Metal joint body and apparatus for manufacturing the metal joint body

A miniaturized metal joint body and an apparatus for manufacturing the metal joint body to be improved about strength are provided. By cutting three overlapped metal sheets along a first cutting line and a pair of second cutting lines extending so as to intersect the first cutting line at each end of the first cutting line and pressing areas surrounded with the first cutting line and the pair of second cutting lines and each of a pair of bending lines connecting both ends of the pair of second cutting lines, each of the pairs of projecting members is formed so as to project in a pressing direction of arrow Z.

TECHNICAL FIELD

This invention relates to a metal joint body and an apparatus for manufacturing the metal joint body, especially a metal joint body which is formed by joining two or more metal sheets to each other, and an apparatus for manufacturing the metal joint body by joining two or more metal sheets to each other.

BACKGROUND ART

In general, a method of clamping and adhering metal sheets to each other by pressure is known as a method for joining metal sheets to each other. The joining by adhering by pressure depends on residual stress by clamping and contact, so that electric characteristics thereof are not satisfied. At a contact area of the metal sheets, there are many gaps so that it is has a problem that the electric characteristics cannot be easily maintained in a long period because of corrosion. For maintaining the electric characteristics, it is considerable to welding the metal sheets to each other by melting the metal sheets with gas or plasma. It is not easily to be automatized and not suitable for mass production and has a cost problem.

For overcoming the above problems, a patent document 1 proposes a method for joining sheet metals, in which the metal sheets110,111are joined as shown inFIGS. 10, 11by cutting the two metal sheets110,111along a cutting line L2from one end of a bending line L1, extending vertically apart from the bending line L1, toward the other end of the bending line L1, and by pressing and bending an area surrounded with the cutting line L1and bending line L2of the two metal sheets110,111about the bending line L1. According to the method, outer surrounding cutting surfaces along the cutting line L2of the metal sheet110is pushed so as to rub on inner surrounding cutting surfaces along the cutting line2of the metal sheet111. By rubbing on each other, oxidized surface thereof is removed and fresh surface is exposed, and the both outer and inner cutting surfaces are adhered so as to generate a metal contact area of the metal sheets. A metal joint body101having the metal contact area is provided with a pair of projecting members113projecting in a pressing direction (i.e. arrow Z) by pressing the area surrounded with the cutting line L2and the bending line L1. Each one of the projecting members113is formed into a trapezoidal shape in a top view, and arranged with a space therebetween so as to oppose each short side (i.e. the bending line L1) of the pair of projecting members113formed into the trapezoidal shape.

A die used for pressing the two metal sheets110,111includes a pair of press jigs formed gradually narrowing toward a top end thereof. The pair of press jigs is arranged with a space corresponding to the pair of projecting members113formed into a trapezoidal shape.

CITATION LIST

Patent Document

Patent Document 1: Japan Patent Application Published No. 2009-66616

SUMMARY OF INVENTION

Objects to be Solved

In the metal joint body101by prior art, for preventing the metal sheets110,111from tearing (breaking) when pressing the two metal sheets110,111, the two bending lines L1are arranged with a space therebetween. Thereby, the metal joint body101may be increased in a direction of row of the two bending lines L1(direction of arrow X).

The die is provided with the pair of press jigs arranged with a space therebetween, so that the press jigs cannot be formed to have enough strength, and the press jigs may be easily broken.

According to the above problems, an object of the present invention is to provide a metal joint body which is miniaturized and an apparatus for manufacturing the metal joint body, which apparatus is improved about the strength.

