Method for manufacturing composite members and gauge

Abstract

To facilitate the joining of sheet metal. [Solution] The manufacturing method for the composite member includes the step of bending at least a portion of a plate-shaped first member 12 having protrusions 12c and 12d so that the surface on which the protrusions 12c and 12d are provided faces inward, thereby forming a folded portion 13. The manufacturing method for the composite member also includes the step of inserting the protrusions 12c and 12d into mounting holes 11a and 11b of a plate-shaped second member 11. Furthermore, the manufacturing method for the composite member involves pressing the folded portion 13 toward the surface on which the protrusions 12c and 12d are provided.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a composite member and a gauge.

Background Art

[0002] There is a process of joining plate-like members such as sheet metal. As a method of joining sheet metal, for example, there is spot welding in which the joining portion between sheet metals is locally heated and melted for joining.

[0003] As a technique related to sheet metal processing, for example, a hemming processing device for hemming a pair of sheet metals with the minimum number of processes reliably and firmly has been proposed. Also, for example, a sheet metal joining structure has been proposed that can relax the constraints on the space around the sheet metal to be joined.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] When joining sheet metal by spot welding, a large current flows. To pass such a large current, electrical work, addition of a device for cooling water, piping work, etc. also need to be carried out, so the preparation becomes complicated.

[0006] On one side, the present case aims to facilitate the joining of sheet metal.

Means for Solving the Problems

[0007] One proposal provides a method for manufacturing a composite member, comprising the steps of: bending at least a portion of a plate-shaped first member having a protrusion so that the surface on which the protrusion is provided faces inward to form a folded portion; inserting the protrusion into a mounting hole of a plate-shaped second member; and pressing the folded portion toward the surface on which the protrusion is provided. [Effects of the Invention]

[0008] According to one embodiment, the joining of sheet metal can be facilitated. [Brief explanation of the drawing]

[0009] [Figure 1] This figure shows a composite member according to the first embodiment. [Figure 2] This diagram shows the first and second components when the composite component is disassembled. [Figure 3] This diagram shows the process for forming the protruding part. [Figure 4] The diagram shows the preparation stage for forming the folded portion; (A) is a perspective view of the first member, lower mold, and upper mold, and (B) is a side view of the first member, lower mold, and upper mold. [Figure 5] The diagram shows the bending process that forms the folded portion; (A) is a perspective view of the first member, lower die, and upper die, and (B) is a side view of the first member, lower die, and upper die. [Figure 6] This diagram shows the preparation stage for joining the first and second members. (A) is a perspective view of the first member, the second member, and the lower mold, and (B) is a perspective view of the first member, the second member, and the lower mold from a different angle. [Figure 7] The diagram shows the protruding part inserted into the mounting hole. (A) is a perspective view of the first member, second member, and lower mold, and (B) is a perspective view of the first member, second member, and lower mold from a different angle. [Figure 8] The diagram shows the state before flat pressing. (A) is a perspective view of the first member, second member, lower die, and upper die, and (B) is a side view of the first member, second member, lower die, and upper die. [Figure 9]The diagram shows the state during flat pressing. (A) is a perspective view of the first member, second member, lower die, and upper die, and (B) is a side view of the first member, second member, lower die, and upper die. [Figure 10] This figure shows a gauge according to the second embodiment. [Figure 11] This diagram shows the handle and measuring components when the gauge is disassembled. [Figure 12] In the diagram showing the folded portion, (A) is a perspective view of the portion of the handle member where the folded portion is provided, and (B) is a perspective view of the portion of the handle member where the folded portion is provided, viewed from a different angle. [Figure 13] The diagram shows the preparation stage for forming the folded portion; (A) is a perspective view of the handle member, lower mold, and upper mold, and (B) is a side view of the handle member, lower mold, and upper mold. [Figure 14] The diagram shows the bending process that forms the folded-over portion. (A) is a perspective view of the handle member, lower die, and upper die, and (B) is a side view of the handle member, lower die, and upper die. [Figure 15] This diagram shows the preparation stage for joining the handle member and the measuring member. (A) is a perspective view of the handle member, measuring member and lower mold, and (B) is a perspective view of the handle member, measuring member and lower mold from a different angle. [Figure 16] The diagram shows the protruding part inserted into the mounting hole. (A) is a perspective view of the handle member, measuring member, and lower mold, and (B) is a perspective view of the handle member, measuring member, and lower mold from a different angle. [Figure 17] The diagram shows the state before flat pressing. (A) is a perspective view of the handle member, measuring member, lower die, and upper die, and (B) is a perspective view of the handle member, measuring member, lower die, and upper die from a different angle. [Figure 18] The diagram shows the state during flat pressing; (A) is a perspective view of the handle member, measuring member, lower die, and upper die, and (B) is a side view of the handle member, measuring member, lower die, and upper die. [Figure 19]A diagram showing a gauge, where (A) is a top view of the gauge and (B) is a cross-sectional view of the gauge. [Figure 20] A diagram showing how to use the gauge, where (A) is a diagram showing the unit to be measured by the gauge and (B) is a diagram showing the measurement by the gauge.

