Masking tool, masking tool unit, and spraying method

Abstract

The present invention relates to a masking tool, a masking tool unit and a spraying method. The masking tool used for spraying on a sprayed body comprises: a first surface for facing the sprayed body; a second surface on the side opposite to the first surface; a tool through hole penetrating from the first surface to the second surface; and a supporting protrusion provided at a position on the first surface overlapping with the sprayed body, protruding from the first surface and used to support the sprayed body.

Description

Technical Field

[0001] The present disclosure relates to a masking tool, a masking tool unit and a spraying method. Background Art

[0002] There is known a technique in which a thermal spraying body is arranged on a masking tool having a through hole, and a thermal spraying material is sprayed from the through hole toward the thermal spraying body on a fixed component to fix the thermal spraying body to the fixed component (for example, Japanese Patent Application Laid-Open No. 2015-112534).

[0003] In thermal spraying using a masking tool, when the thermal spraying material collides with the thermal spraying object, vibration of the thermal spraying object may occur, and the thermal spraying material may not be sufficiently deposited on the thermal spraying object. Summary of the invention

[0004] The present disclosure can be implemented as the following aspects.

[0005] (1) According to one aspect of the present disclosure, a masking tool for use in thermal spraying on a thermally sprayed object is provided. The masking tool comprises: a first surface for facing the thermally sprayed object; a second surface located on the opposite side of the first surface; a tool through hole extending from the first surface to the second surface; and a supporting protrusion provided at a position of the first surface overlapping with the thermally sprayed object, protruding from the first surface and used to support the thermally sprayed object.

[0006] According to the masking tool of this mode, the support convex portion can support the thermally sprayed body in a state of protruding from the first surface. Since the thermally sprayed body is thermally sprayed while being supported by the support convex portion, the thermally sprayed body can be thermally sprayed in a stable state, and the thermally sprayed material can be sufficiently deposited on the thermally sprayed body.

[0007] (2) In the masking tool of the above aspect, the supporting protrusion may be arranged at least at a position including a first position near the tool through hole and a second position opposite to the first position across the tool through hole.

[0008] According to the masking tool of this aspect, the thermally sprayed object can be supported by the supporting protrusions on both sides of the tool through hole. As a result, thermal spraying can be performed on the thermally sprayed object in a more stable state, and the thermal spraying material can be sufficiently deposited on the thermally sprayed object.

[0009] (3) In the masking tool of the above aspect, the supporting protrusion may include a first supporting protrusion arranged at the first position and a second supporting protrusion arranged at the second position.

[0010] According to the masking tool of this aspect, the thermal spraying body can be supported by the supporting protrusions on both sides of the tool through hole, and the area occupied by the supporting protrusions on the first surface can be reduced, so that the supporting protrusions can be efficiently arranged on the first surface.

[0011] (4) In the masking tool of the above embodiment, the first supporting protrusion may include a first top portion farthest from the first surface in the direction from the first surface toward the second surface, and the second supporting protrusion may include a second top portion farthest from the first surface in the direction from the first surface toward the second surface.

[0012] According to this method, the masking tool can linearly support the sprayed body near the tool through hole. When the masking tool is fixed to the object during spraying, the sprayed body is easily pressed against the surface of the object, and spraying can be performed in a more stable state of the sprayed body.

[0013] (5) In the masking tool of the above aspect, the supporting protrusion may include a supporting protrusion front end surface having a surface shape corresponding to a surface shape of a fixed component, and the fixed component is an object to be fixed by thermally spraying the thermally sprayed body.

[0014] According to the masking jig of this aspect, the contact area between the supporting protrusion and the surface of the object to be fixed becomes larger, and thermal spraying can be performed in a state where the adhesion between the thermal spraying body and the object to be fixed is further improved.

[0015] (6) In the masking tool of the above aspect, the first surface may include a positioning mechanism for arranging the thermally sprayed object at a predetermined position on the first surface at a position corresponding to the outer shape of the thermally sprayed object.

[0016] According to the masking jig of this aspect, the thermally sprayed body can be easily arranged at a predetermined position on the first surface.

[0017] (7) According to another aspect of the present disclosure, a masking tool unit is provided. The masking tool unit includes the masking tool of the above aspect and a three-dimensional forming tool, wherein the three-dimensional forming tool is pressed against the first surface for use, and has a masking tool opposing surface opposite to the first surface and a receiving recess capable of receiving the supporting protrusion. The receiving recess can be formed in the masking tool opposing surface in a range including the supporting protrusion and the tool through hole in a plan view when the three-dimensional forming tool is arranged on the first surface.

[0018] According to the masking tool unit of this mode, by accommodating the supporting protrusion in the accommodating recess, a three-dimensional shape protruding from the first surface can be easily formed on the sprayed body. Therefore, it is possible to reduce or prevent the contact of the sprayed body other than the three-dimensional shape with parts other than the masking tool unit such as the fixed part.

[0019] (8) In the masking tool unit of the above aspect, it is possible that the opposing surface of the masking tool is a curved surface.

[0020] According to the masking tool unit of this aspect, it is possible to reduce or suppress the occurrence of wrinkles and the like on the thermally sprayed object when forming the three-dimensional shape on the thermally sprayed object.

[0021] (9) In the masking tool unit of the above aspect, the masking tool may include a positioning mechanism that fits with a part of the three-dimensional forming tool.

[0022] According to the masking tool unit of this aspect, the three-dimensional forming tool can be easily arranged at a predetermined position on the first surface.

[0023] (10) According to another aspect of the present disclosure, a thermal spraying method is provided. In the thermal spraying method, a masking tool and a thermal spraying object are prepared, the masking tool having a first surface and a supporting protrusion, the supporting protrusion being arranged near a tool through hole on the first surface, the thermal spraying object is arranged opposite to the first surface in a manner such that at least a portion of the thermal spraying object overlaps with the supporting protrusion, the thermal spraying object arranged on the first surface is pressed toward the first surface, and a three-dimensional shape protruding at a predetermined position where a thermal spraying material is to be sprayed on the thermal spraying object is formed, and the thermal spraying material is sprayed from the tool through hole toward the thermal spraying object arranged on the first surface and formed with the three-dimensional shape.

[0024] According to the spraying method of this mode, the spraying can be performed on the sprayed body in a state supported by the supporting protrusion, and the spraying can be performed in a stable state of the sprayed body. Since the sprayed body is a three-dimensional shape, it is possible to reduce or prevent the contact between the parts of the sprayed body other than the three-dimensional shape and the masking tool and the parts other than the sprayed body.

[0025] (11) In the thermal spraying method of the above aspect, the three-dimensional shape may be formed on the thermal spraying object by pressing at least a portion of the thermal spraying object toward the first surface while the thermal spraying object is stretched along the surface direction of the masking tool.

[0026] According to the thermal spraying method of this aspect, by forming the three-dimensional shape on the thermal spraying object while generating tension, it is possible to reduce or suppress the occurrence of wrinkles on the thermal spraying object when forming the three-dimensional shape on the thermal spraying object.

[0027] The present disclosure can also be implemented in various forms other than masking tools, masking tool units, and spraying methods. For example, it can be implemented in the form of a three-dimensional forming tool, an electrically heated catalyst, a vehicle part, a method for manufacturing a vehicle part, a method for processing a vehicle part, a surface treatment method, a construction method, a method for forming a sprayed film, a method for manufacturing a masking tool, a method for manufacturing a masking tool unit, a method for manufacturing an electrically heated catalyst, and the like. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Features, advantages, and technical and industrial significance of exemplary embodiments of the present invention will be described below with reference to the accompanying drawings, in which like reference numerals represent like elements, and in which:

[0029] Figure 1 It is a perspective view showing the appearance structure of a masking tool as a first embodiment of the present disclosure.

