WO2017047786A1 - 熱かしめ方法、熱かしめ装置、及び、被かしめ材 - Google Patents

熱かしめ方法、熱かしめ装置、及び、被かしめ材 Download PDF

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Publication number
WO2017047786A1
WO2017047786A1 PCT/JP2016/077541 JP2016077541W WO2017047786A1 WO 2017047786 A1 WO2017047786 A1 WO 2017047786A1 JP 2016077541 W JP2016077541 W JP 2016077541W WO 2017047786 A1 WO2017047786 A1 WO 2017047786A1
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Prior art keywords
heat
bosses
melted
peripheral surface
inner peripheral
Prior art date
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PCT/JP2016/077541
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English (en)
French (fr)
Inventor
嘉則 鶴貝
石川 寛
重人 赤堀
Original Assignee
本田技研工業株式会社
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Application filed by 本田技研工業株式会社 filed Critical 本田技研工業株式会社
Priority to JP2017540023A priority Critical patent/JP6479197B2/ja
Priority to US15/760,415 priority patent/US10864683B2/en
Priority to CN201680053879.3A priority patent/CN108136689B/zh
Publication of WO2017047786A1 publication Critical patent/WO2017047786A1/ja

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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60Riveting or staking
    • B29C65/606Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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    • B29C65/224Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip being a resistive ribbon, a resistive band or a resistive strip
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    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/73General 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
    • B29C66/739General 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
    • B29C66/7392General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00Components
    • F05D2240/10Stators
    • F05D2240/12Fluid guiding means, e.g. vanes
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2250/00Geometry
    • F05D2250/20Three-dimensional
    • F05D2250/23Three-dimensional prismatic
    • F05D2250/232Three-dimensional prismatic conical
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00Materials; Properties thereof
    • F05D2300/40Organic materials
    • F05D2300/43Synthetic polymers, e.g. plastics; Rubber

Definitions

  • the present invention relates to a heat caulking method, a heat caulking device for performing heat caulking by melting a plurality of bosses at once, and a caulking material obtained by these methods and devices.
  • a heat caulking method in which the first member to be heat caulked is tilted so that the welding tip can be accessed at a portion of the first member to be caulked (for example, Patent Document 1). ).
  • a heat caulking device having two molten chips is conventionally known (for example, Patent Document 2).
  • the two melting tips are respectively pressed against the plurality of welding bosses, whereby the plurality of welding bosses are melted.
  • the heat chip which has the front end surface which has a big contact area which can weld several places is conventionally known (for example, patent document 3).
  • the plurality of portions of the second member are uniformly welded to the inclined first member portion at a time. It was difficult to obtain weld strength.
  • a plurality of parts of the second member can be welded to the part of the first member inclined with respect to the vertical direction at a time, and heat that can stably obtain high bonding strength by welding. It is an object of the present invention to provide a caulking method, a heat caulking device, and a caulking material obtained by these methods and devices.
  • the present invention is provided on the inner peripheral surface of the hollow portion of a first member (for example, a main plate 10 to be described later) having a substantially cone-shaped hollow portion (for example, a later-described hollow portion 11).
  • a heat caulking method that melts at a time and joins to the first member, and has a shape that is continuous along the inner peripheral surface and in the circumferential direction of the hollow portion (for example, a heat chip 51 described later) ) Is used to melt the plurality of bosses at once, and a heat caulking method in which the melted adjacent bosses are joined to each other in a connected state is provided.
  • the adjacent outer boss of the plurality of bosses protruding from the inner peripheral surface inclined with respect to the vertical direction is melted by the outer peripheral surface of the heat chip formed by the continuous surface having a continuous shape. Can be linked. For this reason, the joining strength can be increased and the second member having the boss can be prevented from falling out of the hole.
  • the plurality of bosses can be melted at a uniform temperature and a uniform pressing force at a time, the bonding strength can be made uniform.
  • the present invention provides a plurality of first members (for example, a main plate 10 to be described later) having a substantially cone-shaped hollow portion (for example, a later-described hollow portion 11) provided on the inner peripheral surface of the hollow portion.
  • a plurality of bosses (for example, a boss 33 to be described later) of a second member (for example, a blade member 30 to be described later) that are fitted into a hole (for example, a bonding hole 132 to be described later) and protrude toward the inner peripheral surface side are melted at a time.
  • a heat staking device (for example, a heat staking device 50 to be described later) that is joined to the first member, and has a shape that is continuous with the inner peripheral surface and in the circumferential direction of the hollow portion (for example, A heat caulking device including a heat chip 51) to be described later is provided.
  • the outer peripheral surface of the heat chip is constituted by a continuous surface having a continuous shape, adjacent bosses among a plurality of bosses protruding from the inner peripheral surface inclined with respect to the vertical direction are melted. Can be linked. For this reason, the joining strength can be increased and the second member having the boss can be prevented from falling out of the hole.
  • the plurality of bosses can be melted at a uniform temperature and a uniform pressing force at a time, the bonding strength can be made uniform.
  • the heat chip has a shape that is continuous in the circumferential direction of the hollow portion, the pressing force applied to the melting point of the boss in a plurality of bosses arranged on the inclined surface such as the inner peripheral surface of the substantially conical hollow portion. Can be made uniform, and a plurality of bosses can be reliably pressed. As a result, a plurality of bosses arranged on the slope can be heat squeezed simultaneously.
  • a convex stepped portion (for example, a melting portion (for example, a melting portion 33A described later) formed by melting the boss is prevented from flowing out above the heat chip at an upper end portion of the heat chip.
  • a step portion 517 which will be described later, is formed continuously in the circumferential direction of the upper end portion of the heat chip.
  • the present invention provides a first member (for example, a main plate 10 to be described later) having a hollow portion having a substantially conical shape (for example, a later-described hollow portion 11) and an inner peripheral surface of the hollow portion of the first member.
  • a plurality of bosses for example, a boss 33 to be described later
  • a second member for example, a blade member 30 to be described later
  • a plurality of bosses melted at one time and joined to the first member, and a melting part (for example, a melting part 33A described later) constituted by melting the plurality of bosses is connected.
  • a caulking material for example, an impeller 1 described later) is provided.
  • the present invention since the melted portions formed by melting adjacent bosses are connected, it is possible to make the bonding strength of all the second members to the first member uniform. Moreover, the intensity
  • a partition wall (for example, a partition wall 134 which will be described later) is formed.
  • the inner peripheral surface forming the hollow portion of the first member is substantially conical, the molten boss attempts to flow downward, but the portion of the first member corresponding to the lower end of the molten portion Therefore, the melted portion does not flow below the partition wall, but remains in the partition wall portion. Then, the strength is maintained because there is a sufficient amount of melted part when adjacent bosses are connected. Further, when the heat chip is inserted to the lower end, the partition wall is also melted, so that the amount of the melted portion is increased and a connection portion having higher strength can be formed. Further, when the partition wall extends upward of the first member when the heat caulking is performed, when the partition wall is melted, the melted partition wall does not flow downward, and the boss is melted. It can be made to flow toward the melted part.
  • the first member is composed of a main plate (for example, a main plate 10 described later), the second member is composed of a plurality of blade members (for example, a blade member 30 described later), and the caulking material is the first member.
  • An impeller for example, an impeller 1 described later having a member and the second member.
  • an impeller arranged such that the blade members overlap when the impeller is viewed from the direction of the rotation axis of the impeller can be easily manufactured by heat caulking.
  • a plurality of parts of the second member can be joined to the part of the first member inclined with respect to the vertical direction at a time, and a high bond strength by joining can be obtained stably. It is possible to provide a heat-caulking method, a heat-caulking apparatus, and a caulking material obtained by these methods and apparatuses.
  • FIG. 1 is a plan view showing an impeller 1 as a caulking material according to a first embodiment of the present invention.
  • FIG. 2 is a side view showing the impeller 1 as a caulking material according to the first embodiment of the present invention.
  • FIG. 3 is a lower perspective view showing the impeller 1 as a caulking material according to the first embodiment of the present invention.
