JOINED BODY AND METHOD FOR PRODUCING SAME

Abstract

A joined body includes a tubular first member, and a second member including a plate-shaped wall portion in which a through-hole is formed, the first member being inserted into the through-hole. The collar member is interposed between the first member and the second member in at least a part of the hole peripheral wall of the through-hole. The first member and the second member are joined by expanding the first member at a portion corresponding to the through-hole.

Claims

1. A joined body comprising: a tubular first member; a second member including a plate-shaped wall portion in which a through-hole is formed, the first member being inserted into the through-hole; and a collar member interposed between the first member and the second member in at least a part of a hole peripheral wall of the through-hole, wherein the first member and the second member are joined by expanding the first member at a portion corresponding to the through-hole.

2. The joined body according to claim 1, wherein the wall portion comprises a first main surface and a second main surface facing each other in a thickness direction of the wall portion, and the collar member comprises: a first base portion disposed on the first main surface; and a tubular portion connected to the first base portion, extending in the thickness direction to penetrate the through-hole, including a first end portion located at a distance from the second main surface in the thickness direction, and having an inner peripheral surface in contact with the first member and an outer peripheral surface in contact with the hole peripheral wall of the through-hole.

3. The joined body according to claim 2, wherein the collar member further comprises a second base portion connected to the tubular portion and disposed on the second main surface, and the wall portion is interposed between the first base portion and the second base portion.

4. The joined body according to claim 3, in which the tubular portion further includes a second end portion located at a distance from the first main surface in the thickness direction.

5. The joined body according to claim 1, wherein the first member is made of a first metal material, and the second member is made of a second metal material different from the first metal material.

6. The joined body according to claim 5, wherein the first metal material is aluminum or an aluminum alloy, and the second metal material is high tensile steel.

7. The joined body according to claim 5, wherein the collar member is made of the first metal material.

8. The joined body according to claim 7, further comprising an adhesive layer interposed between the collar member and the wall portion.

9. The joined body according to claim 5, wherein the collar member is made of a resin material.

10. The joined body according to claim 1, wherein the collar member is annular.

11. The joined body according to claim 1, wherein the collar member is non-annular.

12. A method for producing a joined body, comprising the following steps of: preparing a tubular first member, a second member including a plate-shaped wall portion in which a through-hole is formed, and a collar member; inserting the first member into the through-hole so that the collar member is interposed between the first member and the second member on a hole peripheral wall of the through-hole; and expanding the first member toward the second member in a portion corresponding to the through-hole, thereby caulking and joining the first member and the second member.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 is a perspective view of a joined body according to a first embodiment of the present invention;

[0025] FIG. 2 is a vertical cross-sectional view of the joined body according to the first embodiment;

[0026] FIG. 3 is a perspective view for explaining mounting of a collar member on a second member (wall portion);

[0027] FIG. 4 is a perspective view for explaining insertion of the collar member into a mounted first member;

[0028] FIG. 5 is a partial cross-sectional view taken along a line V-V of FIG. 4;

[0029] FIG. 6 is a vertical cross-sectional view in a state where a rubber member is inserted in the first member;

[0030] FIG. 7 is a partial cross-sectional view similar to FIG. 5 of a first alternative of the collar member;

[0031] FIG. 8 is a partial cross-sectional view similar to FIG. 5 of a second alternative of the collar member;

[0032] FIG. 9 is a partial cross-sectional view similar to FIG. 5 of a third alternative of the collar member;

[0033] FIG. 10 is a partial cross-sectional view similar to FIG. 5 of a fourth alternative of the collar member;

[0034] FIG. 11 is a partial cross-sectional view similar to FIG. 5 of a fifth alternative of the collar member;

[0035] FIG. 12 is a partial cross-sectional view similar to FIG. 5 of a sixth alternative of the collar member;

[0036] FIG. 13 is a perspective view of a seventh alternative of the collar member;

[0037] FIG. 14 is a perspective view of an eighth alternative of the collar member;

[0038] FIG. 15 is a perspective view of a joined body according to a second embodiment of the present invention;

[0039] FIG. 16 is a vertical cross-sectional view of the joined body according to the second embodiment;

[0040] FIG. 17 is a vertical cross-sectional view in the state where the rubber member is inserted in the first member; and

[0041] FIG. 18 is a partial cross-sectional view illustrating an example in which the joined body of the second embodiment is applied to a bumper member.