[0030] Figure 2 It is a perspective view showing the structure of an electrode member as a thermally sprayed object.

[0031] Figure 3 It is a perspective view showing the structure of the surface of the masking tool.

[0032] Figure 4 It is an explanatory diagram showing the structure of the back side of the masking tool.

[0033] Figure 5 yes Figure 3 as well as Figure 4 Cross-sectional view of the VV position.

[0034] Figure 6 This is an explanatory diagram showing the appearance structure of a three-dimensional forming tool.

[0035] Figure 7 yes Figure 6 A cross-sectional view at position VII-VII.

[0036] Figure 8 1 is a flowchart showing the thermal spraying method according to the present embodiment.

[0037] Fig. 9 This is a flowchart showing in detail a method of forming a three-dimensional shape on an electrode component.

[0038] Fig.10 It is an explanatory diagram showing a state where the electrode member is arranged on the back side of a masking tool.

[0039] Fig.11 This is an explanatory diagram showing a state where a three-dimensional forming tool is arranged on a masking tool in a state where an electrode member is arranged on the back surface.

[0040] Fig.12 It is an explanatory diagram showing a state where a three-dimensional shape is formed on an electrode member by a three-dimensional forming tool.

[0041] Fig.13 It is an explanatory diagram showing a cross section of an electrode member in a state where a three-dimensional shape is formed.

[0042] Fig.14 It is an explanatory diagram schematically showing a thermal spraying method using a masking tool according to the present embodiment.

[0043] Fig.15 It is a perspective view showing a masking tool according to a second embodiment.

[0044] Fig.16 It is a perspective view showing a supporting protrusion included in the masking jig according to the third embodiment. DETAILED DESCRIPTION

[0045] A. First Implementation Method:

[0046] Figure 1 2 is a perspective view showing the appearance structure of a masking tool 200 as a first embodiment of the present disclosure. The masking tool 200 is, for example, a flat plate-shaped component formed using aluminum or an aluminum alloy. The masking tool 200 is used when spraying a spraying material onto a sprayed body. The sprayed body refers to an object to which the spraying material is sprayed. The masking tool 200 is not limited to aluminum, and can also be formed using various metal materials such as iron materials, ceramic materials, and composite materials thereof.

[0047] As the spraying material, various materials such as metal, ceramic, plastic, cermet, etc. can be used. In the present embodiment, the spraying material uses a powdered composite material in which metal and ceramic are mixed. The material of the spraying material is not limited to powder, and can also be a wire or a rod.

[0048] exist Figure 1 In order to facilitate understanding of the technology, the masking tool 200 is shown as being removed from the electrode member 60 as the object to be sprayed. When the masking tool 200 sprays the spraying material onto the object to be sprayed, the spraying material passes through the tool through hole 242 by covering the surface of the object to be sprayed and the spraying material is prevented from adhering to an unpredicted position of the object to be sprayed. The masking tool 200 is used together with the three-dimensional forming tool 100 described later as a part of the masking tool unit.

[0049] In this embodiment, the spray-coated body is Figure 1The electrode member 60 shown. The electrode member 60 as a sprayed body is electrically connected to a surface electrode 460 for conducting electricity provided in an electrically heated catalyst (EHC: Electrically Heated Catalyst) 400. The electrically heated catalyst 400 is used, for example, to forcibly activate the catalyst by electrically heating it, thereby improving the purification efficiency of exhaust gas. As the electrically heated catalyst 400, for example, a substantially cylindrical carrier having a honeycomb structure that carries a catalyst such as platinum or palladium is used.

[0050] The surface electrode 460 is, for example, Figure 1 As shown in FIG. 1 , the planar shape is approximately rectangular. Figure 1 In the figure, only one surface electrode 460 is shown, but a group of surface electrodes 460 corresponding to the anode and the cathode are arranged on the outer surface of the electrically heated catalyst 400 in a manner opposite to each other. The electrode component 60 is fixed to the surface electrode 460 by the sprayed material. The object to be fixed to the sprayed body is also called a "fixed component". In the present embodiment, the electrically heated catalyst 400 and the surface electrode 460 are examples of fixed components. The electrode component 60 supplies power supplied from a power source not shown in the figure to the electrically heated catalyst 400 via the surface electrode 460. It is also possible to make the electrically heated catalyst 400 a fixed component without using the surface electrode 460. In this case, the electrode component 60 can be fixed on the surface TP of the electrically heated catalyst 400. The shape of the surface electrode 460 is not limited to a rectangular shape, and can be a variety of shapes.

[0051] Figure 2 1 is a perspective view showing the structure of the electrode member 60 as a thermally sprayed body. In the present embodiment, the electrode member 60 functions as an anode of a pair of electrodes provided in the electrically heated catalyst 400 . Figure 2 FIG. 6 shows the electrode component 60 in a manufactured state. The electrode component 60 after manufacture is, for example, Figure 2 As shown in FIG. 1 , the electrode component 60 has a substantially flat plate-like appearance. The thickness of the electrode component 60 is about 0.1 mm. The electrode component 60 is formed by die forming using a metal material such as a stainless steel alloy. The electrode component 60 is not limited to a stainless steel alloy, and can be formed using a variety of metals, for example, various alloys such as a Ni alloy and a Co alloy can be used. The electrode component 60 is not limited to an anode, and can also be used as a cathode, and can also be used for both an anode and a cathode.

[0052] like Figure 2As shown, the electrode component 60 includes a first wiring 61 and a second wiring 62. The electrode component 60 has a shape that is elongated along one direction, and the first wiring 61 and the second wiring 62 are arranged in sequence along the extending direction. The first wiring 61 is a portion of the electrode component 60 that is directly or indirectly connected to a power source (not shown) such as a battery.

[0053] The second wiring 62 is a portion fixed to the surface electrode 460 of the electrically heated catalyst 400 and electrically connected to the surface electrode 460. The second wiring 62 is formed continuously with the first wiring 61, and supplies the power supplied from a power source (not shown) such as a battery through the first wiring 61 to the surface electrode 460 of the electrically heated catalyst 400. In the present embodiment, the second wiring 62 has 15 straight wirings 621, and has a so-called combteeth appearance. The width of each wiring 621 of the second wiring 62 is, for example, about 0.5 to 1.0 mm.

[0054] exist Figure 2 In order to facilitate the understanding of the technology, the sprayed position PT is conceptually shown. The sprayed position refers to the predetermined position where the sprayed material is sprayed relative to the sprayed body. The sprayed position is preset. In the present embodiment, the sprayed position PT is arranged on the second wiring 62. In the case where the sprayed body is fixed to the fixed component by the sprayed material, the sprayed position includes a part of the fixed component. In the present embodiment, the sprayed position PT includes a part of each wiring 621 of the second wiring 62 arranged on the surface electrode 460 and the surface electrode 460 around each wiring 621. The electrode component 60 is fixed to the surface electrode 460 within the range of the surface electrode 460 around the part of each wiring 621 of the second wiring 62 and each wiring 621 arranged by the sprayed material. It should be noted that the second wiring 62 and the wiring 621 are included in the sprayed body.