Embodiments for Carrying out the Invention

[0010] Hereinafter, the present embodiment will be described with reference to the drawings. Note that the embodiments can be implemented in combination with a plurality of embodiments within a non - conflicting range. 〔First Embodiment〕 Hereinafter, a method for manufacturing a composite member according to the first embodiment will be described.

[0011] FIG. 1 is a diagram showing a composite member according to the first embodiment. The composite member 10 is a member in which a first member 12 and a second member 11 are joined. The first member 12 is a plate - shaped member with a rectangular surface. The first member 12 is a foldable member, for example, sheet metal. The first member 12 has a folded - back portion 13 formed by being folded in half in the longitudinal direction.

[0012] The second member 11 is a plate - shaped member with one end formed in a semi - circular shape. The second member 11 is, for example, sheet metal. The second member 11 is sandwiched and fixed by the surface of the first member 12 that is not the folded - back portion 13 and the folded - back portion 13 so that the semi - circularly formed end is exposed. Note that the first member 12 is thicker than the second member 11. For example, the thickness of the first member 12 is 1.0 mm. Also, for example, the thickness of the second member 11 is 0.1 mm.

[0013] Figure 2 shows the first and second members when the composite member is disassembled. Protrusions 12c and 12d are provided on the surface of the first member 12 that is not the folded portion 13. The protrusions 12c and 12d are cylindrical and are formed by extruding the first member 12 through a partial punching process. The height of the protrusions 12c and 12d is, for example, 50-60% of the thickness of the first member 12 (i.e., 0.5-0.6 mm).

[0014] The second member 11 is provided with mounting holes 11a and 11b. The mounting holes 11a and 11b are holes for attaching the second member 11 to the first member 12 by being inserted into the protrusions 12c and 12d. The mounting holes 11a and 11b are provided on the side opposite to the semicircular end.

[0015] The folded portion 13 is provided with relief holes 12a and 12b. The relief holes 12a and 12b are holes into which the protrusions 12c and 12d are inserted when the second member 11 is sandwiched between the surface of the first member 12 on which the protrusions 12c and 12d are provided and the folded portion 13.

[0016] The diameters of the mounting holes 11a, 11b and the relief holes 12a, 12b are larger than the diameters of the protrusions 12c, 12d. For example, the diameters of the protrusions 12c, 12d are 3.0 mm. Also, for example, the diameters of the mounting holes 11a, 11b are 3.1 mm. Also, for example, the diameters of the relief holes 12a, 12b are 3.5 mm. Note that there may be one of each of the protrusions, relief holes, and mounting holes, or there may be three or more of each.

[0017] Next, the manufacturing process of the composite member 10 will be described. First, the process of forming the protrusions 12c and 12d of the first member 12 will be described. Figure 3 shows the process of forming the protrusions. The protrusions 12c and 12d are formed when the first member 12 is partially punched by a punching machine. The punching machine includes a lower die 1 and an upper die 2. The lower die 1 is a base on which the member to be punched is placed. The lower die 1 has a flat top and a groove 1a. The groove 1a is a cylindrical groove provided so that the member on top of the lower die 1 is not punched through but only partially punched.

