JP2004058391A - Thermally caulking structure and method for thermally caulking and connecting - Google Patents

Thermally caulking structure and method for thermally caulking and connecting Download PDF

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Publication number
JP2004058391A
JP2004058391A JP2002218237A JP2002218237A JP2004058391A JP 2004058391 A JP2004058391 A JP 2004058391A JP 2002218237 A JP2002218237 A JP 2002218237A JP 2002218237 A JP2002218237 A JP 2002218237A JP 2004058391 A JP2004058391 A JP 2004058391A
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Japan
Prior art keywords
caulking
substrate
protrusion
caulked
projection
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JP2002218237A
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Japanese (ja)
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Hiroki Hara
原　弘樹
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Toyota Motor Corp
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Toyota Motor Corp
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Priority to JP2002218237A priority Critical patent/JP2004058391A/en
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    • 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
    • B29C65/08—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
    • B29C65/78—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
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B29C65/782—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined
    • B29C65/7823—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint
    • B29C65/7829—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint said distance pieces being integral with at least one 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
    • B29C66/01—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
    • B29C66/40—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
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/431—Joining the articles to themselves
    • 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
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
    • 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
    • B29C66/80—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
    • B29C66/814—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 design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/843—Machines for making separate joints at the same time in different planes; Machines for making separate joints at the same time mounted in parallel or in series
    • B29C66/8432—Machines for making separate joints at the same time mounted in parallel or in series
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91421—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91441—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time
    • B29C66/91443—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile
    • B29C66/91445—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile by steps
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/924—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/9241—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force or the mechanical power
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B29C66/9292—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges in explicit relation to another variable, e.g. pressure diagrams
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