[0055] The configuration position of the sprayed positions PT is defined by the tool through-holes 242 of the masking tool 200. That is, the number of the sprayed positions PT and their configuration positions can be arbitrarily set by the number and configuration of the tool through-holes 242. In the present embodiment, the number of the sprayed positions PT is 15, which is the same as the number of the wirings 621 possessed by the second wiring 62. In other words, the 15 wirings 621 possessed by the second wiring 62 are fixed to the surface electrode 460 by the sprayed material, respectively. The sprayed positions PT are arranged linearly in the first column PL1 and the second column PL2, respectively. It should be noted that the first column PL1 has 8 sprayed positions PT, and the second column PL2 has 7 sprayed positions PT. Each of the sprayed positions PT is arranged in a so-called staggered array in which they are alternately arranged in sequence on the first column PL1 and the second column PL2.

[0056] Figure 3 2 is a perspective view showing the structure of the surface TP of the masking tool 200. The surface TP of the masking tool 200 is the surface on the side opposite to the surface opposite to the body to be sprayed, and is the surface opposite to the supply source of the spraying material (the spraying nozzle 80 described later in this embodiment) when the spraying material is sprayed. In the masking tool 200, the surface opposite to the body to be sprayed, that is, the back side BP described later, is also referred to as the "first surface", and the surface on the side opposite to the surface opposite to the body to be sprayed, that is, the surface TP is also referred to as the "second surface".

[0057] The masking tool 200 includes a tool through hole 242 and a recess 261. The tool through hole 242 is a through hole for passing the spraying material during spraying. The tool through hole 242 penetrates the masking tool 200 from the front surface TP to the back surface BP of the masking tool 200, that is, in the thickness direction. The spraying material passes through the tool through hole 242 and collides with the spraying position PT.

[0058] like Figure 3 As shown, the tool through holes 242 are provided in a number corresponding to the number of the positions PT to be sprayed. In the present embodiment, there are 15 tool through holes 242, which are arranged linearly in the first column JL1 corresponding to the first column PL1 of the positions PT to be sprayed and the second column JL2 corresponding to the second column PL2 of the positions PT to be sprayed. It should be noted that the first column JL1 has 8 tool through holes 242, and the second column JL2 has 7 tool through holes 242. Each of the tool through holes 242 is arranged in a so-called staggered array in which the first column JL1 and the second column JL2 are alternately arranged in the order of the first column JL1 and the second column JL2.

[0059] The recess 261 has a concave appearance from the outer edge toward the center of the masking tool 200. The width of the recess 261 is substantially the same as the width of the first wiring 61 of the electrode member 60. The recess 261 functions as a guide portion when the first wiring 61 is bent in a direction away from the fixed member in order to connect the first wiring 61 to a power source after the electrode member 60 is fixed to the surface electrode 460 by the spraying material.

[0060] Figure 4 1 is an explanatory diagram showing the structure of the back side BP of the masking tool 200. The back side BP of the masking tool 200 is a surface for arranging the electrode member 60 during the spraying, and is a surface opposite to the electrode member 60. A masking tool fitting portion 270, a sprayed body fixing portion 280, and a supporting protrusion 250 are formed on the back side BP of the masking tool 200.

[0061] As described later, the masking tool fitting portion 270 is a recessed portion that can be fitted with a portion of the three-dimensional forming tool 100. In the present embodiment, the masking tool fitting portion 270 is a recessed portion corresponding to the outer shape of the three-dimensional forming tool fitting portion 170 formed on the three-dimensional forming tool 100. The masking tool fitting portion 270 fits with the three-dimensional forming tool fitting portion 170 when the three-dimensional forming tool 100 is used, and functions as a position alignment mechanism for arranging the three-dimensional forming tool 100 at an initial position of the back surface BP of the masking tool 200.

[0062] The sprayed body fixing portion 280 functions as a position alignment mechanism for arranging the electrode member 60 at a predetermined position on the back side BP when the electrode member 60 is arranged on the back side BP of the masking tool 200. Figure 4 As shown, the back surface BP includes four thermally sprayed body fixing portions 280 corresponding to the four corners of the second wiring 62. If the electrode member 60 can be easily arranged at a predetermined position on the back surface BP, the thermally sprayed body fixing portion 280 may not be provided.

[0063] and Figure 4 Refer to Figure 5 The supporting protrusion 250 formed on the back surface BP of the masking jig 200 will be described. Figure 5 yes Figure 3 as well as Figure 4 Sectional view of the VV position. Figure 5 In FIG. 4 , the outer surface 400S of the electrically heated catalyst 400 is indicated by a solid line, and the position of the outer surface of the electrically heated catalyst 400 in contact with the masking tool 200 is schematically indicated by a dotted line 400F. Figure 5 In the figure, the electrode component 60 and the surface electrode 460 are omitted.

[0064] like Figure 4 as well as Figure 5 As shown, the supporting protrusion 250 is a portion protruding from the back side BP of the masking tool 200, which is the first surface of the masking tool 200. The supporting protrusion 250 is provided near the tool through hole 242, and supports the portion near the tool through hole 242 in the electrode member 60 when the spraying material is sprayed relative to the electrode member 60. In this embodiment, a plurality of supporting protrusions 250 are provided. The plurality of supporting protrusions 250 are provided separately for the plurality of tool through holes 242 of the masking tool 200. The supporting protrusions 250 are provided in the same number as the number of the tool through holes 242 and the number of the wirings 621 in order to support each of the wirings 621 of the second wiring 62 near each of the plurality of tool through holes 242.

[0065] exist Figure 4In order to facilitate the understanding of the technology, the configuration predetermined position AP of the second wiring 62 in the configuration predetermined position of the electrode member 60 on the back side BP of the masking tool 200 is schematically shown by a dotted line. The configuration position of the supporting protrusion 250 is included in the configuration predetermined position AP. More specifically, the supporting protrusion 250 is respectively configured at the configuration predetermined position of each wiring 621 of the second wiring 62 in the configuration predetermined position AP. As a result, the supporting protrusion 250 can support each wiring 621 configured at the configuration predetermined position AP with its front end.

[0066] In the present embodiment, the supporting protrusion 250 is arranged at a second position PT2 near the tool through hole 242 and on the central side of the back surface BP in the predetermined arrangement position AP of the second wiring 62, and at a first position PT1 near the tool through hole 242 and on the opposite side of the second position PT2 across the tool through hole 242. The first position PT1 and the second position PT2 are included in the range of the predetermined arrangement position AP. In the present embodiment, the first position PT1 and the second position PT2 are equidistant from the tool through hole 242. The supporting protrusion 250 arranged at the first position PT1 is also referred to as a "first supporting protrusion 251", and the supporting protrusion 250 arranged at the second position PT2 is also referred to as a "second supporting protrusion 252". "Arranged at the first position PT1" means that the center of the first supporting protrusion 251 is arranged at the first position PT1 when viewed from above, and "arranged at the second position PT2" means that the center of the second supporting protrusion 252 is arranged at the second position PT2 when viewed from above. Thus, the supporting protrusion 250 can support each wiring 621 included in the second wiring 62 at two points on both sides of the tool through-hole 242 .

[0067] like Figure 5 As shown, the first supporting protrusion 251 includes a first supporting protrusion front end surface 251S at the front end, an inner wall surface 251F facing the tool through hole 242, and an outer wall surface 251E on the side opposite to the inner wall surface 251F. The second supporting protrusion 252 includes a second supporting protrusion front end surface 252S at the front end, an inner wall surface 252F facing the tool through hole 242, and an outer wall surface 252E on the side opposite to the inner wall surface 252F. The inner wall surface 251F of the first supporting protrusion 251 and the inner wall surface 252F of the second supporting protrusion 252 are opposite to each other.