  • FIG. 4 is a lower perspective view showing the uncaulked material 1A before the heat caulking is performed by the heat caulking method according to the first embodiment of the present invention.
  • FIG. 5 is a plan view showing a state before the unswaged material 1A according to the first embodiment of the present invention is assembled.
  • an impeller 1 as a caulking material, which will be described later, and an uncaulking material 1A are below the main plate 10 having an isosceles trapezoidal shape as viewed from the side, as shown in FIG.
  • a direction from the bottom to the upper base is defined as an upward direction
  • the opposite direction is defined as a downward direction.
  • the direction from the upper base to the lower base of the main plate 10 having an isosceles trapezoidal shape when viewed from the side is defined as the upward direction, contrary to the impeller 1.
  • the opposite direction is defined as the downward direction.
  • the caulking material is specifically an impeller 1 used for blowing air in a fan or the like.
  • the impeller 1 has a resin-made first member and second member each made of polypropylene (PP).
  • the first member has a main plate 10 whose outer shape has a truncated cone shape.
  • the main plate 10 has a hollow inside, and thus the main plate 10 has a substantially conical hollow portion 11 (see FIG. 3).
  • the upper end portion of the main plate 10 is closed by the upper plate 12, and the upper plate 12 is formed with a mounting hole 121 constituted by a through hole into which a rotating shaft extending from the drive source is inserted.
  • a plurality of joint holes 132 are formed in the side plate 13 of the main plate 10. As shown in FIG. 5 and the like, the joining hole 132 extends from the substantially central position of the side plate 13 of the main plate 10 in the axial direction of the main plate 10 toward the lower side of the side plate 13 of the main plate 10 in the circumferential direction of the side plate 13 of the main plate 10. It extends diagonally to the vicinity of the lower end of the side plate 13 of the main plate 10.
  • the upper part of the joining hole 132 is constituted by a through hole.
  • the lower part of the joining hole 132 is constituted by a groove recessed from the outer peripheral surface of the side plate 13, and the side plate 13 is not penetrated in this portion.
  • the joining hole 132 Since the upper part of the joining hole 132 is constituted by a through-hole, the joining hole is also formed on the inner circumferential surface of the hollow portion 11, that is, on the inner circumferential surface of the main plate 10 forming the hollow portion 11, similarly to the outer circumferential surface of the main plate 10. 132 is provided with an opening. There are 14 joining holes 132 at equal intervals in the circumferential direction of the side plate 13 of the main plate 10.
  • a central convex portion 123 exists on the inner surface of the upper plate 12 of the main plate 10.
  • the central convex portion 123 has a cylindrical shape, has a coaxial positional relationship with the upper plate 12 having a disk shape (see FIG. 2 etc.), and extends downward from the inner surface of the upper plate 12. It is connected by being integrally formed with the plate 12.
  • the mounting hole 121 passes through the central convex portion 123 and the upper plate 12.
  • a melting portion 33 ⁇ / b> A (see FIG. 3), which is an inner peripheral surface of the side plate 13 of the main plate 10 before heat caulking, and is configured by melting a boss 33 described later by heat caulking.
  • a partition wall 134 is formed at a position corresponding to the lower end portion (the lower end portion of the melting portion 33A on the inner peripheral surface of the hollow portion 11).
  • the partition wall 134 has a cylindrical shape, has a coaxial positional relationship with the central convex portion 123, and is connected by being integrally formed with the side plate 13.
  • the outer diameter and inner diameter of the partition wall 134 are larger than the outer diameter of the central convex portion 123, and the partition wall 134 is disposed so as to surround the central convex portion 123.
  • the partition wall 134 has such a height that the partition wall 134 is not yet in contact with the heat chip 51 when the heat chip 51 contacts the boss 33 in heat caulking described later. And the side plate 13 of the main plate 10 have a height that does not overflow.
  • the partition wall 134 keeps the molten portion 33 ⁇ / b> A constituted by the boss 33 melted by heat caulking from flowing downward from the partition wall 134.
  • the side plate 13 of the main plate 10 has an inner peripheral enlarged diameter portion 135.
  • the inner peripheral enlarged diameter portion 135 is constituted by a portion of the side plate 13 in which the inner peripheral surface of the side plate 13 is formed thin.
  • the side plate 13 to which the partition wall 134 is connected is formed in the vertical direction. It exists from the portion of the side plate 13 between the portion and the lower end of the partition wall 134 (upper end of the partition wall 134 shown in FIG. 8) to the lower end portion of the main plate 10 (upper end portion of the main plate 10 shown in FIG. 8). .
  • the inner diameter of the side plate 13 is increased so that a step is generated at the upper end of the inner peripheral expanded portion 135 (the lower end portion of the inner peripheral expanded portion 135 shown in FIG. 8).
  • a predetermined gap is secured between the inner peripheral surface of the inner peripheral enlarged diameter portion 135 and the outer peripheral surface of the heat chip 51 (described later) during heat caulking described later, and is constituted by the molten boss 33.
  • a predetermined amount of the melting portion 33A can be held.
  • an adjustment convex portion 136 is formed on the inner peripheral surface of the side plate 13 before heat caulking, and in the vicinity of the joint hole 132 in the circumferential direction of the side plate 13. ing.
  • the adjustment protrusions 136 are formed one by one with respect to the bonding hole 132 and are provided to supply an amount of resin necessary for bonding the blade member 30 to the main plate 10. It is melted by heat caulking and is integrated with the melted boss 33 to constitute a melted portion 33A.
  • the second member has a blade member 30.
  • the blade member 30 includes a bone portion 31, a blade body portion 32, and a boss 33.
  • the bone part 31 has a shape substantially coinciding with the joint hole 132, and fits into the joint hole 132 one by one. That is, 14 blade members 30 having the bone portions 31 are provided in the same number as the number of the joining holes 132.
  • the lower end portion of the bone portion 31 is connected by being integrally formed with the lower end portion of the side plate 13 of the main plate 10 and forming the lower end portion of the joint hole 132. For this reason, as shown in FIG.
  • the blade member 30 is centered on the connection portion 301 of the blade member 30 connected to the lower end portion of the main plate 10 from the state where the bone portion 31 is not fitted in the joint hole 132. As shown in FIG. 4, the bone portion 31 is fitted in the joint hole 132 by being rotated (bent around the connection portion 301).
  • the blade main body portion 32 has a curved plate shape extending from the entire bone portion 31.
  • the blade body 32 When viewed from the axial direction of the main plate 10, the blade body 32 is disposed so that the blade bodies 32 of the blade members 30 disposed adjacent to each other overlap as shown in FIG. 1 and the like.
  • the boss 33 has a substantially triangular plate shape.
  • the entire bottom side of the boss 33 having a substantially triangular shape is integrally formed and connected to the upper portion of the bone portion 31.
  • the boss 33 is fitted into the joining hole 132 to form the hollow portion 11 from the inner peripheral surface of the side plate 13 of the main plate 10. Projecting inward of the hollow portion 11.
  • FIG. 4 As shown in FIG. 4, when the bone portion 31 is fitted in the joining hole 132, the boss 33 is fitted into the joining hole 132 to form the hollow portion 11 from the inner peripheral surface of the side plate 13 of the main plate 10. Projecting inward of the hollow portion 11. As shown in FIG.
  • the bosses 33 of the plurality of blade members 30 are melted at a time by heat caulking to form a molten portion 33 ⁇ / b> A, and are integrally connected to the bosses 33 of the adjacent blade members 30.
  • the main plate 10 is joined.
  • the impeller 1 having the above configuration constitutes a so-called mixed flow fan.
  • FIG. 6 is a perspective view showing the heat caulking device 50 according to the first embodiment of the present invention.
  • FIG. 7 is a perspective view showing the heat chip 51 of the heat caulking device 50 according to the first embodiment of the present invention.
  • the heat caulking device 50 includes a heat chip 51, a heat chip driving unit 52, and a holding base 53.
