Method for manufacturing fastening structure

Abstract

To provide a method for manufacturing a fastening structure that allows for easy release of fastening by rotating bodies such as bolts and nuts that fasten structures.SOLUTION: A manufacturing method of the present disclosure includes steps S10 and S6. The step S10 is a molding process in which a hardenable material 80, which hardens when predetermined conditions are met, is molded using a molding jig 100 into a predetermined shape including a portion that supports a release jig for releasing fastening by the rotating body 1, so that the side of the rotating body 1, which is a nut into which a bolt for fastening a structure is inserted, is buried. The step S6 is a hardening step for hardening the hardenable material 80 formed in the step S10 (molding process). In the step S10, the hardenable material 80 is placed around at least a portion of the periphery of the rotating body 1, and the hardenable material 80 placed around the periphery of the rotating body 1 is pressed against the molding jig 100, thereby molding the hardenable material 80 containing the rotating body 1 into the predetermined shape.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a fastening structure, a forming jig, and a method for releasing a fastening structure. [Background technology]

[0002] In order to protect the bolts and nuts that fasten structures, certain treatments are sometimes performed on the bolts and nuts. Patent Document 1 describes a bolt protection technology as follows: "A bolt head cap for rust prevention, having a closed upper end and an opening at the lower end, which covers the bolt head, wherein a base portion that covers the bolt head is connected to a base portion that covers a washer located below the bolt head, the base portion and the base portion are formed of a flexible material, and a lower end abutment portion is formed at the lower end of the base portion that abuts against the surface of the bolt fastening portion, and a circumferentially continuous annular rib is formed on at least one of the inner peripheral surface of the body portion and the inner peripheral surface of the base portion, which deforms by pressing against the outer peripheral surface of the bolt head or the washer, and a plurality of the ribs are arranged vertically at intervals." [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-127780 Summary of the Invention [Problem to be solved by the invention]

[0004] In the structure described in Patent Document 1, a cap is placed to cover the bolt head. The cap is made of a flexible material. Therefore, even if an attempt is made to rotate the cap using a release tool (such as a wrench) to release the fastening of the bolt, the force applied by the release tool escapes, making it impossible to rotate the bolt inside the cap. The problem to be solved by the present disclosure is to provide a method for manufacturing a fastening structure, a forming jig, and a method for releasing a fastening structure that can easily release fastening by rotating bodies such as bolts and nuts that fasten structures. [Means for solving the problem]

[0005] The method for manufacturing a fastening structure of the present disclosure includes a molding step of using a molding jig to mold a hardenable material that hardens when a predetermined condition is met, across a side surface of a rotating body that can fasten a structure by rotating in one direction and can release the fastening of the structure by rotating in the other direction, and at least a portion of the structure that faces the rotating body, into a predetermined shape that includes a portion that supports a release jig that releases the fastening by the rotating body, and a hardening step of hardening the hardenable material molded in the molding step. Other solutions will be described later in the description of embodiments of the invention. [Effects of the Invention]

[0006] According to the present disclosure, it is possible to provide a method for manufacturing a fastening structure, a forming jig, and a method for releasing a fastening structure, which can easily release fastening by rotating bodies such as bolts and nuts that fasten structures. [Brief explanation of the drawings]

[0007] [Figure 1] 10 is a flowchart illustrating a manufacturing method of the fastening structure of the present disclosure. [Figure 2] FIG. 2 is a side view of the fastening structure of the present disclosure. [Figure 3] FIG. 1 is a perspective view of a fastening structure of the present disclosure. [Figure 4] FIG. 10 is a top perspective view of the molding jig, showing a schematic diagram of a state in which the first fixing portion and the second fixing portion are released from contact with each other. [Figure 5] FIG. 5 is a bottom perspective view of the forming jig in the state shown in FIG. 4. [Figure 6] 5 is a top perspective view of the forming jig in the state of FIG. 4, seen from a direction different from that of FIG. 4. [Figure 7] FIG. 2 is a top perspective view of the molding jig, showing a schematic diagram of a state in which the first housing and the second housing are in contact with each other. [Figure 8] 8 is a bottom perspective view of the molding jig in the state of FIG. 7, and is a schematic diagram showing a state in which the first housing and the second housing are in contact with each other. [Figure 9] FIG. 2 is a top perspective view of the molding jig, and is a schematic diagram showing a state in which the molding jig is fixed to a rotating body. [Figure 10] 10 is a perspective view from below of the forming jig in the state of FIG. 9, and is a schematic diagram showing a state in which the forming jig is fixed to a rotating body. [Figure 11] 10 is a cross-sectional view of the forming jig in the state of FIG. 9, and is a schematic diagram showing a state in which the forming jig is fixed to a rotating body. [Figure 12] FIG. 1 is a process diagram showing the manufacturing method of the present disclosure using a molding jig, and is a schematic diagram showing a state in which the molding jig is positioned to sandwich a rotating body around which a hardenable material is arranged. [Figure 13] FIG. 1 is a process diagram illustrating a manufacturing method of the present disclosure using a molding jig, and is a schematic diagram illustrating the state in which the molding jig is pressed against a hardenable material. [Figure 14] FIG. 1 is a process diagram showing a manufacturing method of the present disclosure using a molding jig, and is a schematic diagram showing the state in which a curable material has been molded by the molding jig. [Figure 15] FIG. 1 is a perspective view of a hardenable material molded using a molding jig. [Figure 16] FIG. 10 is a cross-sectional view of a molded curable material according to another embodiment. [Figure 17] FIG. 10 is a perspective view of a fastening structure according to another embodiment. [Figure 18] FIG. 10 is a perspective view of a fastening structure according to yet another embodiment. [Figure 19] FIG. 2 is a perspective view showing a plurality of fastening structures arranged on a structure. [Figure 20] 10 is a flowchart illustrating a method for releasing the fastening structure of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0008] Hereinafter, modes for carrying out the present disclosure (hereinafter referred to as "embodiments") will be described with reference to the drawings. In the following description of one embodiment, other embodiments applicable to the one embodiment will also be described as appropriate. The present disclosure is not limited to the one embodiment described below, and different embodiments can be combined with each other or modified as desired without significantly impairing the effects of the present disclosure. Furthermore, the same components will be given the same reference numerals, and redundant descriptions will be omitted. Furthermore, components having the same functions will be given the same names. The contents shown are merely schematic, and for convenience of illustration, changes may be made from the actual configuration within the scope of not significantly impairing the effects of the present disclosure, and some components may be omitted or modified between drawings. Furthermore, the same embodiment does not necessarily have to include all of the configurations.

