Stock material or miscellaneous articles – Hollow or container type article – Polymer or resin containing
Patent
1998-03-11
2000-10-17
Dye, Rena L.
Stock material or miscellaneous articles
Hollow or container type article
Polymer or resin containing
428 58, 428192, 264513, 26417126, 2641721, 2643281, 156 731, 416223R, 416232, 416241A, B29C 4516, B32B 3120
Patent
active
06132826&
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
This invention relates to a method of manufacturing a hollow blade and a hollow blade manufactured by the method.
BACKGROUND ART
FIG. 7 shows one of procedures in a conventionally typically method of manufacturing a hollow blade. FIGS. 8 and 9 each show an essential part of a hollow blade 50 manufactured by the conventional method.
In the conventional method of manufacturing a hollow blade, a first blade body 51 with a recessed part 53 and a second blade body 52 formed so as to close the recessed part 53 are first put together. Then, the first and second blade bodies 51, 52 are joined by welding by means of a ultrasonic welding device thereby forming the hollow blade 50 internally provided with a hollow part 56 composed of a part of the recessed part 53.
In this case, the first blade body 51 is provided with a shelf surface 54 formed at an outer periphery of the recessed part 53. An outer peripheral part of the back face 52b of the second blade body 52 is laid on the shelf surface 54 of the first blade body 51 so that the second blade body 52 is faced with the first blade body 51 in a partly contact state. An outer peripheral end surface 51b between the shelf surface 54 and the surface 51a of the first blade body 51 is opposed to an outer peripheral end surface 52c of the second blade body 52 with a set space left, thereby creating a clearance 59 between both the outer peripheral end surfaces 51b, 52c.
In the state that the first and second blade bodies 51, 52 are faced with each other in a contact state, a horn 60 of the ultrasonic welding device is moved down from above the clearance 59. Thus, the end surface 60a of the horn 60 is located at a position of crossing the first and second blade bodies 51, 52 interposing the clearance 59 therebetween and comes into contact with both the blade bodies 51, 52 while pressing them. In this state, ultrasonic vibrations are applied to the blade bodies 51, 52 by the horn 60 in its pressing direction (direction of arrows a-b of FIG. 7).
Frictional heat resulting from the ultrasonic vibrations is produced between the shelf surface 54 of the first blade body 51 and the outer peripheral part of the back face 52b of the second blade body 52 which come into face-to-face contact with each other, and is also produced between each of the surfaces 51a, 52a of the first and second blade bodies 51, 52 and the end surface 60a of the horn 60 which come into face-to-face contact with each other.
If frictional heat produced due to contact between resin materials is compared with frictional heat produced due to contact between metal and resin, the former has a higher temperature. Accordingly, resin is more readily melted at a part where the back face 52b of the second blade body 52 is laid on the shelf surface 54 of the first blade body 51, so that a resin melting part 55 shown in FIG. 8 or a first resin melting part 55A shown in FIG. 9 is produced. The first and second blade bodies 51, 52 are joined to each other through the resin melting part 55 or the first resin melting part 55A.
On the other hand, on each of the surfaces 51a, 52a of the first and second blade bodies 51, 52, resin is softened through the application of pressure and ultrasonic vibrations by the horn 60 so that a circular impression 58 along the shape of the horn 60 is produced. As shown in FIG. 8, when the pressing force of the horn 60 is set smaller so as to reduce the depth of the impression 58 as small as possible, an amount of melting resin produced by the formation of the impression 58 is decreased. As a result, an amount of flow of the melting resin into the clearance 59 is also decreased so that the clearance 59 is substantially kept in its original state.
On the contrary, when the pressing force of the horn 60 is increased, the depth of the impression 58 becomes larger as shown in FIG. 9, so that the amount of meltingresin produced accompanying the formation of the impression 58 is increased. As a result, a part of the melting resin flows into the clearance 59 so that a second resin mel
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Kawasaki Hiraku
Simomura Takeo
Daikin Industries Ltd.
Dye Rena L.
Studebaker Donald R.
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