JPH0642493A - Manufacture of cylindrical impeller - Google Patents

Abstract

PURPOSE:To provide a manufacturing method for a cylindrical blade wheel which can reduce the energy loss in the supersonic vibration and permits the firm and stable welding, in the welding of elements. CONSTITUTION:Each blade 3 installed on the upper and lower elements is made of thermoplastic resin and set upward, and the supporting plate 2 for the upper element 1 is supported on the top edge part of the blade 3 of the lower element 1, and the supporting plate 2 and the top edge part of the blade 3 are supersonic-wave-welded by a horn 13 inserted to the center side of the blade 3 of the upper element 1. Since the blades 3 of the upper and lower elements 1 are set upward, and a horn 13 is inserted into the blade 3 of the upper element 1, the close welding is enabled, and the supersonic welding with high frequency can be executed. Accordingly, the loss of the vibration energy can be reduced, and it is enough only to apply a small pressurizing force to the welded part in a short time by supersonic oscillator having a small capacity, and the deformation of the blade and the center deflection of the upper and lower elements 1 in welding can be prevented.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a cylindrical impeller such as a cross flow fan used in an air conditioner, and more particularly, to a plurality of blades extending axially on one end surface of a support plate in the circumferential direction. The present invention relates to a method for manufacturing a cylindrical impeller in which a plurality of elements made of thermoplastic resin molded products formed at predetermined intervals are ultrasonically welded in the axial direction.

[0002]

2. Description of the Related Art Conventionally, Japanese Patent Publication No. 54-25643 discloses a method for manufacturing the above-mentioned tubular impeller. As shown in FIG. 6, this tubular impeller has upper and lower elements 1 and 1 having the above-mentioned configuration, ring-shaped support plates 2 and 2 upward,
The blades 3 are arranged downward, and the tips of the blades 3 of the upper element 1 are engaged with the engaging recesses 6 formed on the upper surface of the support plate 2 of the lower element 1, respectively. It is supported by the support plate 2 of the upper element 1.

In this state, the horn 13 of the ultrasonic welder
Is pressed against the support plate 2 of the upper element 1 so that the tips of the blades 3 of the upper element 1 and the lower element 1
Of the supporting plate 2 is ultrasonically welded, and by repeating this, a large number of elements 1 are ultrasonically welded in the axial direction as shown in FIG. 7 to form a cylindrical blade such as a cross flow fan. Manufactures cars.

[0004]

However, in the above-mentioned conventional method for manufacturing the cylindrical impeller, the horn of the ultrasonic welder is pressed against the support plate of the upper element, and the blade extending below the upper element is interposed. Since the tips of these blades and the supporting plate of the lower element are ultrasonically welded, the distance between the horn and the welding surface is long and the welding is carried out.

Therefore, not only an ultrasonic oscillator having a large loss of vibration energy and a large capacity is required, but also it is necessary to apply a large pressure for a long time to weld the tips of the blades to the supporting plate. , It is difficult to make strong welding. Further, as described above, when a large pressure is applied, the blades are long and thin, so there is a risk of bending, and there is the problem that runout easily occurs between the upper element and the lower element, and stable welding cannot be performed. It was

The present invention solves the above-mentioned problems,
An object of the present invention is to provide a method for manufacturing a tubular impeller, which is capable of firmly and stably ultrasonically welding a plurality of elements made of a thermoplastic resin molded product with little energy loss due to ultrasonic vibration.

[0007]

SUMMARY OF THE INVENTION The present invention is a method for manufacturing a cylindrical impeller in which a plurality of elements made of a thermoplastic resin molded product are ultrasonically welded in the axial direction. The supporting plate of the upper element is supported on the tip of the blade formed on the lower element, and the horn of the ultrasonic welder is inserted into the center side of the blade extending above the supporting plate of the upper element. This is a method for manufacturing a tubular impeller in which the lower end is brought into pressure contact with the support plate of the upper element, and the support plate of the upper element and the tips of the blades of the lower element are ultrasonically welded by proximity welding.

[0008]

In the method of manufacturing the tubular impeller according to the present invention, when the elements are ultrasonically welded, the direction of the elements is vertically reversed from that of the above-described conventional manufacturing method, and the elements are upwardly arranged on the tips of the blades formed in the lower elements. It is possible to perform proximity welding by supporting the element support plate and inserting the ultrasonic welder horn into the center side of the upper element blade, and it is possible to perform high-frequency welding compared to conventional element ultrasonic welding. Ultrasonic welding can be performed.

