Method for manufacturing wiring fasteners and method for manufacturing three-dimensional objects

Abstract

To obtain a wiring fastener that can prevent contact between wiring materials and surrounding structures without using adhesive spacers. [Solution] The wiring fastener 100 of this disclosure comprises an adhesive portion 10 fixed to a structural member, a pair of space-securing portions 20 that rise from the side end of the adhesive portion 10 and have an opening 21 that is closed at least at the top, and a connecting portion 30 that connects the upper ends of the space-securing portions 20. Furthermore, in order to obtain the above wiring fastener 100, the manufacturing method of the wiring fastener in this disclosure comprises a molding step of molding a plurality of wiring fasteners 100 on a base plate, and a product separation step of separating the wiring fasteners 100 molded in the molding step by wire electrical discharge machining.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a wiring fixture and a method for manufacturing a three-dimensional object.

Background Art

[0002] As a conventional wiring fixture, Patent Document 1 discloses a fixture having a convex portion that is attached to a flat plate and has a height that secures a space between the bottom surface and the top surface.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the above-described conventional wiring fixture, there is a problem in that in order to prevent contact between the wiring material and the surrounding structure, it is necessary to adhere a spacer under the flat plate to increase the height.

[0005] The present disclosure has been made to solve the above-described problems, and an object thereof is to obtain a wiring fixture that can prevent contact between a wiring material and a surrounding structure without adhering a spacer.

Means for Solving the Problems

[0006] The method for manufacturing a wiring fixture according to the present disclosure manufactures a wiring fixture including a bottom plate portion, a space securing portion that stands up from a side end of the bottom plate portion and has an opening, and a connecting portion that connects an upper end of the space securing portion, by additive manufacturing in which conductive metal powder is sintered.

Effects of the Invention

[0007] The wiring fixture of the present disclosure can prevent contact between a wiring material and a surrounding structure without adhering a spacer. [Brief explanation of the drawing]

[0008] [Figure 1] This figure shows an example of how to use the wiring fastener in Embodiment 1. [Figure 2] This is a perspective view of the wiring fastener in Embodiment 1. [Figure 3] This is a side view of the wiring fastener in Embodiment 1. [Figure 4] This is a front view of the wiring fastener in Embodiment 1. [Figure 5] Figure 1 shows (a) a view of the wiring material from the axial direction and (b) a part of Figure 1. [Figure 6] This diagram shows the manufacturing flow of wiring fasteners. [Figure 7] Figure (a) shows an example of the molding process, and Figure (b) shows the layering direction. [Figure 8] This diagram shows the direction of wire movement during the product separation process. [Figure 9] This diagram shows an example of a product separation process. [Figure 10] This is a diagram showing a portion of Figure 8. [Modes for carrying out the invention]

[0009] Embodiments of this disclosure will be described below with reference to the drawings. In the following description, similar components will be denoted by the same reference numerals, and their names and functions will be the same or similar. Therefore, detailed descriptions of them may be omitted.

[0010] Embodiment 1. ***Explanation of the structure*** An example of using the wiring fixture 100 in Embodiment 1 will be described with reference to FIG. 1. FIG. 1 is a diagram showing an example of using the wiring fixture 100 in Embodiment 1. As shown in FIG. 1, the wiring fixture 100 is fixed to the structural member 200 via the adhesive 300. The wiring fixture 100 has opposing openings 21. Also, a wiring material 400 is placed on the wiring fixture 100. Furthermore, the wiring fixture 100 and the wiring material 400 are fixed by a binding band 500 passing through the opening 21.

[0011] Also, the material of the wiring fixture 100 is, for example, metal. When the wiring fixture 100 is manufactured from a metal material, the adhesive 300 may be conductive. Also, when the wiring fixture 100 is manufactured from a metal material, the wiring fixture 100 may be manufactured using a metal 3D printer.

[0012] FIG. 2 is a perspective view of the wiring fixture 100 in Embodiment 1. The wiring fixture 100 has an adhesive portion 10, a space securing portion 20, and a connecting portion 30. Also, the adhesive portion 10, the space securing portion 20, and the connecting portion 30 are integrally formed.