  • the heat chip 51 includes a heating unit 511 and an electrode unit 512.
  • the outer shape of the heating unit 511 has a shape that is obtained by turning the upside-down substantially conical shape upside down, and openings are formed at the upper end and the lower end of the heating unit 511.
  • the heating part 511 occupying most of the heat chip 51 has a shape that is continuous with the inner peripheral surface of the side plate 13 of the main plate 10 forming the hollow part 11 and in the circumferential direction of the hollow part 11. .
  • the heating unit 511 does not have a completely continuous shape, but the width of the slit is extremely small. It means “continuous”. Further, the slit can be filled with an insulating material or the like to form a continuous surface for use.
  • the heating unit 511 is made of a steel material.
  • the heating unit 511 is formed with slits 514 and 515 that connect the outer peripheral surface and the inner peripheral surface of the heating unit 511.
  • the slits 514 and 515 divide the heating unit 511 into a plurality in the circumferential direction of the heating unit 511. More specifically, the slit 515 does not completely divide the heating unit 511 but is formed leaving the upper end or lower end of the heating unit 511. Therefore, the individual portions of the heating unit 511 partitioned by the slits 515 are hereinafter referred to as substantially divided pieces.
  • one of the slits 514 is formed from the upper end of the heating unit 511 to the lower end of the heating unit 511, and this one slit 514 allows the heating unit 511 is divided.
  • none of the other slits 515 is formed from the upper end of the heating unit 511 to the lower end of the heating unit 511, and the other slits 515 adjacent to the one slit 514 are not included in the heating unit 511.
  • the lower end portion of the heating portion 511 is formed up to the upper end portion. Therefore, in the part of the heating part 511 in which the other slits 515 are formed, the heating part 511 is not divided and connected at the lower end part of the heating part 511.
  • Another slit 515 adjacent to the other slit 515 is formed up to the lower end of the heating unit 511, leaving the upper end of the heating unit 511. Therefore, in the part of the heating part 511 in which another slit 515 is formed, the heating part 511 is not divided and connected at the upper end part of the heating part 511. In this way, the slits 515 are alternately formed, so that the heating unit 511 moves from one side of the heating unit 511 to the other side with the one slit 514 as a boundary, in the circumferential direction of the heating unit 511. It is electrically connected so as to make a round zigzag in the vertical direction.
  • a convex stepped portion 517 is formed at the upper end portion of the outer peripheral surface of the heating portion 511.
  • the step 517 protrudes from the upper end of the outer peripheral surface of the heating unit 511 outward in the radial direction of the heating unit 511 and continuously extends so as to make one round in the circumferential direction of the upper end of the outer peripheral surface of the heating unit 511. Is formed.
  • the stepped portion 517 is not formed completely continuously. However, since the width of the slit is extremely small, it is substantially “continuous” here. "Means.
  • the stepped portion 517 prevents the molten portion 33 ⁇ / b> A configured by the boss 33 melted by heat caulking from flowing out above the heat chip 51 from the upper end portion of the heat chip 51.
  • the electrode part 512 has a substantially rectangular plate shape.
  • the lower end portion of the electrode portion 512 is connected by being integrally formed with each of two substantially divided pieces adjacent to one slit 514.
  • the upper end part of the electrode part 512 is fixed to and electrically connected to the positive electrode and the negative electrode of the power supply support part 521 of the heat chip driving part 52, respectively.
  • electricity is supplied from the power supply support unit 521 of the heat chip driving unit 52 to the heating unit 511 through the electrode unit 512. Since the heating unit 511 has an electrical resistance, when the electricity is supplied to the heating unit 511, the entire heating unit 511 generates heat substantially uniformly.
  • the heat chip driving unit 52 is configured to be able to move the power supply support unit 521 in the vertical direction, and the heat chip driving unit 52 drives the power supply support unit 521 in the vertical direction so that the heat chip 51 is moved. , And can be moved in the vertical direction of FIG.
  • the holding base 53 includes a base 531 and a cylindrical portion 532 positioned on the top of the base 531.
  • the cylindrical portion 532 has a blade body portion fitting recess 534.
  • the blade body fitting recess 534 has substantially the same shape as the upper part of the blade body 32 of the impeller 1 (the lower part of the blade body 32 shown in FIG. 6) and is formed to be depressed downward. Therefore, in the blade main body fitting recess 534, the blade main body portion 32 of the blade member 30 in a state where the bone portion 31 is fitted in the joint hole 132 of the main plate 10 before the heat caulking is performed is the rotation of the main plate 10. They can be fitted in a positional relationship in which the axial direction coincides with the vertical direction.
  • the holding base 53 allows the main plate 10 and the blade member 30 (hereinafter referred to as “unswaged material 1 ⁇ / b> A”) in a state in which the bone portion 31 is fitted into the joint hole 132 before heat caulking is performed. , Stably hold it upside down.
  • FIG. 8 is a cross-sectional view showing a state in which the heat chip 51 starts to melt the boss 33 in the heat caulking method according to the first embodiment of the present invention.
  • FIG. 9 is a cross-sectional view showing a state where the heat chip 51 melts the boss 33 and the partition wall 134 in the heat caulking method according to the first embodiment of the present invention.
  • the vane body portion 32 of the vane member 30 of the uncaulking material 1A is placed in the vane body portion fitting recess 534 with the positional relationship in which the rotational axis of the main plate 10 of the uncaulking material 1A coincides with the vertical direction.
  • the unswaged material 1 ⁇ / b> A is held by the holding table 53.
  • the heat chip 51 is lowered by driving the heat chip driving unit 52, and the heat chip 51 is inserted into the hollow portion 11 of the main plate 10.
  • the adjustment convex part 136 is melted and the plurality of bosses 33 are melted at once.
  • the melting part 33A flows downward, but is not yet in contact with the heating part 511 of the heat chip 51 and is not melted, and is prevented from flowing downward from the partition wall 134. It collects between the side plates 13 of the main plate 10. Thereby, the resin amount of the melting part 33A is maintained at a predetermined amount.
  • the heat chip 51 is further lowered, brought into contact with the partition wall 134, the lowering of the heat chip 51 is stopped, and the partition wall 134 is melted.
  • the partition wall 134 is deformed and melted away from the rotational axis of the main plate 10 radially outward.
  • the melted partition wall 134 is integrated with the melted part 33A, and the amount of resin in the melted part 33A further increases.
  • the melting portion 33A is pressed so that the edge of the lower end portion of the heat chip 51 has the same height as the inner surface of the central convex portion 123.
  • the partition wall 134 is integrated with the melting portion 33A, and the melting portion 33A is connected to each other and is mainly disposed in the inner peripheral enlarged diameter portion 135. Then, the melting part 33A is solidified by lowering the temperature of the heat chip 51.
  • the bosses 33 of the plurality of blade members 30 constituting the melting portion 33 ⁇ / b> A are melted and integrated, then solidified and connected, and joined to the main plate 10.
  • the main plate 10 as the first member having the substantially conical hollow portion 11 is fitted into a plurality of holes (joining holes 132) provided on the inner peripheral surface of the hollow portion 11.
  • the plurality of bosses 33 of the blade member 30 as the second member protruding toward the inner peripheral surface side are melted at a time and joined to the main plate 10 as the first member.
  • a plurality of bosses 33 are melted at a time using the heat chip 51 having a shape that is continuous along the inner circumferential surface and in the circumferential direction of the hollow portion 11, and the adjacent bosses that are melted are melted.
  • the members 33 are joined to the first member in a connected state.
  • the adjacent bosses 33 among the plurality of bosses 33 protruding from the inner peripheral surface forming the hollow portion 11 can be melted and connected. For this reason, the joining strength can be increased, and the blade member 30 having the boss 33 can be prevented from falling out of the joining hole 132. Further, since the plurality of bosses 33 can be melted at a uniform temperature and a uniform pressing force at a time, the bonding strength can be made uniform.
  • a plurality of holes provided on the inner peripheral surface of the hollow portion 11 of the main plate 10 as the first member having the substantially conical hollow portion 11.
