Method for joining members, and joint body

Abstract

A method for joining members includes: providing a wall surface body which is a die-molded article provided with a hole portion with a draft angle provided from its opposite end portions toward its center portion, a tubular body with a hollow shape, and an elastic body; inserting the tubular body into the hole portion in the wall surface body; inserting the elastic body into the inside of the tubular body; and compressing the elastic body in the direction of an axial line L of the tubular body to expand the elastic body outwardly in the radial direction of the axial line L, thereby deforming and expanding the tubular body to joint the tubular body to the wall surface body by press-fitting.

Claims

1. A method for joining members, comprising: providing a first member which is a die-molded article provided with a hole portion with a draft angle provided from its opposite end portions toward its center portion, a second member with a hollow shape, and an elastic body; inserting the second member into the hole portion in the first member; inserting the elastic body into an inside of the second member; and compressing the elastic body in a direction of an axial line of the second member to expand the elastic body outwardly in a radial direction of the axial line, thereby expanding and deforming the second member to join the second member to the first member by press-fitting; wherein the first member is provided in its inner surface with an uninclined surface having no draft angle, and the first member is provided with an opening portion at a position facing the uninclined surface.

2. The method for joining members according to claim 1, further comprising: providing a core; providing a plurality of the elastic body; inserting the core into the inside of the second member; and inserting the elastic bodies into the second member in opposite sides with the core sandwiched between the elastic bodies.

3. The method for joining members according to claim 2, wherein the hole portion in the first member has a trapezoid cross section, the uninclined surface is provided in an upper bottom side of the hole portion, the opening portion is provided in a lower bottom side of the hole portion, and the upper bottom side of the hole portion is provided with a draft angle larger than a draft angle provided in the lower bottom side.

4. The method for joining members according to claim 2, wherein the second member has a diameter increased in a trumpet shape at its one end portion.

5. The method for joining members according to claim 2, further comprising: providing an outer frame die; placing the outer frame die on an outer side of the first member; and joining the first member and the second member to each other by press-fitting in a state where the first member is suppressed from deforming by the outer frame die.

6. The method for joining members according to claim 1, wherein the hole portion in the first member has a trapezoid cross section, the uninclined surface is provided in an upper bottom side of the hole portion, the opening portion is provided in a lower bottom side of the hole portion, and the upper bottom side of the hole portion is provided with a draft angle larger than a draft angle provided in the lower bottom side.

7. The method for joining members according to claim 1, wherein the second member has a diameter increased in a trumpet shape at its one end portion.

8. The method for joining members according to claim 1, further comprising: providing an outer frame die; placing the outer frame die on an outer side of the first member; and joining the first member and the second member to each other by press-fitting in a state where the first member is suppressed from deforming by the outer frame die.

9. A joint body comprising: a first member which is a die-molded article provided with a hole portion with a draft angle provided from its opposite end portions toward its center portion; and a second member with a hollow shape which is inserted into the hole portion of the first member, wherein the second member is jointed to the first member by press-fitting in a state where the second member is expanded; wherein the first member has, in its inner surface, an uninclined surface having no draft angle, and the first member has an opening portion at a position facing the uninclined surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A is a perspective view of a wall surface body and a tubular body to be subjected to a method for joining members according to a first embodiment, before they are jointed to each other;

(2) FIG. 1B is a perspective view of the wall surface body and the tubular body after they are jointed to each other according to the method for joining members according to the first embodiment;

(3) FIG. 2A is a cross-sectional view of a first process in the method for joining members according to the first embodiment;

(4) FIG. 2B is a cross-sectional view of a second process in the method for joining members according to the first embodiment;

(5) FIG. 2C is a cross-sectional view of a third process in the method for joining members according to the first embodiment;

(6) FIG. 2D is a cross-sectional view of a fourth process in the method for joining members according to the first embodiment;

(7) FIG. 2E is a cross-sectional view of a fifth process in the method for joining members according to the first embodiment;

(8) FIG. 2F is a cross-sectional view of a sixth process in the method for joining members according to the first embodiment;

(9) FIG. 3A is a cross-sectional view of a comparison example before joining, regarding the method for joining members according to the first embodiment;