[0068] The positions of the first supporting protrusion 251 and the second supporting protrusion 252 relative to the tool through hole 242, i.e., the first position PT1 and the second position PT2, can be set arbitrarily. The positions of the first supporting protrusion 251 and the second supporting protrusion 252 relative to the tool through hole 242 can be set based on the rigidity of the wiring 621, the type of spraying material, the area of ​​the first supporting protrusion front end face 251S and the second supporting protrusion front end face 252S, the spraying amount and the spraying speed of the spraying material, etc., on the premise that the supporting protrusion 250 can fully support the wiring 621. "The supporting protrusion 250 can fully support the wiring 621" means that the supporting protrusion 250 can support the wiring 621 to a degree that it does not bend during spraying. "The supporting protrusion 250 can fully support the wiring 621" includes the degree that the wiring 621 can be supported to a degree that it does not bend by being clamped between the supporting protrusion 250 and the electrically heated catalyst 400 during spraying.

[0069] The first position PT1 and the second position PT2 may be set individually using the distance from the tool through hole 242 to the first position PT1 and the distance from the tool through hole 242 to the second position PT2, or may be set using the distance from the first position PT1 to the second position PT2. The distance from the first position PT1 to the second position PT2 is preferably close to a degree that can fully support the wiring 621. For example, Figure 5 As shown, the first position PT1 and the second position PT2 are preferably arranged at a position included from the outer edge E1 of the tool through hole 242 to the distance L1 which is 3 times the width W1 of the tool through hole 242, and more preferably arranged at a position included from the outer edge E1 of the tool through hole 242 to the distance L2 which is 1.5 times the width W1 of the tool through hole 242. However, the distance L3 from the tool through hole 242 to the inner wall surface 251F of the first supporting protrusion 251 and the distance from the tool through hole 242 to the inner wall surface 252F of the second supporting protrusion 252 are preferably far enough away to avoid the spraying material from adhering to the supporting protrusion 250. The arrangement position of the second supporting protrusion 252 is the same as the arrangement position of the first supporting protrusion 251, so the description is omitted. The first position PT1 and the second position PT2 are not limited to being equidistant from the tool through hole 242, and can also be set to different distances from each other.

[0070] The first supporting protrusion front end surface 251S and the second supporting protrusion front end surface 252S are surfaces for supporting the wiring 621. Figure 5As shown, the first support convex portion front end face 251S and the second support convex portion front end face 252S have a surface shape corresponding to the surface shape of the outer surface 400S of the substantially cylindrical electrically heated catalyst 400. Specifically, the first support convex portion front end face 251S and the second support convex portion front end face 252S are formed as a curved surface having a curvature substantially the same as the curvature of the outer surface 400S. Thus, the contact area between the first support convex portion front end face 251S and the outer surface 400S and the contact area between the second support convex portion front end face 252S and the outer surface 400S are increased. It should be noted that the first support convex portion front end face 251S and the second support convex portion front end face 252S are not limited to curved surfaces, but may also be flat surfaces. In the case where the first support convex portion front end face 251S and the second support convex portion front end face 252S are flat surfaces, it is preferred that the surface direction thereof be arranged along the outer surface 400S from the perspective of increasing the contact area with the outer surface 400S. It should be noted that the first supporting protrusion 251 and the second supporting protrusion 252 may have various shapes other than columnar, such as a flat plate or a cone, and may not have the first supporting protrusion front end surface 251S and the second supporting protrusion front end surface 252S.

[0071] The outer wall surface 251E of the first supporting protrusion 251 is inclined relative to the front end surface 251S of the first supporting protrusion. The outer wall surface 252E of the second supporting protrusion 252 is inclined relative to the front end surface 252S of the second supporting protrusion. It should be noted that the outer wall surface 251E and the outer wall surface 252E are also inclined relative to the back surface BP. By configuring in this way, when the three-dimensional shape described later is formed, the wiring 621 is easily formed into a shape along the surface of the first supporting protrusion 251 and the second supporting protrusion 252.

[0072] The position where the distance between the electrically heated catalyst 400 and the back surface BP of the masking tool 200 is the smallest is set as Figure 5 When the top 400T is shown, a back side recess 260 is provided at a position opposite to the top 400T in the back side BP. Figure 4 The illustration is omitted. The back recess 260 is a recess formed on the back surface BP, and is formed continuously from the outer wall surface 252E of the second supporting protrusion 252. In a state where the electrode component 60 is fixed to the surface electrode 460 by the spraying material, from the perspective of reducing or preventing an electrical short circuit between the electrode component 60 and the surface electrode 460, the electrode component 60 is preferably in a state away from the outer surface 400S. From the perspective of reducing or suppressing the contact between the wiring 621 in a state of forming a three-dimensional shape described later and the outer surface 400S near the top 400T, as shown in FIG. Figure 5 As shown as the separation distance L4 in FIG. 2 , the separation distance from the second supporting protrusion front end surface 252S to the back surface BP is increased by the back surface recess 260 .

[0073] use Figure 6 as well as Figure 7 The structure of the three-dimensional forming tool 100 used in the thermal spraying method of this embodiment will be described. Figure 6 1 is an explanatory diagram showing the external appearance structure of the three-dimensional forming tool 100 . Figure 7 yes Figure 6 The three-dimensional forming tool 100 includes a gripping portion 110 and a main body 120 having a masking tool facing surface 100S. Figure 7 As shown, the masking tool opposing surface 100S is a curved surface having a predetermined curvature.

[0074] The three-dimensional forming tool 100 is used by pressing against the back side BP of the masking tool 200, and a three-dimensional shape is formed on the electrode component 60 arranged on the back side BP of the masking tool 200, more specifically, on the wiring 621 of the electrode component 60. The position where the three-dimensional shape is formed in the wiring 621 is a position near the sprayed position PT. The three-dimensional forming tool 100 is pressed against the back side BP of the masking tool 200 in such a manner that the masking tool opposing surface 100S is opposite to the back side BP of the masking tool 200. The three-dimensional forming tool 100 is used together with the masking tool 200 as a part of the masking tool unit. It should be noted that, in the case where the three-dimensional shape of the electrode component 60 is formed by manual operation of an operator, for example, the three-dimensional forming tool 100 can also be omitted.

[0075] The holding portion 110 is used to operate the three-dimensional forming tool 100 when forming the three-dimensional shape of the electrode component 60 on the back surface BP. By operating the holding portion 110, the masking tool opposite surface 100S rolls on the back surface BP of the masking tool 200 and contacts the sprayed body on the back surface BP, thereby forming a three-dimensional shape on the electrode component 60.

[0076] like Figure 6 as well as Figure 7 As shown, a storage recess 150, a three-dimensional forming tool protrusion 160, and a three-dimensional forming tool fitting portion 170 are provided in the masking tool opposite surface 100S. The storage recess 150 is a recess capable of storing the supporting protrusion 250. In the present embodiment, the storage recess 150 is formed in a range including the first supporting protrusion 251, the second supporting protrusion 252, and the tool through hole 242 in a plan view. The storage recess 150 forms a three-dimensional shape on the wiring 621 by storing the supporting protrusion 250 in a state of supporting the wiring 621. The storage recess 150 stores both the first supporting protrusion 251 and the second supporting protrusion 252 included in the supporting protrusion 250.