[0009] 1 is a flowchart illustrating a manufacturing method for a fastening structure 10 according to the present disclosure (hereinafter, appropriately abbreviated as the manufacturing method according to the present disclosure). The manufacturing method according to the present disclosure is a method for manufacturing a fastening structure 10 that allows for easy fastening and unfastening of a structure 50 by a rotating body 1. The manufacturing method according to the present disclosure is also a method for applying the fastening structure 10 to a structure 50 (FIG. 2), a method for protecting the rotating body 1, a method for arranging hard members, etc.

[0010] In this specification, the rotating body 1 is a nut into which the bolt 2 is inserted. However, the rotating body 1 is not limited to a nut and may be a bolt 2 or a stud bolt (not shown). In the case of a stud bolt, for example, a nut is inserted into each end of the stud bolt. The rotating body 1 of the present disclosure may be only one of the nuts arranged at both ends, or may be both nuts. Furthermore, the structure 50 is, for example, a structure such as a flange, but is not limited to this and may be, for example, a structure with an internal thread.

[0011] FIG. 2 is a side view of a fastening structure 10 according to the present disclosure. FIG. 3 is a perspective view of the fastening structure 10 according to the present disclosure. The fastening structure 10 is installed on a structure 50 and includes a rotating body 1, a bolt 2, and a hard member 3 that contains the rotating body 1 and the bolt 2. The rotating body 1 is a structure that can fasten the structure 50 by rotating it in one direction (e.g., counterclockwise) and can release the fastening of the structure 50 by rotating it in the other direction (e.g., clockwise). The hard member 3 preferably completely covers the entire rotating body 1 and the bolt 2, but does not necessarily have to completely cover the entire rotating body 1 and the bolt 2. It is sufficient that the hard member 3 contains the rotating body 1 to the extent that it covers at least the side surface 11 of the rotating body 1 (for example, at least a portion of the side surface 11 in the height direction is buried). The fastening and release can be achieved by rotating the rotating body 1 in a predetermined direction. However, it is preferable that the hard member 3 covers the entire side surface 11. This makes it possible to prevent water from entering the gap between the hardenable material 80 and the bolt 2 and causing crevice corrosion to progress even if the hardenable material 80 and the bolt 2 are slightly separated.

[0012] The hard member 3 is molded into a predetermined shape, such as a regular hexagonal prism, as will be described in detail later. Therefore, by covering the hard member 3 with a socket 60 having an inner surface of the predetermined shape and rotating the socket 60 using a release jig 70 (described later), such as a power tool, the rotating body 1 contained in the hard member 3 can be rotated. In other words, the rotating body 1 rotates together with the hard member 3 in a plane parallel to the extension direction of the structure 50. This allows the fastening to the structure 50 to be released.

[0013] When releasing the fastening, a holding jig (not shown) such as a wrench may be placed on a member (not shown) that supports the rotation of the rotating body 1 and is arranged on the opposite side of the release jig 70 (such as a power tool) that supports the hard member 3. This prevents the entire fastening structure 10 from rotating (co-rotating), allowing for easy release. Regarding the "member that supports rotation" here, for example, if the rotating body 1 is a nut, the member in question is, for example, the head of a bolt that is arranged on the opposite side of the nut across the structure 50 (such as a flange).

[0014] Returning to FIG. 1 , the manufacturing method of the present disclosure includes steps S1 to S6. Of these, steps S1 to S4 constitute step S10. Therefore, the manufacturing method of the present disclosure also includes step S10. Step S10 is a molding process in which a hardenable material 80 is molded into a predetermined shape using a molding jig 100, spanning the side surface 11 of the rotating body 1 and at least a portion of the surface of the structure 50 facing the rotating body 1. In the example of the present disclosure, the hardenable material 80 is disposed across the side surface 11 and the surface of the structure 50 that is near the rotating body 1 and around the outer periphery of the rotating body 1. The hardenable material 80 is molded to cover the side surface 11 and the structure 50. The predetermined shape is a shape that includes a portion that supports the release jig 70. The hard member 3 described above is formed by hardening the hardenable material 80. The release jig 70 is a jig (tool) for releasing the fastening by the rotating body 1, and is, for example, at least one of a pipe wrench, a wrench, a power tool, a socket 60 that can be rotated by a power tool, and the like.

[0015] The hardenable material 80 is a material that hardens when certain conditions are met. Therefore, the hardenable material 80 has plasticity when filled into the molding jig 100 (when placed, when the rotating body 1 is inserted), but loses its plasticity and changes into the hard member 3 when certain conditions are met. The hardness of the hard member 3 is not particularly limited, but it is preferably hard enough that the hard member 3 does not deform when rotated by the release jig 70. Specific examples of the hardenable material 80 include one-component or two-component epoxy putty, resins that harden when exposed to light such as ultraviolet light, materials that harden over time (concrete, plaster, etc.), and green sheets that harden by sintering.

[0016] In step S1, the hardenable material 80 is disposed on at least a portion of the circumference of the rotating body 1. The disposition can be performed, for example, by wrapping (disposing) a flat-shaped hardenable material 80 around the entire circumference of the rotating body 1. In this case, the hardenable material 80 is disposed on the entire circumference of the rotating body 1, but it may be disposed on only a portion of the circumference. The disposition can also be performed by disposing, for example, flat-shaped hardenable material 80 on each of one end and the other end in the radial direction of the rotating body 1 between the fixed part 101 (described later) and the rotating body 1. In this case, the hardenable material 80 is disposed on a portion of the circumference of the rotating body 1. Furthermore, when the hardenable material 80 is disposed between the fixed part 101 and the rotating body 1, it can be disposed in any one of the following forms: in contact with the fixed part 101 but not with the rotating body 1; in contact with the fixed part 101 but not with the rotating body 1; or in contact with neither the fixed part 101 nor the rotating body 1.