Therefore, the loss of vibration energy can be reduced, and a small pressure is applied to the welding portion for a short time by the ultrasonic oscillator having a small capacity, whereby the support plate and the blade can be firmly welded. Also, since the pressure applied to the bonded part is small and the processing time is short, the blades may be deformed during welding,
Stable welding is possible without the upper and lower elements swinging.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. In FIG. 1, reference numeral 1 is an element made of an injection molded product in which a filler such as glass powder is mixed in a thermoplastic resin. The element 1 has a large number of blades 3 projecting from one surface of a ring-shaped support plate 2 along the axial direction at predetermined intervals, and an engaging projection 4 is provided at the tip of each blade 3.
Are formed, and the welding projections 5 are projected from the tips of these engaging projections 4. Further, on the other surface of the support plate 2, an engagement concave portion 6 with which the engagement convex portion 4 of the blade 3 is engaged is formed so as to correspond to the center of the interval between the blades 3.

Then, as shown in FIGS. 2 and 3, the lowermost element 1 is placed on the receiving jig 7 which is vertically moved by a proper means.
Holding the support plate 2 in a detachable manner with the blades 3 facing upward,
The engaging recesses 6 of the element 1 of the next stage are engaged with the engaging projections 4 formed at the tips of the blades 3 of the element 1 of the lowermost stage, and the element 1 of the next stage is placed on the blade 3 of the lowermost stage. The supporting plate 2 is supported with the blades 3 facing upward.

Next, the middle and upper outer peripheral jigs 8 and 9 are used to position and support the elements 1 and 1 at the lowermost stage and the next stage from the outer peripheral side. That is, each of the middle and upper outer peripheral jigs 8 and 9 has a flat arc-shaped divided piece 10 obtained by equally dividing a cylinder having an inner diameter, which is closely fitted to the outer circumference of the element 1, into four equal parts in the circumferential direction. It has the same structure in which a ridge 11 having a horizontal cross-section that is fitted between the blades 3 of the element 1 without a gap is integrally formed on the peripheral surface. Below the middle and outer circumference jigs 8, the middle and outer circumference jigs 8
A lower outer peripheral jig 12 having substantially the same configuration as that of the lower outer peripheral jig 1 is arranged.
At the lower end of each of the two divided pieces 10, a planar arcuate extension 12a having no ridge 11 is formed.

Then, the divided pieces 10 of the middle and upper outer peripheral jigs 8 and 9 are horizontally moved in the direction of arrow b while being rotated in the direction of arrow a by an appropriate means from the open state shown by the chain line in FIG. ,During,
The inner peripheral surfaces of the divided pieces 10, 10 of the upper and outer peripheral jigs 8, 9 are brought into close contact with the outer peripheral surfaces of the elements 1, 1 at the lowermost stage and the next stage, and the protrusions 11, 11 11 at the bottom,
The middle and upper outer peripheral jigs 8 and 9 are closed by being fitted between the blades 3 of the elements 1 and 1 of the next stage. In this state, the protrusion 11 of the middle and outer circumference jig 8 is the element 1 of the next stage.
The lower surface of the support plate 2 is supported.

In this state, the horn 13 of the ultrasonic welder
Is loosely inserted from the respective blades 3 of the element 1 of the next stage located above to the center side, and the support plate 2 of the element 1 of the next stage is pressed from above by the tip surface of the horn 13, and the ultrasonic oscillator of the ultrasonic welder is pressed. By actuating 14, the supporting plate 2 of the element 1 at the next stage and the engaging convex portion 4 formed at the tip of the blade 3 of the element 1 at the lowermost stage are provided on these convex portions 4 for welding. While being melted and crushed, ultrasonic welding is performed for a predetermined time.

After the lapse of a predetermined time, the ultrasonic oscillator 14 is stopped, and the divided pieces 10, 10 of the middle and upper outer peripheral jigs 8, 9 are rotated in the direction of arrow c opposite to the arrow a and indicated by the arrow b. The divided pieces 10, 10 are opened by horizontally moving in the opposite arrow d direction, and the ridges 11, 11 are arranged at the lowermost stage and the next stage elements 1, 1
The blades 3 and 3 are pulled out to separate the divided pieces 10 and 10 from the outer circumferences of the elements 1 and 1.

Next, the divided piece 10 of the lower peripheral jig 12 is
Like the upper elements 8 and 9, open the receiving jig 7
Is lowered to bring the element 1 of the next stage to the position where the element 1 of the lowest stage was located and stop. In this state, the lowermost element 1 is at a height position corresponding to the divided piece 10 of the lower outer peripheral jig 12. Then, the middle and upper outer peripheral jigs 8 and 9
The divided pieces 10 and 10 are indexed and rotated in the same direction by an amount corresponding to ½ of the interval between the blades 3 and stopped.

Further, the supporting plate of the element of the third stage is engaged and supported on the blade 3 of the element 1 of the next stage, and the lower, middle,
The divided pieces of the upper and outer jigs 12, 8, 9 are closed, and the same operation as the ultrasonic welding operation of the elements 1 and 1 of the lowermost step and the next step described above is repeated to remove the elements of the next and third steps. Weld. Similarly, a required number of elements are ultrasonically welded to the uppermost element 1 above the third element.

