WO2015145258A1 - Joining method - Google Patents

Joining method Download PDF

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Publication number
WO2015145258A1
WO2015145258A1 PCT/IB2015/000557 IB2015000557W WO2015145258A1 WO 2015145258 A1 WO2015145258 A1 WO 2015145258A1 IB 2015000557 W IB2015000557 W IB 2015000557W WO 2015145258 A1 WO2015145258 A1 WO 2015145258A1
Authority
WO
WIPO (PCT)
Prior art keywords
protrusion
hole
cylindrical portion
joining method
resin
Prior art date
Application number
PCT/IB2015/000557
Other languages
French (fr)
Inventor
Yasuhiro Ueno
Original Assignee
Toyota Jidosha Kabushiki Kaisha
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Toyota Jidosha Kabushiki Kaisha filed Critical Toyota Jidosha Kabushiki Kaisha
Publication of WO2015145258A1 publication Critical patent/WO2015145258A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60—Riveting or staking
    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/0681—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding created by a tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/324—Avoiding burr formation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72143—Fibres of discontinuous lengths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/816—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the mounting of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8161—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the mounting of the pressing elements, e.g. of the welding jaws or clamps said pressing elements being supported or backed-up by springs or by resilient material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys

Definitions

  • the invention relates to a joining method, more particularly, a joining method for joining together different types of members such as two metal members, a metal member and a resin member, or two resin members, for example.
  • Known methods for joining together two different types of members such as a metal member and a resin member include a method that uses an adhesive (e.g., Japanese Patent Application Publication No. 11-173356 (JP 11-173356 A)), and a method that uses a fastening member such as a rivet or a screw.
  • JP 11-173356 A Japanese Patent Application Publication No. 11-173356
  • a fastening member such as a rivet or a screw.
  • the former method is problematic in that it requires time for the adhesive to harden, and the adhesive force may decrease due to, for example, deterioration over time of the adhesive.
  • the latter method is problematic in that the product weight increases due to the rivet or screw or the like, and it takes time and man-hours to fasten the rivet or screw or the like.
  • a metal member A having a through-hole Aa, a resin member B having a protrusion Ba that is inserted through the through-hole Aa of the metal member A, and an ultrasonic horn C in which an indentation of a predetermined shape is formed, are prepared, as shown in FIG. 4.
  • the protrusion Ba of the resin member B is then inserted into the through-hole Aa of the metal member A, and the metal member A is placed on top of the resin member B.
  • the ultrasonic horn C is moved from the metal member A side toward the resin member B while making the indentation in the ultrasonic horn C contact an upper end portion of the protrusion Ba of the resin member that is inserted through the through-hole Aa of the metal member A, and the protrusion Ba of the resin member B is melted and deformed by the ultrasonic vibration of the ultrasonic horn C.
  • a head portion H having an anchor portion Ha that holds the resin member B to the metal member A is formed on an upper end portion of the protrusion Ba of this resin member B, thereby joining the metal member and the resin member together.
  • the protrusion Ba of the resin member B is melted and deformed while the ultrasonic horn C is moved from the metal member A side toward the resin member B. Therefore, a portion of the deformed protrusion Ba of the resin member B gets between the ultrasonic horn C and the metal member A, and a burr is created on an outer edge of the head portion H formed on the resin member B, more specifically, at a location on the outer edge of the head portion H formed on the resin member, between the ultrasonic horn C and the metal member A. The work of removing this burr takes time and money, which is problematic.
  • the invention thus provides a joining method capable of inhibiting a burr from being created, when joining together different types of members such as two metal members, a metal member and a resin member, or two resin members, for example.
  • One aspect of the invention relates to a joining method for joining a first member in which a through-hole is formed from one surface toward the other surface, and a second member having a protrusion to be inserted through the through-hole.
  • This joining method includes: preparing a cylindrical portion having an inside diameter that is larger than a hole diameter of the through-hole, and a movable portion that is slidably arranged inside the cylindrical portion; arranging the second member on one surface of the first member, with the protrusion inserted through the through-hole, and arranging the cylindrical portion abutting against the other surface of the first member such that the inside of the cylindrical portion is communicated with the through-hole; and forming an anchor portion that holds the second member to the first member by moving the movable portion inside the cylindrical portion toward the protrusion, abutting the movable portion against the protrusion, and deforming the protrusion.
  • the protrusion of the second member is inserted through the through-hole of the first member and the second member is arranged on one surface of the first member, and the cylindrical portion is arranged abutting against the other surface of the first member such that the inside of the cylindrical portion is communicated with the through-hole. Then the movable portion is moved inside the cylindrical member toward the protrusion, and abutted against the protrusion, consequently deforming the protrusion, such that an anchor portion that holds the second member to the first member is formed on the protrusion.
  • the anchor portion is able to be formed on the protrusion inside of a closed space defined by the cylindrical portion, the movable portion, and the first member, while the cylindrical portion is abutted against the other surface of the first member. Therefore, the first member and the second member are able to be joined together, while inhibiting a burr from being created on the outer edge of the anchor portion that is formed on the protrusion of the second member.
  • the movable portion may be rotatable around an axis inside the cylindrical portion, and in forming the anchor portion, the movable portion may be moved toward the protrusion while being rotated around the axis inside the cylindrical portion, and be abutted against the protrusion.