    • B29C66/949—Measuring or controlling the joining process by measuring or controlling the time characterised by specific time values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3038—Air bag covers

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Air Bags (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a thermally caulking structure which can improve an appearance quality. <P>SOLUTION: The thermally caulking structure includes a caulking member 1 made of a thermoplastic resin having a base plate 1a, a caulking projection 1b projected from one surface of the plate 1a and a gap holding projection 1d, and a member 2 to be caulked having an engaging hole 2a to be engaged with the projection 1b. Thus, the projection 1b is engaged with the hole 2a, a tip of the projection 1d is positioned at a position where the tip of the projection 1d is brought into contact with the member 2. the projection 1b is heated and deformed to thereby caulk the member 2 to the member 1. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、熱可塑性樹脂製の部材と他の部材とを熱かしめ接合により接合された熱かしめ構造体及びその熱かしめ接合方法に関するものである。
【０００２】
【従来の技術】
例えば、自動車のエアバックの開閉ドアは、熱可塑性樹脂製の板状の部材に鉄板等の補強部材をかしめて形成された構造となっている。そして、熱可塑性樹脂製の板状の部材は、一方の面が意匠面を形成し、その反対面側に補強部材が接合されている。このように形成されたエアバックの開閉ドアの従来の構成について、図面を参照して説明する。
【０００３】
エアバックの開閉ドアの断面図を図９（ａ）（ｂ）に示す。図９（ａ）に示すように、エアバックの開閉ドアは、熱可塑性樹脂製の板状の部材（以下、「かしめ部材」という）２１に補強部材（以下、「被かしめ部材」という）２２から構成されている。具体的には、かしめ部材２１は、意匠面２１ｃを有する板状の基板２１ａと、基板２１ａと一体成形されたかしめ突起２１ｂとからなる。また、被かしめ部材２２は、かしめ部材２１のかしめ突起２１ｂに嵌合する嵌合穴２２ａを有している。そして、かしめ部材２１と被かしめ部材２２とを熱かしめ接合により接合する。
【０００４】
次に、熱かしめ接合方法について説明する。まず、かしめ部材２１のかしめ突起２１ｂと被かしめ部材２２の嵌合穴２２ａとを嵌合させ、かしめ部材２１の基板２１ａと被かしめ部材２２とを接触させた状態に位置決めする。続いて、超音波加熱器２０により所定の加圧力と熱が、かしめ突起２１ｂに付与される。これにより、かしめ突起２１ｂが溶融されて変形する。その後、変形したかしめ突起２１ｂを冷却する。かしめ突起２１ｂの変形後の状態を図９（ｂ）に示す。すなわち、被かしめ部材２２は、かしめ部材２１の基板２１ａと変形したかしめ突起２１ｂとによりかしめて接合される。
【０００５】
【発明が解決しようとする課題】
しかし、かしめ突起２１ｂを加熱し冷却する結果、図９（ｂ）に示すように、かしめ部材２１の基板２１ａの意匠面２１ｃに凹凸形状が生じる。このことは、意匠面２１ｃの外観品質を低下させることになる。この凹凸形状が生じる原因としては、かしめ突起２１ｂを加熱し冷却することにより生じるヒケやかしめ突起２１ｂを変形させるための加圧力が意匠面２１ｃまで伝わることによるものと考えられる。
【０００６】
また、意匠面２１ｃの反対面においては、超音波加熱器２０による成形部分の外側にバリ２３が生ずる。一般に、変形後のかしめ突起２１ｂにより被かしめ部材２２を確実にかしめるため、かしめ突起２１ｂは超音波加熱器２０の成形部分の体積より大きな体積を有するようにしている。つまり、超音波加熱器２０の成形部分に収納されないかしめ突起２１ｂがバリ２３となって現れる。
【０００７】
本発明は、このような事情に鑑みてなされたものであり、熱かしめ接合によりかしめ部材と被かしめ部材とを接合する場合に、かしめ部材の意匠面に凹凸形状を生じさせず、意匠面の反対面にバリを生じさせないようにすることにより、外観品質を向上させることができる熱かしめ構造体及び熱かしめ接合方法を提供することを目的とする。
【０００８】
【課題を解決するための手段】
そこで、本発明者はこの課題を解決すべく鋭意研究し、試行錯誤を重ねた結果、かしめ部材と被かしめ部材との間に隙間を設けて熱かしめ接合を行うことを思いつき、本発明を完成するに至った。
【０００９】
すなわち、本発明の熱かしめ構造体は、かしめ部材と、被かしめ部材とを有する。ここで、かしめ部材は、基板と、基板の一方の面に突設したかしめ突起と、からなる熱可塑性樹脂製の部材である。被かしめ部材は、かしめ突起に嵌合される嵌合穴を有する部材である。そして、かしめ突起に嵌合穴を嵌合させ、かしめ部材の基板と被かしめ部材との間に所定の隙間を設けて位置決めし、かしめ突起を加熱し変形させることによりかしめ部材に被かしめ部材をかしめて形成されることを特徴とする。
【００１０】
つまり、かしめ部材と被かしめ部材との間に所定の隙間を設けることで、かしめ突起を加熱し冷却することにより生じるヒケやかしめ突起を変形させるための加圧力が、かしめ部材の基板のかしめ突起を有しない面（以下、「意匠面」という）に伝わらない。その結果、意匠面に凹凸形状が生じることがなく、意匠面の外観品質を向上させることができる。また、成形器の成形部分に収納できないかしめ突起は、かしめ部材の基板と被かしめ部材との間の所定の隙間部分に移動し、意匠面の反対面にバリが生じることがない。つまり、意匠面とその反対面の外観品質を向上させることができる。さらに、意匠面の反対面にバリが生じないため、例えば、エアバッグの展開時等にバリの飛散を防止できる。
【００１１】
また、本発明の熱かしめ構造体におけるかしめ部材の基板と被かしめ部材との間に形成された隙間は、かしめ部材の被かしめ部材に対向する面および／または被かしめ部材のかしめ部材に対向する面に形成された複数の隙間保持用突起により形成されるようにしてもよい。これにより、被かしめ部材をかしめ部材の基板との間に所定の隙間を容易に形成することができる。例えば、かしめ部材が隙間保持用突起を有する場合に、かしめ部材と被かしめ部材を位置決めするには、かしめ突起と嵌合穴とを嵌合させ、隙間保持用突起が被かしめ部材に接触する位置に固定すればよい。すなわち、隙間保持用突起の高さ分が、形成される隙間になる。
【００１２】
また、本発明の熱かしめ構造体の被かしめ部材は、かしめ部材の基板を補強する補強部材としてもよい。かしめ部材は樹脂製であるため割れやすいという問題がある。そこで、例えば、被かしめ部材として鉄板等を用いることにより、かしめ部材を補強することができる。
【００１３】
