Ultrasonic joining method, ultrasonic joining device and unit joined by ultrasonic joining

Abstract

In an ultrasonic joining method for joining a flange portion of a first member to a portion of a second member, a first horn and a second horn are arranged on the flange portion on a side opposite to the second member, and the first horn is vibrated in a condition that the second horn is biased against the first horn and the first horn and the second horn are pressed against the flange portion such that the flange portion is vibrated while being pressed against the portion of the second member. Because the first horn is vibrated in a condition that the first horn and the second horn are pressed against each other at press-contact portions thereof, vibration of the first horn is transferred to the second horn through the press-contact portions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, features and advantages of the present invention will become more apparent from the following detailed description made with reference to the accompanying drawings, in which like parts are designated by like reference numbers and in which:

FIG. 1 is a schematic cross-sectional view of a part of an ultrasonic joining apparatus and pipes to be joined by the ultrasonic joining apparatus according to an embodiment of the present invention;

FIG. 2 is a cross-sectional view taken along a line II-II in FIG. 1;

FIG. 3A is a schematic side view of horns of the ultrasonic joining apparatus when viewed along an arrow IIIA in FIG. 2;

FIG. 3B is a plan view of the horns when viewed along an arrow IIIB in FIG. 3A;

FIG. 4 is a perspective view of the pipes joined by the ultrasonic joining apparatus according to the embodiment;

FIG. 5A is a schematic cross-sectional view of the ultrasonic joining apparatus according to the embodiment;

FIG. 5B is a graph showing vibration amplitude of the horns according to the embodiment;

FIGS. 6A to 6C are schematic views for respectively showing different steps of ultrasonic joining by the ultrasonic joining apparatus according to the embodiment;

FIG. 7 is a perspective view of an example of a unit of pipes joined by ultrasonic joining according to another embodiment of the present invention;

FIG. 8 is a schematic view of horns of an ultrasonic joining apparatus according to a further another embodiment of the present invention;

FIG. 9 is a cross-sectional view of an example of a unit of pipes joined by ultrasonic joining according to a still another embodiment of the present invention; and

FIG. 10 is a cross-sectional view of an example of a pipe and a block member joined by ultrasonic joining according to a yet another embodiment of the present invention.

Claims

1. An ultrasonic joining method comprising: arranging a first horn and a second horn of a horn unit in a circumferential direction of a flange portion of a first member on a first side of the flange portion, a second side of a flange portion, which is opposite to the first side, facing a portion of a second member, the first horn being connected to an oscillator; andjoining the flange portion to the portion of the second member by applying vibration to the flange portion by the first horn and the second horn in a condition that the first horn and the second horn are pressurized to the flange portion so that the flange portion is vibrated while being pressurized to the portion of the second member, whereinin the arranging, the second horn is biased against the first horn such that the first horn and the second horn are in press-contact with each other at press-contact portions thereof, andin the joining, the first horn is vibrated by an oscillator and the second horn is vibrated by receiving vibration of the first horn through the press-contact portions.

2. The ultrasonic joining method according to claim 1, wherein the arranging includes connecting the first horn and the second horn such that the press-contact portions are disposed on opposite sides of the first member.

3. The ultrasonic joining method according to claim 1, wherein the arranging includes connecting the first horn and the second horn such that the press-contact portions are located in an area where amplitude of vibration of the first horn is substantially in a maximum level.

4. The ultrasonic joining method according to claim 1, wherein the arranging includes connecting the first horn and the second horn such that plurality of projections provided on surfaces of the first horn and the second horn are arranged at substantially uniformed intervals over the surfaces of the first horn and the second horn, the surfaces facing the first surface of the flange portion.

5. The ultrasonic joining method according to claim 1, wherein the first member has a tubular portion defining an opening therein and the flange is disposed at an end of the tubular portion, and the second member defines an opening within the portion to which the flange portion is joined, the ultrasonic joining method further comprising:placing the flange portion onto the portion of the second member such that the opening of the tubular portion is in communication with the opening of the second member.

6. The ultrasonic joining method according to claim 5, wherein the arranging includes connecting the first horn and the second horn such that the tubular portion of the first member is located in an opening defined by the first horn and the second horn.

7. An ultrasonic joining apparatus for joining a flange portion of a first member to a portion of a second member, the ultrasonic joining apparatus comprising: an oscillator;a horn unit including a first horn and a second horn for applying vibration to the flange portion while being pressed against the flange portion, whereinthe first horn is connected to the oscillator to be vibrated, the first horn has a first press-contact portion and the second horn has a second press-contact portion,the first horn and the second horn are connectable such that the first contact portion and the second contact portion are in contact with each other and an opening for receiving at least a portion of the first member is defined between the first horn and the second horn, wherein the second horn is held to be biased against the first horn such that vibration of the first horn is transferred to the second horn through the first and second press-contact portions.

8. The ultrasonic joining apparatus according to claim 7, wherein the first contact portion and the second contact portion are disposed on a plane that intersects the opening defined by the first horn and the second horn.

9. The ultrasonic joining apparatus according to claim 6, wherein the first horn and the second horn are connected such that the first and second contact portions are located in an area where amplitude of the vibration of the first horn is substantially in a maximum level.

10. The ultrasonic joining apparatus according to claim 7, wherein, the first horn and the second horn have surfaces to be pressed against the flange portion,the first horn and the second horn have projections on the surfaces, andthe projections are arranged at substantially uniformed intervals over the surfaces in a condition that the first horn and the second horn are connected at the first and second press-contact portions.

11. The ultrasonic joining apparatus according to claim 7, wherein the first horn has a first recess recessed from an end surface thereof,the second horn has a second recess recessed from an end surface thereof, andthe first horn and the second horn are connected such that the end surface of the first horn contacts the end surface of the second horn and the opening is provided by the first and second recesses of the first horn and the second horn.

12. The ultrasonic joining apparatus according to claim 7, further comprising: a first supporting member for supporting the first horn; anda second supporting member for supporting the second horn, whereinthe first and second supporting members are located at positions where amplitude of vibration of the first and second horns is substantially in a minimum level.

13. A joined unit comprising a first member that ahs a first portion and a second portion flanged from the first portion at an end of the first portion and a second member, the flanged second portion has a first surface and a second surface joined to a portion of the second member by ultrasonic joining using a horn unit that includes a first horn vibrated by an oscillator and a second horn pressed against the first horn, the first horn and the second horn having projections at substantially uniformed intervals over surfaces that are pressed against the first surface of the flanged second portion for applying vibration to the flanged second portion, wherein the first portion of the first member has at least one of a bent and an overhang portion, andthe flanged second portion has impressions on the first surface due to the projections of the first horn and the second horn.

14. The joined unit according to claim 13, wherein the first portion of the first member has a tubular shape and the first member defines an opening through the first portion and the flanged second portion,the portion of the second member to which the first surface of the flanged second portion is joined defines an opening, andthe flanged second portion is joined such that the opening of the first member is in communication with the opening of the second member.

15. An ultrasonic joining method for joining a first member having a columnar portion and a flange portion at an end of the columnar portion and a second member, the ultrasonic joining method comprising: placing the flange portion of the first member onto a portion of the second member;connecting a first horn and a second horn on a side opposite to the second member with respect to the flange portion such that the columnar portion of the first member is disposed in an opening provided between the first horn and the second horn, and the first horn and the second horn are in press-contact with each other at press-contact portions thereof; andapplying vibration to the first horn by an oscillator in a condition that the first horn and the second horn are pressed against the flange portion and are in contact with each other at the press-contact portions thereof for transferring vibration of the first horn to the second horn through the press-contact portions.