[0018] The upper die 2 descends from the top of the lower die 1 to punch the material placed on the lower die 1. The upper die 2 has a punch section 2a and a stripper section 2b. The punch section 2a is a cylindrical part for punching the material on top of the lower die 1 in a circular shape. The punch section 2a is positioned above the groove 1a. The stripper section 2b is a part provided around the punch section 2a to hold down the material on top of the lower die 1 when punching it.

[0019] In the partial punching process, first, the first member 12 is placed on the lower die 1. Next, the upper die 2 descends toward the lower die 1. As a result, the first member 12 is sandwiched and fixed between the stripper portion 2b and the lower die 1. Then, as the punch portion 2a descends further, a part of the first member 12 is pushed out along the groove 1a, forming a protrusion 12c. After that, the upper die 2 rises away from the lower die 1, and the first member 12 with the formed protrusion 12c becomes removable. The protrusion 12d is formed in the same way as the protrusion 12c. The relief holes 12a and 12b are formed by punching out the first member 12. The mounting holes 11a and 11b are formed by punching out the second member 11.

[0020] Next, the process of forming the folded portion 13 will be described. Figure 4 shows the preparation stage for forming the folded portion, where (A) is a perspective view of the first member, lower mold, and upper mold, and (B) is a side view of the first member, lower mold, and upper mold. The folded portion 13 is formed by folding the first member 12 using the lower mold 3 and upper mold 4. The lower mold 3 is a stand on which to place the member to be folded. The lower mold 3 has a flat top and a groove 3a. The groove 3a is formed in the shape of a right triangular prism with its height direction parallel to the horizontal plane.

[0021] The upper mold 4 bends the member placed on the lower mold 3 by descending from the top of the lower mold 3. The upper mold 4 is a member whose tip facing the lower mold 3 is formed in the shape of a right triangular prism. The upper mold 4 is installed so that the height direction of the right triangular prism at the tip is parallel to the height direction of the right triangular prism in the groove 3a.

[0022] In forming the folded portion 13, first, the first member 12, which is in a flat state, is placed on the lower mold 3 with the side having the protrusions 12c and 12d facing upwards. The first member 12 has relief holes 12a and 12b on one side when divided in the longitudinal direction, and protrusions 12c and 12d on the other side. The first member 12 is also positioned so that the short direction of the first member 12 is parallel to the height direction of the right triangular prism of the tip of the upper mold 4 and groove 3a.

[0023] Figure 5 shows the bending process that forms the folded portion, where (A) is a perspective view of the first member, lower die, and upper die, and (B) is a side view of the first member, lower die, and upper die. In the bending process, the upper die 4 descends toward the lower die 3 from the state shown in Figure 4. Then, the edge of the tip of the upper die 4 is pressed against the central part of the first member 12.

[0024] As a result, the first member 12 is bent into a V-shape along the bottom of the groove 3a so that the surfaces with the protrusions 12c and 12d face inward. The side of the V-shaped bent first member 12 with the relief holes 12a and 12b is then formed as the folded portion 13.

[0025] Next, the process of joining the first member 12 and the second member 11 will be described. Figure 6 shows the preparation stage for joining the first member and the second member, where (A) is a perspective view of the first member, the second member and the lower mold, and (B) is a perspective view of the first member, the second member and the lower mold from a different angle. The first member 12 and the second member 11 are joined by flat pressing with the second member 11 sandwiched between the surfaces provided with protrusions 12c and 12d and the folded portion 13. Flat pressing refers to sandwiching the member between the upper and lower molds, as shown in Figures 8 and 9, which will be described later.

[0026] First, the first member 12, which has the folded portion 13 formed thereon, is placed on the lower mold 5. The lower mold 5 is a platform with a flat top for placing the member to be flat-pressed. The first member 12 is positioned so that the back surface of the surface on which the protrusions 12c and 12d are provided is in contact with the top of the lower mold 5. The folded portion 13 is positioned at an angle to the top of the surface on which the protrusions 12c and 12d are provided. In the state shown in Figure 6, the protrusions 12c and 12d are inserted into the mounting holes 11a and 11b of the second member 11.

