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Patent · US10064245B2 · B2 · US

Joining device and joining method

(11) Publication number
US10064245B2
(21) Application number
15/159,203
(22) Filing date
2016-05-19
(30) Priority date
2013-11-22
(43) Publication date
2018-08-28
(45) Date of grant
2018-08-28
(51) IPC
B23K 11/02; B23K 11/24; B23K 11/25; B23K 11/30; H05B 6/10; H05B 6/36; B23K 11/00; B23K 11/16; B23K 11/36; B29C 65/00; B29C 65/56; B29C 65/64
(52) CPC
  • B23K Soldering or unsoldering; welding; cladding or plating by soldering or welding; cutting by applying heat locally, e.g. flame cutting; working by laser beam: 11/0026, 11/0053, 11/02, 11/16, 11/241, 11/25, 11/258, 11/3009, 11/36
  • 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: 65/46, 65/562, 65/564, 65/64, 65/7841, 66/1122, 66/21, 66/41, 66/43, 66/474, 66/71, 66/721, 66/7212, 66/742, 66/8322
  • B29K Indexing scheme associated with subclasses B29B, B29C or B29D, relating to moulding materials or to materials for {moulds, } reinforcements, fillers or preformed parts, e.g. inserts: 2023/06, 2023/12, 2055/02, 2059/00, 2069/00, 2077/00
  • C21D Modifying the physical structure of ferrous metals; general devices for heat treatment of ferrous or non-ferrous metals or alloys; making metal malleable, e.g. by decarburisation or tempering: 1/42
  • H05B Electric heating; electric light sources not otherwise provided for; circuit arrangements for electric light sources, in general: 6/101, 6/36
  • Y02P Climate change mitigation technologies in the production or processing of goods: 10/25, 10/253
(73) Assignee
Newfrey LLC
(72) Inventors
Yoshiteru Kondo; Daisuke Miura
(54) Title
Joining device and joining method
(57) Abstract

A joining device for connecting a metal member and a resign member with a metal fastener including a penetrating tip comprises: a cylindrical nosepiece; a high frequency electromagnetic induction coil around the nosepiece; an electrode punch for pressing the fastener into the resign member; a electronic chopper for producing a high frequency current; a high frequency power supply for supplying an induction current to the induction coil; a welding power supply for supplying a welding current between the electrode punch and the metal member; a contact detector for sensing when the fastener tip touches the metal member; and a switching unit for automatically switching from the induction current to the welding current when the contact detector senses that the tip has contacted the metal member.

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Claims (16)