(10) FIG. 3B is a cross-sectional view of the comparison example after joining, regarding the method for joining members according to the first embodiment;

(11) FIG. 4A is a cross-sectional view of a method for joining members according to a second embodiment, before joining;

(12) FIG. 4B is a cross-sectional view of the method for joining members according to the second embodiment, after joining;

(13) FIG. 5A is a cross-sectional view of a method for joining members according to a third embodiment, before joining;

(14) FIG. 5B is a cross-sectional view of the method for joining members according to the third embodiment, after joining;

(15) FIG. 6A is a cross-sectional view of a method for joining members according to a fourth embodiment, before joining;

(16) FIG. 6B is a cross-sectional view of the method for joining members according to the fourth embodiment, after joining;

(17) FIG. 7A is a lateral cross-sectional view taken along line A-A in FIG. 5B;

(18) FIG. 7B is a lateral cross-sectional view taken along line B-B in FIG. 5B;

(19) FIG. 8A is a cross-sectional view of a method for joining members according to a fifth embodiment, before joining;

(20) FIG. 8B is a cross-sectional view of the method for joining members according to the fifth embodiment, after joining;

(21) FIG. 9A is a cross-sectional view of a method for joining members according to a sixth embodiment, before joining; and

(22) FIG. 9B is a cross-sectional view of the method for joining members according to the sixth embodiment, after joining.

MODE FOR CARRYING OUT THE INVENTION

(23) Hereinafter, embodiments of the present invention will be described with reference to the drawings.

First Embodiment

(24) With reference to FIGS. 1A to 2D, there will be described a method for joining members for joining a wall surface body (first member) 10 and a tubular body (second member) 20 to each other by press-fitting.

(25) As illustrated in FIG. 1A, the wall surface body 10 is a circular pipe with a hole portion 11 with a circular cross section. The wall surface body 10 is a die-molded article fabricated through die casting and is formed from an aluminum alloy, a magnesium alloy, a zinc alloy, or a copper alloy, for example. Since the wall surface body 10 is a die-casted article, the wall surface body 10 is provided with a draft angle in its hole portion 11. The draft angle is provided from the opposite end portions 12 and 13 toward the center portion 14, namely in different directions, rather than being provided in a single direction from one end portion 12 toward the other end portion 13 (see FIG. 2A). More specifically, the draft angle is provided such that the hole diameter decreases gradually from the opposite end portions 12 and 13 of the hole portion 11 toward the center portion 14 (see FIG. 2A). Similarly, the wall surface body 10 is provided with a draft angle in its outer surface, such that the outer diameter increases gradually from the opposite end portions 12 and 13 toward the center portion 14 (see FIG. 2A). The magnitudes of the draft angles are about 2 to 5 degrees, for example.

(26) As illustrated in FIG. 1A, the tubular body 20 according to the present embodiment is a hollow circular pipe extending in the direction of an axial line L. The outer diameter of the tubular body 20 is smaller than the inner diameter of the hole portion 11 in the wall surface body 10, namely the tubular body 20 has a size which can be inserted in the hole portion 11 of the wall surface body 10. The tubular body 20 is an extruded member formed from an aluminum alloy, for example.

(27) As illustrated in FIG. 1B, by utilizing the method for joining members according to the present embodiment, the tubular body 20 expands outwardly in the radial direction of the axial line L, and the tubular body 20 is jointed to the hole portion 11 in the wall surface body 10 by press-fitting, thereby forming a joint body 1. When viewed in the direction of the axial line L, the hole portion 11 in the wall surface body 10 preferably has an inner shape similar to the outer shape of the tubular body 20 and, further, preferably has a smallest possible size which enables inserting the tubular body 20 therein.

(28) The materials of the wall surface body 10 and the tubular body 20 are not limited to those described above. More specifically, the wall surface body 10 may be any die-molded article required to have a draft angle and may be also a casted article, a forged article or a resin product, for example, as well as the aforementioned die-casted article. Further, the tubular body 20 is required only to have a hollow shape and plastic deformability. The tubular body 20 may be also a pressed member formed from a high-tension steel, for example, and can be formed from arbitrary materials, as well as the aforementioned extruded member formed from an aluminum alloy. The same applies to second to sixth embodiments which will be described later.