DESCRIPTION OF EMBODIMENTS

[0042] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

First Embodiment

[0043] Referring to FIGS. 1 and 2, a joined body 1 of the present embodiment includes a first member 10, a second member 20, a collar member 30, and an adhesive layer 40. The joined body 1 is configured by caulking and joining the first member 10 and the second member 20 with the collar member 30 interposed therebetween. Further, the adhesive layer 40 is interposed between the collar member 30 and the second member 20.

[0044] The first member 10 of the present embodiment is a circular tubular member having both ends open, and is made of aluminum or an aluminum alloy. The first member 10 includes a circular tubular main body 11 and bulging portions 12A and 12B extending in a circumferential direction of the main body 11 and bulging outward in a radial direction of the main body 11. The bulging portions 12A and 12B are arranged on both sides (upper and lower sides in FIGS. 1 and 2) in an axial direction of the main body 11 with respect to the second member 20.

[0045] Referring to FIG. 3 together, the second member 20 of the present embodiment includes only the plate-shaped wall portion 21 having an annular shape as a whole. The wall portion 21 which is the second member 20 includes a pair of main surfaces 21a and 21b (first main surface and second main surface) facing each other in a thickness direction of the wall portion 21. In the present embodiment, both the main surfaces 21a and 21b are flat surfaces. As long as joint strength between the first member 10 and the second member 20 can be ensured, one or both of the main surfaces 21a and 21b may be curved surfaces. The wall portion 21, which is the second member 20, is formed with a through-hole 22 that penetrates the wall portion 21 in the thickness direction. In the present embodiment, the through-hole 22 is a circular hole corresponding to that the first member 10 is circular tubular as described above.

[0046] Referring to FIG. 3 together, the collar member 30 of the present embodiment is a torus having an integral structure having a narrow width and a thin thickness, and is made of the same material (aluminum or aluminum alloy) as the first member 10. In a region surrounded by the collar member 30, a through-hole 31 that penetrates the collar member 30 in the thickness direction is defined. The collar member 30 includes a base portion 30a (first base portion) and a tubular portion 30b.

[0047] The base portion 30a of the present embodiment is flat annular and includes a pair of main surfaces 30c and 30d facing each other in the thickness direction of the base portion 30a. In the present embodiment, the main surfaces 30c and 30d are both flat surfaces. Depending on the shape of the main surfaces 21a and 21b of the wall portion 21 (second member 20), one or both of the main surfaces 30c and 30d of the base portion 30a may be curved surfaces. The base portion 30a is located on the main surface 21a of the wall portion 21. Specifically, a main surface 30d of the base portion 30a is in contact with the main surface 20a of the wall portion 21a via the adhesive layer 40.

[0048] The tubular portion 30b of the present embodiment is an opening at both ends, and as illustrated most clearly in FIG. 2, is connected to an end portion on the inner peripheral side (through-hole 31 side) of the base portion 30a. The tubular portion 30b in the present embodiment extends from one side (the main surface 30d side) of the base portion 30a in the thickness direction of the wall portion 21 which is the second member 20, and penetrates the through-hole 22. Therefore, the tubular portion 30b includes an end portion 30e (a first end portion) located at a distance from the main surface 21b in the thickness direction of the wall portion 21. A diameter of the tubular portion 30b is larger on the end portion 30e side than a portion connected to the base portion 30a due to deformation during caulking joining using a rubber member 50 to be described below. An inner peripheral surface 30f of the tubular portion 30b is in direct contact with the first member 10. Further, an outer peripheral surface 30g of the tubular portion 30b is in contact with a hole peripheral wall 22a of the through-hole 22 formed in the wall portion 21 which is the second member 20 via the adhesive layer 40.

[0049] Hereinafter, a method for manufacturing the joined body 1 according to the present embodiment will be described.

[0050] First, as illustrated in FIG. 3, the collar member 30 is attached to the wall portion 21 which is the second member 20. Specifically, the tubular portion 30b of the collar member 30 is inserted into the through-hole 22 of the wall portion 21, and the base portion 30a of the collar member 30 is disposed on the main surface 21a of the wall portion 21. Before mounting the collar member 30 on the wall portion 21 in this way, a non-conductive adhesive that becomes an adhesive layer 40 when cured is applied to a periphery of the through-hole 22 of the main surface 21a of the wall portion 21, and the hole peripheral wall 22a of the through-hole 22. A part or all of the adhesive may be applied to the main surface 30d of the base portion 30a of the collar member 30 and the outer peripheral surface 30g of the tubular portion 30b.