[0017] Step S2 is a process of placing the molding jig 100 at a predetermined position relative to the rotating body 1. In other words, step S2 is a process of placing the molding jig 100 so that the rotating body 1 fits between the housings 110 and 111. First, the structure of the molding jig 100 will be described, and then the curable material 80 will be described.

[0018] Fig. 4 is a top perspective view of forming jig 100, and is a schematic diagram showing a state in which fixing portion 102 (first fixing portion) and fixing portion 103 (second fixing portion) are released from contact with each other. Fig. 5 is a bottom perspective view of forming jig 100 in the state shown in Fig. 4. Fig. 6 is a top perspective view of forming jig 100 in the state shown in Fig. 4, seen from a direction different from that shown in Fig. 4.

[0019] The molding jig 100 is a molding jig that can be used in the manufacturing method of the present disclosure. The molding jig 100 is used when molding the hardenable material 80 that contains the rotating body 1. The molding jig 100 is a molding jig that can mold the hardenable material 80 after molding so that the central axes of the hardenable material 80 and the rotating body 1 are roughly aligned (or may be completely aligned), and can mold the hardenable material 80 so that even the part with the smallest thickness is preferably the minimum thickness necessary to rotate the rotating body 1. The molding jig 100 includes a fixing portion 101 and a wall portion 104. The molding jig 100 further includes a housing 110, a housing 111, and a housing 112.

[0020] The housing 110 and the housing 112 are fixed so as not to be able to move relative to each other via a pair of shafts 113. On the other hand, the housing 111 disposed between the housing 110 and the housing 112 is inserted through the shaft 113 and is able to move along the shaft 113 between the housing 110 and the housing 112. A drive unit 108 fixed to the housing 112 is connected to the housing 111.

[0021] Housing 110 is provided with fixed portion 102 of fixed portion 101, wall portion 104, roof 105, and handle 106. Housing 111 is provided with fixed portion 103 of fixed portion 101 and wall portion 104. Housing 112 is provided with drive unit 108. All of these are provided in forming jig 100 as described above.

[0022] The housing 110 has a semicircular shape with a recessed radial portion, and the wall portion 104 and the fixing portion 101 are provided on the inner wall of the recessed portion. The fixing portion 101 stands upright from the wall portion 104.

[0023] The fixing portion 101 is a structure (protrusion, convex portion) that supports at least one of the following: a portion of the side surface 11 of the rotating body 1 in the height direction; or a side surface 21 of the bolt 2, which is an example of a member that protrudes upward from the rotating body 1 and has an axis L2 aligned with the rotation axis L1 of the rotating body 1. In the example disclosed herein, the fixing portion 101 aligns the rotating body 1 by sandwiching (contacting) the rotating body 1 between the fixing portion 102 and the fixing portion 103. The alignment causes the rotation axis L1 to coincide with the central axis L3. However, as described above, the fixing portion 101 may also be a structure that supports the portion of the bolt 2 having the axis L2 that protrudes upward from the rotating body 1 (part of the bolt 2, the side surface 21). The fixing portion 101 allows the rotating body 1 to be positioned at the center of the multiple fixing portions 101, enabling alignment. Furthermore, the rotation axis L1 of the rotating body 1 coincides with the central axis L3 of the hardenable material 80, stabilizing rotation during release.

[0024] The fixed portion 101 includes a fixed portion 102 (first fixed portion) and a fixed portion 103 (second fixed portion) that is drivable (movable) relative to the fixed portion 102 and that is disposed opposite the fixed portion 102.

[0025] The fixing portion 101 has a shape corresponding to the rotating body 1, and supports the side surface 11 of the rotating body 1 by contacting with the side surface 11 of the rotating body 1. At this time, the forming jig 100 is fixed to the rotating body 1. In one embodiment, the rotating body 1 is a nut having the shape of a regular hexagonal prism, as described above.

[0026] The fixing portion 101 is provided on a portion of the wall portion 104 in the circumferential direction (the circumferential direction of the rotating body 1). In this manner, the portions where the fixing portion 101 is not provided can be filled with the hardenable material 80, thereby increasing the amount of hardenable material 80 filled and improving the strength of the hard member 3. In the example of the present disclosure, the fixing portion 101 includes four fixing portions 102, 103 having side shapes bent at an angle of 120° so that four of the six upper corners of the regular hexagonal prism can be fixed (supported, contacted). Of these, two fixing portions 102 are provided on the housing 110. The remaining two fixing portions 103 (second fixing portions) are provided on the housing 111. The fixing portion 103 is a structure that is provided on the housing 111, is drivable relative to the fixing portion 102, and is disposed opposite the fixing portion 102. The fixing portion 101 may be provided over the entire circumferential area of ​​the rotating body 1.

[0027] The wall portion 104 is a structure that is arranged in the remaining portion (the remaining portion other than the installation location of the fixed portion 101) in the height direction of the rotating body 1, and is spaced apart from the side surface 11 of the rotating body 1 when fixed to the rotating body 1 by the fixed portion 101. Therefore, the wall portion 104 is arranged so as to surround the rotating body 1 on the side thereof.

[0028] The wall portion 104 has a shape similar to the overall shape of the side surface 11 of the rotating body 1, and in the illustrated example, is a regular hexagonal prism that is larger than the dimensions of the rotating body 1. Specifically, the wall portion 104 provided on the housing 110 and the wall portion 104 provided on the housing 111 form the wall portion 104 that is a regular hexagon in top view. Therefore, the wall portion 104 provided on the housing 110 forms a semi-regular hexagon cut so as to pass through two opposing corners of the six corners, and the wall portion 104 provided on the housing 111 forms the remaining semi-regular hexagon.

[0029] However, the shape of the wall portion 104 (i.e., the hard member 3) does not need to be similar to the shape of the side surface 11 of the rotating body 1. For example, if the shape of the side surface 11 of the entire rotating body 1 is not a general-purpose shape, a dissimilar shape is preferable. That is, for example, by molding the hardenable material 80 into a shape (e.g., the side surface shape of a regular hexagonal prism) into which a general-purpose socket 60 can be fitted, the rotating body 1 can be easily rotated using a power tool.