  • the movable portion in forming the anchor portion, is moved inside the cylindrical portion toward the protrusion while being rotated around the axis, and this movable portion is abutted against the protrusion of the second member. As a result, the protrusion is deformed relatively easily, and the anchor portion is consequently able to be formed on this protrusion.
  • the protrusion of the second member is inserted through the through-hole of the first member and the second member is arranged on one surface of the first member, and this cylindrical portion is arranged abutting against the other surface of the first member such that the inside of the cylindrical portion is communicated with the through-hole.
  • the movable portion is moved inside the cylindrical portion toward the protrusion, and abutted against the protrusion such that the protrusion deforms, thus forming an anchor portion that holds the second member to the first member.
  • a burr is able to be inhibited from being created on the anchor portion, and time and cost that it takes to remove the burr is able to be reliably reduced.
  • FIG. 1A is a longitudinal sectional view illustrating an example embodiment of a joining method of the invention, and illustrates an arranging process in this method;
  • FIG. IB is a longitudinal sectional view illustrating the example embodiment of the joining method of the invention, and illustrates an anchor forming process in this method;
  • FIG. 1C is a longitudinal sectional view illustrating the example embodiment of the joining method of the invention, and illustrates a removal process in this method;
  • FIG. 2 A is a longitudinal sectional view illustrating a modified example of the joining method shown in FIGS. 1 A to 1C, and illustrates an arranging process in this method;
  • FIG 2B is a longitudinal sectional view illustrating the modified example of the joining method shown in FIGS. 1 A to 1C, and illustrates an anchor forming process in this method;
  • FIG. 2C is a longitudinal sectional view illustrating the modified example of the joining method shown in FIGS. lAto 1C, and illustrates a removal process in this method;
  • FIG. 3 is a longitudinal sectional view showing a frame format of the internal structure when a second member shown in FIGS. 1A to 1C is a fiber-reinforced resin member;
  • FIG. 4 is a longitudinal sectional view illustrating a related joining method.
  • FIG. 1 is a longitudinal view illustrating an example embodiment of the joining method of the invention, with FIG. 1 A being a view of an arranging process, FIG. IB being a view of a head forming process, and FIG. 1C being a view of a removal process.
  • the joining method according to this example embodiment of the invention is carried out using a single action type friction stir welding apparatus which is a representative example of the friction stir welding apparatus. Therefore, first the representative example of the single action type Friction Stir Welding (FSW) apparatus used with the joining method according to this example embodiment will be outlined with reference to FIG. 1 A.
  • FSW Friction Stir Welding
  • the FSW apparatus 50 used with the joining method according to this example embodiment mainly includes a rotating jig portion (a movable portion) 51, a clamp member (a cylindrical portion) 54, and a backing member 55, as well as a supporting member, not shown in FIG. 1A, that supports these, and a driving mechanism, also not shown in FIG. 1A, that drives the rotating jig portion 51, and the like.
  • the clamp member 54 is fixed via a spring 53 to the supporting member that is not shown.
  • the rotating jig portion (movable portion) 51 has a generally circular cylindrical shape, and is configured to rotate around an axis (rotational axis) Xr by the driving mechanism, not shown, and slide relative to the clamp member 54 in the direction of the broken arrow PI, i.e., the direction of the axis Xr (the vertical direction in FIG 1 A).
  • the clamp member (cylindrical portion) 54 is provided to the outside of the rotating jig portion 51, and has a generally circular cylindrical shape that has a void.
  • the rotating jig portion 51 is inserted in this void.
  • the clamp member 54 is supported by the supporting member, not shown, via the spring 53, so as to push on processing material
  • the clamp member 54 is configured to move in the direction of the broken arrow P2, i.e., the direction of the axis Xr, in a state urged to the processing material side.
  • the rotating jig portion 51 of this structure includes an abutting surface
  • abutting surface 54a is moved in the direction of the axis Xr by the driving mechanism, not shown, so as to abut against one surface of the processing material (i.e., an upper surface 2ca of the protrusion 2c of the second member 2, and the upper surface la of the first member 1, respectively, in FIG. 1A).
  • the backing member 55 is provided in a position facing the clamp member 54 and the rotating jig portion 51, and abuts against the other surface of the processing material (i.e., a lower surface 2b of the second member 2 in FIG 1 A).
  • the specific structure of the single action type friction stir welding (FSW) apparatus 50 in this example embodiment is not limited to the structure described above.
  • the backing member 55 may be omitted from the FSW apparatus 50, or other members and the like not described with the FSW apparatus 50 described above may have provided.
  • the joining method according to this example embodiment mainly includes a preparation process, an arranging process, an anchor forming process, and a removal process.
  • the first member 1 in which a linear through-hole lc is formed from one surface (the lower surface in FIG. 1A) lb toward the other surface (the upper surface in FIG. 1 A) la, the second member 2 in which a protrusion 2c that is inserted through the through-hole lc of ⁇ he first member 1 is integrally formed on the upper surface 2a thereof, and the FSW apparatus 50 described above, are prepared.
  • the through-hole lc of the first member 1 and the protrusion 2c of the second member 2 both have generally circular sectional shapes, and the clamp member 54 of the FSW apparatus 50 has an inner diameter that is larger than the hole diameter of the through-hole lc of the first member 1.