また、本発明の熱かしめ構造体の被かしめ部材は、基板の延長線上に基板と一体成形され、基板に対して折り曲げて形成される折曲部としてもよい。通常、かしめ部材の基板の板厚が薄いほど基板に割れが生じやすい。そこで、基板の一部を折り曲げた折曲部を被かしめ部材として用いることにより、板厚を増加させることができ、強度を増加させることができる。さらに、被かしめ部材として、かしめ部材の一部を用いているため、補強部品として別部品を使用することもなく、コストダウンにつながる。つまり、部品点数を増加させることなく、かしめ部材の強度を増加させることができる。
【００１４】
また、本発明の熱かしめ接合方法は、かしめ部材に被かしめ部材を、かしめ部材のかしめ突起を加熱し変形させることによりかしめて接合する熱かしめ接合方法であって、部材位置決めステップと、かしめ突起変形ステップと、からなることを特徴とする。ここで、かしめ部材は、基板と、基板の一方の面に突設したかしめ突起と、からなる熱可塑性樹脂製の部材である。被かしめ部材は、かしめ部材のかしめ突起に嵌合される嵌合穴を有する部材である。そして、部材位置決めステップは、かしめ突起と嵌合穴とを嵌合させ、基板と被かしめ部材との間に所定の隙間を設けてかしめ部材及び被かしめ部材を位置決めするステップである。かしめ突起変形ステップは、かしめ突起を加熱し変形させるステップである。
【００１５】
つまり、かしめ部材と被かしめ部材との間に所定の隙間を設けることで、かしめ突起を加熱し冷却することにより生じるヒケやかしめ突起を変形させるための加圧力が、意匠面に伝わらない。その結果、意匠面に凹凸形状が生じることがなく、意匠面の外観品質を向上させることができる。また、成形器の成形部分に収納できないかしめ突起は、かしめ部材の基板と被かしめ部材との間の所定の隙間部分に移動し、意匠面の反対面にバリが生じることがない。つまり、意匠面とその反対面の外観品質を向上させることができる。さらに、意匠面の反対面にバリが生じないため、例えば、エアバッグの展開時等にバリの飛散を防止できる。
【００１６】
【発明の実施の形態】
次に、実施形態を挙げ、本発明をより詳しく説明する。本実施形態においては、本発明の熱かしめ構造体として、自動車の助手席用エアバッグの開閉ドアを例にとり説明する。図１に示すように、自動車のフロントガラス側に装備されたインストルメントパネル１０の上側内部にエアバッグ装置が配置されている。そして、インストルメントパネル１０の補強部材（図示せず）にエアバッグケース１１が連結固定されている。このエアバッグケース１１に、インストルメントパネル１０の頂面１０ａと略面一となるように配置される開閉ドア１２，１２が組付けられている。そして、エアバッグ動作時には、フロントガラスに近い側の開閉ドア１２はフロントガラス側へ、フロントガラスから遠い側の開閉ドア１２はフロントガラスと反対側へ開き、エアバッグケース１１内に収納されているエアバッグ（図示せず）が膨張展開する。
【００１７】
次に、開閉ドア１２について図２を参照して詳細に説明する。図２は、図１に示す開閉ドア１２の裏面を示す斜視図である。すなわち、開閉ドア１２のうち図１におけるインストルメントパネル１０の頂面１０ａと略面一となる面が図２における裏面の意匠面１ｃである。この開閉ドア１２は、熱可塑性樹脂製の部材（以下、「かしめ部材」という）１に鉄板の補強部材（以下、「被かしめ部材」という）２が熱かしめ接合されている。すなわち、図２においては、８箇所の熱かしめ接合部１ｅによりかしめ部材１に被かしめ部材２が接合されている。なお、開閉ドア１２の被かしめ部材２がエアバッグケース１１に連結固定されている。また、本実施形態におけるかしめ部材１は、ポリプロピレン樹脂を用いている。
【００１８】
次に、熱かしめ接合される前のかしめ部材１と被かしめ部材２の形状について、図３及び図４を参照して説明する。図３に示すように、かしめ部材１は、基板１ａと、かしめ突起１ｂと、隙間保持用突起１ｄとが一体成形されている。基板１ａは、板厚３．５ｍｍであって、一方の面が意匠面１ｃを形成している。かしめ突起１ｂは、基板１ａの意匠面１ｃの反対面に形成されている。図３における近隣する３つのかしめ突起１ｂは、変形後の図２における熱かしめ接合部１ｅの１箇所に相当する。このかしめ突起１ｂは、根元部が約１．７ｍｍ×１８．０ｍｍ、高さが約１８ｍｍである。さらに、かしめ突起１ｂは、先端側が細く形成されている。そして、隙間保持用突起１ｄは、基板１ａの意匠面１ｃの反対面であって、近隣する３つのかしめ突起１ｂの周囲に４箇所形成されている。この隙間保持用突起１ｄの高さは、約１．５ｍｍである。
【００１９】
図４に示すように、被かしめ部材２は、板厚約１．３ｍｍであって、嵌合穴２ａを有している。この嵌合穴２ａは、かしめ部材１のかしめ突起１ｂと嵌合するように形成されている。すなわち、図４に示す３つの嵌合穴が、図３における３つのかしめ突起１ｂに嵌合する。この嵌合穴２ａの大きさは、約２．３ｍｍ×１９ｍｍである。
【００２０】
続いて、このように形成されたかしめ部材１と被かしめ部材２との熱かしめによる接合方法について図５を参照して説明する。図５（ａ）は、熱かしめ接合前における開閉ドア１２の断面図である。図５（ｂ）は熱かしめ接合された開閉ドア１２の断面図である。まず、図５（ａ）に示すように、かしめ部材１のかしめ突起１ｂと被かしめ部材２の嵌合穴２ａとを嵌合させる。その際、かしめ部材１の隙間保持用突起１ｄの先端と被かしめ部材２とが接触する位置にかしめ部材１及び被かしめ部材２を位置決めする（部材位置決めステップ）。すなわち、かしめ部材１の基板１ａと被かしめ部材２との隙間は、隙間保持用突起１ｄの高さと同様であるので、１．５ｍｍとなる。そして、かしめ突起変形工程（かしめ突起変形ステップ）を開始する。まず、かしめ突起１ｂの先端側を超音波加熱器２０により加熱しながら加圧する。具体的には、約２００℃の温度で加熱しながら、約１．８ＭＰａの加圧力で約４〜７秒間かしめ突起１ｂを加圧する。これにより、かしめ突起１ｂが溶融して変形する。その後、超音波加熱器２０を約８０℃の温度まで下げて、溶融したかしめ突起１ｂを約４秒間冷却する。
【００２１】
かしめ突起１ｂを変形させて被かしめ部材２をかしめた形状を、図５（ｂ）に示す。すなわち、かしめ部材１の意匠面１ｃは、凹凸形状が生じていない。これは、かしめ部材１の基板１ａと被かしめ部材２との間に隙間を設けたことにより、超音波加熱器２０による熱や加圧力が意匠面１ｃまで伝わらないためであると考えられる。また、変形したかしめ突起１ｃは、意匠面１ｃの反対面においては、超音波加熱器２０の成形部分を転写した形状に形成されている。すなわち、従来発生していたバリが生じていない。これは、かしめ部材１の基板１ａと被かしめ部材２との間の隙間に変形したかしめ突起１ｂの一部が移動したためであると考えられる。このように、意匠面１ｃ及び意匠面の反対面の外観品質が非常に良好となる。また、かしめ部材１の基板１ａと被かしめ部材２との隙間に変形したかしめ突起１ｃが移動することにより、より強固に被かしめ部材２をかしめることができる。
【００２２】
次に、かしめ部材１の基板１ａと被かしめ部材２との間の隙間を変更して、熱かしめ接合を行った場合における外観品質について説明する。隙間を０ｍｍ、１．０ｍｍ、１．５ｍｍ、２．０ｍｍとした場合について上述の熱かしめ接合を行った。なお、かしめ部材１及び被かしめ部材２の形状は上記実施形態と同様である。また、超音波加熱器２０による加熱温度及び加圧力は、上記実施形態と同様である。また、加圧工程時間及び冷却工程時間も上記実施形態とほぼ同様である。この結果を図６に示す。
【００２３】
図６に示すように、隙間が０ｍｍの場合、すなわち、従来の熱かしめ接合方法の場合は、意匠面１ｃに凹凸形状が生じ、意匠面１ｃの反対面にはバリが生じるため、外観品質は非常に悪い。隙間が１．０ｍｍの場合には、意匠面１ｃ及び意匠面１ｃの反対面共にほぼ良好な外観品質を得ることができた。また、隙間が１．５ｍｍ及び２．０ｍｍの場合には、意匠面１ｃ及び意匠面１ｃの反対面共に非常に良好な外観品質を得ることができた。