[0030] The installation height of the fixing portion 101 on the wall portion 104 is, for example, the upper half in the height direction of the wall portion 104, but is not limited to this. As will be described in detail later, after the rotating body 1 is supported on the fixing portion 101, the hardenable material 80 is filled (placed) in the space 121 between the side surface 11 of the rotating body 1 and the wall portion 104.

[0031] Furthermore, the protruding height of the fixed portion 101 from the wall portion 104 is the same for all fixed portions 101. Therefore, all fixed portions 101 have the same shape. Therefore, when the fixed portion 102 (first fixed portion) and the fixed portion 103 (second fixed portion) support the side surface 11 of the rotating body 1, the distance between the wall portion 104 and the side surface 11 of the rotating body 1 is the same throughout the circumferential direction of the rotating body 1. By doing so, the thickness of the hard member 3 generated by hardening of the hardenable material 80 can be made the same throughout the circumferential direction. As a result, when rotating the hard member 3 from the outside with the release jig 70, it is easy to transmit force evenly throughout the entire rotating body 1, making it easy to rotate the rotating body 1.

[0032] However, the distance between the wall portion 104 and the side surface 11 of the rotating body 1 (the thickness of the hardenable material 80) does not need to be the same over the entire circumferential direction of the rotating body 1. That is, as will be described in detail later, as long as the hard member 3 has enough rigidity to rotate when rotated, the distance does not need to be the same.

[0033] The surfaces of the wall portion 104 and the fixed portion 101 (portions of the molding jig 100 that come into contact with the hardenable material 80) are treated to improve the releasability of the hardenable material 80. As described above, the hardenable material 80 is a material that hardens when certain conditions are met. By being treated to improve the releasability, the molding jig 100 can be easily removed after filling and molding with the hardenable material 80.

[0034] Specific examples of the process for improving releasability include providing a textured surface, or forming the surface from a material that has low affinity with the curable material 80. Examples of materials that have low affinity with the curable material 80 include polytetrafluoroethylene, polyethylene, wax, and oils. Further specific examples of the process for improving releasability include forming the surface from a water-containing material such as polyvinyl chloride, or applying a filler to the surface. Furthermore, adhesion of the curable material to the molding jig 100 may be suppressed by attaching a film (e.g., a disposable film) to the wall 104, removing the curable material 80 from the molding jig 100, and peeling the film off after curing.

[0035] The roof 105 is a structure provided on the molding jig 100 and covers a contact area 120 (described later) between the housing 110 (first housing) and the housing 111. Providing the roof 105 can prevent the hardenable material 80 from spilling over the contact area 120 to the outside. In the example of the present disclosure, there are two contact areas 120, and therefore the roofs 105 are provided in two locations.

[0036] The housing 110 is provided with a handle 106 on the side opposite to the side on which the structure 50 is placed, as viewed from the housing 110. This allows an operator to operate the drive unit 108 while gripping the handle 106, thereby bringing the housing 111 closer to the housing 110. In addition, it is possible to prevent the housing 110 from shifting from the center position of the rotating body 1 while operating the drive unit 108. Furthermore, after the hardenable material 80 is molded with the forming jig 100, the forming jig 100 can be opened to break the tight contact between the hardenable material 80 and the forming jig 100, making it easier to lift the forming jig 100. In addition, because the installation side of the handle 106 is upward as viewed from the structure 50, it is easy to distinguish between the top surface (the side on which the handle 106 is installed) and the bottom surface of the forming jig 100.

[0037] The driving unit 108 is a driving mechanism that brings the housing 110 having the fixed portion 102 into contact with or separates the housing 111 having the fixed portion 103 arranged opposite the fixed portion 102. The driving unit 108 is provided in the forming jig 100 and is, for example, a screw mechanism. By rotating the driving unit 108, the operator can change the relative position of the housing 111 with respect to the housing 110, and can bring the housing 111 into contact with the housing 110. The hardenable material 80 is filled into a space 121 formed between the housings 110 and 111.

[0038] The driving unit 108 has a structure capable of electrically driving the housing 111 (second housing). The housing 111 can be driven relative to the housing 110, for example, by the driving unit 108. By having a structure capable of being electrically driven, the housing 111 can be moved with a large torque in a state in which the hardenable material 80 is filled in the molding jig 100, and the hardenable material 80 can be molded.

[0039] As will be described in detail later with reference to FIG. 12 and the like, when the rotating body 1 is supported on the fixed part 101, the fixed part 102 supports the rotating body 1 first out of the fixed part 101 or the fixed part 102. Furthermore, of the side surfaces 1101 of the housing 110 (first housing), the side surface 1103 opposite the side surface 1102 on the side where the housing 111 (second housing) is installed includes a curved surface. This allows the housing 110 to be installed first to have a rounded shape, which increases the degree of freedom in installation compared to when it includes corners. For example, in the case of a structure 50 in which multiple rotating bodies 1 are arranged adjacent to each other or in the case of a structure 50 in which the rotating body 1 is arranged in a recessed location, the rotating body 1 can be easily inserted between the fixed part 102 and the fixed part 103 by appropriately rotating the housing 110.

[0040] Fig. 7 is a top perspective view of forming jig 100, and is a schematic diagram of a state in which housings 110 and 111 are in contact with each other. Fig. 8 is a bottom perspective view of forming jig 100, and is a schematic diagram of a state in which housings 110 and 111 are in contact with each other.

[0041] The housing 110 has a corner 107 at a location facing the housing 111. The corner 107 is located below the roof 105. The corner 107 is provided at a portion corresponding to a corner of a regular hexagon. Furthermore, the housing 111 has a protrusion 114 that gradually tapers toward the tip at a location facing the housing 110 (particularly the corner 107). The protrusion 114 abuts the corner 107. An abutment portion 120 between the corner 107 and the protrusion 114 is located below the roof 105. For this reason, the installer cannot see the abutment portion 120 from above. Furthermore, a space 121 that is closed around the periphery (however, it is open above and below) is formed between the housings 110 and 111. The rotating body 1 and the hardenable material 80 are placed in the space 121.