  • the protrusion 2c of the second member 2 is formed such that the height in the up-down direction (i.e., the direction of the axis Xr) thereof is larger than the thickness in the up-down direction of the first member 1, and the volume of the protrusion 2c of the second member 2 is formed larger than the volume of the through-hole lc of the first member 1.
  • the second member 2 is arranged on the lower surface lb of the first member 1 such that the protrusion 2c of the second member 2 is inserted through the through-hole lc of the first member 1 and the lower surface lb of the first member 1 abuts against the upper surface 2a of the second member 2, as shown in FIG. 1 A.
  • the clamp member 54 of the FSW apparatus 50 is arranged on the upper surface la of the first member 1 with the abutting surface 54a of the clamp member 54 abutting against the upper surface la of the first member 1 so as to cover the through-hole lc of the first member 1, i.e., such that the inside of the clamp member 54 and the through-hole lc of the first member 1 are communicated with each other.
  • the backing member 55 of the FSW apparatus 50 is arranged on a lower surface 2b side of the second member 2, such that the first member 1 and the second member 2 are sandwiched by the clamp member 54 and the backing member 55.
  • the rotating jig portion 1 is moved downward in the direction of the axis Xr while being rotated around the axis Xr inside the clamp member 54, and an abutting surface 51a of this rotating jig portion 51 is abutted against the upper surface 2ca of the protrusion 2c protruding from the through-hole lc of the first member 1, as shown in FIG. IB.
  • the protrusion 2c softens or melts and deforms from friction heat generated between the abutting surface 51a of the rotating jig portion 51 and the upper surface 2ca of the protrusion 2c.
  • a head portion 2h having an anchor portion 2ha that holds the second member 2 to the first member 1 is formed on an upper end portion of the protrusion 2c of the second member 2.
  • the anchor portion 2ha of this head portion 2h is formed on the upper surface la of the first member 1 so as to spread out above and around the through-hole lc of the first member 1 , such that the head portion 2h comes to have an outer diameter that is larger than the through-hole lc of the first member 1.
  • the FSW apparatus 50 is removed from the first member 1 and the second member 2 after rotation of the rotating jig portion 51 is stopped and the softened or melted protrusion 2c of the second member 2 hardens, as shown in FIG. 1C.
  • the first member 1 and the second member 2 are integrally joined together via the head portion 2h formed by the deformed protrusion 2c of the second member 2, or more specifically, via the anchor portion 2ha formed on the upper surface la of the first member 1 to the outer peripheral side of the head portion 2h.
  • the second member 2 is arranged on the lower surface lb side of the first member 1, with the protrusion 2c of the second member 2 inserted through the through-hole lc of the first member 1.
  • the rotating jig portion 51 and the clamp member 54 of the FSW apparatus 50 are arranged on the upper surface la side of the first member 1 , with the abutting surface 54a of the clamp member 54 abutted against the upper surface la of the first member 1 such that the inside of the clamp member 54 is communicated with the through-hole lc of the first member 1.
  • the rotating jig portion 51 is moved toward the protrusion 2c of the second member 2 inside the clamp member 54 of the FSW apparatus 50, and is abutted against the protrusion 2c, thereby deforming the protrusion 2c, thus forming the anchor portion 2ha that holds the second member 2 to the first member 1, on the upper end portion of this protrusion 2c.
  • the anchor portion 2ha is able to be formed on the protrusion 2c inside a closed space defined by the clamp member 54, the rotating jig portion 51 that slides inside the clamp member 54, and the first member 1, while the clamp member 54 of the FSW apparatus 50 is abutted against the upper surface la of the first member 1. Therefore, the first member 1 and the second member 2 that are different types of members are able to be elaborately joined, while inhibiting a burr from being created on the anchor portion 2ha of the second member 2.
  • the shapes (longitudinal sectional shapes and cross-sectional shapes) of the through-hole lc provided in the first member 1 and the protrusion 2c provided on the second member 2 may be set as appropriate according to the joint strength and the like between the first member 1 and the second member 2.
  • the cross-sectional shape of both the through-hole lc provided in the first member 1 and the protrusion 2c provided on the second member 2 is a generally circular shape, but it may of course also be a generally oblong shape, a generally long hole shape, or a multiangular shape such as a square shape or the like.
  • the through-hole lc provided in the first member 1 and the protrusion 2c provided on the second member 2 both have a linear shape in the up-down direction (i.e., the direction of the Xr axis, the thickness direction of the first member 1 and the second member 2), but a through-hole lc' of a first member may also be formed so as to become smaller in diameter either continuously or in steps from an upper surface la' toward a lower surface lb', for example, as shown in FIGS. 2 A to 2C.
  • an anchor portion 2ha' that holds a second member 2' to the first member 1 ' may be formed inside the through-hole lc' of the first member 1 ' by moving the rotating jig portion 51 to a position in which it abuts against the upper surface la' of the first member ⁇ , and deforming a protrusion 2c' of the second member 2', or an anchor portion that holds the second member 2' to the first member 1 ' may be formed above the upper surface la' of the first member , as in the example embodiment described above.