  • the bosses 33 of the blade member 30 as the plurality of second members protruding toward the inner peripheral surface side are melted at once and joined to the main plate 10 as the first member.
  • the heat caulking device 50 includes a heat chip 51 having a shape that extends along the inner peripheral surface and continues in the circumferential direction of the hollow portion 11.
  • the outer peripheral surface of the heat chip 51 is constituted by a continuous surface, the inner peripheral surface (main plate) that is inclined with respect to the axis of the main plate 10 as the first member that is in a positional relationship that coincides with the vertical direction.
  • the adjacent bosses 33 among the plurality of bosses 33 protruding from the inner peripheral surface forming the ten hollow portions 11 can be melted and connected. For this reason, the joining strength can be increased, and the blade member 30 having the boss 33 can be prevented from falling out of the joining hole 132. Further, since the plurality of bosses 33 can be melted at a uniform temperature and a uniform pressing force at a time, the bonding strength can be made uniform.
  • the boss 33 is melted in the plurality of bosses 33 arranged on the inclined surface such as the inner peripheral surface of the substantially conical hollow portion 11.
  • the pressing force applied to the points can be made uniform, and the plurality of bosses 33 can be reliably pressed.
  • the plurality of bosses 33 disposed on the slope can be heat squeezed simultaneously.
  • the upper end portion of the heat chip 51 is provided with a convex stepped portion 517 that prevents the molten portion 33A formed by melting the boss 33 from flowing out above the heat chip 51. It is formed continuously in the circumferential direction.
  • the melting portion 33A configured by melting the boss 33 from flowing out above the heat chip 51, and to fix the melting portion 33A to the outer peripheral surface of the heating portion 511 of the heat chip 51 and the inner periphery of the main plate 10. Can be kept between the faces. Thereby, it is possible to ensure a melting portion 33A composed of a sufficient amount of resin for connecting adjacent bosses 33, that is, the height in the axial direction of the substantially conical hollow portion 11, and The melting portion 33A having a thickness in the radial direction of the hollow portion 11 can be secured, and the bonding strength can be reliably maintained.
  • the caulking material is provided in the first member having the substantially conical hollow portion 11 and the plurality of holes (joining holes 132) provided on the inner peripheral surface of the hollow portion 11 of the first member.
  • a plurality of second member bosses 33 that are fitted and projecting toward the inner peripheral surface side, and are melted at a time and joined to the first member.
  • a melting portion 33A configured by melting a plurality of bosses 33 is connected.
  • the strength of joining all the blade members 30 to the main plate 10 can be made uniform.
  • the strength of joining the blade member 30 to the main plate 10 can be increased, and the blade member 30 having the boss 33 can be prevented from falling out of the joining hole 132.
  • a partition wall 134 is formed in the portion of the main plate 10 as the corresponding first member to block the melting portion 33A.
  • the resin that is the melting portion 33A formed by melting the boss 33 attempts to flow downward, but the flow of the resin is blocked at the lower end of the melting portion 33A. Since the partition wall 134 is provided, the resin does not flow below the partition wall 134 and remains in the melting portion 33A. For this reason, the strength is maintained because there is a sufficient amount of the melting portion 33A when the adjacent melting portions 33A are connected. Furthermore, since the partition wall 134 is also melted when the heat chip 51 is inserted to the lower end, the amount of the melted portion 33A (resin amount) is increased, and a higher strength connecting portion (melted portion 33A) can be formed.
  • the partition wall 134 extends downward from the portion of the side plate 13 in the vicinity of the upper plate 12 of the main plate 10 (from the portion disposed below the unswaged material 1A when heat caulking is performed). Therefore, when the partition wall 134 is melted, the melted partition wall 134 does not flow toward the upper plate 12 but flows toward the melting portion 33A formed by melting the boss 33. Can do.
  • the first member is composed of the main plate 10.
  • the second member is composed of a plurality of blade members 30.
  • the caulking material is an impeller 1 having a first member and a second member. Thereby, the impeller 1 having the blade member 30 disposed so that the blade main body portion 32 overlaps when the impeller 1 is viewed from the rotation axis direction of the impeller 1 can be easily manufactured by heat caulking.
  • FIG. 10 is a perspective view showing a heat chip 51B of the heat caulking device according to the second embodiment of the present invention.
  • the heat chip 51B has a heating part 511B and an electrode part 512B.
  • the outer shape of the heating unit 511 ⁇ / b> B has a shape in which the substantially conical shape of the head is turned upside down, similar to the heating unit 511 in the first embodiment, and the upper end of the heating unit 511 ⁇ / b> B and An opening is formed at the lower end.
  • the following effects are produced.
  • no slit is formed.
  • the thermal uniformity is achieved by partially changing the thickness of the chip or adjusting the terminal mounting position. Thereby, it can be set as the heat chip
  • each part of the heat staking apparatus is not limited to the structure of each part of the heat staking apparatus 50 in the present embodiment.
  • the shape of the heat chip is not limited to the shape of the heat chip 51 in the present embodiment.
  • the shape and configuration of each part of the caulking material and the uncaulking material are not limited to the shape of each part of the impeller 1 and the uncaulking material 1A as the caulking material in the present embodiment.
  • the shape of the stepped portion, the boss, the partition, and the like is not limited to the shape of the stepped portion 517, the boss 33, the partition 134, and the like in the present embodiment.
  • the impeller 1 as a caulking material manufactured by a heat caulking method performed using the heat caulking device 50 is used for blowing air in a fan or the like, and constitutes a so-called mixed flow fan.
  • the caulking material may be a so-called sirocco fan that is a centrifugal type and has blade members arranged forward, or a so-called turbofan that has blade members arranged backward.
  • the main plate 10 has a substantially conical shape, but is not limited to this. What is necessary is just a substantially pyramid shape, for example, a substantially triangular pyramid shape etc. may be sufficient.