How to Attain the Object of the Present Invention

In order to overcome the above problems and attain the object, the present invention is to provide a metal joint body, which includes a pair of projecting members formed by cutting two or more overlapped metal sheets along a first cutting line and a pair of second cutting lines extending so as to intersect the first cutting line at each end of the first cutting line and pressing areas surrounded with the first cutting line and the pair of second cutting lines and each of a pair of bending lines connecting both ends of the pair of second cutting lines so as to bend the each area about the bending line and project the areas in a direction of pressing, and a hole formed by arranging the projecting members, and a metal contact area arranged between an outer surrounding cutting surface of the projecting member arranged at a first metal sheet of the metal sheets located at a pressing side and an inner surrounding cutting surface of the hole arranged at a position to oppose to the outer surrounding cutting surface and arranged in a second metal sheet of the metal sheets overlapped on the first metal sheet and located at a far side from the pressing side.

According to the present invention, each width of the projecting members and the hole along a direction parallel to the first cutting line is increasing toward the first cutting line.

According to the present invention, an apparatus for manufacturing the metal joint body by joining two or more metal sheets to each other includes a first die having a press hole formed into a shape same as the area surrounded with the pair of second cutting lines intersecting the first cutting line at each end of the first cutting line and the pair of bending lines connecting both ends of the pair of second cutting lines and being shallower from a bottom corresponding to the first cutting line toward each edge corresponding to the bending lines; and a second die having a press projection formed to be fitted to the press hole and be gradually narrower toward a top corresponding to the bottom of the press hole.

Effects of the Invention

According to the present invention, by cutting two or more overlapped metal sheets along the first cutting line and the pair of second cutting lines extending so as to intersect the first cutting line at each end of the first cutting line and pressing the areas surrounded with the first cutting line and the pair of second cutting lines and each of the pair of bending lines connecting both ends of the pair of second cutting lines so as to bend the each area about the bending line, the first cutting line is arranged between the pair of bending lines, so that the miniaturized metal joint body is manufactured along the direction of the row of the pair of bending lines.

According to the present invention, because each width of the projecting member and the hole along the direction parallel to the first cutting line is increasing toward the first cutting line, the projecting member is pushed into the hole. Thereby, in the outer surrounding cutting surface of the projecting member and the inner surrounding cutting surface of the hole, normal load is generated. Therefore, joining of the metal contact area is advanced, so that the electric characteristics and reliability thereof are improved.

In the die by prior art, a pair of press jig is arranged with a space therebetween at positions corresponding to each one of the pair of projecting members. According to the present invention, in the apparatus, one press projection die for forming the pair of projecting members is provided. Therefore, the press projection die can be formed with an enough size, so that the apparatus for manufacturing the metal joint body can be provided with the press projection die having improved strength.

DESCRIPTION OF EMBODIMENTS

A metal joint body of a first embodiment according to the present invention is described with reference toFIGS. 1-6.

As shown inFIGS. 1-6, the metal joint body1includes three metal sheets10,11,12structured with, for example, the same material and the same thickness. As shown inFIGS. 5, 6, the metal joint boy1includes projecting members13,14,15and holes16,17,18and metal contact areas19,20.

Pairs of projecting members13,14,15are provided at each of metal sheets10,11,12. Each of the pairs of projecting members13,14,15is formed by cutting three overlapped metal sheets10,11,12along a first cutting line L2and a pair of second cutting lines L3extending so as to intersect the first cutting line L2at each end of the first cutting line L2and pressing areas surrounded with the first cutting line L2and the pair of second cutting lines L3and each of a pair of bending lines L1connecting both ends of the pair of second cutting lines L3so as to bend the each area about the bending line L1and project the areas in a pressing direction (arrow Z). A direction shown by an arrow X is a direction of row of the bending lines L1and a direction of lengthwise of the metal sheets10,11,12. A direction shown by an arrow Y is a direction parallel to the first cutting line L2and a direction of widthwise of the metal sheets10,11,12. A direction shown by an arrow Z is a direction of overlapping three metal sheets10,11,12and a direction of pressing the metal sheets10,11,12.

As shown inFIG. 2, each width of the projecting members13,14,15and holes16,17,18in the direction parallel to the first cutting line L2(arrow Y) of the projecting members13,14,15and holes16,17,18is increasing toward the first cutting line L2. Thus, the metal joint body1is formed into a hexagonal shape surrounded with the pair of bending lines L1arranging the first cutting line L2therebetween, and the second cutting lines L3.