[0027] Figure 7 shows the state in which the protrusions are inserted into the mounting holes, where (A) is a perspective view of the first member, second member and lower mold, and (B) is a perspective view of the first member, second member and lower mold from a different angle. In the state shown in Figure 6, the second member 11 is positioned such that the protrusion 12c is inserted into the mounting hole 11a and the protrusion 12d is inserted into the mounting hole 11b. As a result, the second member 11 is positioned on the upper part of the surface of the first member 12 where the protrusions 12c and 12d are provided, and the folded portion 13 is positioned at an angle to the upper part of the second member 11. In this way, the mounting holes 11a and 11b of the second member 11 and the protrusions 12c and 12d of the first member 12 are provided, making it easy to position the second member 11.

[0028] In the first embodiment, the folded portion 13 is formed before inserting the protruding portions 12c and 12d into the mounting holes 11a and 11b. However, the protruding portions 12c and 12d may be inserted into the mounting holes 11a and 11b before forming the folded portion 13.

[0029] Figure 8 shows the state before flat pressing, where (A) is a perspective view of the first member, second member, lower die, and upper die, and (B) is a side view of the first member, second member, lower die, and upper die. The first member 12 and the second member 11 are joined by flat pressing by the lower die 5 and the upper die 6. The upper die 6 descends from the top of the lower die 5, flat pressing the members placed on the lower die 5. The upper die 6 has a flat bottom and is installed on top of the lower die 5 on which the first member 12 and the second member 11 are placed.

[0030] When flat pressing begins, the upper die 6 descends toward the lower die 5. The upper die 6 then strikes the folded portion 13, pressing it toward the surface where the protrusions 12c and 12d are located. Here, the upper die 6 presses the folded portion 13 so that the protrusions 12c and 12d are inserted into the relief holes 12a and 12b.

[0031] Figure 9 shows the state during flat pressing, where (A) is a perspective view of the first member, second member, lower die, and upper die, and (B) is a side view of the first member, second member, lower die, and upper die. When the upper die 6 presses the folded portion 13 against the second member 11, the first member 12 and the second member 11 are flat pressed by the lower die 5 and the upper die 6 with the second member 11 sandwiched between the surface provided with the protrusions 12c, 12d and the folded portion 13. Here, the flat pressing may continue until the thickness of the portion in which the second member 11 is sandwiched is equal to the sum of the thickness of the two first members 12 and the thickness of the second member 11, or until it is less than that sum.

[0032] In this way, a portion of the second member 11 is sandwiched between the folded portion 13 and the surface of the first member 12 on which the protrusions 12c and 12d are provided, thereby joining the second member 11 to the first member 12 and manufacturing the composite member 10. Furthermore, in the composite member 10, the protrusions 12c and 12d of the first member 12 are inserted into the mounting holes 11a and 11b of the second member 11, thereby firmly joining the first member 12 and the second member 11. Thus, the composite member 10 can be easily manufactured using only the first member 12, the second member 11, and a device for flat pressing. This manufacturing method for the composite member 10 makes it easy to join sheet metal.

[0033] [Second Embodiment] Next, a method for manufacturing the gauge according to the second embodiment will be described. Figure 10 shows a gauge according to a second embodiment. The gauge 20 is an instrument for measuring whether or not there is a gap greater than a predetermined value. The gauge 20 has a handle member 22 and a measuring member 21.

[0034] The handle member 22 is an elongated, plate-shaped member used as the handle portion of the gauge 20. The handle member 22 is a bendable member, for example, sheet metal. The handle member 22 has a folded portion 23 formed by partially cutting out a U-shape and folding the portion surrounded by the cut-out towards one end in the longitudinal direction.

[0035] The measuring member 21 is the part that is inserted into the measurement target location by the gauge 20. In the measurement using the gauge 20, if the measuring member 21 can be inserted, it is determined that there is a gap at the measurement target location that is greater than or equal to the thickness of the measuring member 21. If the measuring member 21 cannot be inserted, it is determined that there is no gap at the measurement target location that is greater than or equal to the thickness of the measuring member 21.

[0036] The measuring member 21 is a plate-shaped member with one end formed in a semicircular shape. The measuring member 21 is, for example, made of sheet metal. The measuring member 21 is fixed by being sandwiched between the non-folded portion 23 surface of the handle member 22 and the folded portion 23, so that the semicircular end is exposed.