[0051] Next, as illustrated in FIGS. 4 and 5, the first member 10 is inserted into the through-hole 22 of the wall portion 21 which is the second member 20. More specifically, the first member 10 is inserted into the through-hole 31 defined by the collar member 30 attached to a portion of the through-hole 22 of the wall portion 21.

[0052] In this state, as illustrated in FIG. 6, the rubber member 50 is inserted into the first member 10. In the present embodiment, the rubber member 50 is columnar and has dimensions that can be inserted into the first member 10. An outer shape of the rubber member 50 is similar to an inner shape of the first member 10 in a cross-section perpendicular to the axial direction of the first member 10, and is preferably as large as possible to be inserted. The rubber member 50 has flat surfaces perpendicular to the axial direction of the first member 10 at both ends in a longitudinal direction of the rubber member 50. A material of the rubber member 50 is preferably, for example, either urethane rubber, chloroprene rubber, CNR rubber (chloroprene rubber and nitrile rubber), or silicone rubber. Further, hardness of the rubber member 50 is preferably 30 or more on the shore A scale.

[0053] The rubber member 50 may be disposed in the first member 10 before the first member 10 is inserted into the through-hole 22 of the wall portion 21 which is the second member 20.

[0054] Subsequently, pushers 60 are arranged at both ends of the rubber member 50. Each pusher 60 includes a pressing portion 60a that presses the rubber member 50. The pressing portion 60a has a columnar shape, and the pressing portion 60a has a pressing surface which is a flat pressing surface at an end portion thereof. The pusher 60 is attached to a press device or the like (not illustrated), and is driven by the press device to compress the rubber member 60 in the axial direction of the first member 10 (see arrows in FIG. 6). With this compression, the rubber member 50 expands radially outward of the first member 10. Due to expansion of the rubber member 50, the first member 10 is expanded, and the first member 10 and the wall portion 21, which is the second member 20, are caulked and joined. At this time, the bulging portions 12A and 12B are formed on both sides in the axial direction of the first member 10 with respect to the wall portion 21. As the bulging portion 12B is formed on the first member 10, the diameter of the end portion 30e side of the tubular portion 30 of the collar member 30 is expanded.

[0055] After caulking and joining the first member 10 and the wall portion 21 which is the second member 20, a press device (not illustrated) is driven to release the compression of the rubber member 50 by the pusher 60. Since the rubber member 50 from which a compressive force of the pusher 60 has been removed is restored to its original shape by elasticity of the rubber member 50 itself, it can be easily removed from the first member 10.

[0056] As is most clearly illustrated in FIG. 5, in a stage before caulking joining using the rubber member 50, the tubular portion 30b of the collar member 30 has not been expanded in diameter on the end portion 30e side, and has a cylindrical shape with a substantially constant diameter as a whole. Further, the inner peripheral surface 30f of the tubular portion 30b and the main surface 30c of the base portion 30a are connected substantially perpendicular to each other.

[0057] The collar member 30 having the tubular portion 30b is interposed between the first member 10 and the wall portion 21 which is the second member 20. The inner peripheral surface 30f of the tubular portion 30b that comes into contact with the first member 10 has a larger area than the hole peripheral wall 22a of the through-hole 22 provided in the wall portion 21. Therefore, by interposing the collar member 30 between the first member 10 and the wall portion 21, a joint area between the first member 10 and the wall portion 21 (second member 20) can be increased. As a result, the joint strength and joint durability of the first member 10 and the second member 20 can be improved. Further, by increasing the joint area, it is possible to prevent or suppress biting of the wall portion 21, which is the second member 20, into the first member 10. By interposing the collar member having the tubular portion 30b between the first member 10 and the wall portion 21 (second member 20), strain of the first member due to expansion during caulking joining is reduced, so that it is possible to prevent or suppress cracking of the first member 10.

[0058] FIGS. 7 to 14 illustrate modifications of the first embodiment. The modifications can also be applied to a second embodiment to be described below.