Finally, on the blade 3 of the uppermost element 1, as shown in FIG. 4, the engaging recess 6 is formed in the shape of a disk made of a thermoplastic resin molded product in which the shaft 15 is insert-molded. The end plate 16 is ultrasonically welded in substantially the same manner as the mutual welding of the elements, the lower, middle, and upper outer peripheral jigs 12, 8, 9 are opened, and the receiving jig 7 is raised and returned to receive the receiving jig 7.
Remove the tubular impeller to which the element 1 is welded. The boss 17 is attached to the support plate 2 of the lowermost element 1 by an appropriate means.
And the cylindrical impeller shown in FIG. 5 is obtained.

[0019]

[Examples] Material used for the element ABS resin containing 30% glass fiber Molding conditions for the element Cylinder rear temperature 270 ° C Cylinder middle temperature 280 ° C Cylinder front temperature 310 ° C Nozzle temperature 280 ° C Molding pressure 600kg / cm ² Mold temperature 85 ° C Element specifications Blade length 90 mm Blade width 12 mm Number of blades 24 Support plate outer diameter 90 mm Support plate thickness 3 mm Welding condition frequency 20 KHz Horn pressure 1 kg / cm ² Welding time ² to 3 sec / 1 Element element welded number 7 Result Blade deformation None Straightness Good Good Welded Part Strength Good In this invention, the lowermost element is one in which a boss is attached to the annular support plate in advance, or a disc-shaped support plate is insert-molded as the lowermost element. May be. Further, the structure and operation of the jigs such as the lower, middle and upper outer peripheral jigs are not necessarily limited to those of the above-mentioned embodiment, and can be changed appropriately. Further, the deviation of the blades of the elements adjacent to each other above and below is not limited to 1/2 of the interval between the blades, and may be set to an appropriate deviation.

In the present invention, the material used for the element, the molding material, and the specifications are not necessarily limited to the specific examples described above, and can be changed as appropriate. Although the welding conditions can be changed as appropriate, the frequency can be appropriately changed because the present invention is the proximity welding in which the distance between the horn tip and the welding portion is 10 mm or less.

[0021]

As described above, according to the present invention, a plurality of moldings made of a thermoplastic resin having a large number of blades extending in the axial direction on one end surface of a support plate are formed at predetermined intervals in the circumferential direction. In the method of manufacturing a tubular impeller in which an element is ultrasonically welded in the axial direction, the blades of the upper and lower elements are directed upward, and the upper element support plate is supported on the tip of the blade formed in the lower element, By inserting the horn of the ultrasonic welder into the center of the blade extending above the support plate of the upper element, it becomes possible to perform proximity welding, and ultrasonic welding with a higher frequency than ultrasonic welding of conventional elements is possible. Can be done.

Therefore, the loss of vibration energy can be reduced, and by applying a small pressure to the welding portion for a short time by the ultrasonic oscillator having a small capacity, the support plate and the blade can be firmly welded. Also, since the pressure applied to the bonded part is small and the processing time is short, the blades may be deformed during welding,
There is an effect that stable welding can be performed without the upper and lower elements being shaken.

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of an element used in a method for manufacturing a tubular impeller according to the present invention.

FIG. 2 is a vertical cross-sectional view of an element welding state showing an embodiment of a method for manufacturing a cylindrical impeller according to the present invention.

3 is a cross-sectional view taken along the line AA of FIG.

FIG. 4 is an explanatory view showing an example of an end plate used in the method for manufacturing a cylindrical impeller according to the present invention.

FIG. 5 is a schematic perspective view showing an example of a cylindrical impeller obtained by the manufacturing method according to the present invention.

FIG. 6 is a perspective view showing elements used in a method for manufacturing a tubular impeller of a conventional example.

FIG. 7 is a schematic perspective view showing a cylindrical impeller obtained by a conventional manufacturing method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Element 2 Support plate 3 Blade 4 Engagement convex part 6 Engagement concave part 13 Horn

Claims (1)

[Claims] 1. A plurality of elements made of a thermoplastic resin molded product, in which a large number of blades extending in the axial direction are formed at predetermined intervals in the circumferential direction on one end surface of a support plate, are ultrasonically welded in the axial direction. In the method for manufacturing a tubular impeller, the blades of the upper and lower elements are directed upward, and the supporting plate of the upper element is supported on the tips of the blades formed in the lower element, and the supporting plate of the upper element is positioned above the supporting plate. Insert the horn of the ultrasonic welder into the center of the extending blade, press the lower end of this horn against the support plate of the upper element, and bring the support plate of the upper element and the tip of the blade of the lower element by proximity welding. A method for manufacturing a cylindrical impeller, characterized by ultrasonic welding.