[0013] The adhesive portion 10 has a flat lower surface and is fixed to the structural member 200. Also, the space securing portion 20 rises from the side end of the adhesive portion 10.

[0014] The space securing portion 20 consists of a pair of space securing portions 20a and 20b. The height of the upper part of the space securing portion 20 with respect to the adhesive portion 10 is determined by the positional relationship between the wiring material 400 and the structural member 200 and other structures.

[0015] Also, the space securing portions 20a and 20b have an opening 21 with a closed cross-section. FIG. 3 is a side view of the wiring fixture 100 in Embodiment 1. As shown in FIG. 3, the opening 20 includes linear straight portions 211a and 211b at the upper and lower parts. Also, the opening 20 includes beam portions 212a and 212b connecting the straight portions 211a and 211b.

[0016] The beam portions 212a and 212b have an angle of θ (described later) or less with respect to the straight portions 211a and b. θ is the angle of the beam portions 212a and 212b with respect to the straight portion 211a, or the angle of the beam portions 212a and 212b with respect to the straight portion 211b. Also, θ is an angle at which the wiring fixture 100 can be formed without adding support when it is formed by a metal 3D printer, and is, for example, 45°. However, the angle formed by the straight portion 211 and the beam portion 212 (hereinafter referred to as the binding band fastening portion) has an R shape of R2 or more in R processing.

[0017] FIG. 4 is a front view of the wiring fixture 100 in Embodiment 1. The space securing portion 20 forms a hollowed-out portion 22 with a closed cross-section in the front direction of the wiring fixture 100. Also, the surface on which the hollowed-out portion 22 is formed, that is, the end face in the axial direction of the wiring material 400, stands perpendicular to the lower surface of the adhesion portion 10. That is, the space securing portions 20a and 20b form the hollowed-out portion 22 by a surface perpendicular to the surface on which the opening 21 is formed.

[0018] Here, when the wiring fixture 100 is manufactured by a metal 3D printer, it may be formed by laminating in a direction perpendicular to the two surfaces on which the hollowed-out portion 22 is formed, that is, the opposing flat surfaces.

[0019] Note that the opening 20 only needs to be closed at least at the upper part, and the lower part may be open. In this case, the portion of the adhesion portion 10 corresponding to the lower part of the opening 20 opens. Also, the beam portions 212a and 212b only need to have an angle of θ or less at the upper part of the opening 21, that is, the portion connected to the straight portion 211a, and the shape of the lower part connected to the straight portion 211b is not limited.

[0020] Returning to FIG. 2, the connection portion 30 connects the upper ends of the pair of space securing portions 20a and 20b. FIG. 5 is a view (a) of FIG. 1 seen from the axial direction of the wiring material 400 and a view (b) showing a part of FIG. 1. As shown in FIGS. 5(a) and 5(b), the connection portion 30 contacts the wiring material 400 by its contact surface 31 which is the upper surface.

[0021] The contact surface 31 may be curved in the direction of the adhesive portion 10. In that case, the radius of curvature of the contact surface 31 is equal to or smaller than the lower limit of the radius of the wiring material 400. Furthermore, the contact surface 31 has a sufficient arc length to make contact with the bundled wiring on the wiring material 400 at at least two points.

[0022] In other words, the wiring fastener 100 has an external shape in which a truncated pyramidal hexahedron outer wall surface is formed by combining an adhesive portion 10 which is a rectangular base plate portion, a space-securing portion 20 which has trapezoidal first and second side plate portions that rise from both short sides of the rectangular base and rectangular first and second inclined plate portions that rise from both short sides of the rectangular base, and a connecting portion 30 which is a top plate portion that connects the upper edges of the first and second side portions and the upper edges of the first and second inclined portions.

[0023] Furthermore, the aforementioned first and second side sections each have a trapezoidal cutout 22. In addition, the first and second inclined plate sections each have a cocoon-shaped opening 21. In other words, the first and second side sections form a space-retaining section 20b, and the first and second inclined plate sections form the space-retaining section 20a.