  • the upper surface 2ca of the protrusion 2c of the second member 2 of course does not have to protrude from the through-hole lc of the first member 1 when the second member 2 is arranged on the lower surface lb of the first member 1.
  • the joining method according to the example embodiment described above is not particularly limited to the type of members that are to be joined together.
  • the second member 2 having the protrusion 2c is formed by a fiber-reinforced resin member in which reinforcing fiber material is mixed into resin (matrix resin) with a lower melting temperature than the material of which the first member 1 is formed
  • the fibers included in the second member 2 become oriented in a direction substantially orthogonal to abutting surfaces (boundary surfaces) of the upper surface 2a of the second member 2 and the lower surface lb of the first member 1, near these abutting surfaces (region R2 in FIG. 3) and inside the protrusion 2c of the second member 2 (region Rl in FIG. 3), as shown in FIG. 3, so joint strength between the first member 1 and the second member 2 may not be able to be sufficiently ensured.
  • the resin (matrix resin) that forms the second member may be either a thermosetting resin or a thermoplastic resin.
  • thermosetting resin are epoxy resin, phenol resin, and melamine resin.
  • thermoplastic resin is one or two or more types of an admixture such as polypropylene (PP), polyethylene (PE), polystyrene (PS), AS resin, ABS resin, polyvinyl chloride (PVC), methacryl resin, polyamide (PA), polyester, polyacetal (POM), polycarbonate (PC), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polymethylmethacrylate (PMMA), polyvinylidene fluoride, polyphenylene oxide, polyphenylene sulfide, polyether ether ketone, liquid crystal polymer, polyetherimide, polyether sulfone, polyamide-imide, and thermoplastic epoxy resin, and the like.
  • PP polypropylene
  • PE polyethylene
  • PS polystyrene
  • AS resin ABS resin
  • PVC polyvinyl chloride
  • PA polyamide
  • PET polyacetal
  • PET polycarbonate
  • PET polyethylene terephthalate
  • PBT polybuty
  • a blend resin, graft resin, or copolymer with the thermoplastic resin as its main component e.g., an ethylene - vinyl chloride copolymer, a vinyl acetate - ethylene copolymer, a vinyl acetate - vinyl chloride copolymer, a urethane - vinyl chloride copolymer, acrylic acid-modified polypropylene, or maleic acid-modified polyethylene may also be introduced.
  • an example of the reinforcing fiber material that forms the second member is one or two or more types of an admixture of ceramic fiber such as boron, alumina, silicon carbide, silicon nitride, or zirconia, inorganic fiber such as glass fiber or carbon fiber, metallic fiber such as copper, steel, aluminum, or stainless steel, and organic fiber such as polyamide, polyester, or cellulose.
  • ceramic fiber such as boron, alumina, silicon carbide, silicon nitride, or zirconia
  • inorganic fiber such as glass fiber or carbon fiber
  • metallic fiber such as copper, steel, aluminum, or stainless steel
  • organic fiber such as polyamide, polyester, or cellulose.
  • the protrusion 2c is integrally formed on the second member 2 by injection molding or press-forming or the like, but the protrusion 2c may also be formed separately from the second member 2 as long as the protrusion 2c and a flat plate-shaped portion of the second member 2 are integrally joined in an anchor forming process or the like, for example.
  • a friction stir welding apparatus is used to join the first member 1 and the second member 2 together, but any apparatus may be used as long as it is able to soften or melt the protrusion 2c of the second member 2 and deform it into a desired shape.
  • the protrusion 2c of the second member 2 may be softened or melted using heat generated by ultrasonic vibration or a preheated heat plate or the like, instead of friction heat.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

A joining method for joining a first member in which a through-hole is formed from one surface toward the other surface, and a second member having a protrusion to be inserted through the through-hole, includes preparing a cylindrical portion having an inside diameter that is larger than a hole diameter of the through-hole, and a movable portion that is slidably arranged inside the cylindrical portion; arranging the second member on one surface of the first member, with the protrusion inserted through the through-hole, and arranging the cylindrical portion abutting against the other surface of the first member such that the inside of the cylindrical portion is communicated with the through-hole; and forming an anchor portion that holds the second member to the first member by moving the movable portion inside the cylindrical portion toward the protrusion, abutting the movable portion against the protrusion, and deforming the protrusion.

Description

JOINING METHOD
BACKGROUND OF THE INVENTION 1. Field of the Invention
[0001] The invention relates to a joining method, more particularly, a joining method for joining together different types of members such as two metal members, a metal member and a resin member, or two resin members, for example. 2. Description of Related Art
[0002] Known methods for joining together two different types of members such as a metal member and a resin member, for example, include a method that uses an adhesive (e.g., Japanese Patent Application Publication No. 11-173356 (JP 11-173356 A)), and a method that uses a fastening member such as a rivet or a screw. However, the former method is problematic in that it requires time for the adhesive to harden, and the adhesive force may decrease due to, for example, deterioration over time of the adhesive. Also, the latter method is problematic in that the product weight increases due to the rivet or screw or the like, and it takes time and man-hours to fasten the rivet or screw or the like.
[0003] With regards to these kinds of problems, related art that joins together two different types of members such as a metal member and a resin member without using an adhesive or a fastening member or the like, by deforming a portion of a member to be joined using ultrasonic vibration or the like, for example, is known.