[0059] In the modifications of FIGS. 7 and 8, a chamfered portion 30h is provided at a portion where the inner peripheral surface 30f of the tubular portion 30b and the main surface 30c of the base portion 30a are connected. The chamfered portion 30h in FIG. 7 is a flat surface, and the chamfered portion 30h in FIG. 8 is a convex curved surface.

[0060] The collar member 30 of the modifications of FIGS. 9 to 12 further includes a base portion 30i (second base portion) that is connected to the tubular portion 30b and in contact with the main surface 21b of the wall portion 21 which is the second member 20 via the adhesive layer 40. The base portion 30i includes a pair of main surfaces 30j and 30k facing each other in the thickness direction of the base portion 30i. The wall portion 21 is sandwiched between the main surface 30d of the base portion 30a and the main surface 30j of the base portion 30i via the adhesive layer 40. In this way, the wall portion 21 (second member 20) is sandwiched between the pair of base portions 30a and 30i, so that the collar member 30 can be reliably held against the wall portion 21 when the first member 10 and the second member 20 are caulked and joined.

[0061] In the modifications of FIGS. 9 and 10, the end portion 30e of the tubular portion 30b does not protrude beyond the base portion 30i. In the modification of FIG. 9, the inner peripheral surface 30f of the tubular portion 30b is a cylindrical surface having a substantially constant diameter. In the modification of FIG. 10, the inner peripheral surface 30f of the tubular portion 30b is a cylindrical surface having a diameter expanded at both ends in a curved shape.

[0062] In the modifications of FIGS. 11 and 12, the end portion 30e of the tubular portion 30b protrudes from the base portion 30i. Further, in addition to the end portion 30e protruding from the base portion 30i, the tubular portion 30b of the collar member 30 of the modification of FIG. 12 includes an end portion 30m (a second end portion) that protrudes from the main surface 30c of the base portion 30i and is located at a distance from the main surface 21a in the thickness direction of the wall portion 21 (second member 20). By having the end portions 30e and 30m respectively protruding from the base portions 30i and 30a, the area of the inner peripheral surface 30f of the tubular portion 30b can be further increased, and the joint area can be further increased.

[0063] In the method for manufacturing the joined body 1 of the first embodiment described above, the collar member 30 is fixed to the through-hole 22 of the wall portion 21 which is the second member 20 with the adhesive layer 40, and then the first member 10 is inserted into the through-hole 22. However, in the case of the collar member 30 of the first embodiment, the collar member 30 of the modification of FIG. 7, and the collar member 30 of the modification of FIG. 8, the collar member 30 may be fixed to the first member 10 by means such as adhesion, and then the first member 10 may be inserted into the through-hole 22 of the wall portion 21 which is the second member 20.

[0064] In the modifications of FIGS. 13 and 14, a split-type non-annular collar member is employed instead of the annular collar member 30 as in the first embodiment.

[0065] In the modification of FIG. 13, the through-hole 22 of the second member 20 is a circular hole similar to that of the first embodiment, and two semicircular collar members 61 and 62 are mounted on the through-hole 22.

[0066] The through-hole 22 in the modification of FIG. 14 is a rectangle having arcuate four corners. The hole peripheral wall 22a of the through-hole 22 includes two pairs of linear portions, that is, a pair of long side portions 22b and 22c and a pair of short side portions 22d and 22e. Collar members 63 are respectively attached to the long side portions 22b and 22c, and collar members 64 are respectively attached to the short side portions 22d and 22e.

[0067] Cross-sectional shapes of the collar members 61 to 64 of FIGS. 13 and 14 are the same as those of the collar member 30 of the first embodiment. However, the collar members 61 to 64 of FIGS. 13 and 14 may have a cross-sectional shape as in the modifications of FIGS. 7 to 12.

[0068] The collar members 30 and 61 to 64 may be made of a non-conductive resin material. In this case, by interposing the collar members 30 and 61 to 64 between the first member 10 and the second member 20, it is possible to prevent electrolytic corrosion from occurring between the first member 10 made of, for example, aluminum or an aluminum alloy and the second member 20 made of, for example, high tensile steel. That is, it is possible to prevent electrolytic corrosion between the first member 10 and the second member 20 without providing the adhesive layer 40.