[0077] The three-dimensional forming tool protrusion 160 has a shape substantially the same as that of the rear surface concave portion 260. The three-dimensional forming tool protrusion 160 fits with the rear surface concave portion 260 supporting the wiring 621 to form the wiring 621 in a three-dimensional shape having a height approximately equal to the separation distance L4.

[0078] The three-dimensional forming tool fitting portion 170 is provided with Figure 4 The concave masking tool fitting portion 270 shown in the figure has a shape corresponding to the outer shape. In the present embodiment, the three-dimensional forming tool fitting portion 170 is a roughly cylindrical component. The three-dimensional forming tool fitting portion 170 is arranged at a position corresponding to the configuration position of the masking tool fitting portion 270 in the masking tool opposite surface 100S. The three-dimensional forming tool fitting portion 170 acts as a position alignment mechanism when the three-dimensional forming tool 100 is arranged at the initial position in the back side BP of the masking tool 200 by fitting with the masking tool fitting portion 270. The three-dimensional forming tool fitting portion 170 is not limited to a cylindrical shape, and can also be a spherical, disc, annular, or a prism, polyhedron, and other various shapes. In the case where the three-dimensional forming tool 100 can be easily arranged at the initial position of the back side BP, the three-dimensional forming tool fitting portion 170 and the masking tool fitting portion 270 can also be omitted.

[0079] Figure 8 Flow chart showing the spraying method of the present embodiment. In step S10, a masking tool 200, an electrode component 60 as a sprayed body, and a three-dimensional forming tool 100 are prepared. In step S20, the electrode component 60 is arranged on the back side BP of the masking tool 200. In step S30, the three-dimensional forming tool 100 is used to form a three-dimensional shape on the electrode component 60 in a state of being arranged on the back side BP. In step S40, the masking tool 200 in a state of being arranged with the electrode component 60 forming a three-dimensional shape on the back side BP is arranged on the surface electrode 460 of the electrically heated catalyst 400 as a fixed component. In step S50, the spraying material is sprayed from the surface TP side of the masking tool 200 through the tool through hole 242 toward the electrode component 60. In step S60, when the spraying material solidifies and the electrode component 60 is fixed relative to the surface electrode 460, the masking tool 200 is removed from the electrode component 60 fixed to the electrically heated catalyst 400. Through the above steps, the thermal spraying method of this embodiment is completed.

[0080] Fig. 91 is a flowchart showing in detail the method of forming a three-dimensional shape on the electrode component 60 as the spray-coated body in step S30. In step S32, the three-dimensional forming tool 100 is arranged on the back side BP of the masking tool 200 in a state where the electrode component 60 is arranged on the back side BP. In step S34, a tension is generated along the surface direction of the masking tool 200 in the second wiring 62 of the electrode component 60 arranged on the back side BP. In step S36, the gripping portion 110 of the three-dimensional forming tool 100 is operated to press the electrode component 60 on the back side BP in a manner that the masking tool opposite surface 100S rolls on the back side BP of the masking tool 200. As a result, a three-dimensional shape is formed on the electrode component 60 as the spray-coated body. These processes can be performed using a robot or a dedicated device, or can be performed by an operator.

[0081] Fig.10 1 is an explanatory diagram showing the electrode member 60 disposed on the back side BP of the masking tool 200. The electrode member 60 is in a state before being formed into a three-dimensional shape by the three-dimensional forming tool 100, and each wiring of the second wiring 62 is supported by the first supporting protrusion 251 and the second supporting protrusion 252 by its own weight and is bent.

[0082] In this embodiment, if Fig.10 As shown, four spray-coated body fixing portions 280 are provided on the back side BP. The four spray-coated body fixing portions 280 are respectively arranged at positions corresponding to the four corners of the second wiring 62. When the electrode component 60 is arranged on the back side BP of the masking tool 200, the spray-coated body fixing portions 280 abut against the outer peripheral ends of the four corners of the second wiring 62. By configuring in this way, the position alignment of the electrode component 60 relative to the back side BP of the masking tool 200 can be easily performed. As a result, the position alignment of the sprayed position PT of the electrode component 60 relative to the tool through hole 242 of the masking tool 200 can be easily performed.

[0083] Fig.11 1 is an explanatory diagram showing a state where the three-dimensional forming tool 100 is arranged on the masking tool 200 in a state where the electrode member 60 is arranged on the back surface BP. Fig.11 It is shown in Fig.10 The cross section of the masking tool 200 at the XI-XI position and the cross section of the stereo tool 100 at the position corresponding to the position. The stereo tool 100 is moved in the direction D1 toward the back surface BP of the masking tool 200 and is pressed on the back surface BP. At this time, by fitting the stereo tool fitting part 170 of the stereo tool 100 with the masking tool fitting part 270 of the masking tool 200, the stereo tool 100 can be arranged at a predetermined initial position on the back surface BP.

[0084] Fig.121 is an explanatory diagram showing a state where a three-dimensional shape is formed on the electrode member 60 by operating the three-dimensional forming tool 100. Fig.12 Zhongyu Fig.11 It also shows Fig.10 The cross section of the masking tool 200 at the XI-XI position and the cross section of the stereoscopic forming tool 100 at the position corresponding to the position. Fig.12 In FIG. 1 , the three-dimensional forming tool 100 arranged in the initial position is shown by the dotted line, and the three-dimensional forming tool 100 in a state where the three-dimensional shape of the electrode member 60 is formed is schematically shown by the solid line.

[0085] In this embodiment, after the three-dimensional forming tool 100 is arranged at the initial position, the second wiring 62 of the electrode member 60 is tensioned along the surface direction of the masking tool 200. Specifically, the tension of the second wiring 62 can be increased by, for example, moving the electrode member 60 along the surface direction of the masking tool 200 while the electrode member 60 is fixed to the back surface BP. Fig.12 The surface direction D2 of the masking tool 200 shown is produced by stretching the first wiring 61 of the electrode member 60. By forming a three-dimensional shape on the wiring 621 in this state, the wiring 621 can be reduced or suppressed from forming a three-dimensional shape with undulations or wrinkles.

[0086] While generating tension on the electrode member 60, the gripping portion 110 of the three-dimensional forming tool 100 disposed at the initial position is operated to form a three-dimensional shape on the electrode member 60. Specifically, while pressing the back surface BP with the masking tool opposing surface 100S, for example Fig.12 As indicated by arrow D3 in the figure, the holding portion 110 is rotated around the central axis AX near the opposite surface 100S of the masking tool. The wiring 621 of the second wiring 62 is pressed toward the back side BP, and a three-dimensional shape is formed on the electrode component 60 due to the ductility of the metal. Since the opposite surface 100S of the masking tool is a curved surface, the wiring 621 is easy to extend in a direction away from the starting position of the pressing when the wiring 621 is pressed. The direction away from the starting position of the pressing includes the surface direction D2 as a directional component. By forming a three-dimensional shape in the wiring 621 in this state, it is possible to reduce or suppress the wiring 621 from forming a three-dimensional shape in a wavy state or a wrinkled state. It should be noted that the operation of the holding portion 110 can be either manual operation by an operator or a robot or a dedicated device.

