIGS. 5 and 6 again, the mica plate 2 is placed on the work table 36 during the spin caulking process by the spin caulking machine 30. Further, for example, the screw shaft portion 14 of the terminal member 10 is supported by the support member 37 or the like. In the spin caulking process, first, the rotation axis L <b> 2 of the main shaft 32 is arranged so as to overlap the center axis L <b> 1 of the terminal member 10. Then, when the drive motor 31 of the spin caulking machine 30 is driven, the main shaft 32 and the caulking punch 33 rotate around the rotation axis L2. In this state, by driving the moving mechanism 34, the caulking punch 33 is linearly displaced toward the caulking portion 13 side along the axial direction S1. By this operation, the outer peripheral portion of the front end of the caulking punch 33 pressurizes the end surface 18b of the cylindrical plastic deformation portion 18 before being plastically deformed.

  Then, the tip of the caulking punch 33 rotates around the rotation axis L2 while pressurizing the plastic deformation portion 18, so that the plastic deformation portion 18 expands outward in the radial direction R and is plastic toward the base portion 17 side. Deform. The amount of linear deformation of the caulking punch 33 toward the end surface 18b after the caulking punch 33 comes into contact with the end surface 18b of the plastic deformation portion 18 during caulking is the deformation amount D1. It can be said that the caulking deformation amount D1 is an amount of plastic deformation of the base end face 18b of the plastic deformation portion 18 along the axial direction S1. By the above-described operation of the spin caulking machine 30, the plastic deformation portion 18 expands in the radial direction R1 and is pressed against the washer 21, and the caulking process is completed. The plastic deformation amount of the plastic deformation portion 18 by the spin caulking machine 30 at this time, that is, the caulking deformation amount D1 is set in advance.

  Next, a method for setting the caulking deformation amount D1 will be described.

  More specifically, a caulking portion that joins the terminal plate 7 as a plurality of caulking members, the one end portion 3a of the belt-like heating member 3, the dummy member 8, and the washers 21 and 22 to each other by caulking. A method for setting the caulking deformation amount D1 of 13 will be described.

  In the present embodiment, the caulking deformation amount D1 is set based on the result of simulating (simulating) caulking using a configuration simulating the configuration related to the caulking portion 13 in the mounting structure 4.

  FIG. 7 is a schematic side view of the mounting structure sample 4S before simulated caulking, and a part thereof is shown in cross section. 6 and 7, the mounting structure sample 4S is a structure used for setting the caulking deformation amount D1, and has a configuration simulating the configuration related to the caulking portion 13 of the mounting structure 4. ing. In other words, the mounting structure sample 4 </ b> S has the same configuration as a part of the mounting structure 4.

  The mounting structure sample 4S includes a mica plate sample 2S, a terminal plate sample 7S, a belt-like heating member sample 3S, a dummy member sample 8S, washer samples 21S and 22S, and a terminal member sample 10S.

  The mica plate sample 2S, the terminal plate sample 7S, the belt-like heating member sample 3S, the dummy member sample 8S, the washer samples 21S and 22S, and the terminal member sample 10S are respectively corresponding to the mica plate 2 and the terminal plate 7 Further, since it has the same configuration as the one end portion 3a of the belt-like heat generating member 3, the dummy member 8, the washers 21, 22 and the terminal member 10, detailed description thereof will be omitted.

  The terminal plate sample 7S, the belt-like heating member sample 3S, the dummy member sample 8S, and the washer samples 21S and 22S are examples of the “caulking member sample as a sample of plural caulking members” of the present invention. The terminal plate sample 7S is an example of the “plate member sample” in the present invention. The belt-shaped heat generating member sample 3S and the dummy member sample 8S are examples of the “band-shaped member sample” of the present invention, and the belt-shaped heat generating member sample 3S is also an example of the “resistance heat generating member sample”. The caulking portion sample 13S of the terminal member sample 10S is an example of the “caulking portion sample” in the present invention.

  The belt-like heat generating member sample 3S and the dummy member sample 8S extend from the front surface 7c to the rear surface 7d of the terminal plate sample 7S through the through hole portion 7a of the terminal plate sample 7S, and are caulked portion samples 13S around the through hole portion 7a. It is caulked by.

  Further, the caulking portion sample 13S includes a base portion 17 and a plastic deformation portion 18. The base portion 17 receives the terminal plate sample 7S, the belt-like heat generating member sample 3S, the dummy member sample 8S, and the washer samples 21S and 22S. The plastic deformation portion 18 caulks the terminal plate sample 7S, the belt-like heating member sample 3S, the dummy member sample 8S, and the washer samples 21S and 22S in cooperation with the base portion 17 by plastic deformation.