  1. A joining device for joining a metal member and a resin member using a metal fastener that penetrates the resin member and fuses to the metal member, the metal fastener including a tip, and the joining device comprises: a cylindrical nose piece operable for up and down movement; a high-frequency induction heating coil disposed around the nose piece; an electrode punch operable for up and down movement inside of the nose piece and for conducting a welding current; a high frequency electronic chopper device operable for converting an input power into one of a welding current and an induction heating current; a high-frequency induction output device operable for receiving the induction current from the chopper device, and for supplying the induction current to the high-frequency induction heating coil; a resistance welding output device operable for receiving welding current from the chopper device and supplying welding current between the electrode punch and the metal member; and wherein the tip portion of the fastener penetrating the resin member and contacting the metal member is sensed; and wherein a connection of the chopper device is switched from the high-frequency induction output device to the resistance welding output device after contact of the tip portion of the fastener with the metal member is sensed.
  2. The joining device of claim 1, wherein the nose piece is made of an insulator.
  3. The joining device of claim 1, wherein the nose piece includes a cylindrical portion and a high-frequency induction coil retaining portion holding the high-frequency induction heating coil radially outside the cylindrical portion, and the nose piece is operable for releasably retaining the fastener radially inward of the high-frequency induction coil retaining portion.
  4. The joining device of claim 1, further comprising a chuck operable for holding the fastener on the inside of the nose piece and between the electrode punch and the resin member.
  5. The joining device of claim 1, wherein: the high-frequency induction output device is operable to inductively heat the fastener in the nose piece by supplying the high-frequency induction current to the high-frequency induction coil, and the electrode punch is operable to drive the heated fastener into and through the resin member which is softened and melted by the heated fastener.
  6. The joining device of claim 1, wherein contact of the tip of the fastener with the metal member is sensed by applying a voltage between the electrode punch and the metal member and sensing when a current flows from the electrode punch through the fastener to the metal member.
  7. The joining device of claim 6, wherein: when the tip portion of the fastener is not contacting the metal member, the chopper device is connectable to the high-frequency induction output device; and when the tip portion of the fastener has contacted the metal member, the chopper device is connectable to the resistance welding output device.
  8. A method for joining a metal member and a resin member using a fastener including a tip, the method comprising the steps of: placing the resin member above the metal member; placing the fastener within a cylindrical nose piece and under an electrode punch and above the resin member; lowering the nose piece and the fastener into contact with the resin member; supplying a high-frequency induction current to a high-frequency induction coil disposed radially around the nose piece, heating the fastener tip by high-frequency induction heating; softening the resin member by heating proximate to the fastener tip; lowering the electrode punch and pushing the fastener through the softened resin member; sensing with a contact sensing device when the fastener tip contacts the metal member; turning off the high-frequency induction current upon sensing that the fastener tip has contacted the metal member; supplying a welding current to flow via the electrode punch through the fastener to the metal member; welding the fastener tip to the metal member; and turning off the welding current and allowing the melted fastener tip and the metal member to cool and fuse.
  9. A method for joining according to claim 8, wherein the step of placing the fastener within a cylindrical nose piece and under an electrode punch and above the resin member further includes a sub-step of releaseably holding the fastener with a chuck.
  10. A joining device for joining a metal member and a resin member using a metal fastener that penetrates the resin member and fuses to the metal member, the metal fastener including a tip, and the joining device comprises: a cylindrical nose piece operable for up and down movement; a high-frequency induction heating coil disposed around the nose piece; an electrode punch operable for up and down movement inside of the nose piece and for conducting a welding current; a high frequency electronic chopper device operable for converting an input power into one of a welding current and an induction heating current; a high-frequency induction output device operable for receiving the induction current from the chopper device, and for supplying the induction current to the high-frequency induction heating coil; a resistance welding output device operable for receiving welding current from the chopper device and supplying welding current between the electrode punch and the metal member; a contact sensor between the metal member and the electrode punch and sending an output signal when the tip portion of the fastener has penetrated the resin member and contacted the metal member; and a switch connected to the chopper device for supply of electric power and selectively connectable to one load of either the high-frequency induction output device or the resistance welding output device based on the output signal from the contact sensor.
  11. The joining device of claim 10, wherein the nose piece is made of an insulator.
  12. The joining device of claim 10, wherein the nose piece includes a cylindrical portion and a high-frequency induction coil retaining portion holding the high-frequency induction heating coil radially outside the cylindrical portion, and the nose piece is operable for releasably retaining the fastener radially inward of the high-frequency induction coil retaining portion.
  13. The joining device of claim 10, further comprising a chuck operable for holding the fastener on the inside of the nose piece and between the electrode punch and the resin member.
  14. The joining device of claim 10, wherein: the high-frequency induction output device is operable to inductively heat the fastener in the nose piece by supplying the high-frequency induction current to the high-frequency induction coil, and the electrode punch is operable to drive the heated fastener into and through the resin member which is softened and melted by the heated fastener.
  15. The joining device of claim 10, wherein the contact sensor senses that the tip of the fastener has contacted the metal member by applying a voltage between the electrode punch and the metal member and sensing when a current flows from the electrode punch through the fastener to the metal member.
  16. The joining device of claim 15, wherein: when the contact sensor senses that the tip portion of the fastener is not contacting the metal member, then the switching device is operable to connect the chopper device and the high-frequency induction output device; and when the contact sensor senses that the tip portion of the fastener has contacted the metal member, then the switching device is operable to connect the chopper device and the resistance welding output device.