[0042] FIG. 9 is an upper perspective view of the forming jig 100, and is a schematic diagram showing the forming jig 100 fixed to the rotating body 1. FIG. 10 is a bottom perspective view of the forming jig 100, and is a schematic diagram showing the forming jig 100 fixed to the rotating body 1. FIG. 11 is a cross-sectional view of the forming jig 100, and is a schematic diagram showing the forming jig 100 fixed to the rotating body 1. For the sake of simplicity, the hardenable material 80 is not shown in FIGS. 9 to 11. Furthermore, for convenience of illustration, part of the structure of the forming jig 100 is omitted or modified in FIG. 11.

[0043] The forming jig 100 is fixed by bringing the fixing portion 101 of the forming jig 100 into contact with four of the six corners of the regular hexagonal prism of the rotating body 1. Then, when the forming jig 100 is fixed, the positioning and molding operations are completed simultaneously. Fixing is performed on roughly the upper half of the side surface 11 of the rotating body 1 (the fixing portion accounts for approximately 50% in the height direction). A space 121 is formed between the side surface 11 of the rotating body 1 and the wall portion 104. The hardenable material 80 is placed in the space 121 through an opening formed above the forming jig 100. In other words, the hardenable material 80 is present in the space 121 at this point. However, the hardenable material 80 may be placed first, and then the forming jig 100 may be installed from above.

[0044] 12 is a process diagram illustrating the manufacturing method of the present disclosure using a forming jig 100, and is a schematic diagram illustrating a state in which the forming jig 100 is arranged so as to sandwich the rotor 1 around which the hardenable material 80 is arranged. In FIGS. 12 to 14, the forming jig 100 is illustrated in a simplified form for the sake of simplicity.

[0045] As described above, in step S1, the hardenable material 80 is placed in contact with the rotating body 1 (which may be the molding jig 100). In the example of Fig. 12, the hardenable material 80 is placed over the entire circumferential area of ​​the rotating body 1. When placing the hardenable material 80, it is preferable to control the driving unit 108 so that the housing 111 is positioned at the farthest position from the housing 110.

[0046] The thickness of the hardenable material 80 to be placed is preferably the same over the entire circumferential direction of the rotating body 1. However, it is not necessary for the thickness to be completely uniform; for example, it is sufficient if the thickness is uniform to an extent that it appears to be the same to the worker when the hardenable material 80 is placed (wrapped) around the rotating body 1. For example, the hardenable material 80 may be a shapeless hardenable material 80 that is piled along the wall portions 104 using, for example, wet work gloves or a spatula, or the hardenable material 80 formed into a sheet shape having a predetermined thickness may be placed along each wall portion 104.

[0047] Furthermore, in step S10 (specifically, steps S1 and S2), the hardenable material 80 is preferably placed across the rotor 1 and the structure 50 so as to cover the side surface 11 of the rotor 1 and at least a portion of the structure 50. That is, the hardenable material 80 is preferably placed so as to reach the structure 50 placed below the forming jig 100, that is, so as to cover the rotor 1 from the top end to the base. This makes it possible to prevent foreign matter such as air or water from penetrating the gap formed between the rotor 1 and the surface of the structure 50, thereby suppressing deterioration such as rust, crevice corrosion, and the like.

[0048] In the example of the present disclosure, the hardenable material 80 is arranged so as to be in contact with the rotating body 1, but it may also be arranged so as to be in contact with the molding jig 100 (e.g., the fixed portion 101) rather than the rotating body 1. In this case, for example, by placing two flat-plate-shaped hardenable materials 80 on each of the opposing fixed portions 102, 103 and placing the rotating body 1 between them, the hardenable material 80 can be molded around the rotating body 1.

[0049] Returning to FIG. 1, step S3 is a step of pressing the molding jig 100 against the hardenable material 80. Step S4 is a step of operating the drive unit 108 to tighten the molding jig 100 (bringing the housing 111 closer to the housing 110). By step S4, at least the side surface 11 of the hardenable material 80 is buried in the hardenable material 80, and the hardenable material 80 is molded into the predetermined shape on the side of the rotating body 1. In steps S3 and S4, the hardenable material 80 arranged around the rotating body 1 is pressed against the molding jig 100, and the hardenable material 80 containing the rotating body 1 is molded into the predetermined shape.

[0050] 13 is a process diagram illustrating the manufacturing method of the present disclosure using a forming jig 100, and is a schematic diagram showing the state in which the forming jig 100 is pressed against the hardenable material 80. The pressing can be performed, for example, by an operator pulling the entire forming jig 100 in a direction in which the housing 111 moves away from the rotating body 1. By pressing, the hardenable material 80 between the housing 110 and the rotating body 1 overflows outside the housing 110, for example, from the side of the housing 110.

[0051] FIG. 14 is a process diagram illustrating the manufacturing method of the present disclosure using the molding jig 100, and is a schematic diagram illustrating the state in which the hardenable material 80 has been molded by the molding jig 100. When the operator operates the drive unit 108, the housing 111 moves toward the rotating body 1. The housing 111 then abuts against the housing 110, forming an abutment area 120. The creation of the abutment area 120 causes the hardenable material 80 to be densely molded in the space 121 between the housings 110 and 111. At the same time, the side surface 81 of the hardenable material 80 is molded to the shape of the wall portion 104 of the housings 110 and 111. Furthermore, as described above, the distance between the side surface 11 and the wall portion 104 of the rotating body 1 is uniform throughout the circumferential direction of the rotating body 1. Therefore, the thickness of the hardenable material 80 is also uniform throughout the circumferential direction of the rotating body 1. Furthermore, the positioning of the rotating body 1 with respect to the entire hardenable material 80 is also performed.

[0052] Excess hardenable material 80 leaks into space 122 adjacent to space 121 as excess material 82. The leaked hardenable material 80 is removed as appropriate.

[0053] As in steps S1 to S4, in step S10 (molding step), for example, a predetermined thickness of hardenable material 80 is placed between the molding jig 100 and the rotating body 1. Then, by pressing the molding jig 100 against the hardenable material 80 placed around the rotating body 1, the hardenable material 80 containing the rotating body 1 is molded into the predetermined shape. In this way, it is easy to make the thickness of the hardenable material 80 formed around the rotating body 1 uniform.