The holes16,17,18are shaped by forming the projecting members13,14,15at the metal sheets10,11,12. The projecting member13at a first metal sheet10located at a pressing side in a pressing direction (along arrow Z) is pushed into the hole17at a second metal sheet11located adjacent to a surface of a far side from the pressing side in the pressing direction (arrow Z) of the first metal sheet10. The projecting member14at the second metal sheet11located adjacent to the surface of the far side from the pressing side (arrow Z) of the first metal sheet10is pushed into the hole18at a third metal sheet12located adjacent to a surface of a far side from the pressing side of the second metal sheet11. Thereby, the outer surrounding cutting surface of the projecting member13is pushed into the hole17so as to rub on the inner surrounding cutting surface of the hole17, and the outer surrounding cutting surface of the projecting member14is pushed into the hole18so as to rub on the inner surrounding cutting surface of the hole18. Oxidized surfaces of the outer surrounding cutting surfaces of the projecting members13,14and the inner surrounding cutting surfaces of the holes17,18are removed by rubbing and fresh surfaces thereof are exposed so that the outer surrounding cutting surfaces of the projecting members13,14and the inner surrounding cutting surfaces of the holes17,18are adhered and the metal contact areas19shown inFIG. 6are formed. By pressing, the projecting members13,14,15are deformed so that the metal contact areas20shown inFIG. 20are produced between overlapped projecting members13,14and between overlapped projecting members14,15by rubbing.

A metal joint body of the second embodiment according to the present invention will be described with reference toFIG. 7. As shown inFIG. 7, the second cutting line L3of the metal joint body1A is arranged with an arc shape. The widths of the projecting members13,14,15and the holes16,17,18along the direction parallel to the first cutting line L2(arrow Y) are increasing toward the first cutting line L2. Thus, the metal joint body1A surrounded with the pair of bending lines L1arranging the first cutting line12therebetween and the second cutting lines L3is shaped into an ellipse.

According to the metal joint body1,1A mentioned above, by cutting three overlapped metal sheets10,11,12along the first cutting line L2and the pair of second cutting lines L3extending so as to intersect the first cutting line L2at each end of the first cutting line L2; and pressing areas surrounded with the first cutting line L2and the pair of second cutting lines L3and each of the pair of bending lines L1connecting both ends of the pair of second cutting lines L3so as to bend the each area about the bending line L1, the first cutting line L2is arranged between the pair of bending lines L1. Thereby, the metal joint body1,1A miniaturized in the direction of row of the pair of bending lines L1(arrow X) can be manufactured.

The widths of the projecting members13,14,15and the holes16,17,18along the direction parallel to the first cutting line L2(arrow Y) are increasing toward the first cutting line L2, so that the projecting members13,14are pushed into the holes17,18. Thereby, normal loads are produced at the outer surrounding cutting surfaces of the projecting members13,14and the inner surrounding cutting surfaces of the holes17,18. Thus, joining of the metal joint area19is advanced so that the electric characteristics and reliability thereof are further improved.

An apparatus for manufacturing the metal joint body1,1A mentioned above will be described with reference toFIGS. 8, 9. As shown inFIGS. 8, 9, the apparatus2for manufacturing metal joint body includes a first die21, a second die22and a guide23.

The first die21is arranged with a rectangular parallelopiped shape, on a top surface of which a press hole24is provided. The press hole24is formed same as an area surrounded with the second cutting lines L3and the bending lines L1(hexagonal shape). The press hole24is formed into a V-shape in cross-sectional view gradually shallower from a bottom24acorresponding to the first cutting line L2toward each of edges24bcorresponding to each of the pair of the bending lines L1. The edges24bare formed in even plane as the top surface, or not deep of cutting off the metal sheets10,11,12.