【００２４】
次に、超音波加熱器２０による加圧力を変化させて熱かしめ接合を行った。他の条件については、上記実施形態と同様である。この結果を図７に示す。図７より、加圧力が１．３ＭＰａの場合に比べて１．９ＭＰａの場合は、外観品質が良好となることがわかる。すなわち、加圧力が大きい程、外観品質は向上する。なお、加圧力が１．３ＭＰａより小さい場合には、かしめ突起１ｂが溶融しないため、かしめ接合を行うことができない。さらに、加圧力が１．９ＭＰａより大きい場合には、かしめ突起１ｂが破断するため、かしめ接合を行うことができない。
【００２５】
なお、上記実施形態では、隙間保持用突起１ｄをかしめ部材１が有しているが、これに限られるものではない。すなわち、被かしめ部材２が隙間保持用突起１ｄを有するようにしてもよい。この場合には、上記と同様の熱かしめ接合方法により行うことができる。もちろん、かしめ部材１及び被かしめ部材２の双方が隙間保持用突起１ｄを有するようにしてもよい。また、熱かしめ接合をする際に、かしめ部材１の基板１ａと被かしめ部材２との間に所定の隙間を有するようにかしめ部材１及び被かしめ部材２を位置決めすることができれば、かしめ部材１及び被かしめ部材２の双方が隙間保持用突起１ｄを有しない他の方法でもよい。例えば、熱かしめ接合を行う際に、所定の隙間を確保できる他の部材を挿入しておき、熱かしめ接合終了後に挿入していた他の部材を取り除く方法であってもよい。
【００２６】
また、上記実施形態では、かしめ突起１ｃを溶融するために、超音波加熱器２０を使用したが、これに限られるものではない。例えば、熱風加熱、高周波加熱、熱ヒーター加熱や振動溶着等、熱可塑性樹脂製のかしめ部材１のかしめ突起１ｃを溶融し圧力をかけることができるものであればよい。
【００２７】
（他の実施形態）
上記実施形態では、かしめ部材１と被かしめ部材２とを別部材としたが、本実施形態では同一部材としている。本実施形態について、図８（ａ）（ｂ）（ｃ）を参照して説明する。
【００２８】
図８（ａ）に、熱かしめ接合を行う前の部材５の側面図を示す。この部材５は、熱可塑性樹脂、例えばポリプロピレン樹脂により形成されている。そして、部材５は、基板部５ａ、折曲部５ｂ、かしめ突起５ｃ、隙間保持用突起５ｄとからなる。基板部５ａは、上記実施形態における基板１ａの相当する。かしめ突起５ｃ及び隙間保持用突起５ｄは、それぞれ上記実施形態におけるかしめ突起１ｂ及び隙間保持用突起１ｄに相当する。折曲部５ｂは、かしめ突起５ｃ側へ折り曲げられた場合に、かしめ突起５ｃに勘合する嵌合穴５ｅを有している。
【００２９】
次に、このような形状からなる部材５の熱かしめ接合について説明する。まず、折曲部５ｂをかしめ突起５ｃ側へ図８（ｂ）に示すように折り曲げる。個の場合、嵌合穴５ｅは、かしめ突起５ｃに嵌合するようになっている。さらに、折曲部５ｂは、隙間保持用突起５ｄの先端に接触する位置に固定しておく（部材位置決めステップ）。つまり、折り曲げられた折曲部５ｂが、上記実施形態における被かしめ部材に相当することになる。続いて、かしめ突起変形工程（かしめ突起変形ステップ）を開始する。まず、かしめ突起５ｃの先端側を超音波加熱器２０により加熱しながら加圧する。具体的には、約２００℃の温度で加熱しながら、約１．８ＭＰａの加圧力で約４〜７秒間かしめ突起５ｃを加圧する。これにより、かしめ突起５ｃが溶融して変形する。その後、超音波加熱器２０を約８０℃の温度まで下げて、溶融したかしめ突起５ｃを約４秒間冷却する。
【００３０】
かしめ突起５ｃを変形させて折曲部５ｂをかしめた形状を、図８（ｃ）に示す。この場合においても、図８（ｃ）に示すように、上記実施形態と同様の効果を奏することができる。すなわち、意匠面及び意匠面の反対面の外観品質が非常に良好となる。さらに、部材５の一部を用いて熱かしめ接合を行っていることから、上記実施形態のように別部品を使用することなく、一つの部材で補強することができる。つまり、コストダウン化を図ることができると共に、補強することができる。
【００３１】
なお、この実施形態における熱かしめ構造体は、例えば、自動車のバンパー等に使用することができる。すなわち、バンパーの端部の強度増加を容易にかつ低コストで行うことができる。
【００３２】
また、上記実施形態では、エアバッグの開閉ドアやバンパーを例にとり説明したが、これに限られるものではない。本発明が適用することができる限り、他の部分でもよい。
【００３３】
なお、被かしめ部材は、金属、非金属又は樹脂等どのような部材であってもよい。また、上記実施形態では、補強部材と熱かしめ接合を行うことについて説明したが、これに限られるものではなく、例えば、他の部品と一体に接合する場合にも適用することができる。
【００３４】
【発明の効果】
本発明の熱かしめ構造体及び熱かしめ接合方法によれば、外観品質を向上させることができる。すなわち、かしめ部材の意匠面に凹凸形状を生じさせることがなく、意匠面の反対面にバリを生じさせることがない。
【図面の簡単な説明】
【図１】自動車のフロントガラス側に装備されたインストルメントパネルを示す斜視図である。
【図２】本発明の熱かしめ構造体を示す斜視図である。
【図３】本発明のかしめ部材を示す斜視図である。
【図４】本発明の被かしめ部材を示す斜視図である。
【図５】本発明の熱かしめ接合方法について説明する断面図である。
【図６】隙間に対する外観品質を示す図である。
【図７】加圧力に対する外観品質を示す図である。
【図８】他の実施形態における熱かしめ接合方法について説明する図である。
【図９】従来の熱かしめ接合方法について説明する断面図である。
【符号の説明】
１　・・・　かしめ部材
１ａ　・・・　基板
１ｂ　・・・　かしめ突起
１ｃ　・・・　意匠面
１ｄ　・・・　隙間保持用突起
２　・・・　被かしめ部材
２ａ　・・・　嵌合穴
５　・・・　部材
５ａ　・・・　基板部
５ｂ　・・・　折曲部
５ｃ　・・・　かしめ突起
５ｄ　・・・　隙間保持用突起
１０　・・・　インストルメントパネル
１１　・・・　エアバッグケース
１２　・・・　開閉ドア
２０　・・・　超音波加熱器[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a heat caulking structure in which a member made of a thermoplastic resin and another member are bonded by heat caulking, and a method of heat caulking the same.
[0002]
[Prior art]
For example, an opening / closing door of an airbag of an automobile has a structure formed by caulking a reinforcing member such as an iron plate on a plate-shaped member made of a thermoplastic resin. One surface of the plate-shaped member made of a thermoplastic resin forms a design surface, and a reinforcing member is joined to the opposite surface. The conventional configuration of the airbag opening / closing door thus formed will be described with reference to the drawings.