  Next, an example of a setting flow of the caulking deformation amount D1 using the mounting structure sample 4S will be described.

  FIG. 8 is a flowchart for explaining an example of a flow of setting the caulking deformation amount D1. In addition, below, when it demonstrates with reference to a flowchart, it demonstrates, referring also to figures other than a flowchart suitably. Each step in the present embodiment is an example of the “process” in the present invention.

  Referring to FIG. 8, when setting the caulking deformation amount D1, first, the worker prepares a mounting structure sample 4S shown in FIG. 7 (step S1). In the caulking sample structure 4S, the terminal plate sample 7S, the belt-like heating member sample 3S, the dummy member sample 8S, and the washer samples 21S and 22S, which are overlapped with each other, are caulked portion samples of the terminal member sample 10S before being caulked and deformed. It is attached to 13S.

  Next, the control unit 35 of the worker or the spin caulking machine 30 sets a simulated caulking deformation amount D2 (step S2). The simulated caulking deformation amount D2 is a predetermined plastic deformation amount that plastically deforms the plastic deformation portion 18 of the caulking portion sample 13S using the spin caulking machine 30. The simulated caulking deformation amount D2 is an amount by which the end surface 18b of the plastic deformation portion 18 is displaced along the axial direction of the terminal member sample 10S, and corresponds to the caulking deformation amount D1. The simulated caulking deformation amount D2 is also the amount of movement of the caulking punch 33 in the axial direction S1 after the caulking punch 33 starts to press the caulking portion sample 13S. The variable n when step S2 is first executed is n = 1.

  Next, simulated caulking is performed using the spin caulking machine 30 (step S3). In the simulation caulking, the plastic deformation portion 18 of the caulking portion sample 13S is plastically deformed with the simulated caulking deformation amount D2, thereby simulating the caulking processing of the plastic deformation portion 18 of the caulking portion 13.

  At the time of the simulation caulking, the position is adjusted so that the rotation axis L2 of the main shaft 32 overlaps the center axis L1S of the terminal member 10S. Then, when the drive motor 31 of the spin caulking machine 30 is driven, the main shaft 32 and the caulking punch 33 are rotated in the circumferential direction around the rotation axis L2. In this state, the caulking punch 33 is linearly displaced along the axial direction S <b> 1 toward the caulking portion sample 13 </ b> S by driving the moving mechanism 34. By this operation, the outer peripheral portion of the tip of the caulking punch 33 pressurizes the end face 18b of the plastic deformation portion 18 in the caulking portion sample 13S before being plastically deformed. The tip of the caulking punch 33 is plastically deformed toward the base portion 17 by rotating the plastic deformable portion 18 around the rotation axis L2 while applying pressure.

  That is, the plastic deformation portion 18 of the caulking portion sample 13S is plastically deformed toward the base portion 17 side from the state of being formed in a cylindrical shape (columnar shape), so that the terminal plate cooperates with the base portion 17. The sample 7S, the belt-like heat generating member sample 3S, the dummy member sample 8S, and the washer samples 21S and 22S are sandwiched. An amount of linear displacement of the caulking punch 33 toward the end surface 18b after the caulking punch 33 comes into contact with the end surface 18b at this time is a simulated caulking deformation amount D2. By this simulated caulking, the caulking portion sample 13S is caulked and deformed so as to sandwich the terminal plate sample 7S, the belt-like heating member sample 3S, the dummy member sample 8S, and the washer samples 21S and 22S.

  After the simulation caulking is completed, the worker evaluates the result of the simulation caulking performed in step S3 (step S4). Specifically, the worker disassembles the mounting structure sample 4S after spin caulking. Thereby, the terminal board sample 7S, the strip-like heat generating member sample 3S, the dummy member sample 8S, and the washer samples 21S and 22S are separated from each other. In the present embodiment, in the evaluation step, for example, the belt-like heat generating member sample 3S out of the belt-like heat generating member sample 3S and the dummy member sample 8S is an evaluation target. And an operator evaluates the surface crack 41 formed in the contact part 42 which overlaps with the terminal board sample 7S in the peripheral part of the through-hole part 7a of the terminal board sample 7S among the strip | belt-shaped heat generating member samples 3S. The surface scratch of the dummy member sample 8S may be evaluated by the same method as the surface scratch 41.