[0024] Thus, in a wiring fastener 100 comprising an adhesive portion 10 fixed to a structural member 200, a pair of space-retaining portions 20 that rise from the side ends of the adhesive portion 10 and have an opening 21 that is closed at least at the top, and a connecting portion 30 that connects the upper ends of the space-retaining portions 20, the wiring material 400 can be positioned at a point higher than the adhesive portion 10 that is in contact with the structural member 200 by passing a cable tie 500 through the opening 21 of the space-retaining portion 20 and fixing the wiring material 400. As a result, the wiring fastener 100 of Embodiment 1 has the effect of preventing contact between the structural member 200 and the wiring material 400 without having to adhere a spacer to the lower surface of the adhesive portion 10.

[0025] Furthermore, since the spacer is not glued when using the wiring fastener 100, the amount of work required can be reduced.

[0026] Furthermore, by changing the height of the upper part of the space-securing portion 20 relative to the adhesive portion 10 and using wiring fasteners 100 of different heights, the wiring fastener 100 of Embodiment 1 can prevent contact between the wiring materials 400 even when the wiring materials 400 are arranged in a crisscross pattern.

[0027] In addition, the connecting portion 30 connects to the upper end of the space-saving portion 20. As a result, the wiring fixing device 100 of Embodiment 1 can prevent damage to the wiring material 400 due to contact between the upper end of the space-saving portion 20 and the wiring material 400, compared to the case where the upper end of the space-saving portion 20 is open.

[0028] In addition, the space-retaining portion 20 rises from the side edge of the adhesive portion 10 and is formed integrally. As a result, compared to the case in which the space-retaining portion 20 is raised on a flat plate, the wiring fixing device 100 of Embodiment 1 can improve the mechanical strength of the adhesive portion 10 and the connecting portion of the space-retaining portion 20 that correspond to the contact area between the flat plate and the space-retaining portion 20.

[0029] For example, suppose a force is applied to the connection portion 30 in a direction perpendicular or horizontal to the adhesive surface of the adhesive portion 10 and the structural member 200. In this case, the wiring fastener 100 of Embodiment 1 experiences a larger load that causes plastic deformation at the connection portion between the adhesive portion 10 and the space-securing portion 20 compared to the case where the space-securing portion 20 does not rise from the side end of the adhesive portion 10.

[0030] When the wiring fastener 100 is manufactured integrally from a metal material, the wiring fastener 100 of Embodiment 1 can prevent static charge and outgassing of the wiring fastener 100 compared to when resin is used.

[0031] In addition, if the contact surface 31 of the connection part 30 has a curved shape, the wiring material 400 can be placed on it stably. As a result, the wiring fastener 100 of Embodiment 1 has the effect of improving workability during the fastening work with cable ties 500 and the reliability of the wiring fastener 100 during operation.

[0032] Furthermore, the corners formed by the cable tie fastening portion have an R shape of R2 or greater in the R processing. As a result, the wiring fastener 100 of Embodiment 1 can prevent damage to the cable tie 500 due to contact between the corners formed by the cable tie fastening portion and the cable tie 500 during the fastening work with the cable tie 500 and during the operation of the wiring fastener 100.

[0033] Furthermore, the surface on which the weight-reducing portion 22 is formed stands perpendicular to the lower surface of the adhesive portion 10. In addition, the beam portions 212a and 212b have an angle θ relative to the straight portions 211a and 211b that allows the wiring fastener 100 to be fabricated with a metal 3D printer without the need for additional supports. As a result, the wiring fastener 100 of Embodiment 1 can reduce the processing time compared to when adding supports to the space of the cable tie fastening portion when fabricating it with a metal 3D printer.

[0034] Furthermore, the formation of the weight-reducing portion 22 results in the wiring fastener 100 of Embodiment 1 being lighter than the one without the weight-reducing portion 22.

[0035] The adhesive portion 10 may be fixed to the structural member 200 without using the adhesive 300. For example, the adhesive portion 10 and the structural member 200 may be fixed together with a cable tie passed through the opening 21. Here, the cable tie used to fix the adhesive portion 10 and the structural member 200 is different from the cable tie 500 described above.