[0003]
FIGS. 9A and 9B are cross-sectional views of the opening / closing door of the airbag. As shown in FIG. 9 (a), the opening / closing door of the airbag is constituted by a plate-like member (hereinafter, referred to as a “caulking member”) 21 made of a thermoplastic resin and a reinforcing member (hereinafter, referred to as a “caulking member”) 22. It is composed of Specifically, the caulking member 21 includes a plate-like substrate 21a having a design surface 21c and a caulking protrusion 21b integrally formed with the substrate 21a. The member to be caulked 22 has a fitting hole 22a that fits into the caulking protrusion 21b of the caulking member 21. Then, the caulking member 21 and the caulking member 22 are joined by heat caulking.
[0004]
Next, a heat caulking method will be described. First, the caulking protrusion 21b of the caulking member 21 and the fitting hole 22a of the caulking member 22 are fitted, and the substrate 21a of the caulking member 21 and the caulking member 22 are positioned in contact with each other. Subsequently, a predetermined pressure and heat are applied to the caulking protrusion 21b by the ultrasonic heater 20. Thereby, the caulking protrusion 21b is melted and deformed. Thereafter, the deformed swaging protrusion 21b is cooled. FIG. 9B shows a state after the deformation of the caulking projection 21b. That is, the member to be caulked 22 is caulked by the substrate 21a of the caulking member 21 and the deformed caulking protrusion 21b.
[0005]
[Problems to be solved by the invention]
However, as a result of heating and cooling the caulking projection 21b, as shown in FIG. 9B, an irregular shape is formed on the design surface 21c of the substrate 21a of the caulking member 21. This degrades the appearance quality of the design surface 21c. It is considered that the reason why the uneven shape is generated is that a sink pressure generated by heating and cooling the caulking protrusion 21b and a pressing force for deforming the caulking protrusion 21b are transmitted to the design surface 21c.
[0006]
Further, on the surface opposite to the design surface 21c, burrs 23 are generated outside the portion formed by the ultrasonic heater 20. Generally, in order to securely caulk the member to be caulked 22 by the caulking protrusion 21b after the deformation, the caulking protrusion 21b has a volume larger than the volume of the molded portion of the ultrasonic heater 20. That is, the caulking protrusion 21 b that is not accommodated in the molded portion of the ultrasonic heater 20 appears as the burr 23.
[0007]
The present invention has been made in view of such circumstances, and when a caulking member and a member to be caulked are joined by heat caulking, the design surface of the caulking member does not have an uneven shape, and the design surface An object of the present invention is to provide a heat caulking structure and a heat caulking method that can improve appearance quality by preventing burrs from being generated on the opposite surface.
[0008]
[Means for Solving the Problems]
The inventor of the present invention has intensively studied to solve this problem, and after repeated trial and error, came up with the idea of performing a heat caulking joint by providing a gap between the caulking member and the member to be caulked, and completed the present invention. I came to.
[0009]
That is, the heat caulking structure of the present invention has a caulking member and a member to be caulked. Here, the caulking member is a member made of a thermoplastic resin including a substrate and a caulking projection protruding from one surface of the substrate. The member to be swaged is a member having a fitting hole fitted into the swage projection. Then, the fitting hole is fitted to the caulking protrusion, a predetermined gap is provided between the substrate of the caulking member and the member to be caulked, the positioning is performed, and the caulking member is heated by the caulking protrusion to deform the caulking member. It is characterized by being formed by caulking.
[0010]
That is, by providing a predetermined gap between the caulking member and the member to be caulked, the pressing force generated by heating and cooling the caulking protrusion and deforming the caulking protrusion, the caulking protrusion of the substrate of the caulking member. (Hereinafter referred to as “design surface”). As a result, there is no unevenness on the design surface, and the appearance quality of the design surface can be improved. In addition, the caulking protrusion that cannot be accommodated in the molding portion of the molding machine moves to a predetermined gap between the substrate of the caulking member and the member to be caulked, and burrs do not occur on the surface opposite to the design surface. That is, the appearance quality of the design surface and the opposite surface can be improved. Furthermore, since burrs do not occur on the surface opposite to the design surface, the burrs can be prevented from scattering when, for example, the airbag is deployed.
[0011]
Further, in the heat caulking structure of the present invention, the gap formed between the substrate of the caulking member and the member to be caulked is opposed to the surface of the caulking member facing the caulking member and / or the surface of the caulking member facing the caulking member. It may be formed by a plurality of gap holding projections formed on the surface. Thus, a predetermined gap can be easily formed between the member to be swaged and the substrate of the member to be swaged. For example, in the case where the caulking member has the gap holding projection, in order to position the caulking member and the member to be swaged, the position where the caulking projection and the fitting hole are fitted to each other, and the gap holding projection contacts the member to be swaged. It should be fixed to. That is, the height of the gap holding projection is the gap to be formed.
[0012]
The member to be caulked of the heat caulking structure of the present invention may be a reinforcing member for reinforcing the substrate of the caulking member. Since the caulking member is made of resin, there is a problem that the caulking member is easily broken. Therefore, for example, by using an iron plate or the like as the member to be swaged, the member to be swaged can be reinforced.
[0013]
Further, the member to be caulked of the heat caulking structure of the present invention may be a bent portion formed integrally with the substrate on an extension of the substrate, and formed by bending the substrate. Usually, as the thickness of the substrate of the caulking member is smaller, the substrate is more likely to crack. Therefore, by using a bent portion obtained by bending a part of the substrate as a caulking member, the plate thickness can be increased, and the strength can be increased. Furthermore, since a part of the caulking member is used as the member to be caulked, there is no need to use another component as a reinforcing component, leading to cost reduction. That is, the strength of the caulking member can be increased without increasing the number of components.
[0014]
Further, the heat caulking method according to the present invention is a heat caulking method in which a member to be caulked to a caulking member is caulked and joined by heating and deforming a caulking projection of the caulking member. And a transformation step. Here, the caulking member is a member made of a thermoplastic resin including a substrate and a caulking projection protruding from one surface of the substrate. The member to be caulked is a member having a fitting hole to be fitted to a caulking projection of the caulking member. Then, the member positioning step is a step of fitting the caulking projection and the fitting hole, and providing a predetermined gap between the substrate and the member to be caulked to position the caulking member and the member to be caulked. The caulking protrusion deformation step is a step of heating and deforming the caulking protrusion.