Description

The present invention pertains to a joining device and joining method for joining a resin member and metal member using a fastener. More particularly, the invention pertains to a joining device and joining method for joining a resin member and metal member whereby a fastener is press-fit from the resin member side, and the fastener and the metal member are welded to join the resin member and the metal member.

Joining methods for joining a resin member and a metal member include screw fastening, rivet punching, adhesion and the like. Screw fastening is accomplished by pre-drilling a swaging hole in a resin member and a metal member, matching the positions of the holes in the resin member and the metal member, inserting a screw into the hole formed in the resin member from the resin member side and affixing the screw by screwing it into the hole formed in the metal member. However, fastening by screw requires formation in advance of screw holes in the resin member and metal member, which is laborious. It is also difficult to match the screw position to the screw holes in the resin member and metal member for screwing in. The presence of the screw hole makes it difficult to maintain waterproofness and airtightness.

In rivet punching, a rivet is punched in from the resin member side through to the metal member to join the resin member and the metal member. With rivet punching, there is no need to drill holes in the resin member and the metal member; wherefore, the resin member and metal member can be joined in a simple manner.

Citations (60)

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Record as JSON 
{
  "publication_number": "US10064245B2",
  "country": "US",
  "kind": "B2",
  "title": "Joining device and joining method",
  "abstract": "A joining device for connecting a metal member and a resign member with a metal fastener including a penetrating tip comprises: a cylindrical nosepiece; a high frequency electromagnetic induction coil around the nosepiece; an electrode punch for pressing the fastener into the resign member; a electronic chopper for producing a high frequency current; a high frequency power supply for supplying an induction current to the induction coil; a welding power supply for supplying a welding current between the electrode punch and the metal member; a contact detector for sensing when the fastener tip touches the metal member; and a switching unit for automatically switching from the induction current to the welding current when the contact detector senses that the tip has contacted the metal member.",
  "claims": [
    "1. A joining device for joining a metal member and a resin member using a metal fastener that penetrates the resin member and fuses to the metal member, the metal fastener including a tip, and the joining device comprises: a cylindrical nose piece operable for up and down movement; a high-frequency induction heating coil disposed around the nose piece; an electrode punch operable for up and down movement inside of the nose piece and for conducting a welding current; a high frequency electronic chopper device operable for converting an input power into one of a welding current and an induction heating current; a high-frequency induction output device operable for receiving the induction current from the chopper device, and for supplying the induction current to the high-frequency induction heating coil; a resistance welding output device operable for receiving welding current from the chopper device and supplying welding current between the electrode punch and the metal member; and wherein the tip portion of the fastener penetrating the resin member and contacting the metal member is sensed; and wherein a connection of the chopper device is switched from the high-frequency induction output device to the resistance welding output device after contact of the tip portion of the fastener with the metal member is sensed.",
    "2. The joining device of claim 1, wherein the nose piece is made of an insulator.",
    "3. The joining device of claim 1, wherein the nose piece includes a cylindrical portion and a high-frequency induction coil retaining portion holding the high-frequency induction heating coil radially outside the cylindrical portion, and the nose piece is operable for releasably retaining the fastener radially inward of the high-frequency induction coil retaining portion.",
    "4. The joining device of claim 1, further comprising a chuck operable for holding the fastener on the inside of the nose piece and between the electrode punch and the resin member.",
    "5. The joining device of claim 1, wherein: the high-frequency induction output device is operable to inductively heat the fastener in the nose piece by supplying the high-frequency induction current to the high-frequency induction coil, and the electrode punch is operable to drive the heated fastener into and through the resin member which is softened and melted by the heated fastener.",