  • Impeller 10 Main plate (first member) 11 ... hollow part 30 ... blade member (second member) 33 ... Boss 33A ... Melting part 51 ... Heat chip 132 ... Joining hole (hole) 134 ... partition wall 517 ... step portion

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Ceramic Engineering (AREA)
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Abstract

鉛直方向に対して傾斜した第一部材の部分に、第二部材の複数の部分を、一度に接合させることができ、安定して、接合による高い結合強度を得ることができる熱かしめを行う、熱かしめ方法、熱かしめ装置、及び、これらの方法、装置により得られる被かしめ材を提供する。略錐体形状の中空部11を有する第一部材10の、中空部11の内周面に設けられた複数の孔132に嵌め込まれ、内周面側に突出した第二部材30の複数のボス33を、一度に溶融させて第一部材10に接合させる熱かしめ方法であって、内周面に沿い、且つ中空部11の周方向に連続した形状を有するヒートチップ51を用いて、複数のボス33を一度に溶融し、溶融した隣接するボス33同士が連結した状態で第一部材10に接合される熱かしめ方法である。

Description

熱かしめ方法、熱かしめ装置、及び、被かしめ材
 本発明は、複数のボスを一度に溶融させて熱かしめを行う熱かしめ方法、熱かしめ装置、及び、これらの方法、装置により得られる被かしめ材に関する。
 従来より、熱かしめされる第一部材を傾斜させて、第一部材の熱かしめが行われる部分に溶着チップをアクセス可能として熱カシメを行う熱かしめ方法が知られている(例えば、特許文献1)。また、溶融チップを2つ有する熱かしめ装置が、従来より知られている(例えば、特許文献2)。2つの溶融チップは、複数の溶着ボスへそれぞれ押しつけられ、これにより複数の溶着ボスは溶融する。また、複数箇所を溶着することができる大きな接触面積を有する先端面を有するヒートチップが、従来より知られている(例えば、特許文献3)。
登録実用新案第3161142号公報 特許第3899355号公報 特開2007-307812号公報
 上記特許文献1に記載の熱かしめ方法では、樹脂製の溶着ボスに対して溶着チップが斜めに作用すると、溶着ボスを構成する樹脂の溶融が不均一になり、溶着強度にバラツキが発生しやすい。このため、同公報においては、クランク形状のチップを用いて、熱かしめを行う技術が記載されている。
 また、上記特許文献2に記載の熱かしめ装置では、溶融チップにより溶融させる箇所毎に温度や溶融状態が異なってしまい、全体を均一に管理することが困難である。また、上記特許文献3に記載のチップでは、ヒートチップにより溶融して生ずる溶融部が拡がってしまうため、溶着による安定した結合強度を得ることは困難である。
 従って、第一部材に対して溶着させられる第二部材の部分が複数存在する場合に、傾斜した第一部材の部分に、第二部材の複数の部分を、一度に均一に溶着させて、高い溶着強度を得ることは困難であった。
 本発明は、鉛直方向に対して傾斜した第一部材の部分に、第二部材の複数の部分を、一度に溶着させることができ、安定して、溶着による高い結合強度を得ることができる熱かしめを行う、熱かしめ方法、熱かしめ装置、及び、これらの方法、装置により得られる被かしめ材を提供することを目的とする。
 上記目的を達成するため本発明は、略錐体形状の中空部(例えば、後述の中空部11)を有する第一部材(例えば、後述の主板10)の、前記中空部の内周面に設けられた複数の孔(例えば、後述の接合孔132)に嵌め込まれ、内周面側に突出した第二部材(例えば、後述の羽根部材30)の複数のボス(例えば、後述のボス33)を、一度に溶融させて前記第一部材に接合させる熱かしめ方法であって、前記内周面に沿い、且つ前記中空部の周方向に連続した形状を有するヒートチップ(例えば、後述のヒートチップ51)を用いて、前記複数のボスを一度に溶融し、溶融した隣接する前記ボス同士が連結した状態で前記第一部材に接合される熱かしめ方法を提供する。
 本発明によれば、連続形状による連続面により構成されたヒートチップの外周面により、鉛直方向に対して傾斜している内周面から突出する複数のボスのうちの隣接したボスを溶融させて連結させることができる。このため、接合の強度を高めることができ、ボスを有する第二部材が孔から抜け落ちることを防止できる。また、複数のボスを一度に均一な温度、均一な押圧力にて溶融することができるので、接合の強度を均一とすることができる。
 また、本発明は、略錐体形状の中空部(例えば、後述の中空部11)を有する第一部材(例えば、後述の主板10)の、前記中空部の内周面に設けられた複数の孔(例えば、後述の接合孔132)に嵌め込まれ、内周面側に突出した第二部材(例えば、後述の羽根部材30)の複数のボス(例えば、後述のボス33)を、一度に溶融させて前記第一部材に接合させる熱かしめ装置(例えば、後述の熱かしめ装置50)であって、前記内周面に沿い、且つ前記中空部の周方向に連続した形状を有するヒートチップ(例えば、後述のヒートチップ51)を備えることを特徴とする熱かしめ装置を提供する。
 本発明によれば、ヒートチップ外周面は連続形状による連続面により構成されるため、鉛直方向に対して傾斜している内周面から突出する複数のボスのうちの隣接したボスを溶融させて連結させることができる。このため、接合の強度を高めることができ、ボスを有する第二部材が孔から抜け落ちることを防止できる。また、複数のボスを一度に均一な温度、均一な押圧力にて溶融することができるので、接合の強度を均一とすることができる。
 また、ヒートチップは中空部の円周方向に連続した形状を有するため、略円錐形状の中空部の内周面のような斜面に配置された複数のボスにおいて、ボスの溶融点にかかる押圧力を均一とすることができ、確実に複数のボスを押圧することができる。この結果、斜面に配置された複数のボスを同時に熱かしめすることができる。
 そして、前記ヒートチップの上端部には、前記ボスが溶融して構成される溶融部(例えば、後述の溶融部33A)が前記ヒートチップの上方に流出することを防ぐ凸状の段差部(例えば、後述の段差部517)が、前記ヒートチップの上端部の周方向に連続して形成されている。
 このため、ボスが溶融して構成される溶融部がヒートチップより上方に流出することを抑え、溶融部を、ヒートチップの加熱部の外周面と、主板の内周面との間に留めることができる。これにより、隣接するボス同士が連結するために十分な量の溶融部を確保することができ、接合の強度を確実に維持することができる。
 また、本発明は、略錐体形状の中空部(例えば、後述の中空部11)を有する第一部材(例えば、後述の主板10)と、前記第一部材の前記中空部の内周面に設けられた複数の孔(例えば、後述の接合孔132)に嵌め込まれ、内周面側に突出した第二部材(例えば、後述の羽根部材30)の複数のボス(例えば、後述のボス33)であって、一度に溶融させられて前記第一部材に接合した複数のボスと、を備え、前記複数のボスが溶融して構成される溶融部(例えば、後述の溶融部33A)は連結していることを特徴とする被かしめ材(例えば、後述のインペラ1)を提供する。
 本発明によれば、隣接したボスが溶融して構成される溶融部が連結しているので、第一部材に対する全ての第二部材の接合の強度を均一にすることができる。また、第一部材に対する第二部材の接合の強度を高めることができ、ボスを有する第二部材が孔から抜け落ちることを防止できる。
 そして、前記第二部材が前記第一部材に接合する前の、前記第一部材の中空部の内周面の前記溶融部の下端部に相当する前記第一部材の部分には、前記溶融部をせき止めるための隔壁(例えば、後述の隔壁134)が形成されている。
 このため、第一部材の中空部を形成している内周面は略円錐形であるため溶融したボスは下方に流れて行こうとするが、溶融部の下端に相当する第一部材の部分に溶融部をせき止める隔壁を有するので、溶融部が隔壁よりも下方に流れず、隔壁の部分に留まる。すると隣接するボスが連結する際に十分な量の溶融部があるため強度が維持される。更に、ヒートチップが下端まで挿入される場合には、隔壁も溶融するので溶融部の量が増加し、より強度の高い連結部を形成可能である。また、隔壁は、熱かしめが行われる際の第一部材の上方へ向って延びている場合には、隔壁が溶融する際に、溶融した隔壁が下方へ流れずに、ボスが溶融して構成された溶融部の方へ流れるようにすることができる。