[0087] Fig.13 1 is an explanatory diagram showing a cross section of the electrode member 60 in a state where a three-dimensional shape is formed. Fig.13In FIG. 4 , the outer surface 400S of the electrically heated catalyst 400 is indicated by a solid line, and the position of the outer surface 400S of the electrically heated catalyst 400 in a state of contact with the masking tool 200 is schematically indicated by a dotted line 400F. Fig.13 In the figure, the surface electrode 460 is omitted.

[0088] like Fig.13 As shown as wiring 62B in the example, the wiring 621 of the electrode member 60 is formed into a three-dimensional shape protruding from the back side BP toward the electrically heated catalyst 400 by being pressed toward the back side BP by the three-dimensional forming tool 100. The three-dimensional shape is determined by the outer shape of the supporting protrusion 250 and the outer shape of the receiving recess 150. In the present embodiment, the wiring 62B is formed in the range from the first supporting protrusion 251 to the second supporting protrusion 252 by receiving the first supporting protrusion 251 and the second supporting protrusion 252 of the masking tool 200 through the receiving recess 150 of the three-dimensional forming tool 100. As a result, as Fig.13 As shown, the wiring 621 of the second wiring 62 is formed in a three-dimensional shape protruding from the back surface BP toward the electrically heated catalyst 400 in the vicinity of the tool through-hole 242 .

[0089] exist Fig.13 , the first top 251P of the first supporting protrusion 251 and the second top 252P of the second supporting protrusion 252 are schematically shown. The first top 251P is the portion of the first supporting protrusion 251 that is farthest from the back surface BP in the direction from the surface TP toward the back surface BP, i.e., the protruding direction of the first supporting protrusion 251, and the second top 252P is the portion of the second supporting protrusion 252 that is farthest from the back surface BP in the direction from the surface TP toward the back surface BP, i.e., the protruding direction of the second supporting protrusion 252. Fig.13 As shown, the wiring 62B is in a state of tension and is formed in a substantially straight line connecting the first top 251P to the second top 252P. The straight wiring 62B is formed by pressing the electrode member 60 while generating tension in the electrode member 60 when forming a three-dimensional shape using the three-dimensional forming tool 100 as described above.

[0090] When the masking tool 200 with the electrode member 60 disposed thereon is disposed on the electrically heated catalyst 400, the electrically heated catalyst 400 is directed toward Fig.13 The electrically heated catalyst 400 moves relatively in the direction D4 shown and contacts the first support protrusion front end surface 251S and the second support protrusion front end surface 252S. At this time, the electrically heated catalyst 400 contacts the linear wiring 62B connecting the first top portion 251P to the second top portion 252P before contacting the first support protrusion front end surface 251S and the second support protrusion front end surface 252S.

[0091] The electrically heated catalyst 400 in contact with the wiring 62B keeps moving to the position indicated by the dotted line 400F. Fig.13 As shown, the linear wiring 62B is pushed upward by the outer surface 400S of the electrically heated catalyst 400 and moves in the direction D5 approaching the tool through hole 242. The wiring 62B pushed upward by the electrically heated catalyst 400 is clamped together by the outer surface 400S and the front end surface 251S of the first supporting protrusion and the front end surface 252S of the second supporting protrusion. As a result, the linear wiring 62B is deformed into an arc-shaped wiring 62F along the outer surface 400S. In this way, by making the wiring 621 between the first top 251P and the second top 252P, that is, near the spraying position PT of the second wiring 62, a linear shape like the wiring 62B, the force of pressing the wiring 621 against the outer surface 400S is obtained when the masking tool 200 is arranged on the electrically heated catalyst 400. As a result, the closeness and contact area between the wiring 621 and the outer surface 400S can be improved. When sufficient adhesion between the wiring 621 and the outer surface 400S can be obtained, the first top portion 251P and the second top portion 252P may be omitted.

[0092] Fig.14 2 is an explanatory diagram schematically showing a thermal spraying method using the masking tool 200 of the present embodiment. Fig.14 In order to facilitate understanding of the technology, the masking tool 200 in a state where the electrode member 60 is arranged is schematically shown by an exploded perspective view of the electrode member 60 and the masking tool 200 .

[0093] exist Fig.14 , a spray nozzle 80 is schematically shown. The spray nozzle 80 is connected to a spray device (not shown) to spray the spray material from the injection port at the front end. In the present embodiment, the spray device is a plasma spraying spray device. The spray device imparts thermal energy to the spray material to make the spray material semi-molten, and sprays the semi-molten spray material imparted with kinetic energy from the spray nozzle 80. The spray device is not limited to plasma spraying, and may also be a spray device of various modes such as flame spraying, arc spraying, high-speed flame spraying, laser spraying, etc.

[0094] exist Fig.14The figure schematically shows a jet 82 of the spraying material sprayed from the spraying nozzle 80. The spraying material sprayed from the spraying nozzle 80 becomes a jet 82 and passes through the tool through-hole 242, colliding with the sprayed position PT including a portion of the wiring 621 and a portion of the surface electrode 460. At this time, the wiring 621 near the sprayed position PT is a three-dimensional shape protruding from the back side BP toward the electrically heated catalyst 400 near the tool through-hole 242. The wiring 621 near the sprayed position PT is supported by the first supporting protrusion 251 and the second supporting protrusion 252 in the state of the three-dimensional shape, and is pressed against the outer surface 400S by the front end surface 251S of the first supporting protrusion and the front end surface 252S of the second supporting protrusion. In the present embodiment, the wiring 621 near the sprayed position PT is also as shown using Fig.13 As shown, the wire 62B having tension is pushed upward by the electrically heated catalyst 400 and is deformed into an arc-shaped wire 62F.

[0095] The sprayed material is deposited on the electrode member 60 at the sprayed position PT and on the surface electrode 460. The deposited sprayed material solidifies and forms a sprayed film 70 also called a splat. The sprayed film 70 solidifies on the second wiring 62 and the surface electrode 460, fixes the electrode member 60 relative to the surface electrode 460 through the adhesive force with the surface electrode 460, and electrically connects the electrode member 60 and the surface electrode 460.

[0096] When the spraying is performed in a state where there is a gap between the wiring 621 and the outer surface 400S, the jet 82 of the spraying material may collide with the wiring 621 in a state separated from the outer surface 400S, and the wiring 621 may vibrate. In a state where the wiring 621 vibrates, the spraying material may not be sufficiently deposited on the wiring 621. In addition, when the spraying material is deposited on the wiring 621 in a state separated from the outer surface 400S, there may be a problem that the bonding strength of the spraying film 70 with respect to the wiring 621 and the surface electrode 460 is reduced, and the electrical connection between the electrode member 60 and the surface electrode 460 cannot be sufficiently obtained. In this embodiment, the vicinity of the tool through hole 242 is a three-dimensional shape protruding from the back surface BP toward the electrically heated catalyst 400, and is pressed against the outer surface 400S by the first supporting protrusion 251 and the second supporting protrusion 252, thereby improving the closeness and contact area between the wiring 621 and the outer surface 400S. As a result, the generation of a gap between the wiring 621 and the outer surface 400S can be reduced or prevented, and the wiring 621 can be sufficiently fixed to the surface electrode 460 by making the spray material sufficiently deposited on the wiring 621. In addition, by transforming the straight wiring 62B into the arc-shaped wiring 62F pushed upward by the electrically heated catalyst 400, the force of pressing the second wiring 62 against the outer surface 400S is obtained, and the closeness and contact area between the wiring 621 and the outer surface 400S can be improved. As a result, the vibration of the wiring 621 caused by the collision of the spray material sprayed during spraying with the wiring 621 and the generation of a gap between the wiring 621 and the outer surface 400S can be reduced or prevented.