(29) As illustrated in FIGS. 2A to 2F, the method for joining members according to the present embodiment will be described by being divided into first to sixth processes.

(30) As illustrated in FIG. 2A, in the first process, the wall surface body 10, the tubular body 20, and an elastic body 30 are provided. The elastic body 30 is constituted by a rubber with a circular cylindrical shape with an outer diameter which can be inserted in the tubular body 20. The elastic body 30 is required to have a length enough to deform the tubular body 20 around the joint portion. The material of the elastic body 30 is, for example, a urethane rubber, a chloroprene rubber, a CNR rubber (chloroprene rubber+nitrile rubber), a silicone rubber, or the like.

(31) As illustrated in FIG. 2B, in the second process, the tubular body 20 is inserted into the hole portion 11 in the wall surface body 10. The tubular body 20 is inserted through the wall surface body 10, and the tubular body 20 is exposed out of the wall surface body 10 at its opposite end portions 21 and 22.

(32) As illustrated in FIG. 2C, in the third process, the elastic body 30 is inserted into the inside of the tubular body 20. Instead thereof, the tubular body 20 may be also inserted into the hole portion 11 in the wall surface body 10, in the state where the elastic body 30 is inserted into the inside of the tubular body 20. Namely, the second process and the third process may be interchanged in the order.

(33) As illustrated in FIG. 2D, in the fourth process, the wall surface body 10, the tubular body 20, and the elastic body 30 are set into a pressurizing apparatus 40, in the state of being combined with each other. The pressurizing apparatus 40 according to the present embodiment is a press apparatus and includes two pressurizers 41. Instead thereof, the pressurizing apparatus 40 may be constituted by a hydraulic cylinder and the like. The two pressurizers 41 include a projection portion 42 with a circular cylindrical shape, and a flange portion 43 provided around the projection portion 42. The projection portions 42 of the pressurizers 41 have a circular cylindrical shape with an outer diameter which can be inserted in the tubular body 20 and has substantially the same size as the outer diameter of the elastic body 30. The projection portions 42 have an end surface which is a flat surface perpendicular to the axial line L, in order to evenly press the elastic body 30. In the state where they have been set in the pressurizing apparatus 40, the projection portions 42 of the two pressurizers 41 have been inserted in the opposite end portions 21 and 22 of the tubular body 20. Between the two pressurizers 41 having been inserted therein, there is placed the elastic body 30.

(34) As illustrated in FIG. 2E, in the fifth process, the elastic body 30 is compressed in the direction of the axial line L, with the pressurizing apparatus 40. As the elastic body 30 is decreased in size in the direction of the axial line L, the size thereof in the radial direction is increased. Accordingly, the tubular body 20 is subjected to forces from the elastic body 30 being increased in size in the radial direction, thereby being deformed to be expanded outwardly in the radial direction. The tubular body 20 having been deformed to be expanded is jointed to the wall surface body 10 by press-fitting, thereby forming a joint body 1.

(35) As illustrated in FIG. 2F, in the sixth process, after joining, the joint body 1 and the elastic body 30 are disengaged from the pressurizing apparatus 40 (see FIG. 2E). The elastic body 30, from which the compressing force from the pressurizing apparatus 40 (see FIG. 2E) has been removed, is restored to its original shape due to its own elastic force. Accordingly, the elastic body 30 can be easily removed from the joint body 1.

(36) With the method for joining members according to the present embodiment which has been described with respect to the aforementioned first to sixth processes, the tubular body 20 can be evenly deformed to be expanded by the elastic body 30, which can reduce local loads imposed on the tubular body 20, thereby preventing local deformation. This can improve the accuracy of fitting between the wall surface body 10 and the tubular body 20, thereby increasing the joining strength. Further, this method is simple in comparison with joining methods utilizing electromagnetic forming or other processing.