[0037] The handle member 22 is thicker than the measuring member 21. For example, the thickness of the handle member 22 is 1.0 mm. Also, for example, the thickness of the measuring member 21 is 0.1 mm. In this case, the gauge 20 is used to measure whether or not there is a gap of 0.1 mm or more.

[0038] Figure 11 shows the handle and measuring components when the gauge is disassembled. Protrusions 22c and 22d are provided on one end of the handle 22 in the longitudinal direction. The protrusions 22c and 22d are cylindrical and are formed by extruding the handle 22 through a partial punching process. The height of the protrusions 22c and 22d is, for example, 50-60% of the thickness of the handle 22 (i.e., 0.5-0.6 mm).

[0039] The measuring member 21 is provided with mounting holes 21a and 21b. The mounting holes 21a and 21b are holes for attaching the measuring member 21 to the handle member 22 by being inserted into the protrusions 22c and 22d. The mounting holes 21a and 21b are provided on the opposite side from the semicircular end. The handle member 22 is also provided with a folded-over portion 23.

[0040] Figure 12 shows the folded portion, where (A) is a perspective view of the portion of the handle member where the folded portion is provided, and (B) is a perspective view of the portion of the handle member where the folded portion is provided, viewed from a different angle. The folded portion 23 is formed by bending the portion of the handle member 22 that is surrounded by the U-shaped cutout toward the side where the protrusions 22c and 22d are provided. The folded portion 23 is provided with relief holes 22a and 22b. The relief holes 22a and 22b are holes into which the protrusions 22c and 22d are inserted when the measuring member 21 is sandwiched between the surface of the handle member 22 where the protrusions 22c and 22d are provided and the folded portion 23.

[0041] The diameters of the mounting holes 21a, 21b and the relief holes 22a, 22b are larger than the diameters of the protrusions 22c, 22d. For example, the diameters of the protrusions 22c, 22d are 3.0 mm. Also, for example, the diameters of the mounting holes 21a, 21b are 3.1 mm. Also, for example, the diameters of the relief holes 22a, 22b are 3.5 mm. Note that there may be one of each of the protrusions, relief holes, and mounting holes, or there may be three or more of each.

[0042] Furthermore, the protrusions 22c and 22d are formed in the same manner as the protrusions 12c and 12d shown in the first embodiment. Also, the mounting holes 21a and 21b are formed in the same manner as the mounting holes 11a and 11b shown in the first embodiment. Furthermore, the relief holes 22a and 22b are formed in the same manner as the relief holes 12a and 12b shown in the first embodiment.

[0043] Next, we will explain the manufacturing process of the gauge 20. First, we will explain the process of forming the folded portion 23. Figure 13 shows the preparation stage for forming the folded portion, where (A) is a perspective view of the handle member, lower die, and upper die, and (B) is a side view of the handle member, lower die, and upper die. The folded portion 23 is formed by bending the handle member 22 using the lower die 31 and upper die 32. The lower die 31 is a stand on which to place the member to be bent. The lower die 31 has a flat top and a groove 31a. The groove 31a is formed in the shape of a right triangular prism with its height direction parallel to the horizontal plane.

[0044] The upper mold 32 bends the member placed on the lower mold 31 by descending from the top of the lower mold 31. The upper mold 32 is a member whose tip facing the lower mold 31 is formed in the shape of a right triangular prism. The upper mold 32 is installed so that the height direction of the right triangular prism at the tip is parallel to the height direction of the right triangular prism in the groove 31a.

[0045] In forming the folded portion 23, first, the flat handle member 22 is placed on the lower mold 31 with the side having the protrusions 22c and 22d facing upward. The handle member 22 has protrusions 22c and 22d on one end in the longitudinal direction. The handle member 22 also has relief holes 22a and 22b located towards the center of the handle member 22, relative to the protrusions 22c and 22d. Furthermore, the handle member 22 is hollowed out in a U-shape to surround the relief holes 22a and 22b.

[0046] The handle member 22 is installed so that its shorter side is parallel to the tip of the upper mold 32 and the height direction of the right triangular prism of the groove 31a. The width of the handle member 22 in the shorter side of the U-shaped cutout is formed to be greater than the width of the lower mold 31.