  FIG. 9 is a diagram for explaining the evaluation of the surface scratch 41, FIG. 9A is a plan view showing a state in which the surface scratch 41 is not generated, and FIG. FIG. 9C is a cross-sectional view taken along the line IXC-IXC in FIG. 9B and shows a state in which the surface scratch 41 is at an acceptable level. FIG. 9D is a plan view showing a state where the surface scratch 41 is too deep and is at a reject level, and FIG. 9E is a cross-sectional view taken along line IXE-IXE in FIG. 9D. In this case, the surface scratch 41 is too deep and is at a reject level.

  As described above with reference to FIGS. 7 to 9E, the surface scratch 41 faces (contacts) the edge portion of the through-hole portion 7a of the terminal plate sample 7S, for example, of the strip-shaped heating member sample 3S. It is a crack which arises in contact part 42 which carries out. At the time of evaluation of the surface scratch 41, the belt-like heat generating member sample 3S is in a flattened expanded state.

  A predetermined sharp member 43 is used for the evaluation of the surface scratch 41. The sharp member 43 is, for example, a needle-like member having a sharp tip angle. If the sharp member 43 does not substantially get caught even if the sharp member 43 passes through the surface scratch 41 of the contact portion 42, the evaluation is OK. The simulated caulking deformation amount D2 when the evaluation is OK is set as the caulking deformation amount D1.

  More specifically, referring to FIG. 9B and FIG. 9C, when evaluating the surface scratch 41, the worker is bare-handed, for example, of the contact portion 42 in the surface of the belt-like heating member sample 3S. A sharp member 43 is applied to the periphery. Then, the worker moves the sharp member 43 at, for example, the longitudinal direction N1 of the belt-like heat generating member sample 3S at a constant speed, and the sharp member 43 passes the contact portion 42 while the sharp member 43 passes through the contact portion 42 ( Trace the surface scratch 41). When the feel of the operator's hand is not changed before and after passing through the surface scratch 41, the evaluation is OK.

  On the other hand, as shown in FIG. 9A, when the surface scratch 41 is not confirmed by the visual observation of the worker, the evaluation is judged as NG. Further, as shown in FIGS. 9D and 9E, the deep surface scratch 41 changes the feel of the operator's hand through the sharp member 43 before and after passing through the surface scratch 41, and the sharp member. The evaluation NG is also judged when 43 is caught.

  Note that the evaluation OK is not limited to the determination method described above. For example, referring to FIGS. 9B and 9C, the sharp member 43 may be connected to an ultrasonic transducer in order to use the sharp member 43 as a probe. At this time, whether or not the evaluation is OK based on the signal waveform of the reception signal of the ultrasonic transducer when the periphery of the contact portion 42 is traced along the longitudinal direction N1 on the surface of the belt-shaped heating member sample 3S with the sharp member 43. Such a determination may be made. For example, in the signal waveform when the presence of the surface flaw 41 is confirmed by the visual inspection of the worker and the surface flaw 41 and the periphery of the surface flaw 41 are traced by the sharpened member 43, the surface flaw 41 and the surface flaw are passed. If the change in signal intensity in the signal waveform is less than several percent (when the change is about the noise level) when passing other than 41, it is determined as evaluation OK.

  On the other hand, as shown in FIG. 9A, when the surface scratch 41 is not confirmed by the visual observation of the worker, the evaluation is judged as NG. Further, as shown in FIGS. 9D and 9E, when the surface scratches 41 are deep, when the surface scratch 41 passes through the sharp member 43 and when other than the surface scratches 41 pass in the above signal waveform. If the change in signal intensity is larger than several percent, the evaluation is judged as NG.

  As a result, the evaluation in step S4 only requires that a surface scratch 41 that does not cause the sharp member 43 to be substantially caught even if the sharp member 43 passes is generated in the contact portion 42, and is a specific evaluation method. Is not limited to the above example. For example, an inspection apparatus including an imaging camera, a non-contact flaw detection apparatus using a laser beam, and a control unit that controls the camera and the non-contact flaw detection apparatus is prepared, and the evaluation ( Step S4) may be performed.

  Moreover, in this embodiment, although the surface damage 41 of the contact part 42 is made into evaluation object, it does not need to be this way. Of the terminal plate sample 7S, the belt-like heat generating member sample 3S, and the dummy member sample 8S, a portion where stress concentration is likely to occur due to excessive caulking may be set as an evaluation target.