[0004] With this kind of joining method, a metal member A having a through-hole Aa, a resin member B having a protrusion Ba that is inserted through the through-hole Aa of the metal member A, and an ultrasonic horn C in which an indentation of a predetermined shape is formed, are prepared, as shown in FIG. 4. The protrusion Ba of the resin member B is then inserted into the through-hole Aa of the metal member A, and the metal member A is placed on top of the resin member B. Then the ultrasonic horn C is moved from the metal member A side toward the resin member B while making the indentation in the ultrasonic horn C contact an upper end portion of the protrusion Ba of the resin member that is inserted through the through-hole Aa of the metal member A, and the protrusion Ba of the resin member B is melted and deformed by the ultrasonic vibration of the ultrasonic horn C. As a result, a head portion H having an anchor portion Ha that holds the resin member B to the metal member A is formed on an upper end portion of the protrusion Ba of this resin member B, thereby joining the metal member and the resin member together.
[0005] However, with the joining method described above, the protrusion Ba of the resin member B is melted and deformed while the ultrasonic horn C is moved from the metal member A side toward the resin member B. Therefore, a portion of the deformed protrusion Ba of the resin member B gets between the ultrasonic horn C and the metal member A, and a burr is created on an outer edge of the head portion H formed on the resin member B, more specifically, at a location on the outer edge of the head portion H formed on the resin member, between the ultrasonic horn C and the metal member A. The work of removing this burr takes time and money, which is problematic.
SUMMARY OF THE INVENTION
[0006] The invention thus provides a joining method capable of inhibiting a burr from being created, when joining together different types of members such as two metal members, a metal member and a resin member, or two resin members, for example.
[0007] One aspect of the invention relates to a joining method for joining a first member in which a through-hole is formed from one surface toward the other surface, and a second member having a protrusion to be inserted through the through-hole. This joining method includes: preparing a cylindrical portion having an inside diameter that is larger than a hole diameter of the through-hole, and a movable portion that is slidably arranged inside the cylindrical portion; arranging the second member on one surface of the first member, with the protrusion inserted through the through-hole, and arranging the cylindrical portion abutting against the other surface of the first member such that the inside of the cylindrical portion is communicated with the through-hole; and forming an anchor portion that holds the second member to the first member by moving the movable portion inside the cylindrical portion toward the protrusion, abutting the movable portion against the protrusion, and deforming the protrusion.
[0008] According to the joining method described above, the protrusion of the second member is inserted through the through-hole of the first member and the second member is arranged on one surface of the first member, and the cylindrical portion is arranged abutting against the other surface of the first member such that the inside of the cylindrical portion is communicated with the through-hole. Then the movable portion is moved inside the cylindrical member toward the protrusion, and abutted against the protrusion, consequently deforming the protrusion, such that an anchor portion that holds the second member to the first member is formed on the protrusion. As a result, the anchor portion is able to be formed on the protrusion inside of a closed space defined by the cylindrical portion, the movable portion, and the first member, while the cylindrical portion is abutted against the other surface of the first member. Therefore, the first member and the second member are able to be joined together, while inhibiting a burr from being created on the outer edge of the anchor portion that is formed on the protrusion of the second member.
[0009] Also, in the aspect described above, the movable portion may be rotatable around an axis inside the cylindrical portion, and in forming the anchor portion, the movable portion may be moved toward the protrusion while being rotated around the axis inside the cylindrical portion, and be abutted against the protrusion.
[0010] According to the joining method described above, in forming the anchor portion, the movable portion is moved inside the cylindrical portion toward the protrusion while being rotated around the axis, and this movable portion is abutted against the protrusion of the second member. As a result, the protrusion is deformed relatively easily, and the anchor portion is consequently able to be formed on this protrusion.
[0011] As can be understood from the above description, with the joining method according to the foregoing aspect of the invention, when joining together two different types of members such as two metal members, a metal member and a resin member, or two resin members, the protrusion of the second member is inserted through the through-hole of the first member and the second member is arranged on one surface of the first member, and this cylindrical portion is arranged abutting against the other surface of the first member such that the inside of the cylindrical portion is communicated with the through-hole. Then, the movable portion is moved inside the cylindrical portion toward the protrusion, and abutted against the protrusion such that the protrusion deforms, thus forming an anchor portion that holds the second member to the first member. As a result, a burr is able to be inhibited from being created on the anchor portion, and time and cost that it takes to remove the burr is able to be reliably reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Features, advantages, and technical and industrial significance of exemplary embodiments of the invention will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein:
FIG. 1A is a longitudinal sectional view illustrating an example embodiment of a joining method of the invention, and illustrates an arranging process in this method;
FIG. IB is a longitudinal sectional view illustrating the example embodiment of the joining method of the invention, and illustrates an anchor forming process in this method;
FIG. 1C is a longitudinal sectional view illustrating the example embodiment of the joining method of the invention, and illustrates a removal process in this method;
FIG. 2 A is a longitudinal sectional view illustrating a modified example of the joining method shown in FIGS. 1 A to 1C, and illustrates an arranging process in this method;
FIG 2B is a longitudinal sectional view illustrating the modified example of the joining method shown in FIGS. 1 A to 1C, and illustrates an anchor forming process in this method;
FIG. 2C is a longitudinal sectional view illustrating the modified example of the joining method shown in FIGS. lAto 1C, and illustrates a removal process in this method;
FIG. 3 is a longitudinal sectional view showing a frame format of the internal structure when a second member shown in FIGS. 1A to 1C is a fiber-reinforced resin member; and
FIG. 4 is a longitudinal sectional view illustrating a related joining method.