[0047] Figure 14 shows the bending process that forms the folded portion, where (A) is a perspective view of the handle member, lower die, and upper die, and (B) is a side view of the handle member, lower die, and upper die. In the bending process, the upper die 32 descends toward the lower die 31 from the state shown in Figure 13. Then, the edge of the tip of the upper die 32 is pressed against the space between the start and end points of the U-shaped cutout in the handle member 22.

[0048] As a result, the part of the handle member 22 that is pressed against the tip of the upper mold 32 is bent into a V shape along the bottom of the groove 31a so that the surfaces with the protrusions 22c and 22d face inward. The portion of the V-shaped bent handle member 22 with the relief holes 22a and 22b is then formed as the folded portion 23. Furthermore, as the lower mold 31 passes through the window-like portion formed in the handle member 22 by the bending of the folded portion 23, the part of the handle member 22 opposite the end with the protrusions 22c and 22d rotates down to below the upper surface of the lower mold 31.

[0049] Next, the process of joining the handle member 22 and the measuring member 21 will be described. Figure 15 shows the preparation stage for joining the handle member and the measuring member, where (A) is a perspective view of the handle member, measuring member and lower mold, and (B) is a perspective view of the handle member, measuring member and lower mold from a different angle. The handle member 22 and the measuring member 21 are joined by pressing the measuring member 21 flat while sandwiched between the surface provided with protrusions 22c and 22d and the folded portion 23.

[0050] First, the handle member 22 with the folded portion 23 is placed on the lower mold 33. The lower mold 33 is a platform with a flat top for placing the member to be flat-pressed. The handle member 22 is positioned so that the back surface of the side with the protrusions 22c and 22d is in contact with the top of the lower mold 33. The folded portion 23 is positioned at an angle to the top of the side with the protrusions 22c and 22d. In the state shown in Figure 15, the protrusions 22c and 22d are inserted into the mounting holes 21a and 21b of the measuring member 21.

[0051] Figure 16 shows the state in which the protrusions are inserted into the mounting holes, where (A) is a perspective view of the handle member, measuring member and lower mold, and (B) is a perspective view of the handle member, measuring member and lower mold from a different angle. In the state shown in Figure 15, the measuring member 21 is positioned such that the protrusion 22c is inserted into the mounting hole 21a and the protrusion 22d is inserted into the mounting hole 21b. As a result, the measuring member 21 is positioned on the upper part of the surface of the handle member 22 where the protrusions 22c and 22d are provided, and the folded portion 23 is positioned at an angle to the upper part of the measuring member 21.

[0052] In the second embodiment, the folded portion 23 is formed before inserting the protruding portions 22c and 22d into the mounting holes 21a and 21b. However, the protruding portions 22c and 22d may be inserted into the mounting holes 21a and 21b before forming the folded portion 23.

[0053] Figure 17 shows the state before flat pressing, where (A) is a perspective view of the handle member, measuring member, lower die, and upper die, and (B) is a perspective view of the handle member, measuring member, lower die, and upper die from a different angle. The handle member 22 and the measuring member 21 are joined by being flat pressed by the lower die 33 and the upper die 34. The upper die 34 lowers from the top of the lower die 33, flat pressing the member placed on the lower die 33. The upper die 34 has a flat bottom and is installed on top of the lower die 33 on which the handle member 22 and the measuring member 21 are placed.

[0054] When flat pressing begins, the upper die 34 descends toward the lower die 33. The upper die 34 then strikes the folded portion 23 and presses the folded portion 23 toward the surface on which the protrusions 22c and 22d are provided. Here, the upper die 34 presses the folded portion 23 so that the protrusions 22c and 22d are inserted into the relief holes 22a and 22b.

[0055] Figure 18 shows the state during flat pressing, where (A) is a perspective view of the handle member, measuring member, lower die, and upper die, and (B) is a side view of the handle member, measuring member, lower die, and upper die. When the upper die 34 presses the folded portion 23 against the measuring member 21, the measuring member 21 is sandwiched between the surface provided with the protrusions 22c and 22d and the folded portion 23.