[0015]
In other words, by providing a predetermined gap between the caulking member and the member to be caulked, the pressing force generated by heating and cooling the caulking protrusion and the pressing force for deforming the caulking protrusion are not transmitted to the design surface. As a result, there is no unevenness on the design surface, and the appearance quality of the design surface can be improved. In addition, the caulking protrusion that cannot be accommodated in the molding portion of the molding machine moves to a predetermined gap between the substrate of the caulking member and the member to be caulked, and burrs do not occur on the surface opposite to the design surface. That is, the appearance quality of the design surface and the opposite surface can be improved. Furthermore, since burrs do not occur on the surface opposite to the design surface, the burrs can be prevented from scattering when, for example, the airbag is deployed.
[0016]
BEST MODE FOR CARRYING OUT THE INVENTION
Next, the present invention will be described in more detail with reference to embodiments. In the present embodiment, an opening / closing door of an airbag for a passenger seat of an automobile will be described as an example of the heat caulking structure of the present invention. As shown in FIG. 1, an airbag device is arranged inside an upper part of an instrument panel 10 mounted on a windshield side of an automobile. The airbag case 11 is connected and fixed to a reinforcing member (not shown) of the instrument panel 10. Opening / closing doors 12, 12 arranged to be substantially flush with the top surface 10 a of the instrument panel 10 are attached to the airbag case 11. When the airbag operates, the opening and closing door 12 closer to the windshield opens toward the windshield, and the opening and closing door 12 farther from the windshield opens toward the opposite side of the windshield, and is housed in the airbag case 11. An airbag (not shown) is inflated and deployed.
[0017]
Next, the opening and closing door 12 will be described in detail with reference to FIG. FIG. 2 is a perspective view showing the back surface of the opening / closing door 12 shown in FIG. That is, the surface of the opening / closing door 12 that is substantially flush with the top surface 10a of the instrument panel 10 in FIG. 1 is the design surface 1c on the back surface in FIG. In the opening and closing door 12, a reinforcing member (hereinafter, referred to as a "caulking member") 2 of an iron plate is thermally caulked to a member (hereinafter, referred to as a "caulking member") 1 made of a thermoplastic resin. That is, in FIG. 2, the caulking member 2 is joined to the caulking member 1 by eight heat caulking joints 1e. The caulked member 2 of the opening / closing door 12 is connected and fixed to the airbag case 11. The caulking member 1 in the present embodiment uses a polypropylene resin.
[0018]
Next, the shapes of the caulking member 1 and the member to be caulked 2 before the heat caulking will be described with reference to FIGS. As shown in FIG. 3, the caulking member 1 has a substrate 1a, a caulking projection 1b, and a gap holding projection 1d formed integrally. The substrate 1a has a plate thickness of 3.5 mm, and one surface forms a design surface 1c. The caulking protrusion 1b is formed on the surface of the substrate 1a opposite to the design surface 1c. The three adjacent caulking protrusions 1b in FIG. 3 correspond to one place of the heat caulked joint 1e in FIG. 2 after the deformation. The caulking projection 1b has a root portion of about 1.7 mm × 18.0 mm and a height of about 18 mm. Further, the caulking projection 1b is formed to be thin on the tip end side. The gap holding projections 1d are formed at four locations on the surface opposite to the design surface 1c of the substrate 1a and around three adjacent caulking projections 1b. The height of the gap holding projection 1d is about 1.5 mm.
[0019]
As shown in FIG. 4, the member to be caulked 2 has a plate thickness of about 1.3 mm and has a fitting hole 2a. The fitting hole 2a is formed so as to fit with the caulking protrusion 1b of the caulking member 1. That is, the three fitting holes shown in FIG. 4 fit into the three caulking projections 1b in FIG. The size of the fitting hole 2a is about 2.3 mm × 19 mm.
[0020]
Next, a method of joining the caulking member 1 and the member to be caulked 2 thus formed by heat caulking will be described with reference to FIG. FIG. 5A is a cross-sectional view of the opening and closing door 12 before heat caulking. FIG. 5B is a cross-sectional view of the opening and closing door 12 joined by heat caulking. First, as shown in FIG. 5A, the swaging protrusion 1b of the swaging member 1 and the fitting hole 2a of the swaged member 2 are fitted. At this time, the caulking member 1 and the caulking member 2 are positioned at a position where the tip of the gap holding projection 1d of the caulking member 1 and the caulking member 2 are in contact with each other (member positioning step). That is, the gap between the substrate 1a of the caulking member 1 and the member to be caulked 2 is 1.5 mm because it is the same as the height of the gap holding projection 1d. Then, the caulking protrusion deformation step (caulking protrusion deformation step) is started. First, pressure is applied while the tip side of the caulking projection 1b is heated by the ultrasonic heater 20. Specifically, the crimping protrusion 1b is pressed at a pressure of about 1.8 MPa for about 4 to 7 seconds while heating at a temperature of about 200 ° C. Thereby, the caulked protrusion 1b is melted and deformed. Thereafter, the ultrasonic heater 20 is lowered to a temperature of about 80 ° C., and the molten caulked projection 1b is cooled for about 4 seconds.
[0021]
FIG. 5B shows a shape in which the swaging member 1 is swaged by deforming the swaging protrusion 1b. That is, the design surface 1c of the caulking member 1 has no unevenness. It is considered that this is because heat and pressure from the ultrasonic heater 20 are not transmitted to the design surface 1c by providing a gap between the substrate 1a of the caulking member 1 and the member 2 to be caulked. In addition, the deformed caulking projection 1c is formed on the surface opposite to the design surface 1c in a shape obtained by transferring the molded portion of the ultrasonic heater 20. That is, the burrs which have occurred conventionally have not occurred. It is considered that this is because a part of the deformed caulking projection 1b was moved to the gap between the substrate 1a of the caulking member 1 and the member 2 to be caulked. Thus, the appearance quality of the design surface 1c and the surface opposite to the design surface is very good. Further, by moving the deformed caulking protrusion 1c into the gap between the substrate 1a of the caulking member 1 and the caulking member 2, the caulking member 2 can be caulked more firmly.