[0054] The molding jig 100 is not limited to a type that sandwiches the rotating body 1 as in the example of the present disclosure, and may be, for example, a jig that molds the hardenable material 80 and the rotating body 1 in a single mold like a snowball (snowball maker type). The molding jig 100 may also be, for example, a jig that can be molded by arranging the molding jig to surround the rotating body 1, filling the interior with the hardenable material 80, and then removing the molding jig (a mold-removing type jig). Furthermore, the molding jig 100 may be a jig that can be molded by covering the hardenable material 80 containing the rotating body 1 with a molding jig with a closed top surface and removing the protruding portion (a die-cutting type jig).

[0055] Returning to FIG. 1 , in step S5, the operator removes the forming jig 100 from the hardenable material 80. Removal can be performed, for example, by the operator pulling up the handle 106. At the time of removal, the hardenable material 80 may be cured or uncured. That is, the hardenable material 80 may be cured inside the forming jig 100, or may be cured after being removed. In the present disclosure, after step S10 is completed, the forming jig 100 is removed before it is completely cured (it may be slightly cured).

[0056] 15 is a perspective view of a hardenable material 80 molded using a molding jig 100. In step S10 (molding process), the hardenable material 80 is molded into a shape having a pair of opposing flat surfaces, that is, side surfaces 81. In this way, the rotating body 1 can be rotated using a release jig 70 that sandwiches the pair of opposing flat surfaces, that is, side surfaces 81. In addition, a commonly available tool (general-purpose tool) can be used.

[0057] As described above, the shape of the wall portion 104 of the forming jig 100 becomes the shape of the side surface 81 of the hardenable material 80 (the side surface 31 of the hard member 3). Therefore, by forming the wall portion 104 into a desired shape such as a regular hexagon or a cylinder (described later), the shape of the side surface 11 of the hardenable material 80 and the hard member 3 can be formed into a desired shape such as a regular hexagonal prism or a cylinder. Note that the desired shape is not limited to these examples and may be, for example, a rectangular prism such as a square prism, an elliptical prism, a star shape, or the like. Furthermore, the surface of the hard member 3 may be provided with grooves, ribs, irregularities, or the like as appropriate to make it easier to hook the release jig 70.

[0058] In step S10 (molding step), the side surface 81 of the molded hardenable material 80 and the side surface 11 of the rotating body 1 are parallel to each other. By doing so, it is possible to minimize the amount of hardenable material 80 used and reduce the cost of the hardenable material 80. However, the side surface 81 and the side surface 11 do not have to be parallel to each other.

[0059] Furthermore, the thickness of the hardenable material 80 arranged along the side surface 81 is preferably thick enough that the hard member 3 produced by hardening of the hardenable material 80 has a degree of rigidity that allows it to withstand rotation by the release jig 70. In particular, depending on the type of hard member 3, there are hard members that can allow moisture to penetrate into the hard member 3 from the surface thereof when the structure 50 including the rotating body 1 is in use. For this reason, it is also preferable that the hard member 3 has a thickness that prevents moisture from penetrating into the rotating body 1 even if moisture penetrates into the hard member 3 when the structure 50 is in use.

[0060] Furthermore, in step S10, the hardenable material 80 is molded so that at least the portion of the side surface 81 that supports the release jig 70 is parallel to the rotation axis L1 of the rotating body 1. In the illustrated example, the release jig 70 (specifically, the socket 60) supports the entire side surface 81. By doing so, when rotating the rotating body 1 around the rotation axis L1, the release jig 70 can be hooked onto the side surface 81 that is parallel to the rotation axis L1, making it easier to rotate the rotating body 1. In particular, it is preferable that the rotation axis L1 of the rotating body 1 and the central axis L3 of the hardenable material 80 (the central axis, rotation axis, of the hard member 3) coincide or nearly coincide.

[0061] The rotation axis L1 is a line that passes through the center of rotation of the rotating body 1 when the release jig 70 is hooked onto the side surface 31 of the hard member 3 and rotates the rotating body 1, and extends in a direction perpendicular to the structure 50. If the hard member 3 is a cylinder, the rotation axis L1 is a line that passes through the center of the circle, and if the hard member 3 is a regular hexagonal prism, the rotation axis L1 is a line that passes through the center of the regular hexagon.

[0062] Furthermore, when the molding jig 100 is removed, the side surface 81 of the hardenable material 80 has a shape that generally corresponds to the shape of the side surface 11 of the rotating body 1 (for example, a similar shape). However, the hardenable material 80 is not present in the area where the fixing portion 101 was present. Therefore, the shape of the hardenable material 80 is a regular hexagonal prism corresponding to the rotating body 1, with four upper corners having notched portions 83 in the shape of the fixing portion 101, as shown in FIG. 15 . However, if the fixing portion 101 fixes (supports) the bolt 2, there may be cases where the notched portions 83 do not exist at the height of the rotating body 1.

[0063] Therefore, after removing the molding jig 100, it is preferable to fill (fill) the cutout portion 83 with hardenable material 80, preferably before the hardenable material 80 completely hardens. This makes it possible to make the thickness of the hardenable material 80 uniform in the height direction around the rotator 1. However, if the height of the fixing portion 101 is small relative to the height of the rotator 1 (for example, 50% or less, preferably 20% or less in height ratio), it is not necessary to fill the hardenable material 80.

[0064] Furthermore, when piling the cutout portion 83, it is preferable to piling the hardenable material 80 further in the height direction so as to also bury (enclose) the bolt 2 protruding above the rotor 1. By piling the hardenable material 80 further so as to bury the bolt 2, the structure shown in Fig. 2 above etc. (a structure in which the rotor 1 and bolt 2 are completely covered with a hard member) can be obtained. When piling the hardenable material 80 further in the height direction, it is preferable to piling it so as to have the same shape as the shape of the side surface 81 of the hardenable material 80 that has already been formed.