[0056] In this manner, with the measuring member 21 sandwiched between the surface provided with protrusions 22c and 22d and the folded portion 23, the handle member 22 and the measuring member 21 are flattened by the lower die 33 and the upper die 34. Here, the flattening may continue until the thickness of the portion in which the measuring member 21 is sandwiched is equal to the sum of the thickness of the two handle members 22 and the thickness of the measuring member 21, or until it is less than that sum. In this way, the gauge 20 is manufactured.

[0057] Figure 19 shows a gauge, where (A) is a view of the gauge from above and (B) is a cross-sectional view of the gauge. Note that Figure 19(B) is a cross-sectional view taken along the line AA in Figure 19(A). In the gauge 20, one end of the measuring member 21 is fixed by being sandwiched between the surface on which the protrusions 22c and 22d of the handle member 22 are provided and the folded portion 23, and the other end, which is formed in a semicircular shape, is a free end, thus forming a cantilever beam shape.

[0058] As shown in Figure 19(B), the protrusions 22c and 22d of the handle member 22 are inserted into the mounting holes 21a and 21b. This prevents the measuring member 21 from coming off even if a force is applied to pull the measuring member 21 from the handle member 22, as the protrusions 22c and 22d catch on the mounting holes 21a and 21b. Thus, in the gauge 20, the handle member 22 and the measuring member 21 are firmly connected.

[0059] Furthermore, the protrusions 22c and 22d are inserted into the relief holes 22a and 22b. This prevents deformation of the folded portion 23 by allowing the protrusions 22c and 22d, which have penetrated the thin measuring portion 21, to pass through the folded portion 23 when the handle member 22 and measuring member 21 are flattened during the manufacturing of the gauge 20.

[0060] Furthermore, the diameters of the relief holes 22a and 22b are formed to be larger than the diameters of the protrusions 22c and 22d. Here, when the gauge 20 is manufactured, if it is flattened until the thickness of the portion in which the measuring member 21 is sandwiched is less than the sum of the thickness of the two handle members 22 and the thickness of the measuring member 21, the upper die 34 may be flattened while in contact with the protrusions 22c and 22d. In this case, the protrusions 22c and 22d may be crushed and deformed by the upper die 34. At this time, since the diameters of the relief holes 22a and 22b are larger than the diameters of the protrusions 22c and 22d, the deformed protrusions 22c and 22d can be contained in the relief holes 22a and 22b, preventing the shape of the folded portion 23 from being ruined.

[0061] According to this method of manufacturing the gauge 20, sheet metal can be easily joined using only a device for flat pressing. Next, the method of using the gauge 20 will be described. Figure 20 shows how to use the gauge, where (A) shows the unit to be measured by the gauge, and (B) shows the measurement using the gauge. The unit to be measured by the gauge 20 is a combination of the exterior cover 41 and the interior functional unit 42 shown in Figure 20(A).

[0062] The exterior cover 41 encloses the interior functional unit 42 on both sides, the rear, and the bottom with its walls. The exterior cover 41 has reference points 41a, 41b, and 41c. Reference points 41a, 41b, and 41c are members that adjust the distance between the walls of the exterior cover 41 and the interior functional unit 42. For example, reference points 41a and 41b are provided on the walls of the same side of the exterior cover 41, and reference point 41c is provided on the rear wall of the exterior cover 41.

[0063] Here, when the exterior cover 41 is attached to the interior functional unit 42, it is preferable that there is no gap between the references 41a, 41b, 41c and the interior functional unit 42. Therefore, as shown in Figure 20(B), the gauge 20 is used to measure whether or not there is a gap between the reference 41b and the interior functional unit 42. Note that in Figure 20(B), the wall surface on which the references 41a and 41b are provided is shown through.

[0064] First, in the measurement using the gauge 20, the measurer holds the handle member 22 of the gauge 20 and inserts the gauge 20 from the top of the interior function unit 42 between the interior function unit 42 and the wall surface of the exterior cover 41. When the measuring member 21 of the gauge 20 reaches the reference 41b, the measurer checks whether the measuring member 21 can be inserted between the interior function unit 42 and the reference 41b. If the measuring member 21 can be inserted between the interior function unit 42 and the reference 41b, it is determined that there is a gap of at least the thickness of the measuring member 21 (i.e., 0.1 mm) between the interior function unit 42 and the reference 41b. If the measuring member 21 cannot be inserted between the interior function unit 42 and the reference 41b, it is determined that there is no gap of at least the thickness of the measuring member 21 between the interior function unit 42 and the reference 41b.