    "6. The joining device of claim 1, wherein contact of the tip of the fastener with the metal member is sensed by applying a voltage between the electrode punch and the metal member and sensing when a current flows from the electrode punch through the fastener to the metal member.",
    "7. The joining device of claim 6, wherein: when the tip portion of the fastener is not contacting the metal member, the chopper device is connectable to the high-frequency induction output device; and when the tip portion of the fastener has contacted the metal member, the chopper device is connectable to the resistance welding output device.",
    "8. A method for joining a metal member and a resin member using a fastener including a tip, the method comprising the steps of: placing the resin member above the metal member; placing the fastener within a cylindrical nose piece and under an electrode punch and above the resin member; lowering the nose piece and the fastener into contact with the resin member; supplying a high-frequency induction current to a high-frequency induction coil disposed radially around the nose piece, heating the fastener tip by high-frequency induction heating; softening the resin member by heating proximate to the fastener tip; lowering the electrode punch and pushing the fastener through the softened resin member; sensing with a contact sensing device when the fastener tip contacts the metal member; turning off the high-frequency induction current upon sensing that the fastener tip has contacted the metal member; supplying a welding current to flow via the electrode punch through the fastener to the metal member; welding the fastener tip to the metal member; and turning off the welding current and allowing the melted fastener tip and the metal member to cool and fuse.",
    "9. A method for joining according to claim 8, wherein the step of placing the fastener within a cylindrical nose piece and under an electrode punch and above the resin member further includes a sub-step of releaseably holding the fastener with a chuck.",
    "10. A joining device for joining a metal member and a resin member using a metal fastener that penetrates the resin member and fuses to the metal member, the metal fastener including a tip, and the joining device comprises: a cylindrical nose piece operable for up and down movement; a high-frequency induction heating coil disposed around the nose piece; an electrode punch operable for up and down movement inside of the nose piece and for conducting a welding current; a high frequency electronic chopper device operable for converting an input power into one of a welding current and an induction heating current; a high-frequency induction output device operable for receiving the induction current from the chopper device, and for supplying the induction current to the high-frequency induction heating coil; a resistance welding output device operable for receiving welding current from the chopper device and supplying welding current between the electrode punch and the metal member; a contact sensor between the metal member and the electrode punch and sending an output signal when the tip portion of the fastener has penetrated the resin member and contacted the metal member; and a switch connected to the chopper device for supply of electric power and selectively connectable to one load of either the high-frequency induction output device or the resistance welding output device based on the output signal from the contact sensor.",
    "11. The joining device of claim 10, wherein the nose piece is made of an insulator.",
    "12. The joining device of claim 10, wherein the nose piece includes a cylindrical portion and a high-frequency induction coil retaining portion holding the high-frequency induction heating coil radially outside the cylindrical portion, and the nose piece is operable for releasably retaining the fastener radially inward of the high-frequency induction coil retaining portion.",
    "13. The joining device of claim 10, further comprising a chuck operable for holding the fastener on the inside of the nose piece and between the electrode punch and the resin member.",
    "14. The joining device of claim 10, wherein: the high-frequency induction output device is operable to inductively heat the fastener in the nose piece by supplying the high-frequency induction current to the high-frequency induction coil, and the electrode punch is operable to drive the heated fastener into and through the resin member which is softened and melted by the heated fastener.",