 そして、前記第一部材は主板(例えば、後述の主板10)により構成され、前記第二部材は複数の羽根部材(例えば、後述の羽根部材30)により構成され、被かしめ材は、前記第一部材と前記第二部材とを有するインペラ(例えば、後述のインペラ1)である。
 このため、インペラの回転軸心方向からインペラを見た場合に羽根部材が重なるように配置されたインペラを、熱かしめにより容易に製造することができる。
 本発明によれば、鉛直方向に対して傾斜した第一部材の部分に、第二部材の複数の部分を、一度に接合させることができ、安定して、接合による高い結合強度を得ることができる熱かしめを行う、熱かしめ方法、熱かしめ装置、及び、これらの方法、装置により得られる被かしめ材を提供することができる。
本発明の第一実施形態に係る被かしめ材としてのインペラ1を示す平面図である。 本発明の第一実施形態に係る被かしめ材としてのインペラ1を示す側面図である。 本発明の第一実施形態に係る被かしめ材としてのインペラ1を示す下方斜視図である。 本発明の第一実施形態に係る熱かしめ方法により熱かしめが行われる前の未かしめ材1Aを示す下方斜視図である。 本発明の第一実施形態に係る未かしめ材1Aが組み立てられる前の状態を示す平面図である。 本発明の第一実施形態に係る熱かしめ装置50を示す斜視図である。 本発明の第一実施形態に係る熱かしめ装置50のヒートチップ51を示す斜視図である。 本発明の第一実施形態に係る熱かしめ方法においてヒートチップ51がボス33を溶融し始めた様子を示す断面図である。 本発明の第一実施形態に係る熱かしめ方法においてヒートチップ51がボス33及び隔壁134を溶融した様子を示す断面図である。 本発明の第二実施形態に係る熱かしめ装置のヒートチップ51Bを示す斜視図である。
 本発明の第一実施形態について、図面を参照しながら詳細に説明する。先ず、被かしめ材について説明する。
 図1は、本発明の第一実施形態に係る被かしめ材としてのインペラ1を示す平面図である。図2は、本発明の第一実施形態に係る被かしめ材としてのインペラ1を示す側面図である。図3は、本発明の第一実施形態に係る被かしめ材としてのインペラ1を示す下方斜視図である。図4は、本発明の第一実施形態に係る熱かしめ方法により熱かしめが行われる前の未かしめ材1Aを示す下方斜視図である。図5は、本発明の第一実施形態に係る未かしめ材1Aが組み立てられる前の状態を示す平面図である。
 以下の説明においては、説明の便宜上、後述する被かしめ材としてのインペラ1、及び、未かしめ材1Aについては、図2に示すように、側方視で等脚台形状を有する主板10の下底から上底へ向う方向(図2における上方向)を上方向と定義し、その逆の方向を下方向と定義する。また、後述するヒートチップ51については、インペラ1とは逆に、側方視で等脚台形状を有する主板10の上底から下底へ向う方向(図7における上方向)を上方向と定義し、その逆の方向を下方向と定義する。
 図1に示すように、被かしめ材は具体的には、ファン等において送風に用いられるインペラ1である。インペラ1は、それぞれポリプロピレン(PP)からなる樹脂製の第一部材と第二部材とを有している。第一部材は、図2に示すように、外形が裁頭円錐形状を有する主板10を有している。主板10は、内部が中空であり、従って主板10は、略円錐形状の中空部11(図3参照)を有している。主板10の上端部は、上板12により塞がれており、上板12には、駆動源から延びる回転軸が挿入される貫通孔により構成される取付穴121が形成されている。
 主板10の側板13には、接合孔132が複数形成されている。接合孔132は、図5等に示すように、主板10の軸方向における主板10の側板13の略中央位置から、主板10の側板13の下方へ向かって、主板10の側板13の周方向に斜めに、主板10の側板13の下端部近傍に至るまで延びている。接合孔132の上部は貫通孔により構成されている。接合孔132の下部は側板13の外周面から窪んだ溝により構成されており、この部分においては、側板13は貫通されていない。接合孔132の上部は貫通孔により構成されているため、中空部11の内周面、即ち、中空部11を形成する主板10の内周面においても、主板10の外周面と同様に接合孔132が開口して設けられている。接合孔132は、主板10の側板13の周方向へ等間隔で14個存在している。
 図3等に示すように、主板10の上板12の内面には、中央凸部123が存在する。中央凸部123は、円柱形状を有しており、円盤形状を有する上板12(図2等参照)と同軸的な位置関係を有して上板12の内面から下方へ延びており、上板12と一体成形されることにより接続されている。取付穴121は、中央凸部123及び上板12を貫通する。
 図4に示すように、熱かしめが行われる前の状態の主板10の側板13の内周面であって、後述のボス33が熱かしめにより溶融して構成された溶融部33A(図3参照)の下端部(中空部11の内周面の溶融部33Aの下端部)に相当する位置には、隔壁134が形成されている。隔壁134は、円筒形状を有し、中央凸部123と同軸的な位置関係を有しており、側板13と一体成形されることにより接続されている。隔壁134の外径及び内径は中央凸部123の外径よりも大きく、隔壁134は中央凸部123を取り囲むように配置されている。
 隔壁134は、後述する熱かしめにおいて、ヒートチップ51がボス33に当接したときに、未だヒートチップ51に隔壁134が当接しない程度の高さであって、且つ、溶融部33Aが隔壁134と主板10の側板13との間から溢れ出ない程度の高さを有している。隔壁134は、熱かしめにより溶融したボス33により構成される溶融部33Aを、隔壁134よりも下方へ流れること堰き止める。
 図4、図8に示すように、主板10の側板13は内周拡径部135を有している。内周拡径部135は、側板13の内周面が薄く形成された側板13の部分により構成されており、図8に示すように、上下方向において、隔壁134が接続されている側板13の部分と、隔壁134の下端(図8に示す隔壁134の上端)との間の側板13の部分から、主板10の下端部(図8に示す主板10の上端部)に至るまで存在している。側板13の内径は、内周拡径部135の上端(図8に示す内周拡径部135の下端部)において、一段段差が生ずるように拡径している。これにより後述の熱かしめの際に、内周拡径部135の内周面と、後述のヒートチップ51の外周面と、の間に所定の隙間が確保され、溶融したボス33により構成される溶融部33Aを所定量保持可能である。
 また、図4等に示すように、熱かしめが行われる前の状態の側板13の内周面であって、側板13の周方向における接合孔132の近傍には、調整凸部136が形成されている。調整凸部136は、接合孔132に対して1つずつ形成されており、主板10への羽根部材30の接合に必要な量の樹脂を供給するために設けられている。熱かしめにより溶融し、溶融したボス33と一体となり溶融部33Aを構成する。
 図5に示すように、第二部材は、羽根部材30を有している。羽根部材30は、骨部31と、羽根本体部32と、ボス33と、を有している。骨部31は、接合孔132に略一致する形状を有しており、接合孔132に1つずつ嵌合する。即ち、骨部31を有する羽根部材30は、接合孔132の数と同数の14枚設けられている。骨部31の下端部は、主板10の側板13の下端部であって接合孔132の下端部を形成している部分に一体成形されることにより接続されている。このため、図5に示すように、骨部31が接合孔132に嵌合していない状態から、主板10の下端部に接続されている羽根部材30の接続部301を中心として羽根部材30が回動させられて(接続部301を中心として折り曲げられて)、図4に示すように、骨部31は接合孔132に嵌合させられる。
 羽根本体部32は、骨部31の全体から延びる湾曲した板状を有している。主板10の軸方向から見たときに、羽根本体部32は、図1等に示すように、隣接して配置された羽根部材30の羽根本体部32が重なるように配置されている。ボス33は、略三角形状の板状を有している。略三角形状を有するボス33の底辺の全体は、骨部31の上部に一体成形されて接続されている。ボス33は、図4に示すように、骨部31が接合孔132に嵌合しているときには、接合孔132に嵌め込まれて中空部11を形成する主板10の側板13の内周面から、中空部11の内方へ突出している。複数の羽根部材30のボス33は、図3に示すように、熱カシメが行われることにより一度に溶融して溶融部33Aとなり、隣接する羽根部材30のボス33と一体的に連結されると共に、主板10に接合される。以上の構成を有するインペラ1は、いわゆる斜流ファンを構成する。
 次に、熱かしめ装置50について説明する。
 図6は、本発明の第一実施形態に係る熱かしめ装置50を示す斜視図である。図7は、本発明の第一実施形態に係る熱かしめ装置50のヒートチップ51を示す斜視図である。