DETAILED DESCRIPTION OF EMBODIMENTS
[0013] Hereinafter, example embodiments of the joining method of the invention will be described with reference to the accompanying drawings.
[0014] FIG. 1 is a longitudinal view illustrating an example embodiment of the joining method of the invention, with FIG. 1 A being a view of an arranging process, FIG. IB being a view of a head forming process, and FIG. 1C being a view of a removal process.
<Friction welding apparatus used in this example embodiment of the joining method of the invention>
[0015] The joining method according to this example embodiment of the invention is carried out using a single action type friction stir welding apparatus which is a representative example of the friction stir welding apparatus. Therefore, first the representative example of the single action type Friction Stir Welding (FSW) apparatus used with the joining method according to this example embodiment will be outlined with reference to FIG. 1 A.
[0016] As shown in FIG. 1 A, the FSW apparatus 50 used with the joining method according to this example embodiment mainly includes a rotating jig portion (a movable portion) 51, a clamp member (a cylindrical portion) 54, and a backing member 55, as well as a supporting member, not shown in FIG. 1A, that supports these, and a driving mechanism, also not shown in FIG. 1A, that drives the rotating jig portion 51, and the like. The clamp member 54 is fixed via a spring 53 to the supporting member that is not shown.
[0017] The rotating jig portion (movable portion) 51 has a generally circular cylindrical shape, and is configured to rotate around an axis (rotational axis) Xr by the driving mechanism, not shown, and slide relative to the clamp member 54 in the direction of the broken arrow PI, i.e., the direction of the axis Xr (the vertical direction in FIG 1 A).
[0018] The clamp member (cylindrical portion) 54 is provided to the outside of the rotating jig portion 51, and has a generally circular cylindrical shape that has a void.
The rotating jig portion 51 is inserted in this void. The clamp member 54 is supported by the supporting member, not shown, via the spring 53, so as to push on processing material
(a first member 1 and a second member 2) from one surface (i.e., an upper surface la of the first member 1 in FIG. 1 A). Therefore, the clamp member 54 is configured to move in the direction of the broken arrow P2, i.e., the direction of the axis Xr, in a state urged to the processing material side.
[0019] The rotating jig portion 51 of this structure includes an abutting surface
51a, and the clamp member 54 of this structure includes an abutting surface 54a. These abutting surfaces 51a and 54a are moved in the direction of the axis Xr by the driving mechanism, not shown, so as to abut against one surface of the processing material (i.e., an upper surface 2ca of the protrusion 2c of the second member 2, and the upper surface la of the first member 1, respectively, in FIG. 1A).
[0020] Also, the backing member 55 is provided in a position facing the clamp member 54 and the rotating jig portion 51, and abuts against the other surface of the processing material (i.e., a lower surface 2b of the second member 2 in FIG 1 A).
[0021] The specific structure of the single action type friction stir welding (FSW) apparatus 50 in this example embodiment is not limited to the structure described above.
For example, the backing member 55 may be omitted from the FSW apparatus 50, or other members and the like not described with the FSW apparatus 50 described above may have provided.
<Joining method using the friction welding apparatus>
[0022] Next, a joining method using the FSW apparatus 50 according to this example embodiment will be outlined with reference to FIG. 1. In this example embodiment, a method for joining together a generally flat plate-shaped first member 1 such as a metal member, a resin member, or a wood, and a generally flat plate-shaped second member 2 such as a metal member or a resin member that includes material with a lower melting temperature than the material out of which the first member 1 is formed, will be described in detail. [0023] The joining method according to this example embodiment mainly includes a preparation process, an arranging process, an anchor forming process, and a removal process.
[0024] First, in the preparation process, the first member 1 in which a linear through-hole lc is formed from one surface (the lower surface in FIG. 1A) lb toward the other surface (the upper surface in FIG. 1 A) la, the second member 2 in which a protrusion 2c that is inserted through the through-hole lc of ^he first member 1 is integrally formed on the upper surface 2a thereof, and the FSW apparatus 50 described above, are prepared.
[0025] Here, the through-hole lc of the first member 1 and the protrusion 2c of the second member 2 both have generally circular sectional shapes, and the clamp member 54 of the FSW apparatus 50 has an inner diameter that is larger than the hole diameter of the through-hole lc of the first member 1. Also, the protrusion 2c of the second member 2 is formed such that the height in the up-down direction (i.e., the direction of the axis Xr) thereof is larger than the thickness in the up-down direction of the first member 1, and the volume of the protrusion 2c of the second member 2 is formed larger than the volume of the through-hole lc of the first member 1.