    "15. The joining device of claim 10, wherein the contact sensor senses that the tip of the fastener has contacted the metal member by applying a voltage between the electrode punch and the metal member and sensing when a current flows from the electrode punch through the fastener to the metal member.",
    "16. The joining device of claim 15, wherein: when the contact sensor senses that the tip portion of the fastener is not contacting the metal member, then the switching device is operable to connect the chopper device and the high-frequency induction output device; and when the contact sensor senses that the tip portion of the fastener has contacted the metal member, then the switching device is operable to connect the chopper device and the resistance welding output device."
  ],
  "description_excerpt": "The present invention pertains to a joining device and joining method for joining a resin member and metal member using a fastener. More particularly, the invention pertains to a joining device and joining method for joining a resin member and metal member whereby a fastener is press-fit from the resin member side, and the fastener and the metal member are welded to join the resin member and the metal member.\n\nJoining methods for joining a resin member and a metal member include screw fastening, rivet punching, adhesion and the like. Screw fastening is accomplished by pre-drilling a swaging hole in a resin member and a metal member, matching the positions of the holes in the resin member and the metal member, inserting a screw into the hole formed in the resin member from the resin member side and affixing the screw by screwing it into the hole formed in the metal member. However, fastening by screw requires formation in advance of screw holes in the resin member and metal member, which is laborious. It is also difficult to match the screw position to the screw holes in the resin member and metal member for screwing in. The presence of the screw hole makes it difficult to maintain waterproofness and airtightness.\n\nIn rivet punching, a rivet is punched in from the resin member side through to the metal member to join the resin member and the metal member. With rivet punching, there is no need to drill holes in the resin member and the metal member; wherefore, the resin member and metal member can be joined in a simple manner.",
  "cpc": [
    "B23K 11/0026",
    "B23K 11/0053",
    "B23K 11/02",
    "B23K 11/16",
    "B23K 11/241",
    "B23K 11/25",
    "B23K 11/258",
    "B23K 11/3009",
    "B23K 11/36",
    "B29C 65/46",
    "B29C 65/562",
    "B29C 65/564",
    "B29C 65/64",
    "B29C 65/7841",
    "B29C 66/1122",
    "B29C 66/21",
    "B29C 66/41",
    "B29C 66/43",
    "B29C 66/474",
    "B29C 66/71",
    "B29C 66/721",
    "B29C 66/7212",
    "B29C 66/742",
    "B29C 66/8322",
    "B29K 2023/06",
    "B29K 2023/12",
    "B29K 2055/02",
    "B29K 2059/00",
    "B29K 2069/00",
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    "C21D 1/42",
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    "Y02P 10/25",
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  ],
  "ipc": [
    "B23K 11/02",
    "B23K 11/24",
    "B23K 11/25",
    "B23K 11/30",
    "H05B 6/10",
    "H05B 6/36",
    "B23K 11/00",
    "B23K 11/16",
    "B23K 11/36",
    "B29C 65/00",
    "B29C 65/56",
    "B29C 65/64"
  ],
  "assignees": [
    "Newfrey LLC"
  ],
  "inventors": [
    "Yoshiteru Kondo",
    "Daisuke Miura"
  ],
  "filing_date": "2016-05-19",
  "publication_date": "2018-08-28",
  "grant_date": "2018-08-28",
  "priority_date": "2013-11-22",
  "application_number": "US-201615159203-A",
  "family_id": "53179244",
  "cited_by_count": 1,
  "citations": [
    "US2205425A",
    "US3033102A",
    "US3592998A",
    "US3659074A",
    "US4336221A",
    "US4045644A",
    "US4273581A",
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    "US4243368A",
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    "US4916931A",
    "US4992133A",
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    "US5035041A",
    "US5705796A",
    "US5373720A",
    "US5296317A",
    "JPH10190243A",
    "US6225591B1",
    "US6265701B1",
    "US6515251B1",
    "US20020117565A1",
    "US20040169017A1",
    "US7176401B2",
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    "US20050133483A1",
    "US7087854B2",
    "DE102004025492A1",
    "US8595914B2",
    "US20080229570A1",
    "US20090122216A1",
    "US20090011269A1",
    "US20090261075A1",
    "US20090139821A1",
    "US20080076351A1",
    "US20080085568A1",
    "US20100201032A1",
    "US7877862B2",
    "US20110097142A1",
    "US20090294410A1",
    "US20110139353A1",
    "US8461484B2",
    "US8211268B1",
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    "US20130248083A1",
    "DE102011009700A1",
    "US8793860B2",
    "US20130112664A1",
    "DE102012004499A1",
    "CN102794557A",
    "US9114481B1"
  ]
}

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