  As a result of the evaluation in step S4, the surface scratch 41 is not generated as shown in FIG. 9A, or the surface scratch 41 is too deep as shown in FIGS. 9D and 9E. Thus, when the evaluation result of the surface scratch 41 is NG (NO in step S4), one value of the variable n is added (incremented) (step S5). That is, in the evaluation step (step S4), when it is evaluated that the simulated caulking deformation amount D2 is inappropriate as the caulking deformation amount D1, the process proceeds to step S5.

  Then, another mounting structure sample 4S is prepared again (step S1). Next, an n-th simulation caulking deformation amount D2 (n is a natural number of 2 or more in this case) is set (step S2). Thereafter, simulation caulking is performed (step S3). Thereafter, the result of the nth simulation caulking process is evaluated (step S4).

  Regarding the setting of the simulated caulking deformation amount D2 in step S2, the simulated caulking deformation amount D2 when n = 1 is set to a relatively small value, and the simulated caulking deformation amount D2 increases as the value of n increases. Good. In this case, until the evaluation OK in step S4, as shown in FIG. 9A, the surface scratch 41 is evaluated in a state where the surface scratch 41 does not occur (step S4).

  On the other hand, regarding the setting of the simulated caulking deformation amount D2 in step S2, the simulated caulking deformation amount D2 when n = 1 is set to a relatively large value, and the simulated caulking deformation amount D2 is decreased as the value of n increases. Also good. In this case, until the evaluation OK is determined in step S4, as shown in FIG. 9D and FIG. 9E, the surface scratch 41 is evaluated in a deep state (step S41). S4).

  Note that the simulated caulking deformation amount D2 may be increased as the value of the variable n increases, and after n exceeds a predetermined value, the simulated caulking deformation amount D2 may be decreased as the value of the variable n increases. . Further, as the value of the variable n increases, the simulated caulking deformation amount D2 may be decreased, and after n exceeds a predetermined value, the simulated caulking deformation amount D2 may be increased as the value of the variable n increases. .

  Then, as shown in FIGS. 9B and 9C, the simulated caulking deformation amount D2 when the surface flaw 41 that results in the evaluation OK occurs (YES in step S4) is set as the caulking deformation amount D1. (Step S5).

  As described above, according to the present embodiment, the terminal member 10 has the tool attachment portion 15 for suppressing the torque from acting on the caulking portion 13. According to this configuration, the worker attaches the nut member 11 to the screw shaft portion 14 of the terminal member 10, and when the electrode portion 5 is fastened to the terminal member 10 using the nut member 11, the tool attachment portion of the terminal member 10 is used. The attachment tool 100 can be attached to 15. Thereby, the torque that acts on the screw shaft portion 14 from the nut member 11 is received by the attachment tool 100 via the tool attachment portion 15, and does not need to act on the caulking portion 13 of the terminal member 10. Therefore, the above torque does not act between the terminal plate 7, the one end portion 3 a of the belt-like heating member 3, the dummy member 8 and the washers 21 and 22, and the caulking portion 13. That is, it is possible to suppress a change in the coupling state of the caulking portion 13 with the terminal plate 7 caulked to the caulking portion 13, the one end portion 3 a of the belt-like heat generating member 3, the dummy member 8 and the washers 21 and 22. Further, it is possible to reliably prevent unnecessary torque from the screw shaft portion 14 from acting between the terminal plate 7, the one end portion 3 a of the belt-like heating member 3, the dummy member 8 and the washers 21 and 22, and the caulking portion 13. it can. As a result, when the electrode part 5 is fastened to the terminal member 10, it is possible to save labor for the operator to be careful not to apply excessive torque to the caulking part 13.

  Moreover, according to this embodiment, the tool attachment part 15 contains the two-surface width part 15a mutually parallel. According to this configuration, a highly versatile attachment tool 100 such as a spanner or a wrench can be attached to the tool attachment portion 15.

  Further, according to the present embodiment, the tool attachment portion 15 is configured to fasten the electrode portion 5 in cooperation with the nut member 11. According to this configuration, the tool attachment portion 15 can exhibit the function of fixing the electrode portion 5 in addition to the function of engaging with the attachment tool 100.

  Further, according to the present embodiment, the torque acting when attaching the nut member 11 to the screw shaft portion 14 is between the thin dummy member 8 and the thin belt-like heating member 3 used as a heating wire and the caulking portion 13. It can suppress acting. Further, the bonding force between the terminal plate 7, the belt-like heating member 3, the dummy member 8 and the washers 21 and 22, and the caulking portion 13 is further reduced due to the thickness reduction due to the deterioration of the mica plate 2. It can be reliably suppressed.