[0065] Thus, the gauge 20 is used to determine whether or not there is a gap at a predetermined location. Other gauges for determining the presence or absence of a gap include elongated gauges that are thin overall (for example, with a thickness of 0.1 mm). However, with thin gauges, the handle portion bends between the handle and the tip for insertion into the object being measured, making it difficult to reach the object. On the other hand, the gauge 20 has a handle portion 22 that is thicker than the measuring member 21, making it easier to reach the object being measured with the measuring member 21.

[0066] Another possible gauge for determining the presence or absence of a gap is to join a thin tip (for example, a 0.1 mm thick member) to a thick handle (for example, a 1.0 mm thick member) by spot welding. However, spot welding a thin tip to a thick handle requires complicated preparations such as electrical work, the addition of cooling water equipment, and piping work to allow a large current to flow. In addition, it can be difficult to form a nugget diameter that provides sufficient welding strength when spot welding with a large plate thickness ratio. On the other hand, gauge 20 can be easily manufactured using only a flat pressing device.

[0067] Another possible gauge for determining the presence or absence of a gap is one in which a thin tip (for example, a 0.1 mm thick member) for insertion into the object to be measured is screwed onto a thick handle (for example, a 1.0 mm thick member). However, in a gauge where a thin tip is screwed onto a thick handle, the thickness of the screwed portion becomes the length of the screw, making it impossible to insert the handle into a narrow space. On the other hand, in gauge 20, the thickness of the thickest part is less than or equal to the sum of the thickness of the two handle members 22 and the thickness of the measuring member 21, making it easy to insert the handle member 22 into a narrow space.

[0068] Another gauge that can determine the presence or absence of a gap is one in which the tip of a long, slender member that is thick overall (for example, 1.0 mm thick) is thinned by machining (for example, machined to a thickness of 0.1 mm). However, in a gauge in which the tip of a thick member is thinned, the strength of the boundary between the machined part and the unmachined part is low, making the tip prone to breaking. On the other hand, in gauge 20, the measuring member 21 is sandwiched between the surfaces provided with the folded part 23 and the protruding parts 22c and 22d, and the protruding parts 22c and 22d are inserted into the mounting holes 21a and 21b, thereby firmly connecting the handle member 22 and the measuring member 21.

[0069] Although embodiments have been illustrated above, the configurations of each part shown in the embodiments can be replaced with others having similar functions. Furthermore, other arbitrary components or processes may be added. Moreover, any two or more configurations (features) from the embodiments described above may be combined. [Explanation of Symbols]

[0070] 1,3,5,31,33 Lower mold 1a,3a,31a Groove 2,4,6,32,34 Upper mold 2a Punch section 2b Stripper section 10 Composite members 11. Second Member 11a, 11b, 21a, 21b Mounting holes 12 First Member 12a, 12b, 22a, 22b relief holes 12c,12d,22c,22d protrusion 13,23 Folding section 20 gauge 21 Measuring components 22 Handle component 41 Exterior cover Criteria 41a, 41b, 41c 42 Interior Functional Units

Claims

1. A step of forming a folded portion by bending at least a part of a plate-shaped first member having a protruding portion so that the surface on which the protruding portion is provided faces inward, The process involves inserting the protruding portion into the mounting hole of the plate-shaped second member, A step of pressing the folded portion in the direction of the surface on which the protruding portion is provided, A method for manufacturing a composite member having [the same characteristics].

2. The folded portion is provided with a relief hole. In the step of pressing the folded portion toward the surface on which the protruding portion is provided, the folded portion is pressed so that the protruding portion is inserted into the relief hole. A method for manufacturing a composite member according to claim 1.

3. The aforementioned protrusion is cylindrical, The diameter of the relief hole is larger than the diameter of the protrusion. A method for manufacturing a composite member according to claim 2.

4. A handle member having a protruding portion and a folded portion formed by bending the surface on which the protruding portion is provided so that the surface faces inward, A plate-shaped measuring member having a mounting hole inserted into the protruding portion, with a portion of it sandwiched between the folded portion and the surface on which the protruding portion is provided, A gauge having

Images