(37) Further, since the wall surface body 10 is a die-molded article, it is necessary to provide a draft angle in the hole portion 11. In the present embodiment, the hole portion 11 in the wall surface body 10 is provided with a draft angle from its opposite end portions 12 and 13 toward its center portion 14, namely is provided with a draft angle in different directions. By providing a draft angle in different directions as described above, it is possible to overcome two problems induced by provision of a draft angle only in a single direction. More specifically, as illustrated in FIGS. 3A and 3B, if the hole portion 11 of the wall surface body 10 is provided with a draft angle in a single direction such that the diameter is gradually decreased from one end portion 12 toward the other end portion 13, there is larger joining strength against a pull-out load in the direction in which the diameter of the hole portion 11 decreases (in the direction of an arrow A1), but there is smaller joining strength against a pull-out load in the direction in which the diameter of the hole portion 11 increases (in the direction of an arrow A2). That is, depending on the direction of the pull-out load, there exists smaller joining strength in a direction (the first problem). Further, in this case, the one end portion 12 of the hole portion 11 has a larger inner diameter than the inner diameter of the other end portion 13. At the one end portion 12 of the hole portion 11 which has a relatively-larger inner diameter, the tubular body 20 deforms to expand in a relatively larger amount, and the tubular body 20 experiences a larger deformation burden (the second problem). For addressing these two problems, there is provided a draft angle in different directions, in the structure according to the present embodiment. This can eliminate the direction in which there is smaller joining strength, which is the first problem, thereby ensuring larger joining strength against pull-out loads in any directions. Further, the one end portion 12 of the hole portion is increased in diameter by a smaller amount in comparison with cases of providing a draft angle only in a single direction, which can reduce the deformation burden imposed on the tubular body 20, which is the second problem.

Second Embodiment

(38) FIGS. 4A and 4B illustrate a method for joining members according to a second embodiment. In the present embodiment, the same constituent elements as those in the first embodiment will be designated by the same reference characters and will not be described redundantly.

(39) In the present embodiment, a core 44 is used unlike in the first embodiment. The core 44 is a steel component with a circular cylindrical shape, for example. The shape and the material of the core 44 are arbitrary, provided that the core 44 is not deformed by the compressing force from the pressurizing apparatus 40.

(40) As illustrated in FIG. 4A, in the present embodiment, in a process corresponding to the third process in the first embodiment, the core 44 is inserted into the inside of the tubular body 20, similarly to elastic bodies 30. When the elastic bodies 30 are inserted into the tubular body 20, they are inserted thereinto in the opposite sides with the core 44 sandwiched therebetween. That is, in the present embodiment, the two elastic bodies 30 are used. The core 44 is placed in the center portion 14 inside the tubular body 20, and the two elastic bodies 30 are placed at joint portions inside the tubular body 20.

(41) As illustrated in FIG. 4B, in a process corresponding to the fifth process in the first embodiment, the two elastic bodies 30 are pressed at the opposite sides by a pressurizing apparatus which is not illustrated, in order to joint the wall surface body 10 and the tubular body 20 by press-fitting.

(42) With the method for joining members according to the present embodiment, the tubular body 20 is suppressed from deforming at its portion where the core 44 is placed therein, which can suppress unnecessary deformation of the tubular body 20 at the other portion than the joint portions, thereby reducing deformation burdens imposed on the tubular body 20. Further, there is no need for the elastic bodies 30 at the portion where the core 44 is placed, which allows the elastic bodies 30 to have a smaller volume, thereby reducing the overall amount of compression.

Third Embodiment

(43) FIGS. 5A to 6B illustrate a method for joining members according to a third embodiment. In the present embodiment, the same constituent elements as those in the first embodiment will be designated by the same reference characters and will not be described redundantly.

(44) In the present embodiment, unlike in the first embodiment, the wall surface body 10 and the tubular body 20 have respective substantially-trapezoid cross sections. The wall surface body 10 includes an upper wall 15, a lower wall 16 which faces the upper wall 15 and has a larger length than that of the upper wall 15, and two side walls 17 coupling these walls to each other. The upper wall 15 in the wall surface body 10 is provided with an uninclined surface 18 with no draft angle in its inner surface, and the lower wall 16 is provided with an opening portion 19 at the position facing the uninclined surface 18. Therefore, the tubular body 20 is exposed from the wall surface body 10 through the opening portion 19.