  Further, according to the present embodiment, the belt-like heat generating member 3 and the dummy member 8 extend from the front surface 7 c to the back surface 7 d of the terminal plate 7 through the through hole portion 7 a of the terminal plate 7, and the through hole portion of the terminal plate 7. It is caulked by caulking part 13 around 7a. According to this configuration, since a larger coupling area can be secured between the terminal plate 7 and the belt-like heat generating member 3 and the dummy member 8, the bonding force between the belt-like heat generating member 3 and the dummy member 8 and the terminal plate 7 can be further increased. .

  Moreover, according to this embodiment, the strip | belt-shaped heat generating member 3 and the dummy member 8 are arrange | positioned in the multiple places of the circumferential direction of the through-hole part 7a of the terminal board 7 as a whole. According to this configuration, the distribution of the load acting on the caulking portion 13 can be further leveled in the circumferential direction C1. As a result, the direction of the caulking portion 13 (terminal member 10) can be prevented from tilting with respect to the terminal plate 7. Further, the number of places where the caulking portion 13 is engaged with the belt-like heat generating member 3 and the dummy member 8 can be increased. Thereby, the coupling force between the caulking portion 13, the belt-like heat generating member 3 and the dummy member 8 can be further increased.

  Further, if the dummy member 8 is provided as in this embodiment, the belt-like heat generating member 3 for resistance heat generation needs to be engaged with the caulking portion 13 at a plurality of positions for the purpose of coupling with the caulking portion 13. There is no. As a result, the position of the caulking portion 13 coupled to the belt-shaped heat generating member 3 and the dummy member 8 can be made more stable, and the degree of freedom in setting the shape of the belt-shaped heat generating member 3 for resistance heat generation can be increased.

  Moreover, according to this embodiment, the metal terminal board 7 is being fixed to the mica plate 2 which is an insulating member. According to this configuration, the metal terminal plate 7 that is caulked to the caulking portion 13 together with the belt-like heat generating member 3 and the dummy member 8 is supported by the mica plate 2 that is an insulating member. And the dummy member 8 can be stabilized electrically.

  Further, according to the present embodiment, when the terminal plate 7 is viewed in plan, the terminal plate 7 is fixed to the mica plate 2 at a plurality of fixed positions (four positions in the present embodiment) arranged with the terminal member 10 interposed therebetween. Has been. According to this configuration, the terminal plate 7 can be coupled to the mica plate 2 that is an insulating member with higher strength. In particular, even when a torque acts on the terminal member 10 when attaching the nut member 11 to the screw shaft portion 14 of the terminal member 10, the terminal plate 7 receives this torque without rotating around the screw shaft portion 14. Can do.

  Further, according to the present embodiment, the caulking portion 13 is deformed by crimping the terminal plate 7, the belt-like heating member 3, and the dummy member 8 and not the mica plate 2 that is an insulating member. According to this configuration, the belt-like heat generating member 3 and the dummy member 8 do not have to be sandwiched between the caulking portion 13 and the mica plate 2. Thereby, it can prevent that the strip | belt-shaped heat generating member 3 and the dummy member 8 are damaged at the edge part of the through-hole part 2d of the mica plate 2.

  Further, according to the present embodiment, the caulking portion 13 and the mica plate 2 are spaced apart. For this reason, the connection state of the terminal plate 7, the belt-like heating member 3, the dummy member 8 and the washers 21 and 22, and the caulking portion 13 is not affected by the state of the mica plate 2. For this reason, even when the mica plate 2 is deteriorated by receiving high-temperature heat for a long period of time and the thickness of the mica plate 2 is reduced, the terminal plate 7, the belt-like heating member 3, the dummy member 8 and the like It can suppress more reliably that an influence arises in the combined state of the washers 21 and 22 and the caulking part 13. Therefore, it is possible to suppress a change in the coupling state of the caulking portion 13 and the terminal plate 7, the belt-like heat generating member 3, the dummy member 8, and the washers 21 and 22 that are caulked to the caulking portion 13.

  Further, according to the present embodiment, the caulking portion 13 is disposed in the through-hole portion 2d of the mica plate 2 when viewed in the axial direction S1. According to this configuration, the state where the caulking portion 13 and the mica plate 2 are separated from each other can be maintained with a more compact configuration.