[0065] Returning to FIG. 1, step S6 is a hardening process for hardening the hardenable material 80 formed in step S10. Step S6 results in a fastening structure 10 (FIG. 2) in which at least the side surface 11 of the rotating body 1 is covered with a hard material. The specific hardening method is not particularly limited and may be determined appropriately depending on the type of hardenable material 80.

[0066] The fastening structure 10 can be applied to any application. For example, examples of the structure 50 on which the fastening structure 10 can be provided include pumps (for example, joints (flanges, etc.) between pipes), bridges (joints using high-strength bolts, etc.), ships (joints between hull parts, parts where structures are attached to hulls, etc.), plant facilities such as factories and power plants (joints between buildings and facilities in general, etc.), offshore structures (wind turbines, gas plants, etc.), dams (joints between parts of gate facilities, etc.), tunnels (parts where structures are attached to anchor bolts, exposed parts of nuts, etc.), etc.

[0067] The fastening structure 10 may be used in any environment. In particular, it is suitable for use in an environment where, for example, a metallic rotating body 1 may rust. This is because the fastening structure 10 suppresses corrosion (rust, etc.) of the rotating body 1. Corrosion also includes crevice corrosion that occurs, for example, between a bolt and a nut, or between the rotating body 1 and a structure 50. Therefore, the fastening structure 10 may be installed in an environment where salt-containing water (saltwater), such as seawater or brackish water, comes into direct contact with the fastening structure 10, or in an environment where it is exposed to an atmosphere containing saltwater vapor. Furthermore, the fastening structure 10 may be installed in an environment where it is exposed to corrosion-causing components (gas, liquid, or solid), such as natural environments such as acid rain, corrosive gases such as hydrogen sulfide in plant facilities, or artificial environments such as environments where antifreeze is sprayed on roads.

[0068] FIG. 16 is a perspective view of a molded hardenable material 80 according to another embodiment. In the example shown in FIG. 16, the hardenable material 80 is molded to be hollow. The bolt 2, which serves as a nut and supports the rotation of the rotating body 1, protrudes above the rotating body 1. The bolt 2 does not rotate even when the rotating body 1 rotates. The hardenable material 80 contacts the side surface 11 of the rotating body 1 but does not contact the bolt 2. That is, a space 85 is formed between the inner surface 84 of the hardenable material 80 and the bolt 2. The space 85 does not have to be hollow; it may be filled with a member other than the hardenable material 80. Therefore, the hardenable material 80 is molded to cover the rotating body 1 and the bolt 2 while not contacting the bolt 2 but contacting the side surface 11 of the rotating body 1. The hardenable material 80 is formed, for example, in a regular hexagonal prism or cylindrical shape on the sides of the rotating body 1 and the bolt 2, but has a hemispherical shape, for example, on the area generally above the bolt 2.

[0069] As described above, the fastening structure 10 is released by supporting the side of the hard member 3 with the release jig 70 and rotating the rotating body 1 from outside the hard member 3. Therefore, the hard member 3 also rotates as the rotating body 1 rotates. This is because the hard member 3 and the rotating body 1 are in contact (preferably in close contact) with enough strength to apply the force of the release jig 70 to the rotating body 1. Therefore, by molding the bolt 2, which does not rotate when the rotating body 1 rotates, so that it does not come into contact with the hardenable material 80, the hard member 3 does not come into contact with the bolt 2. As a result, when the hard member 3 is in contact with the bolt 2 during rotation, no force is required to peel the hard member 3 from the bolt 2 (to rotate against the contact force at the contact surface), and the rotating body 1 can be rotated with a light force.

[0070] Moreover, since both the rotating body 1 and the bolt 2 can be entirely covered with the hardenable material 80, the gap formed between the rotating body 1 and the bolt 2 can also be covered with the hardenable material 80. This makes it possible to prevent fluids (liquids, gases) from entering the gap, thereby suppressing crevice corrosion. Furthermore, as described above, the hardenable material 80 is arranged so as to cover the rotating body 1 and the structure 50, so the gap formed between the rotating body 1 and the structure 50 can also be covered with the hardenable material 80. Furthermore, the gap formed between the bolt 2 and the structure 50 can also be covered with the hardenable material 80. This makes it possible to prevent fluids (liquids, gases) from entering the gap, thereby suppressing crevice corrosion.

[0071] Although crevice corrosion can be prevented by simply filling the gaps, covering the entire surface is preferable because it provides a wider adhesive surface and the hardening material becomes one body, making it easier to prevent falling off. On the other hand, if the rotating body 1 and the structure 50 are made of dissimilar metals, covering only a portion of the rotating body 1 increases the likelihood of galvanic corrosion occurring when part of the structure 50 is exposed due to peeling of the coating, etc., so this is also preferable in terms of preventing this.

[0072] FIG. 17 is a perspective view of a fastening structure 10 according to another embodiment. In the embodiment shown in FIG. 17, in step S10 (FIG. 1, molding step), at least a portion (all of it in the illustrated example) of the hardenable material 80 is molded into a cylindrical shape. Therefore, at least a portion of the hard member 3 that has undergone step S6 also has a cylindrical shape. By providing a cylindrical hard member 3, the fastening of the rotating body 1 can be released by rotating the cylindrical portion using a release jig 70 such as a pipe wrench. In this case, the release jig 70 can rotate the hard member 3 by biting into the side surface 31 of the cylinder.

[0073] FIG. 18 is a perspective view of a fastening structure 10 according to yet another embodiment. In the embodiment shown in FIG. 18, similarly to the embodiment of the regular hexagonal prism shown in FIG. 2, in step S10 (molding step), the hardenable material 80 is molded into a shape having a pair of opposing flat surfaces, and the side surface 81 of the molded hardenable material 80 and the side surface 11 of the rotating body 1 are parallel to each other. Specifically, the hard member 3 obtained by hardening the hardenable material 80 has side surfaces 31 formed by connecting a semi-cylinder to two opposing surfaces of a rectangular prism, such as a rectangular parallelepiped. This structure allows the hard member 3 to be rotated by inserting the side surfaces 31, which are a pair of flat surfaces, into a release tool 70, such as a wrench, thereby rotating the rotating body 1. The side surfaces 31 (flat and curved) are also parallel to the rotation axis L1 of the rotating body 1.