(45) With the method for joining members according to the present embodiment, since the wall surface body 10 is provided with the opening portion 19, it is possible to reduce the weight of the wall surface body 10. Further, by utilizing the opening portion 19 as a die removing hole for use in molding, it is possible to provide the uninclined surface 18 with higher surface accuracy in the wall surface body 10. By utilizing the uninclined surface 18 with such higher surface accuracy, it is possible to cause the wall surface body 10 and the tubular body 20 to come in close contact with each other with higher accuracy to form a joint surface therebetween, which can suppress unstable rattling during joining them, thereby improving the joint strength.

(46) Further, the side walls 17 may be also provided with uninclined surfaces in their inner surfaces, as well as the upper wall 15. Furthermore, although, in the present embodiment, the wall surface body 10 and the tubular body 20 have respective substantially-trapezoid cross sections, their cross-sectional shapes are not limited thereto and may be also arbitrary shapes.

Fourth Embodiment

(47) FIGS. 7A and 7B illustrate a method for joining members according to a fourth embodiment. In the present embodiment, the same constituent elements as those in the third embodiment will be designated by the same reference characters and will not be described redundantly.

(48) In the present embodiment, in the wall surface body 10, the upper wall 15 (the upper bottom side of the trapezoid cross section) is provided in its inner surface with a draft angle larger than the draft angle in the inner surface of the lower wall 16 (the lower bottom side of the trapezoid cross section). For example, the draft angle in the inner surface of the upper wall 15 may be set to be 5 degrees, while the draft angle in the inner surface of the lower wall 16 may be set to be 3 degrees.

(49) With the method for joining members according to the present embodiment, since the draft angle in the upper bottom side is larger than the draft angle in the lower bottom side, when the tubular body 20 deforms to expand, the tubular body 20 comes into contact with the wall surface body 10 at its lower bottom side at first and, thereafter, the tubular body 20 is pressed against the uninclined surface of the upper bottom side. That is, when the tubular body 20 is pressed against the uninclined surface 18 in the upper bottom side, the tubular body 20 is supported by the wall surface body 10 at its lower bottom side, and thus the tubular body 20 is deformed to expand into a state of being in close contact with the uninclined surface in the upper bottom side with substantially no gap therebetween. Since the uninclined surface 18 in the upper bottom side is formed with higher surface accuracy as described above, the wall surface body 10 and the tubular body 20 are allowed to come in close contact with each other with higher accuracy to form a joint surface therebetween, which can suppress unstable rattling during joining, thereby further improving the joint strength.

Fifth Embodiment

(50) FIGS. 8A and 8B illustrate a method for joining members according to a fifth embodiment. In the present embodiment, the same constituent elements as those in the first embodiment will be designated by the same reference characters and will not be described redundantly.

(51) In the present embodiment, as illustrated in FIG. 8A, the elastic body 30 is compressed in the direction of the axial line L by a pressurizing apparatus which is not illustrated, in a state where the elastic body 30 is protruded from the tubular body 20 at one end portion 21 of the tubular body 20. Thus, as illustrated in FIG. 8B, the elastic body 30 is expanded outwardly in the radial direction of the axial line L to bend one end portion 21 of the tubular body 20 toward the wall surface body 10. That is, the one end portion 21 of the tubular body 20 is increased in size into a trumpet shape.

(52) With the method for joining members according to the present embodiment, if a pull-out load is imposed on the tubular body 20, the tubular body 20 having such a trumpet shape is latched at its end portion to play a role in preventing the pull-out thereof, thereby improving the joint strength.

Sixth Embodiment

(53) FIGS. 9A and 9B illustrate a method for joining members according to a sixth embodiment. In the present embodiment, the same constituent elements as those in the first embodiment will be designated by the same reference characters and will not be described redundantly.

(54) In the present embodiment, an outer frame die 45 for suppressing the deformation of the wall surface body 10 is further provided. The tubular body 20 is deformed to be expanded, in a state where the outer frame die 45 is placed on the outer side of the wall surface body 10.

(55) With the method for joining members according to the present embodiment, the wall surface body 10 is suppressed from deforming due to the use of the outer frame die 45. This can prevent plastic deformation of the wall surface body 10.

(56) Although there have been described the concrete embodiments of the present invention and modifications thereof, the present invention is not limited to the aforementioned embodiments and can be implemented by making various changes within the scope of the invention. For example, the contents of the respective embodiments may be properly combined with each other, as an embodiment of the invention.