  In addition, according to the present embodiment, the caulking deformation amount setting method for setting the caulking deformation amount D1 of the caulking portion 13 includes a preparation step (step S1) for preparing the mounting structure sample 4S and a simulated caulking step (step S3). And an evaluation step (step S4) for evaluating the result of the simulated caulking step. In the evaluation step (step S4), the amount of simulated caulking deformation when the surface flaw 41 is formed on the caulking portion sample 13S so that the sharp member 43 does not substantially get caught even if the sharp member 43 passes. D2 is set as the caulking deformation amount D1. According to this configuration, the simulated caulking process (step S3) is performed under an environment very close to the actual caulking environment. In the evaluation step (step S4), the surface scratch 41 of the belt-like heat generating member sample 3S as a result of the actual caulking process on the sample structure 4S is directly evaluated. With such an evaluation method, the appropriate caulking deformation amount D1 can be set more accurately. In addition, since an appropriate caulking deformation amount D1 is set based on a more objective index, it is not necessary to set a different caulking deformation amount D1 for each worker who performs caulking work. In addition, in the evaluation step (step S4), the amount of simulated caulking deformation when the surface flaw 41 is formed on the belt-shaped heating member sample 3S so that the sharp member 43 does not substantially catch even if the sharp member 43 passes. D2 is set as the caulking deformation amount D1. By such an original evaluation method, the caulking deformation amount D1 that is neither excessive nor excessive can be set. Depending on the above, it is possible to realize a caulking deformation amount setting method that can set the caulking amount of the caulking portion 13 more appropriately.

  Further, according to the present embodiment, an appropriate caulking deformation amount D1 is set by a simple method of gradually decreasing or increasing the simulated caulking deformation amount D2 of the caulking portion sample 13S in the second and subsequent simulation caulking steps (step S3). can do.

  Further, according to the present embodiment, in the simulated caulking step (step S3), the caulking portion sample 13S is caulked and deformed so as to sandwich the terminal plate sample 7S, the belt-like heating member sample 3S, and the dummy member sample 8S. According to this configuration, it is possible to set an appropriate caulking deformation amount D1 in the configuration in which the wide terminal plate 7, the narrow belt-like heat generating member 3 and the dummy member 8 are caulked to the caulking portion 13 in a state of being overlapped with each other. .

  Further, according to the present embodiment, the surface scratch 41 to be evaluated in the evaluation step (step S4) overlaps with the terminal plate sample 7S at the peripheral edge portion of the through hole portion 7a of the terminal plate sample 7S in the strip-like heat generating member sample 3S. It is a scratch formed on the contact portion 42. According to this configuration, in the configuration in which the belt-like heat generating member 3 in the portion that passes through the through hole portion 7a of the terminal plate 7 is fixed to the caulking portion 13, an appropriate position is obtained on the basis of a portion that is likely to be scratched by the coupling with the caulking portion 13. The caulking deformation amount D1 can be set.

  Further, according to the present embodiment, it is possible to set an appropriate caulking deformation amount D1 of the caulking portion 13 in the heater (band-like heat generating member 3) used as a heating wire.

  According to the present embodiment, the caulking portion 13 is only caulked and deformed at one of the base portion 17 and the plastic deformation portion 18 (plastic deformation portion 18). For this reason, in the caulking process of the caulking portion 13 in each of the plurality of mica heaters 1, the reproducibility of the mode of plastic deformation in the caulking portion 13 can be further increased. As a result, it is possible to more reliably suppress the occurrence of individual differences in the coupling state between the caulking portion 13 and the caulking member (the terminal plate 7, the belt-like heating member 3, the dummy member 8, and the washers 21, 22).

  Further, according to the present embodiment, the plastic deformation portion 18 formed in a columnar shape (cylindrical shape) is plastically deformed to be caulked portions (the terminal plate 7, the belt-like heating member 3, the dummy member 8, and the washer 21, 22) and the caulking portion 13 are coupled. An appropriate caulking deformation amount D1 in such a configuration can be set.

  According to the present embodiment, in the simulated caulking step (step S3), the caulking punch 33 presses the caulking portion sample 13S along the circumferential direction C1 and moves the caulking punch 33 in the linear movement direction (axial direction S1). Thus, spin caulking, in which the caulking portion sample 13S is plastically deformed, is performed. The simulated caulking deformation amount D2 and the caulking deformation amount D1 are movement amounts of the caulking punch 33 in the linear movement direction (axial direction S1) after the caulking punch 33 starts to press the caulking portion sample 13S. According to this configuration, the caulking deformation amount D1 can be expressed by the movement amount of the caulking punch 33 in the linear movement direction (axial direction S1). That is, the caulking deformation amount D1 can be set as an easily measured value.