[0097] As described above, the masking tool 200 of the present embodiment includes a back surface BP opposite to the electrode member 60 as a sprayed body, a tool through hole 242, and a supporting protrusion 250 protruding from the back surface BP. The supporting protrusion 250 is provided at a position overlapping with the predetermined arrangement position AP of the electrode member 60, and supports the electrode member 60. By performing spraying in a state where the electrode member 60 is supported by the supporting protrusion 250, the spraying can be performed in a stable state of the electrode member 60, and the spraying material can be sufficiently accumulated on the electrode member 60. The electrode member 60 in a state supported by the supporting protrusion 250 is pressed against the outer surface 400S by the supporting protrusion 250, thereby performing spraying in a state where the closeness and contact area between the wiring 621 and the outer surface 400S are improved. Therefore, it is possible to reduce or prevent the generation of a gap between the wiring 621 and the outer surface 400S at the sprayed position PT, and the wiring 621 can be sufficiently fixed to the surface electrode 460. Since the three-dimensional shape protruding from the back surface BP can be formed in the electrode member 60 , it is possible to reduce or prevent the portion of the electrode member 60 other than the three-dimensional shape from contacting the front surface electrode 460 as the fixed member.

[0098] According to the masking tool 200 of the present embodiment, the supporting protrusion 250 is arranged at a first position PT1 near the tool through hole 242 and a second position PT2 on the side opposite to the first position PT1 across the tool through hole 242. Therefore, the wiring 621 included in the second wiring 62 can be supported at two points on both sides of the tool through hole 242. As a result, the electrode component 60 can be sprayed in a more stable state, and the spraying material can be sufficiently deposited on the electrode component 60. The electrode component 60 in a state supported by two points is pressed against the outer surface 400S by the supporting protrusion 250, thereby spraying can be performed in a state where the tightness and contact area between the wiring 621 and the outer surface 400S are further improved.

[0099] According to the masking tool 200 of the present embodiment, the supporting protrusion 250 includes a first supporting protrusion 251 arranged at the first position PT1 and a second supporting protrusion 252 arranged at the second position PT2. Therefore, the wiring 621 included in the second wiring 62 can be supported at two points on both sides of the tool through hole 242, and the area occupied by the supporting protrusion 250 relative to the back surface BP is reduced, so that the supporting protrusion 250 can be efficiently arranged on the back surface BP.

[0100] According to the masking tool 200 of the present embodiment, the first supporting protrusion 251 has a first top 251P farthest from the back surface BP in the direction from the surface TP toward the back surface BP, and the second supporting protrusion 252 has a second top 252P farthest from the back surface BP in the direction from the surface TP toward the back surface BP. The three-dimensional shape of the wiring 621 near the spraying position PT can be made linear, and the force of pressing the wiring 621 against the outer surface 400S when the masking tool 200 is arranged on the electrically heated catalyst 400 can be obtained. Therefore, the spraying can be performed in a state where the closeness and contact area between the wiring 621 and the outer surface 400S are further improved.

[0101] According to the masking tool 200 of the present embodiment, the supporting protrusion 250 has a supporting protrusion front end surface having a surface shape corresponding to the surface shape of the outer surface 400S of the electrically heated catalyst 400 as the fixed member. Therefore, the contact area between the supporting protrusion 250 and the outer surface 400S becomes larger, and the thermal spraying can be performed in a state where the adhesion and contact area between the wiring 621 and the outer surface 400S are further improved.

[0102] According to the masking tool 200 of this embodiment, the sprayed body fixing portion 280 is provided at a position corresponding to the outer shape of the second wiring 62, which functions as a positioning mechanism for arranging the second wiring 62 at a predetermined position on the back surface BP. Therefore, the electrode member 60 can be easily arranged at a predetermined position on the back surface BP.

[0103] The masking tool unit of the present embodiment includes a masking tool 200 and a three-dimensional forming tool 100 used by pressing against the back surface BP. The three-dimensional forming tool 100 has a masking tool opposite surface 100S opposite to the back surface BP and a receiving recess 150 capable of receiving the supporting protrusion 250. The receiving recess 150 is formed in the masking tool opposite surface 100S, and includes a range including the first supporting protrusion 251, the second supporting protrusion 252, and the tool through hole 242 in a top view when the three-dimensional forming tool 100 is arranged on the back surface BP. By receiving the supporting protrusion 250 in the receiving recess 150, a three-dimensional shape protruding from the back surface BP can be formed on the electrode component 60. Therefore, a three-dimensional shape can be formed on the electrode component 60 by a simple method.

[0104] In the masking tool unit of the present embodiment, the masking tool facing surface 100S of the three-dimensional forming tool 100 is a curved surface. When the wiring 621 on the back surface BP is pressed by the masking tool facing surface 100S, it is easier to extend the wiring 621 in a direction away from the three-dimensional forming tool 100 than in the case of a flat surface. Therefore, it is possible to reduce or suppress the wiring 621 from forming a three-dimensional shape with wavy or wrinkled shapes.

[0105] In the masking jig 200 of the present embodiment, the masking jig 200 includes a positioning mechanism that fits with a part of the three-dimensional forming jig 100. Therefore, the three-dimensional forming jig 100 can be easily arranged at the initial position of the back surface BP.

[0106] According to the spraying method of this embodiment, the wiring 621 of the electrode component 60 as the sprayed body is arranged on the back side BP in a manner overlapping with the supporting protrusion 250, the wiring 621 is pressed toward the back side BP, a three-dimensional shape protruding near the spraying position PT is formed on the wiring 621, and the spraying material is sprayed from the tool through hole 242 toward the wiring 621 formed with the three-dimensional shape. Therefore, the electrode component 60 is pressed against the outer surface 400S by the supporting protrusion 250, thereby improving the closeness and contact area between the wiring 621 and the outer surface 400S. It is possible to reduce or prevent the portion other than the three-dimensional shape of the electrode component 60 from contacting the surface electrode 460 as the fixed component, and it is possible to reduce or prevent the generation of a gap between the wiring 621 and the outer surface 400S at the spraying position PT, and the wiring 621 can be fully fixed to the surface electrode 460.

[0107] According to the thermal spraying method of this embodiment, the electrode member 60 is stretched along the surface direction D2 of the masking tool 200, while forming a three-dimensional shape on the wiring 621. By forming a three-dimensional shape on the wiring 621 while generating tension, it is possible to reduce or suppress the wiring 621 from forming a three-dimensional shape in a wavy state or a wrinkled state.

[0108] B. Second Implementation Method:

[0109] Fig.15 2 is a perspective view showing a masking tool 200b of the second embodiment. In the first embodiment, an example is shown in which a supporting protrusion 250 is provided for each tool through hole 242. In contrast, one supporting protrusion 250b may be provided for a plurality of tool through holes 242. The structure of the masking tool 200b is different from that of the masking tool 200 of the first embodiment in that the arrangement of the tool through holes 242 is only the first column JL1 and that a single supporting protrusion 250b corresponding to the first column JL1 is provided instead of the plurality of supporting protrusions 250. The other structures are the same.

[0110] In the present embodiment, the supporting protrusion 250b includes a first supporting protrusion 251b at a first position PT1 and a second supporting protrusion 252b at a second position PT2. The first supporting protrusion 251b has a strip shape in which the first supporting protrusion 251 in the first embodiment is extended along the arrangement direction of the tool through-holes 242. The second supporting protrusion 252b has a strip shape in which the second supporting protrusion 252 in the first embodiment is extended along the arrangement direction of the tool through-holes 242. The first supporting protrusion 251b is configured to include the first position PT1 of each tool through-hole 242, and the second supporting protrusion 252b is configured to include the second position PT2 of each tool through-hole 242.