 図6に示すように、熱かしめ装置50は、ヒートチップ51と、ヒートチップ駆動部52と、保持台53と、を有する。図7に示すように、ヒートチップ51は、加熱部511と電極部512とを有している。加熱部511の外形は、載頭略円錐形状を上下逆さまにしたような形状を有しており、加熱部511の上端部及び下端部は、開口が形成されている。ヒートチップ51の大部分を占める加熱部511は、中空部11を形成している主板10の側板13の内周面に沿い、且つ中空部11の円周方向に連続した形状を有している。ここで、実際には後述するスリット514、515が形成されているため、加熱部511は、完全に連続した形状を有してはいないが、スリットの幅は極めて小さいため、ここでは実質的に「連続」していることを意味する。また、スリットを絶縁材等で埋めて連続面を形成し使用することもできる。加熱部511は、鉄鋼材料により構成されている。
 加熱部511には、加熱部511の外周面と内周面とを連通するスリット514、515が形成されている。スリット514、515は、加熱部511の周方向に、加熱部511を複数個に分割している。より詳細には、スリット515は、加熱部511を完全に分割しているのではなく、加熱部511の上端部又は下端部を残して形成されている。従って、スリット515により区画された加熱部511の個々の部分を以下、略分割片と言うこととする。
 即ち、スリットは、複数形成されているが、そのうちの一のスリット514は、加熱部511の上端部から加熱部511の下端部に至るまで形成されており、この一のスリット514により、加熱部511は分断されている。しかし、他のスリット515は、いずれも加熱部511の上端部から加熱部511の下端部に至るまで、形成されておらず、当該一のスリット514に隣接する他のスリット515は、加熱部511の下端部を残して、加熱部511の上端部に至るまで形成されている。従って、他のスリット515が形成されている加熱部511の部分においては、加熱部511の下端部において、加熱部511は分断されておらず接続されている。他のスリット515に隣接する別の他のスリット515は、加熱部511の上端部を残して、加熱部511の下端部に至るまで形成されている。従って、別の他のスリット515が形成されている加熱部511の部分においては、加熱部511の上端部において、加熱部511は分断されておらず接続されている。このようにして、互い違いにスリット515が形成されており、これにより加熱部511は、一のスリット514を境界とした加熱部511の一方の側から他方の側へ、加熱部511の周方向へ上下方向においてジグザグに一周するように、電気的に接続されている。
 加熱部511の外周面の上端部には、凸状の段差部517が形成されている。段差部517は、加熱部511の外周面の上端部から加熱部511の半径方向外方へ突出するとともに、加熱部511の外周面の上端部の周方向に一周するように連続して延びて形成されている。ここで、実際にはスリット514、515が形成されているため、段差部517は完全に連続して形成されているのではないが、スリットの幅は極めて小さいため、ここでは実質的に「連続」していることを意味する。段差部517は、熱かしめにより溶融したボス33により構成される溶融部33Aが、ヒートチップ51の上端部よりもヒートチップ51の上方に流出することを防ぐ。
 電極部512は、略長方形状の板状を有している。電極部512の下端部は、一のスリット514に隣接する2つの略分割片のそれぞれに一体成形されることにより接続されている。電極部512の上端部は、ヒートチップ駆動部52の電力供給支持部521の正極、負極にそれぞれ固定され、電気的に接続されている。この構成により、ヒートチップ駆動部52の電力供給支持部521から、加熱部511へ、電極部512を通して電気が供給される。加熱部511は、電気抵抗を有しているため、加熱部511へ電気が供給されることにより、加熱部511の全体は略均一に発熱する。また、ヒートチップ駆動部52は、電力供給支持部521を上下方向へ移動可能に構成されており、ヒートチップ駆動部52が電力供給支持部521を上下方向へ駆動することにより、ヒートチップ51を、図5の上下方向に移動可能である。
 保持台53は、基台531と、基台531の上部に位置する円筒状部532と、を有している。円筒状部532は、羽根本体部嵌合凹部534を有している。羽根本体部嵌合凹部534は、インペラ1の羽根本体部32の上部(図6に示す羽根本体部32の下部)の形状と略同一の形状を有して下方へ窪んで形成されている。従って、羽根本体部嵌合凹部534には、熱かしめが行われる前の、主板10の接合孔132に骨部31が嵌合した状態の羽根部材30の羽根本体部32が、主板10の回転軸心方向が鉛直方向に一致する位置関係で嵌合可能である。この嵌合により、保持台53は、熱かしめが行われる前の、接合孔132に骨部31が嵌合した状態の主板10及び羽根部材30(以下、「未かしめ材1A」と言う)を、上下逆にした状態で、安定して固定して保持する。
 次に、熱かしめ方法について説明する。
 図8は、本発明の第一実施形態に係る熱かしめ方法においてヒートチップ51がボス33を溶融し始めた様子を示す断面図である。図9は、本発明の第一実施形態に係る熱かしめ方法においてヒートチップ51がボス33及び隔壁134を溶融した様子を示す断面図である。
 熱かしめ方法では、先ず、未かしめ材1Aの主板10の回転軸心方向を鉛直方向に一致する位置関係として、未かしめ材1Aの羽根部材30の羽根本体部32を羽根本体部嵌合凹部534に嵌合させる。これにより、図5に示すように、保持台53によって未かしめ材1Aを保持する。次に、ヒートチップ駆動部52を駆動させることによりヒートチップ51を下降させてゆき、主板10の中空部11へヒートチップ51を挿入してゆく。
 そして、図8に示すように、一度の複数のボス33にヒートチップ51の加熱部511を当接させることにより、調整凸部136を溶融させると共に、一度に複数のボス33を溶融させて溶融部33Aとする。このとき、溶融部33Aは、下方へ流れるが、未だヒートチップ51の加熱部511に当接しておらず溶融していない隔壁134によって、隔壁134よりも下方へ流れることが阻止され、隔壁134と主板10の側板13との間に溜まる。これにより、溶融部33Aの樹脂量は所定の量に維持される。
 そして、更にヒートチップ51を下降させてゆき、隔壁134に当接させ、ヒートチップ51の下降を停止させて、隔壁134を溶融させる。隔壁134は、主板10の回転軸心から半径方向外方へ離間するように変形し溶融する。溶融した隔壁134は、溶融部33Aと一体となり溶融部33Aの樹脂量は更に増加する。隔壁134が十分に溶融した後に、溶融部33Aを押圧してヒートチップ51の下端部の端縁を中央凸部123の内面と同じ高さとする。これにより、隔壁134は、溶融部33Aと一体化され、溶融部33Aは互いに連結され、主に内周拡径部135に配置される。そして、ヒートチップ51の温度を低下させることにより、溶融部33Aを固化させる。溶融部33Aを構成する複数の羽根部材30のボス33は、溶融して一体化した後に固化して連結した状態となり、主板10に接合される。
 本実施形態によれば、以下の効果が奏される。
 本実施形態では、熱かしめ方法においては、略円錐形状の中空部11を有する第一部材としての主板10の、中空部11の内周面に設けられた複数の孔(接合孔132)に嵌め込まれ、内周面側に突出した第二部材としての羽根部材30の複数のボス33を、一度に溶融させて第一部材としての主板10に接合させる。そして、熱かしめ方法においては、内周面に沿い、且つ中空部11の円周方向に連続した形状を有するヒートチップ51を用いて、複数のボス33を一度に溶融し、溶融した隣接するボス33同士が連結した状態で第一部材に接合される。
 これにより、連続面により構成されたヒートチップ51の外周面により、鉛直方向に一致する位置関係とされる第一部材としての主板10の軸心に対して傾斜している内周面(主板10の中空部11を形成している内周面)から突出する複数のボス33のうちの隣接したボス33を溶融させて連結させることができる。このため、接合の強度を高めることができ、ボス33を有する羽根部材30が接合孔132から抜け落ちることを防止できる。また、複数のボス33を一度に均一な温度、均一な押圧力にて溶融することができるので、接合の強度を均一とすることができる。
 また、本実施形態では、熱かしめ装置50においては、略円錐形状の中空部11を有する第一部材としての主板10の、中空部11の内周面に設けられた複数の孔(接合孔132)に嵌め込まれ、内周面側に突出した複数の第二部材としての羽根部材30のボス33を、一度に溶融させて第一部材としての主板10に接合させる。そして、熱かしめ装置50は、内周面に沿い、且つ中空部11の円周方向に連続した形状を有するヒートチップ51を備える。