  Depending on the above, the mounting structure 4 including the caulking portion 13 that is plastically deformed with an appropriate caulking deformation amount D1 that is neither excessive nor excessive can be realized.

  As mentioned above, although embodiment of this invention was described, this invention is not limited to the above-mentioned embodiment. The present invention can be variously modified as long as it is described in the claims. Hereinafter, differences from the above-described embodiment will be mainly described, and the same components as those in the above-described embodiment may be denoted by the same reference numerals and description thereof may be omitted.

  (1) In the above-described embodiment, an example in which the mica plate 2 is arranged separately from the caulking portion 13 has been described. However, this need not be the case. For example, as shown in the modification of FIG. 10, the mica plate 2 may be disposed so as to be caulked by the caulking portion 13. In this modification, the through hole portion 2d of the terminal mounting portion 2c of the mica plate 2 is formed to have substantially the same size as the through hole portion 7a of the terminal plate 7, and these through hole portions 2d and 7a are coaxial. Has been placed. And the peripheral part of the through-hole part 2d of the terminal attachment part 2c is arrange | positioned between the base part 17 and the plastic deformation part 18 of the crimping part 13. FIG. This peripheral portion is sandwiched between one end portion 3 a of the belt-like heat generating member 3 and the dummy member 8 in a state where the peripheral portion is overlapped with the peripheral portion of the through hole portion 7 a of the terminal plate 7. In this case, the caulking portion 13 is caulked and deformed so as to sandwich the terminal mounting portion 2 c of the mica plate 2, the terminal plate 7, the belt-like heating member 3, the dummy member 8, and the washers 21 and 22.

  According to the modification shown in FIG. 10, when a worker attaches the nut member 11 to the screw shaft portion 14 of the terminal member 10, the torque acting on the terminal member 10 is provided by the tool engaging portion 15. , The mica plate 2, the terminal plate 7, the belt-like heating member 3, the dummy member 8 and the washers 21 and 22, and the caulking portion 13 are prevented from being transmitted. Therefore, the caulking portion 13 is suppressed from sliding with respect to the mica plate 2, the terminal plate 7, the belt-like heating member 3, the dummy member 8, and the washers 21 and 22.

  When setting the caulking deformation amount D1 in the configuration shown in FIG. 10, a sample structure simulating the caulking attachment structure shown in FIG. 10 is prepared, and the above-described steps S1 to S6 are performed using this sample structure. Become.

  In the modification shown in FIG. 10, the terminal mounting portion 2 c of the mica plate 2 may be formed of a conductive member, and the portion other than the terminal mounting portion 2 c may be formed of an insulating member.

  (2) In the above-described embodiment and modification, the embodiment in which the washers 21 and 22 are provided has been described as an example, but at least one of the washers 21 and 22 may be omitted.

  (3) Moreover, the dummy member 8 may be abbreviate | omitted in the above-mentioned embodiment and modification.

  (4) Further, in the above-described embodiment and modification, the configuration in which the tool attachment portion 15 and the base portion 17 of the caulking portion 13 are integrally continuous has been described as an example, but this need not be the case. The tool attachment portion 15 and the base portion 17 of the caulking portion 13 may be separated from each other.

  (5) Further, in the above-described embodiment and modification, the belt-like heat generating member 3 and the dummy member 8 have been described as an example of passing through the through-hole portion 7a of the terminal plate 7, but this need not be the case. For example, at least one of the belt-like heat generating member 3 and the dummy member 8 may be along the terminal plate 7 without passing through the through hole portion 7 a of the terminal plate 7.

  (6) Moreover, in the above-mentioned embodiment and modification, the structure which fastens the electrode part 5 to the terminal member 10 by screw-connecting the nut member 11 to the screw shaft part 14 was demonstrated to the example. However, this need not be the case. For example, in the terminal member 10, a cylindrical shaft without a thread groove may be provided instead of the screw shaft portion 14, and the electrode portion 5 may be fastened (fixed) to the shaft using a fastening member such as a pin or a hook. .

(7) In the above-described embodiment and modification, the mica heater 1 has been described as an example. However, this need not be the case. For example, the present invention may be applied to a heater other than a mica heater. An example of such a heater is a heater that uses a film-like metal foil formed by etching as a resistance heating member. In addition, the present invention can be applied to devices other than the heater.

  The present invention can be widely applied as a caulking deformation amount setting method and a caulking coupling structure manufacturing method.