[0022]
Next, the appearance quality in the case where the gap between the substrate 1a of the caulking member 1 and the member to be caulked 2 is changed and the heat caulking is performed will be described. When the gaps were set to 0 mm, 1.0 mm, 1.5 mm, and 2.0 mm, the above-described heat caulking was performed. The shapes of the caulking member 1 and the member to be caulked 2 are the same as those in the above embodiment. Further, the heating temperature and the pressing force by the ultrasonic heater 20 are the same as in the above embodiment. Further, the pressurizing step time and the cooling step time are almost the same as in the above embodiment. The result is shown in FIG.
[0023]
As shown in FIG. 6, in the case where the gap is 0 mm, that is, in the case of the conventional heat caulking method, irregularities are formed on the design surface 1c, and burrs are generated on the opposite surface of the design surface 1c. Very bad. When the gap was 1.0 mm, substantially good appearance quality could be obtained for both the design surface 1c and the opposite surface of the design surface 1c. When the gaps were 1.5 mm and 2.0 mm, very good appearance quality could be obtained for both the design surface 1c and the opposite surface of the design surface 1c.
[0024]
Next, heat caulking was performed by changing the pressure applied by the ultrasonic heater 20. Other conditions are the same as in the above embodiment. The result is shown in FIG. FIG. 7 shows that the appearance quality is better when the pressure is 1.9 MPa than when the pressure is 1.3 MPa. That is, the higher the pressure, the better the appearance quality. When the pressing force is smaller than 1.3 MPa, the caulking projection 1b does not melt, so that the caulking joint cannot be performed. Further, when the pressing force is larger than 1.9 MPa, the caulking projection 1b is broken, so that caulking cannot be performed.
[0025]
In the above embodiment, the caulking member 1 has the gap holding projection 1d, but the invention is not limited to this. That is, the member to be caulked 2 may have the gap holding projection 1d. In this case, it can be performed by the same heat caulking method as described above. Of course, both the caulking member 1 and the caulking member 2 may have the gap holding projections 1d. Also, when performing the thermal caulking, if the caulking member 1 and the caulking member 2 can be positioned so as to have a predetermined gap between the substrate 1a of the caulking member 1 and the caulking member 2, the caulking member 1 Alternatively, another method may be used in which both the caulking member 2 does not have the gap holding projection 1d. For example, a method may be adopted in which, when performing the heat caulking, another member capable of securing a predetermined gap is inserted, and the other member inserted after the completion of the heat caulking is removed.
[0026]
Further, in the above-described embodiment, the ultrasonic heater 20 is used to melt the caulking protrusion 1c, but the invention is not limited to this. For example, any material capable of melting the caulking protrusion 1c of the caulking member 1 made of a thermoplastic resin and applying pressure, such as hot air heating, high frequency heating, heat heater heating, and vibration welding, may be used.
[0027]
(Other embodiments)
In the above embodiment, the swaging member 1 and the swaged member 2 are separate members, but in the present embodiment, they are the same member. This embodiment will be described with reference to FIGS.
[0028]
FIG. 8A shows a side view of the member 5 before performing the thermal caulking. The member 5 is formed of a thermoplastic resin, for example, a polypropylene resin. The member 5 includes a substrate portion 5a, a bent portion 5b, a caulking protrusion 5c, and a gap holding protrusion 5d. The substrate section 5a corresponds to the substrate 1a in the above embodiment. The caulking projection 5c and the gap holding projection 5d correspond to the caulking projection 1b and the gap holding projection 1d in the above embodiment, respectively. The bent portion 5b has a fitting hole 5e that fits into the caulking protrusion 5c when bent to the caulking protrusion 5c side.
[0029]
Next, the heat caulking of the member 5 having such a shape will be described. First, the bent portion 5b is crimped toward the protrusion 5c as shown in FIG. 8B. In the case of a piece, the fitting hole 5e fits with the caulking projection 5c. Further, the bent portion 5b is fixed at a position where the bent portion 5b contacts the tip of the gap holding projection 5d (member positioning step). That is, the bent portion 5b corresponds to the member to be caulked in the above embodiment. Subsequently, the caulking protrusion deformation step (caulking protrusion deformation step) is started. First, the tip of the caulking projection 5c is pressurized while being heated by the ultrasonic heater 20. Specifically, the caulking projection 5c is pressed at a pressure of about 1.8 MPa for about 4 to 7 seconds while heating at a temperature of about 200 ° C. Thereby, the caulking projection 5c is melted and deformed. Thereafter, the ultrasonic heater 20 is lowered to a temperature of about 80 ° C., and the molten caulked projection 5c is cooled for about 4 seconds.
[0030]
FIG. 8C shows a shape in which the bent portion 5b is caulked by deforming the caulking protrusion 5c. Also in this case, as shown in FIG. 8C, the same effect as in the above embodiment can be obtained. That is, the appearance quality of the design surface and the surface opposite to the design surface becomes very good. Furthermore, since the heat caulking is performed using a part of the member 5, it is possible to reinforce with one member without using a separate component as in the above embodiment. That is, the cost can be reduced and the reinforcement can be achieved.
[0031]
The heat caulking structure according to this embodiment can be used, for example, for a bumper of an automobile. That is, the strength of the end of the bumper can be easily increased at low cost.
[0032]
Further, in the above-described embodiment, the opening / closing door and the bumper of the airbag have been described as examples, but the invention is not limited thereto. Other parts may be used as long as the present invention can be applied.
[0033]
The member to be swaged may be any member such as a metal, a non-metal or a resin. Further, in the above-described embodiment, the description has been given of the case where the heat caulking is performed with the reinforcing member. However, the present invention is not limited to this.
[0034]
【The invention's effect】
According to the heat caulking structure and the heat caulking method of the present invention, the appearance quality can be improved. That is, no irregularities are formed on the design surface of the caulking member, and no burr is generated on the surface opposite to the design surface.
[Brief description of the drawings]
FIG. 1 is a perspective view showing an instrument panel mounted on a windshield side of an automobile.
FIG. 2 is a perspective view showing a heat caulking structure of the present invention.
FIG. 3 is a perspective view showing a caulking member of the present invention.
FIG. 4 is a perspective view showing a caulking member of the present invention.
FIG. 5 is a cross-sectional view illustrating a heat caulking method according to the present invention.
FIG. 6 is a view showing appearance quality with respect to a gap.