The second die22is formed into a rod shape same as an area surrounded with the second cutting lines L3and the bending lines L1(hexagonal shape). The second die22is provided with a pressing projection25formed to be fitted to the press hole24. The pressing projection25is formed slant to be gradually narrower toward a top25acorresponding to the bottom24aof the press hole24.

The guide23is formed into a rectangular shape having a guide hole26corresponding to the press hole24of the first die21. The guide hole26penetrates through the guide23along the pressing direction (arrow Z). The guide hole26is formed same as the area surrounded with the second cutting lines L3and the bending lines L1of the metal sheets10,11,12(hexagonal shape) so as to guide the second die22to the press hole24of the first die21.

A method of manufacturing the metal joint body1,1A will be described by using the above apparatus2. As shown inFIG. 9A, at first, the three overlapped metal sheets10,11,12are arranged on the top of the first die21. After that, the second die22is moved along the guide hole26of the guide23in the pressing direction (arrow Z), and the three overlapped metal sheets10,11,12are clamped between the first die21and the second die22.

The second die22is further moved, so that the three overlapped metal sheets10,11,12are sheared along the first cutting line L2and the second cutting lines L3by edges of the pressing projection25along cutting lines L2, L3and edges of the press hole24along the cutting lines L2, L3. Simultaneously, each of the areas surrounded with the first cutting line L2and the second cutting lines L3of the three overlapped metal sheets10,11,12is pressed in the pressing direction, arrow Z, so as to be bent about each of the pair of bending lines L1. The pair of projecting members13of the first metal sheet10is pushed into the hole17of the second metal sheet11, and pair of projecting members14of the metal second sheet11is pushed into the hole18of the third metal sheet12. The outer surrounding cutting surfaces of the pair of projecting members13,14and the inner surrounding cutting surfaces of the holes17,18are adhered to each other, and the metal contact area19is produced. Thus, the metal joint body1,1A having the metal contact area19is completed.

A die by prior art includes a pair of press jigs arranged with a space to each other corresponding to the pair of projecting members113. In contrast, according to the apparatus for manufacturing metal joint body, the apparatus2for manufacturing the metal joint body1,1A includes one pressing projection25for forming the pair of projecting members13,14,15. The one pressing projection25can be formed in a sufficient size, so that the apparatus for manufacturing metal joint body can be improved about strength.

In the above embodiment, the metal joint body1,1A joins three metal sheets10,11,12. The present invention is not limited above, and the metal joint body1,1A can join two or more metal sheets.

In the above embodiment, the metal joint body1,1A joins the metal sheets10,11,12made of the same material. The present invention is not limited above, and it is confirmed that metal joining for metal sheets made of different metal, such as Sn, Zn, Au and Ag, can be performed when two or more metal sheets can be pressed and sheared. In short, at least one metal sheet during two or more metal sheets may be made of different material.

At least one metal sheet during two or more metal sheets may be plated with Sn, Zn, Au and Ag. At least one metal sheet during two or more metal sheets can be softer by plating, so that the metal sheets can be easily sheared by small force over the yield stress.

In the above embodiment, the metal joint body1,1A joins the metal sheets10,11,12having the same thickness. The present invention is not limited above, and it is confirmed that metal joining for metal sheets having different thickness can be performed when two or more metal sheets can be pressed and sheared. In short, it is confirmed that joining of metal sheets having at least one metal sheet during two or more metal sheets can be performed.

In the above embodiment, the widths of the projecting members13,14,15and the holes16,17,18along the direction parallel to the first cutting line L2(arrow Y) are provided so as to increase toward the first cutting line L2. The present invention is not limited above, and the widths can be constant.

In the above embodiment, the metal joint body1,1A is manufactured by cutting and pressing metal sheets10,11,12. The present invention is not limited above, and the overlapped metal sheets10,11,12can be cut and pressed and simultaneously or after cutting and pressing, by heating, the metal sheets10,11,12can be diffused to each other, for improving strength of joint by diffusion.

While, in the embodiment, the present invention is described, it is not limited thereto. Various change and modifications can be made with the scope of the present invention.