[0111] According to the masking tool 200b of this embodiment, a three-dimensional shape can be formed for a plurality of second wirings 62 by a simple structure based on a supporting protrusion 250b. Even with the masking tool 200b of this mode, a three-dimensional shape can be formed in which each wiring 621 included in the second wiring 62 is supported at two points on both sides of the tool through hole 242.

[0112] According to the masking tool 200b of the present embodiment, the first supporting protrusion 251b and the second supporting protrusion 252b have a strip shape along the arrangement direction of the tool through holes 242. Therefore, it is possible to reduce or prevent the wiring 621 supported by the first supporting protrusion 251b and the second supporting protrusion 252b from falling off the first supporting protrusion 251b and the second supporting protrusion 252b.

[0113] C. Third Implementation Method:

[0114] Fig.162 is a perspective view showing a support protrusion 250c provided in a masking tool 200c of the third embodiment. The masking tool 200c of the present embodiment is different from the masking tool 200 of the first embodiment in that a support protrusion 250 is provided instead of the support protrusion 250, and the other structures are the same.

[0115] like Fig.16 As shown, the support protrusion 250c is a protrusion having a ring shape protruding from the back side BP. The support protrusion 250c is formed at a position including the first position PT1 and the second position PT2. In this way, the support protrusion 250c can also be formed as a protrusion including the first position PT1 and the second position PT2.

[0116] According to the masking tool 200c of this embodiment, by configuring the supporting protrusion 250c surrounding the tool through hole 242, the position and area that can support the sprayed body when forming a three-dimensional shape and during spraying can be increased. Therefore, it is easy to support the sprayed body by the supporting protrusion 250c. Even with the masking tool 200c of this mode, it is possible to form a three-dimensional shape that supports each wiring 621 included in the second wiring 62 at two points on both sides of the tool through hole 242.

[0117] D. Other implementation methods:

[0118] (D1) In the above embodiment, an example is shown in which the fixed component is the surface electrode 460 of the electrically heated catalyst, and the sprayed component is the electrode component 60 fixed to the surface electrode 460. In contrast, the fixed component is not limited to the electrically heated catalyst, and may be, for example, various vehicle parts such as a cylinder head, a cylinder block, a piston, and various components such as mechanical parts, structures, and the like. In this case, the sprayed component is not limited to the electrode component 60, and may be a protective film, a heat insulation film for the various components mentioned above, a film for corrosion prevention and rust prevention of the structure, a film for improving wear resistance and heat resistance, and other components corresponding to various purposes. In addition, it is also possible that there is no fixed component and the sprayed component is not fixed to the fixed component. In this case, the sprayed position includes only the sprayed component, and the spraying material is sprayed only on the sprayed component.

[0119] (D2) In the above-mentioned embodiments, an example is shown in which the first position PT1 and the second position PT2 are equidistant from the tool through hole 242. In contrast, the first position PT1 and the second position PT2 do not need to be configured to be equidistant from the tool through hole 242, and can be set at any position on the premise that the second wiring 62 can be supported at two points.

[0120] (D3) In the above-mentioned embodiments, the masking tool facing surface 100S is an example of a curved surface. On the other hand, the masking tool facing surface 100S is not limited to a curved surface, and may be a flat surface parallel to the back surface BP.

[0121] (D4) In the first embodiment, the example in which the supporting protrusion 250 includes the first supporting protrusion 251 and the second supporting protrusion 252 is shown, and in the second embodiment, the example in which the supporting protrusion 250b includes the first supporting protrusion 251b and the second supporting protrusion 252b is shown. In contrast, the supporting protrusion 250 may include only one of the first supporting protrusion 251 and the second supporting protrusion 252, and the supporting protrusion 250b may include only one of the first supporting protrusion 251b and the second supporting protrusion 252b.

[0122] The present disclosure is not limited to the above-mentioned embodiments, and can be implemented in various structures without departing from its purpose. For example, the technical features of the embodiments corresponding to the technical features in each method recorded in the invention content column can be appropriately replaced or combined in order to solve part or all of the above-mentioned problems, or to achieve part or all of the above-mentioned effects. In addition, if the technical feature is not described as a necessary content in this specification, it can be appropriately deleted.

Claims

1. A masking tool used for spraying on a sprayed body, comprising: A first surface, used to be opposite to the spray-plated body; a second side, located on the opposite side to the first side; a tool through hole extending from the first surface to the second surface; as well as a supporting protrusion, which is provided at a position overlapping with the thermally sprayed object on the first surface, protrudes from the first surface, and is used to support the thermally sprayed object; The supporting protrusion includes a supporting protrusion front end surface having a surface shape corresponding to a surface shape of a fixed member, and the fixed member is an object to be fixed by thermal spraying the thermally sprayed body.

2. The masking tool according to claim 1, wherein: The supporting protrusion is disposed at least at a position including a first position near the tool through-hole and a second position on the opposite side of the first position across the tool through-hole.

3. The masking tool according to claim 2, wherein: The supporting protrusion includes a first supporting protrusion arranged at the first position and a second supporting protrusion arranged at the second position.

4. The masking tool according to claim 3, wherein: The first supporting protrusion includes a first top portion which is farthest from the first surface in a direction from the first surface toward the second surface. The second supporting protrusion includes a second top portion that is farthest from the first surface in a direction from the first surface toward the second surface.

5. The masking tool according to any one of claims 1 to 4, wherein: The first surface includes a positioning mechanism for arranging the thermally sprayed object at a predetermined position on the first surface at a position corresponding to the outer shape of the thermally sprayed object.

6. A masking tool unit, comprising: The masking tool of any one of claims 1 to 5; and a three-dimensional forming tool, which is used by pressing against the first surface, and has a masking tool facing surface facing the first surface and a receiving recessed portion capable of receiving the supporting protrusion; The housing recessed portion is formed in the masking tool facing surface in a range including the supporting protrusion and the tool through hole in a plan view when the three-dimensional forming tool is arranged on the first surface.

7. The masking tool unit according to claim 6, wherein: The opposite surface of the masking tool is a curved surface.

8. A masking tool unit according to claim 6 or 7, wherein: The masking tool includes a positioning mechanism that fits with a portion of the three-dimensional forming tool.

9. A method for spraying, wherein: A masking tool and a thermally sprayed body are prepared, wherein the masking tool has a first surface and a supporting protrusion, wherein the supporting protrusion is arranged near the tool through hole on the first surface, The thermally sprayed body is arranged to face the first surface in such a manner that at least a portion of the thermally sprayed body overlaps with the supporting protrusion. The thermally sprayed body disposed on the first surface is pressed toward the first surface, so that a three-dimensional shape protruding at a predetermined position where the thermal spraying material is sprayed on the thermally sprayed body is formed on the thermally sprayed body, The thermal spraying material is thermally sprayed from the tool through-hole toward the thermally sprayed body which is arranged on the first surface and formed into the three-dimensional shape.

10. The spraying method according to claim 9, wherein: The three-dimensional shape is formed on the thermally sprayed object by pressing at least a portion of the thermally sprayed object toward the first surface while the thermally sprayed object is stretched along the surface direction of the masking tool.

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