2 Mica plate (caulking member)
3 Band-shaped heating member (caulking member)
3S strip-shaped heating member sample (caulking member sample, strip-shaped member sample, resistance heating member sample)
4 Mounting structure (Caulking connection structure)
7 Terminal board (caulking member, plate-like member)
7S terminal plate sample (sampled member sample, plate member sample)
7a Through-hole part (through-hole part of plate-shaped member sample)
7c Surface (surface of plate member sample)
7d Back side (back side of plate member sample)
8 Dummy member (Casting member)
8S dummy member sample (caulking member sample, strip member sample)
13 Caulking part 13S Caulking part sample 17 Base part (caulking base part)
18 Plastic deformation parts 21, 22 Washers (caulking members)
21S, 22S washer sample (caulking member sample)
33 Caulking punch 41 Surface scratch 43 Sharp member C1 circumferential direction (circumferential direction)
D1 Caulking deformation amount D2 Simulated caulking deformation amount (predetermined plastic deformation amount)
S1 axis direction (linear movement direction)

Claims (9)

A caulking deformation amount setting method for setting a caulking deformation amount of a caulking portion that couples a plurality of caulking members superimposed on each other by caulking,
A plurality of caulking member samples as samples of the caulking members, and a preparation step for preparing caulking portion samples as samples of the caulking portions;
The caulking process is simulated by attaching a plurality of the caulking member samples superimposed on each other to the caulking part sample before being caulked and deforming the caulking part sample by a predetermined plastic deformation amount. Simulated caulking process;
An evaluation step for evaluating the result of the simulated caulking step;
Including
In the evaluation step, the predetermined plastic deformation when a surface flaw that does not substantially cause the sharp member to be caught even if the predetermined sharp member passes is formed in the caulking member sample by the simulated caulking step. A caulking deformation amount setting method, characterized in that an amount is set as the caulking deformation amount. A caulking deformation amount setting method according to claim 1,
In the evaluation step, when it is evaluated that the predetermined plastic deformation amount is inappropriate as the caulking deformation amount, the preparation step, the simulated caulking step, and the evaluation step are repeated again,
Caulking deformation characterized in that the predetermined plastic deformation amount in the simulated caulking step after n (n is a natural number of 2 or more) is reduced or increased as the variable n increases. Quantity setting method. A caulking deformation amount setting method according to claim 1 or 2,
The plurality of the caulking member samples include a plate-like member sample, and a band-like member sample formed in a width narrower than the width of the plate-like member sample and superimposed on the plate-like member sample,
In the simulated caulking step, the caulking portion sample is caulked and deformed so as to sandwich the plate-like member sample and the belt-like member sample. A caulking deformation amount setting method according to claim 3,
The plate-like member sample includes a through hole portion,
The strip member sample extends from the front surface to the back surface of the plate member sample through the through-hole portion, and is caulked by the caulking member sample around the through-hole portion,
The method of setting a caulking deformation amount, wherein the surface scratch is a scratch formed in a portion of the belt-like member sample that overlaps the plate-like member sample in a peripheral portion of the through-hole portion. A caulking deformation amount setting method according to claim 3 or claim 4, wherein
The strip member sample includes a resistance heating member sample,
The caulking deformation amount setting method, wherein the plate-like member sample includes a terminal plate sample that receives the resistance heating member sample. A caulking deformation amount setting method according to any one of claims 1 to 5,
The caulking portion sample includes a caulking base portion that receives the plurality of caulking member samples, and a plastic deformation portion that caulks the caulking member samples in cooperation with the caulking base portion by plastic deformation. A caulking deformation amount setting method, comprising: The caulking deformation amount setting method according to claim 6,
In the simulated caulking step, the plastic deformation portion is plastically deformed from a columnar shape toward the caulking base portion, so that a plurality of the caulking members cooperate with the caulking base portion. A caulking deformation amount setting method, characterized by being caulked so as to sandwich a sample. A caulking deformation amount setting method according to any one of claims 1 to 7,
In the simulated caulking step, a spin caulking is performed in which the caulking punch pressurizes the caulking portion sample along a predetermined circumferential direction and moves the caulking punch in a predetermined linear movement direction to plastically deform the caulking portion sample. Done,
The predetermined amount of plastic deformation is a movement amount of the caulking punch in the linear movement direction after the caulking punch starts pressurization of the caulking portion sample. . Including a caulking step in which a plurality of caulking members superimposed on each other are joined by caulking of the caulking portion;
The caulking deformation amount set by the caulking deformation amount setting method according to any one of claims 1 to 8, is set as a caulking deformation amount of the caulking portion in the caulking process. A method for manufacturing a caulking joint structure.

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