 これにより、ヒートチップ51外周面は連続面により構成されているため、鉛直方向に一致する位置関係とされる第一部材としての主板10の軸心に対して傾斜している内周面(主板10の中空部11を形成している内周面)から突出する複数のボス33のうちの隣接したボス33を溶融させて連結させることができる。このため、接合の強度を高めることができ、ボス33を有する羽根部材30が接合孔132から抜け落ちることを防止できる。また、複数のボス33を一度に均一な温度、均一な押圧力にて溶融することができるので、接合の強度を均一とすることができる。
 また、ヒートチップ51は中空部11の円周方向に連続した形状を有するため、略円錐形状の中空部11の内周面のような斜面に配置された複数のボス33において、ボス33の溶融点にかかる押圧力を均一とすることができ、確実に複数のボス33を押圧することができる。この結果、斜面に配置された複数のボス33を同時に熱かしめすることができる。
 そして、ヒートチップ51の上端部には、ボス33が溶融して構成される溶融部33Aがヒートチップ51の上方に流出することを防ぐ凸状の段差部517が、ヒートチップ51の上端部の周方向に連続して形成されている。
 これにより、ボス33が溶融して構成される溶融部33Aがヒートチップ51より上方に流出することを抑え、溶融部33Aを、ヒートチップ51の加熱部511の外周面と、主板10の内周面との間に留めることができる。これにより、隣接するボス33同士が連結するために十分な量の樹脂により構成される溶融部33Aを確保することができ、即ち、略円錐形状の中空部11の軸方向における高さ、及び、中空部11の半径方向における厚さを有する溶融部33Aを確保することができ、接合の強度を確実に維持することができる。
 また、本実施形態では、被かしめ材は、略円錐形状の中空部11を有する第一部材と、第一部材の中空部11の内周面に設けられた複数の孔(接合孔132)に嵌め込まれ、内周面側に突出した複数の第二部材のボス33であって、一度に溶融させられて第一部材に接合した複数のボス33と、を備える。複数のボス33が溶融して構成される溶融部33Aは連結している。
 これにより、隣接したボス33が溶融して構成される溶融部33Aが連結しているので、主板10に対する全ての羽根部材30の接合の強度を均一にすることができる。また、主板10に対する羽根部材30の接合の強度を高めることができ、ボス33を有する羽根部材30が接合孔132から抜け落ちることを防止できる。
 そして、第二部材としての羽根部材30のボス33が第一部材としての主板10に接合する前の、第一部材としての主板10の中空部11の内周面の溶融部33Aの下端部に相当する第一部材としての主板10の部分には、溶融部33Aをせき止めるための隔壁134が形成されている。
 これにより、主板10は略円錐形であるため、ボス33が溶融して構成された溶融部33Aである樹脂は下方に流れて行こうとするが、溶融部33Aの下端に樹脂の流れをせき止める隔壁134を有するので、樹脂が隔壁134よりも下方に流れず、溶融部33Aに留まる。このため、隣接する溶融部33Aが連結する際に十分な量の溶融部33Aがあるため強度が維持される。更に、ヒートチップ51が下端まで挿入された際に隔壁134も溶融するので溶融部33Aの量(樹脂量)が増加し、より強度の高い連結部(溶融部33A)を形成可能である。また、隔壁134は、主板10の上板12近傍の側板13の部分から下方へ向って延びている(熱かしめが行われる際に未かしめ材1Aの下側に配置される部分から上方へ向って延びている)ため、隔壁134が溶融する際に、溶融した隔壁134が上板12の方へ流れずに、ボス33が溶融して構成された溶融部33Aの方へ流れるようにすることができる。
 そして、第一部材は主板10により構成される。第二部材は複数の羽根部材30により構成される。被かしめ材は、第一部材と第二部材とを有するインペラ1である。これにより、インペラ1の回転軸心方向からインペラ1を見た場合に羽根本体部32が重なるように配置された羽根部材30を有するインペラ1を、熱かしめにより容易に製造することができる。
 次に、本発明の第二実施形態について、図面を参照しながら詳細に説明する。
 以下では、上記第一実施形態と同じ構成については同じ符号を付し、その詳細な説明を省略する。本実施形態に係る熱かしめ装置は、ヒートチップ51Bの形状が異なる点で、第一実施形態とは異なる。
 図10は、本発明の第二実施形態に係る熱かしめ装置のヒートチップ51Bを示す斜視図である。
 ヒートチップ51Bは、加熱部511Bと電極部512Bとを有している。加熱部511Bの外形は、図10に示すように、第一実施形態における加熱部511と同様に、載頭略円錐形状を上下逆さまにした形状を有しており、加熱部511Bの上端部及び下端部は、開口が形成されている。
 本実施形態によれば、以下の効果が奏される。
 本実施形態では、スリットは形成されていない。その代わりチップの厚みを部分的に変化させたり、端子取付位置を調整することで均熱性を取っている。これにより、製造が容易なヒートチップ51Bとすることができ、製造を容易な熱かしめ装置とすることができる。
 本発明は上記実施形態に限定されるものではなく、本発明の目的を達成できる範囲での変形、改良等は本発明に含まれる。
 例えば、熱かしめ装置の各部の構成は、本実施形態における熱かしめ装置50の各部の構成に限定されない。例えば、ヒートチップの形状は、本実施形態におけるヒートチップ51の形状に限定されない。同様に被かしめ材や未かしめ材の各部の形状や構成についても、本実施形態における被かしめ材としてのインペラ1や未かしめ材1Aの各部の形状に限定されない。例えば、段差部やボスや隔壁等の形状は、本実施形態における段差部517やボス33や隔壁134等の形状に限定されない。
 また、熱かしめ装置50が用いられて実施される熱かしめ方法により製造される被かしめ材としてのインペラ1は、ファン等において送風に用いられ、いわゆる斜流ファンを構成していたが、これに限定されない。例えば、被かしめ材は、遠心式であって羽根部材が前向きに配置されたいわゆるシロッコファンや、羽根部材が後向きに配置されたいわゆるターボファンであってもよい。
 また、主板10は、略円錐形状を有していたが、これに限定されない。略錐体形状であればよく、例えば、略三角錐形状等であってもよい。
 1…インペラ
 10…主板(第一部材)
 11…中空部
 30…羽根部材(第二部材)
 33…ボス
 33A…溶融部
 51…ヒートチップ
 132…接合孔(孔)
 134…隔壁
 517…段差部

Claims (6)

  1.  略錐体形状の中空部を有する第一部材の、前記中空部の内周面に設けられた複数の孔に嵌め込まれ、内周面側に突出した第二部材の複数のボスを、一度に溶融させて前記第一部材に接合させる熱かしめ方法であって、
     前記内周面に沿い、且つ前記中空部の周方向に連続した形状を有するヒートチップを用いて、前記複数のボスを一度に溶融し、溶融した隣接する前記ボス同士が連結した状態で前記第一部材に接合される熱かしめ方法。
  2.  略錐体形状の中空部を有する第一部材の、前記中空部の内周面に設けられた複数の孔に嵌め込まれ、内周面側に突出した第二部材の複数のボスを、一度に溶融させて前記第一部材に接合させる熱かしめ装置であって、
     前記内周面に沿い、且つ前記中空部の周方向に連続した形状を有するヒートチップを備えることを特徴とする熱かしめ装置。
  3.  前記ヒートチップの上端部には、前記ボスが溶融して構成される溶融部が前記ヒートチップの上方に流出することを防ぐ凸状の段差部が、前記ヒートチップの上端部の周方向に連続して形成されていることを特徴とする請求項2に記載の熱かしめ装置。
  4.  略錐体形状の中空部を有する第一部材と、
     前記第一部材の前記中空部の内周面に設けられた複数の孔に嵌め込まれ、内周面側に突出した第二部材の複数のボスであって、一度に溶融させられて前記第一部材に接合した複数のボスと、を備え、
     前記複数のボスが溶融して構成される溶融部は連結していることを特徴とする被かしめ材。
  5.  前記第二部材が前記第一部材に接合する前の、前記第一部材の中空部の内周面の前記溶融部の下端部に相当する前記第一部材の部分には、前記溶融部をせき止めるための隔壁が形成されていることを特徴とする請求項4記載の被かしめ材。
  6.  前記第一部材は主板により構成され、
     前記第二部材は複数の羽根部材により構成され、
     前記第一部材と前記第二部材とを有するインペラであることを特徴とする請求項4または5に記載の被かしめ材。
PCT/JP2016/077541 2015-09-18 2016-09-16 熱かしめ方法、熱かしめ装置、及び、被かしめ材 WO2017047786A1 (ja)

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