[0074] FIG. 19 is a perspective view showing a plurality of fastening structures 10 arranged on a structure 50. As shown in FIG. 19, a plurality (e.g., a large number) of fastening structures 10 may be arranged on the structure 50. For this reason, it is preferable that the fastening structures 10 be released simply and quickly. Therefore, it is preferable to release the fastening structures 10 using a general-purpose socket 60 and a release jig 70 such as a power tool. Note that the socket 60 is used integrally with the power tool and is therefore part of the release jig 70. Therefore, the release jig 70 includes, for example, a power tool and a general-purpose socket 60 that can be rotated by the power tool. The general-purpose socket 60 is, for example, a socket for a power tool that can fit a regular hexagonal prism. Therefore, in the example of FIG. 19, the hard member 3 has the shape of a regular hexagonal prism. However, the socket 60 does not have to be used. If the socket 60 is not used, the release jig 70 is, for example, a general-purpose tool (spanner, wrench, etc.).

[0075] Fig. 20 is a flowchart illustrating a method for releasing a fastening structure 10 according to the present disclosure (hereinafter, appropriately referred to as the releasing method according to the present disclosure). Fig. 20 illustrates an example in which a plurality of fastening structures 10 shown in Fig. 19 are arranged. The releasing method according to the present disclosure includes steps S11 to S13.

[0076] In step S11, the sockets 60 (part of the release jig 70) are placed over each of the fastening structures 10. As a result, the release jig 70 supports the hard surfaces of the fastening structures 10 (for example, the side surfaces 31 of the hard members 3). Typically, the interior of the hard members 3 is also hard. Therefore, step S11 (supporting step) is a step in which the release jig 70 supports the fastening structures 10 with hard surfaces that are disposed across the side surfaces 11 of the rotating body 1 and at least a portion of the surface of the structure 50 facing the rotating body 1 and have the above-mentioned predetermined shape. In the illustrated example, the rotating body 1 is a nut. As described above, the release jig 70 is a jig that releases the fastening of the rotating body 1. The side surfaces 31 supported by the release jig 70 need only be supported to the extent that force is applied to the side surfaces 31 by the rotation of the release jig 70 during rotation in step S12, which will be described later, causing the rotating body 1 to rotate. That is, in step S11, it is preferable that there be no gap between the power tool and the socket 60, and between the socket 60 and the rotating body 1, but a gap that does not impede rotation is permissible.

[0077] In step S12, the socket 60 is rotated by the power tool. That is, step S12 (rotation step) is a step of rotating the fastening structure 10 (particularly the hard member 3) in the direction of releasing the fastening of the structure 50 while the fastening structure 10 is supported by the release jig 70 (a power tool such as a socket wrench, and the socket 60). This step releases the fastening structure 10, and the rotating body 1 loosens (step S13).

[0078] After step S13, the rotating body 1 such as a nut and the bolt are removed from the structure 50. There is a possibility that the hard member 3 is attached to the rotating body 1 and the bolt. Therefore, depending on the type of hard member 3 (hardenable material 80), the hard member 3 can be removed by a method such as boiling, dissolving with a solvent, or burning. In particular, the rotating body 1 and the bolt are small, so they can be easily removed. [Explanation of symbols]

[0079] 1 Rotating body 10 Fastening structure 100 molding jig 101 Fixed part 102 Fixed part (1st fixed part) 103 Fixed part (second fixed part) 104 Wall section 105 Roof 106 Handle 107 Corner 108 Drive unit 11 Side 110 cabinet (first cabinet) 111 Cabinet (Second Cabinet) 112 Case 113 Shaft 114 Convex part 120 Contact area 121 Space 122 Space 2 bolts 21 Side 3 Hard materials 50 Structures 60 sockets 70 Release jig 80 Curable materials 81 Side 82 Surplus materials 83 Cutout 84 inner surface 85 Space L1 rotation axis L2 axis L3 center axis S1 Step S10 Step (molding process) S11 Step (support process) S12 Step (Rotation Process) S13 Step S2 Step S3 Step S4 Step S5 Step S6 step (curing process)

Claims

1. a molding process in which a hardenable material that hardens when a predetermined condition is satisfied is molded using a molding jig into a predetermined shape including a portion that supports a release jig that releases the fastening by the rotor, the hardenable material being disposed across a side surface of a rotor that can fasten a structure by rotating in one direction and can release the fastening by rotating in the other direction, and at least a portion of a surface of the structure that faces the rotor; and a hardening step of hardening the hardenable material molded in the molding step. A method for manufacturing a fastening structure comprising:

2. In the molding step, at least a portion of the curable material is molded into a cylindrical shape. The method for manufacturing the fastening structure according to claim 1 .

3. In the molding step, the hardenable material is molded so that at least a portion of the side surface that supports the release jig is parallel to the rotation axis of the rotating body. The method for manufacturing the fastening structure according to claim 1 .

4. In the molding step, the hardenable material is disposed on at least a portion of the periphery of the rotating body, The hardenable material disposed around the rotating body is pressed against the molding jig, so that the hardenable material containing the rotating body is molded into the predetermined shape. A method for manufacturing the fastening structure according to any one of claims 1 to 3.

5. a fixing part that supports at least one of a part in the height direction of a side surface of a rotating body that can fasten a structure by rotating in one direction and can release the fastened structure by rotating in the other direction, or a side surface of a member that protrudes above the rotating body and has an axis that coincides with the rotation axis of the rotating body; a wall portion that is spaced apart from the side surface of the rotating body when the fixing portion is fixed to the rotating body. A molding jig characterized by:

6. a supporting step of supporting, with a releasing jig, a fastening structure with a hard surface having a predetermined shape, the fastening structure being disposed across a side surface of a rotating body that can fasten a structure by rotating in one direction and can release the fastening of the structure by rotating in the other direction and at least a part of a surface of the structure that faces the rotating body, and including a portion that supports a releasing jig that releases the fastening by the rotating body; a rotating step of rotating the fastening structure in a direction to release the fastening of the structure while the fastening structure is supported by the release jig. A method for releasing a fastening structure.

Images