[0026] Next, in the arranging process, the second member 2 is arranged on the lower surface lb of the first member 1 such that the protrusion 2c of the second member 2 is inserted through the through-hole lc of the first member 1 and the lower surface lb of the first member 1 abuts against the upper surface 2a of the second member 2, as shown in FIG. 1 A. Also, the clamp member 54 of the FSW apparatus 50 is arranged on the upper surface la of the first member 1 with the abutting surface 54a of the clamp member 54 abutting against the upper surface la of the first member 1 so as to cover the through-hole lc of the first member 1, i.e., such that the inside of the clamp member 54 and the through-hole lc of the first member 1 are communicated with each other. The backing member 55 of the FSW apparatus 50 is arranged on a lower surface 2b side of the second member 2, such that the first member 1 and the second member 2 are sandwiched by the clamp member 54 and the backing member 55.
[0027] Next, in the anchor forming process, the rotating jig portion 1 is moved downward in the direction of the axis Xr while being rotated around the axis Xr inside the clamp member 54, and an abutting surface 51a of this rotating jig portion 51 is abutted against the upper surface 2ca of the protrusion 2c protruding from the through-hole lc of the first member 1, as shown in FIG. IB. As a result, the protrusion 2c softens or melts and deforms from friction heat generated between the abutting surface 51a of the rotating jig portion 51 and the upper surface 2ca of the protrusion 2c. When the rotating jig portion 51 is moved to a position a predetermined distance away from the upper surface la of the first member 1, a head portion 2h having an anchor portion 2ha that holds the second member 2 to the first member 1 is formed on an upper end portion of the protrusion 2c of the second member 2. The anchor portion 2ha of this head portion 2h is formed on the upper surface la of the first member 1 so as to spread out above and around the through-hole lc of the first member 1 , such that the head portion 2h comes to have an outer diameter that is larger than the through-hole lc of the first member 1.
[0028] Then in the removal process, the FSW apparatus 50 is removed from the first member 1 and the second member 2 after rotation of the rotating jig portion 51 is stopped and the softened or melted protrusion 2c of the second member 2 hardens, as shown in FIG. 1C. As a result, the first member 1 and the second member 2 are integrally joined together via the head portion 2h formed by the deformed protrusion 2c of the second member 2, or more specifically, via the anchor portion 2ha formed on the upper surface la of the first member 1 to the outer peripheral side of the head portion 2h.
[0029] In this way, with the joining method of this example embodiment, the second member 2 is arranged on the lower surface lb side of the first member 1, with the protrusion 2c of the second member 2 inserted through the through-hole lc of the first member 1. Along with this, the rotating jig portion 51 and the clamp member 54 of the FSW apparatus 50 are arranged on the upper surface la side of the first member 1 , with the abutting surface 54a of the clamp member 54 abutted against the upper surface la of the first member 1 such that the inside of the clamp member 54 is communicated with the through-hole lc of the first member 1. Then, the rotating jig portion 51 is moved toward the protrusion 2c of the second member 2 inside the clamp member 54 of the FSW apparatus 50, and is abutted against the protrusion 2c, thereby deforming the protrusion 2c, thus forming the anchor portion 2ha that holds the second member 2 to the first member 1, on the upper end portion of this protrusion 2c. As a result, the anchor portion 2ha is able to be formed on the protrusion 2c inside a closed space defined by the clamp member 54, the rotating jig portion 51 that slides inside the clamp member 54, and the first member 1, while the clamp member 54 of the FSW apparatus 50 is abutted against the upper surface la of the first member 1. Therefore, the first member 1 and the second member 2 that are different types of members are able to be elaborately joined, while inhibiting a burr from being created on the anchor portion 2ha of the second member 2.
[0030] In this example embodiment, a method of joining the generally flat plate-shaped first member 1 and the generally flat plate-shaped second member 2 is described, but the shapes of the members that are to be joined together may of course be set as appropriate.
[0031] Also, the shapes (longitudinal sectional shapes and cross-sectional shapes) of the through-hole lc provided in the first member 1 and the protrusion 2c provided on the second member 2 may be set as appropriate according to the joint strength and the like between the first member 1 and the second member 2. For example, in the example embodiment described above, the cross-sectional shape of both the through-hole lc provided in the first member 1 and the protrusion 2c provided on the second member 2 is a generally circular shape, but it may of course also be a generally oblong shape, a generally long hole shape, or a multiangular shape such as a square shape or the like. Also, in the example embodiment described above, the through-hole lc provided in the first member 1 and the protrusion 2c provided on the second member 2 both have a linear shape in the up-down direction (i.e., the direction of the Xr axis, the thickness direction of the first member 1 and the second member 2), but a through-hole lc' of a first member may also be formed so as to become smaller in diameter either continuously or in steps from an upper surface la' toward a lower surface lb', for example, as shown in FIGS. 2 A to 2C. Also, in this case, an anchor portion 2ha' that holds a second member 2' to the first member 1 ' may be formed inside the through-hole lc' of the first member 1 ' by moving the rotating jig portion 51 to a position in which it abuts against the upper surface la' of the first member Γ, and deforming a protrusion 2c' of the second member 2', or an anchor portion that holds the second member 2' to the first member 1 ' may be formed above the upper surface la' of the first member , as in the example embodiment described above.