Second Embodiment

[0069] In the second embodiment described below, the same or similar elements as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted. Further, in the second embodiment, the same operations and effects as those in the first embodiment are obtained, except for the points particularly mentioned.

[0070] Referring to FIGS. 15 and 16, the second member 20 of the present embodiment is a hollow member, and the first member 10 and the second member 20 are caulked and joined at two points.

[0071] The first member 10 of the present embodiment includes the circular tubular main body 11 and bulging portions 12A, 12B, 12C, and 12D extending in the circumferential direction of the main body 11 and bulging outward in the radial direction.

[0072] The second member 10 of the present embodiment includes a pair of wall portions 21 facing each other and side wall portions 23 connecting ends of the wall portions 21. Through-holes 22 are respectively formed in the pair of wall portions 21.

[0073] In the present embodiment, the first member 10 is expanded in a state where the first member 10 is inserted into the through-holes 22 of the pair of wall portions 21 of the second member 20, and the collar members 30 are respectively interposed between the first member 10 and the pair of wall portions 21 of the second member 20. By this expansion, the first member 10 and the pair of wall portions 21 of the second member 20 are caulked and joined. One wall portion 21 of the second member 20 is fitted between the bulging portions 12A and 12B of the first member 10 via the collar member 30, and the other wall portion 21 is fitted between the bulging portions 12C and 12D of the first member 10 via the collar member 30, so that the first member 10 is prevented from coming off in the axial direction.

[0074] Hereinafter, a method for manufacturing the joined body 1 according to the present embodiment will be described.

[0075] First, the collar members 30 are respectively attached to the pair of wall portions 21 of the second member 20 via adhesive layers 40. Subsequently, as illustrated in FIG. 17, the rubber member 50 is inserted into the first member 10. The rubber member 50 may be disposed in the first member 10 before the first member 10 is inserted into the through-hole 22 of the wall portion 21 which is the second member 20. In the present embodiment, the rubber member 50 is divided into two, and a column plate member 51 which is a substantially rigid body is disposed between the rubber members 50.

[0076] Subsequently, the pushers 60 are arranged at both ends of the rubber members 50. Subsequently, the rubber member 60 is compressed in the axial direction of the first member 10 by driving the pusher 60 by the press device (not illustrated) (see arrows in FIG. 17). Due to the expansion of the rubber member 50 due to this compression, the first member 10 is expanded, and the first member 10 and the pair of wall portions 21 of the second member 20 are caulked and joined. At this time, the bulging portions 12A and 12B are formed on both sides in the axial direction of the first member 10 with respect to one wall portion 21, and the bulging portions 12C and 12D are also formed on both sides in the axial direction of the first member 10 with respect to the other wall portion 21.

[0077] After caulking and joining the first member 10 and the pair of wall portions 21 of the second member 20, the press device (not illustrated) is driven to release the compression of the rubber member 50 by the pusher 60. Thereafter, the rubber member 50 is removed from the first member 10.

[0078] FIG. 18 illustrates an example in which the joined body 10 of the second embodiment is applied to a bumper member 100 of an automobile. In FIG. 18, the same or similar elements as those in the second embodiment are denoted by the same reference numerals. The bumper member 100 includes a bumper reinforce 101 and a pair of stays 102 having tips joined to the bumper reinforce 101 and base ends connected to side members (not illustrated). FIG. 18 illustrates only one stay 102.

REFERENCE SIGNS LIST

[0079] 1: Joined body, 10: First member, 11: Main body, 12A; 12B; 12C; 12D: Bulging portion, 20: Second member, 21: Wall portion, 21a; 21b: Main surface (First main surface and second main surface), 22: Through-hole, 22a: Hole peripheral wall, 22b; 22c: Long side portion, 22d; 22e: Short side portion, 23: Side wall portion, 30: Collar member, 30a: Base portion (First base portion), 30c; 30d: Main surface, 30b: Tubular portion, 30e: End portion (First end portion), 30f: Inner peripheral surface, 30g: Outer peripheral surface, 30h: Chamfered portion, 30i: Base portion (Second base portion), 30j; 30k: Main surface, 30m: End portion (Second end portion), 31: Through-hole, 40: Adhesive layer, 50: Rubber member, 51: Plate member, 60: Pusher, 60a: Pressing portion, 61; 62; 63; 64; Collar member, 100: Bumper member, 101: Bumper reinforce, 102: Stay