FIG. 7 is a view showing appearance quality with respect to a pressing force.
FIG. 8 is a view for explaining a heat caulking method in another embodiment.
FIG. 9 is a cross-sectional view illustrating a conventional heat swaging method.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Caulking member 1a ... Substrate 1b ... Caulking protrusion 1c ... Design surface 1d ... Gap holding protrusion 2 ... Caulking member 2a ... Fitting hole 5 ... Member 5a ... board part 5b ... bent part 5c ... caulking protrusion 5d ... gap keeping protrusion 10 ... instrument panel 11 ... airbag case 12 ... opening and closing door 20 ...・ Ultrasonic heater

Claims (5)

基板と該基板の一方の面に突設したかしめ突起とからなる熱可塑性樹脂製のかしめ部材と、
該かしめ突起に嵌合される嵌合穴を有する被かしめ部材とからなり、
該かしめ突起に該嵌合穴を嵌合させ、該かしめ突起を加熱し変形させることにより該かしめ部材に該被かしめ部材をかしめて形成される熱かしめ構造体であって、
前記基板と前記被かしめ部材との間に所定の隙間を形成したことを特徴とする熱かしめ構造体。A caulking member made of a thermoplastic resin composed of a substrate and a caulking projection protruding from one surface of the substrate,
A caulked member having a fitting hole fitted to the caulking projection,
A heat caulking structure formed by caulking the caulking member to the caulking member by fitting the fitting hole into the caulking protrusion and heating and deforming the caulking protrusion;
A heat caulking structure, wherein a predetermined gap is formed between the substrate and the member to be caulked. 前記隙間は、前記かしめ部材の前記被かしめ部材に対向する面および／または前記被かしめ部材の前記かしめ部材に対向する面に形成された複数の隙間保持用突起により形成されることを特徴とする請求項１記載の熱かしめ構造体。The gap is formed by a plurality of gap holding projections formed on a surface of the caulking member facing the member to be caulked and / or a surface of the member to be caulked facing the member for the caulking. The heat caulking structure according to claim 1. 前記被かしめ部材は、前記基板を補強する補強部材であることを特徴とする請求項１又は２に記載の熱かしめ構造体。The heat caulking structure according to claim 1, wherein the caulking member is a reinforcing member for reinforcing the substrate. 前記被かしめ部材は、前記基板の延長線上に前記基板と一体成形され前記基板に対して折り曲げて形成される折曲部であることを特徴とする請求項３記載の熱かしめ構造体。The thermal caulking structure according to claim 3, wherein the caulking member is a bent portion formed integrally with the substrate on an extension of the substrate and formed by bending the substrate. 基板と該基板の一方の面に突設したかしめ突起とからなる熱可塑性樹脂製のかしめ部材に、該かしめ突起に嵌合される嵌合穴を有する被かしめ部材を、該かしめ突起を加熱し変形させることによりかしめて接合する熱かしめ接合方法であって、
前記かしめ突起と前記嵌合穴とを嵌合させ前記基板と前記被かしめ部材との間に所定の隙間を設けて前記かしめ部材及び前記被かしめ部材を位置決めする部材位置決めステップと、
前記かしめ突起を加熱し変形させるかしめ突起変形ステップと、
からなることを特徴とする熱かしめ接合方法。A caulking member made of a thermoplastic resin consisting of a substrate and a caulking protrusion protruding from one surface of the substrate, a member to be caulked having a fitting hole fitted into the caulking protrusion, and the caulking protrusion is heated. A heat caulking method of joining by caulking by deforming,
A member positioning step of positioning the caulking member and the caulking member by providing a predetermined gap between the substrate and the caulking member by fitting the caulking protrusion and the fitting hole,
A caulking protrusion deformation step of heating and deforming the caulking protrusion,
A heat caulking method characterized by comprising:
JP2002218237A 2002-07-26 2002-07-26 Thermally caulking structure and method for thermally caulking and connecting Pending JP2004058391A (en)

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JP2005035534A (en) * 2003-06-25 2005-02-10 Calsonic Kansei Corp Welded part structure of vehicular air bag device
JP2008044242A (en) * 2006-08-17 2008-02-28 Mazda Motor Corp Method for joining resin members and resultant joint structure
JP2012139893A (en) * 2010-12-28 2012-07-26 Kawakami Sangyo Co Ltd Laminated sheet
FR2982791A1 (en) * 2011-11-17 2013-05-24 Renault Sa Method for realizing thermoplastic material part i.e. tailgate, of car, involves providing housing having set of riveting rods and set of reference ribs, and positioning structural insert on another housing
CN105818358A (en) * 2016-05-18 2016-08-03 惠州市壹品科技有限公司 Encompassing type heating component and heating method
CN105820403A (en) * 2015-01-28 2016-08-03 通用汽车环球科技运作有限责任公司 Composition for forming a component structure and method of making and using the same
CN105946221A (en) * 2016-05-18 2016-09-21 惠州市壹品科技有限公司 Ultrasonic hot melting device and method

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2005035534A (en) * 2003-06-25 2005-02-10 Calsonic Kansei Corp Welded part structure of vehicular air bag device
JP4498834B2 (en) * 2003-06-25 2010-07-07 カルソニックカンセイ株式会社 Manufacturing method for welded portion structure of air bag apparatus for vehicle
JP2008044242A (en) * 2006-08-17 2008-02-28 Mazda Motor Corp Method for joining resin members and resultant joint structure
JP2012139893A (en) * 2010-12-28 2012-07-26 Kawakami Sangyo Co Ltd Laminated sheet
FR2982791A1 (en) * 2011-11-17 2013-05-24 Renault Sa Method for realizing thermoplastic material part i.e. tailgate, of car, involves providing housing having set of riveting rods and set of reference ribs, and positioning structural insert on another housing
CN105820403A (en) * 2015-01-28 2016-08-03 通用汽车环球科技运作有限责任公司 Composition for forming a component structure and method of making and using the same
CN105818358A (en) * 2016-05-18 2016-08-03 惠州市壹品科技有限公司 Encompassing type heating component and heating method
CN105946221A (en) * 2016-05-18 2016-09-21 惠州市壹品科技有限公司 Ultrasonic hot melting device and method

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