[0032] Also, in the example embodiment described above, a mode is described in which the height in the up-down direction of the protrusion 2c of the second member 2 is formed greater than the thickness in the up-down direction of the first member 1, and the upper surface 2ca of the protrusion 2c protrudes from the through-hole lc of the first member 1 when the second member 2 is arranged on the lower surface lb of the first member 1. However, as long as the anchor portion 2ha that holds the second member 2 to the first member 1 is formed on the protrusion 2c when the protrusion 2c of the second member 2 is deformed, the upper surface 2ca of the protrusion 2c of the second member 2 of course does not have to protrude from the through-hole lc of the first member 1 when the second member 2 is arranged on the lower surface lb of the first member 1.
[0033] Also, the joining method according to the example embodiment described above is not particularly limited to the type of members that are to be joined together. However, when the second member 2 having the protrusion 2c is formed by a fiber-reinforced resin member in which reinforcing fiber material is mixed into resin (matrix resin) with a lower melting temperature than the material of which the first member 1 is formed, the fibers included in the second member 2 become oriented in a direction substantially orthogonal to abutting surfaces (boundary surfaces) of the upper surface 2a of the second member 2 and the lower surface lb of the first member 1, near these abutting surfaces (region R2 in FIG. 3) and inside the protrusion 2c of the second member 2 (region Rl in FIG. 3), as shown in FIG. 3, so joint strength between the first member 1 and the second member 2 may not be able to be sufficiently ensured.
[0034] When the second member is formed by a fiber-reinforced resin member, the resin (matrix resin) that forms the second member may be either a thermosetting resin or a thermoplastic resin. Some examples of thermosetting resin are epoxy resin, phenol resin, and melamine resin. An example of thermoplastic resin is one or two or more types of an admixture such as polypropylene (PP), polyethylene (PE), polystyrene (PS), AS resin, ABS resin, polyvinyl chloride (PVC), methacryl resin, polyamide (PA), polyester, polyacetal (POM), polycarbonate (PC), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polymethylmethacrylate (PMMA), polyvinylidene fluoride, polyphenylene oxide, polyphenylene sulfide, polyether ether ketone, liquid crystal polymer, polyetherimide, polyether sulfone, polyamide-imide, and thermoplastic epoxy resin, and the like. Also, a blend resin, graft resin, or copolymer with the thermoplastic resin as its main component, e.g., an ethylene - vinyl chloride copolymer, a vinyl acetate - ethylene copolymer, a vinyl acetate - vinyl chloride copolymer, a urethane - vinyl chloride copolymer, acrylic acid-modified polypropylene, or maleic acid-modified polyethylene may also be introduced.
[0035] Also, an example of the reinforcing fiber material that forms the second member is one or two or more types of an admixture of ceramic fiber such as boron, alumina, silicon carbide, silicon nitride, or zirconia, inorganic fiber such as glass fiber or carbon fiber, metallic fiber such as copper, steel, aluminum, or stainless steel, and organic fiber such as polyamide, polyester, or cellulose.
[0036] Also, in the example embodiment described above, a mode in which the protrusion 2c is integrally formed on the second member 2 by injection molding or press-forming or the like is described, but the protrusion 2c may also be formed separately from the second member 2 as long as the protrusion 2c and a flat plate-shaped portion of the second member 2 are integrally joined in an anchor forming process or the like, for example.
[0037] Also, in the example embodiment described above, a friction stir welding apparatus is used to join the first member 1 and the second member 2 together, but any apparatus may be used as long as it is able to soften or melt the protrusion 2c of the second member 2 and deform it into a desired shape. For example, the protrusion 2c of the second member 2 may be softened or melted using heat generated by ultrasonic vibration or a preheated heat plate or the like, instead of friction heat.
[0038] While an example embodiment of the invention has been described in detail with reference to the drawings, the specific structure is not limited to this example embodiment. Design changes and the like within the scope of the invention are also included in the invention.

Claims

CLAIMS:
1. A joining method for joining a first member in which a through-hole is formed from one surface toward the other surface, and a second member having a protrusion to be inserted through the through-hole, comprising:
preparing a cylindrical portion having an inside diameter that is larger than a hole diameter of the through-hole, and a movable portion that is slidably arranged inside the cylindrical portion;
arranging the second member on one surface of the first member, with the protrusion inserted through the through-hole, and arranging the cylindrical portion abutting against the other surface of the first member such that the inside of the cylindrical portion is communicated with the through-hole; and
forming an anchor portion that holds the second member to the first member by moving the movable portion inside the cylindrical portion toward the protrusion, abutting the movable portion against the protrusion, and deforming the protrusion.
2. The joining method according to the claim 1, wherein
the movable portion is rotatable around an axis inside the cylindrical portion; and in forming the anchor portion, the movable portion is moved toward the protrusion while being rotated around the axis inside the cylindrical portion, and is abutted against the protrusion.
3. The joining method according to claim 1 or 2, wherein
in forming the anchor portion, the movable portion is moved inside the cylindrical portion to a position separated from the other surface of the first member, and the anchor portion is formed on the other surface of the first member.
4. The joining method according to claim 1 or 2, wherein
in forming the anchor portion, the movable portion is moved inside the cylindrical portion to a position abutting against the other surface of the first member, and the anchor portion is formed inside the through-hole.
PCT/IB2015/000557 2014-03-27 2015-03-27 Joining method WO2015145258A1 (en)

Applications Claiming Priority (2)

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JP2014-064948 2014-03-27
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