[0036] ***Explanation of Manufacturing Method*** Next, the manufacturing method of the wiring fastener 100 of Embodiment 1 will be explained with reference to Figure 6. Figure 6 is a diagram showing the manufacturing flow of the wiring fastener 100. The manufacturing method of this disclosure uses a 3D printer. First, as a molding process, multiple wiring fasteners 100 are molded using a 3D printer (Step 1).

[0037] Figure 7 shows an example of the fabrication process (a) and a diagram showing the layering direction (b). As shown in Figure 7(a), in the fabrication process, multiple wiring fixtures 100 are fabricated on the base plate 600. At this time, the base plate 600 is fabricated so that the surface on which the weight-reducing portion 22 of the wiring fixture 100 is formed is in contact with the base plate 600. That is, the wiring fixture 100 is fabricated so that the bottom surface of the base plate 600 and the axial direction of the wiring material 400 when the wiring material 400 is placed on the wiring fixture 100 are perpendicular.

[0038] Furthermore, within a plane parallel to the base plate 600, multiple wiring fixtures 100, i.e., multiple three-dimensional objects, are inclined in one arrangement direction and the other arrangement direction intersecting it. Adjacent three-dimensional objects are arranged with gaps between them in both the one and the other directions.

[0039] Furthermore, the wiring fasteners 100 may be stacked perpendicular to the bottom surface of the base plate 600, i.e., in the direction of arrow A in Figure 7(b). Here, the direction of arrow A is the vertical direction. Also, in Figure 7(a), n indicates the number of stacks, and in Figure 7(a) it is 2. n may be a number of 3 or more.

[0040] When stacking the wiring fasteners 100 in the direction of arrow A as described above, the stacking height is set to a height at which the wiring fasteners 100 located vertically downward, i.e., in the -A direction, do not deform due to the load of material powder spreading (recoating) during the molding process. If the maximum height of the 3D printer's molding device is lower than the height at which the wiring fasteners 100 do not deform, the stacking height may be set to the maximum height of the molding device.

[0041] Returning to Figure 6, in the product separation process, the wiring fixture 100 fabricated in the fabrication process is separated by wire electrical discharge machining (WEDM) (Step 2). Figure 8 shows the direction of wire travel in the product separation process. Figure 9 shows an example of the product separation process. Here, the bottom surface of the base plate 600 is parallel to the XZ plane in Figure 8.

[0042] In Figure 8, the wire moves in the direction of arrow B, which is the X direction. The Y direction is the front direction of the wiring fixture 100, that is, the axial direction of the wiring material 400 when the wiring material 400 is placed on the wiring fixture 100. The -Z direction is vertically downward. As the wire moves, the wiring fixture 100 is detached by the dashed line C in Figure 9.

[0043] Figure 10 is a diagram showing a portion of Figure 8. As shown in Figure 10, in the product separation process, the connection surfaces 31 of adjacent wiring fixtures 100 in the Z direction have a distance D between them in the X direction. The distance D is set based on the size, material, and wire electrical discharge machining conditions of the wiring fixtures 100 so that the wiring fixture 100 located in the -Z direction is separated first. The distance D is, for example, 1 mm.

[0044] Furthermore, as shown in Figure 10, adjacent wiring fasteners 100 in the Z direction during the product separation process have a distance E between them in the Z direction. The distance E is set so that, during the process of separating one wiring fastener 100, another wiring fastener 100 adjacent to that wiring fastener 100 in the Z direction does not get caught between that wiring fastener 100 and that other wiring fastener 100. If the distance between the adhesive portion 10 and the connection portion 30 of the wiring fastener 100 is distance F, then the relationship between distance E and distance F is, for example, E <Fである。

[0045] Furthermore, the manufacturing method disclosed herein is also applicable to three-dimensional objects other than the wiring fastener 100. In that case, in the manufacturing process, objects having opposing planes are stacked perpendicular to those planes, similar to the wiring fastener 100. The separation process is the same as for the wiring fastener 100.

[0046] Thus, in a method for manufacturing a wiring fastener, which includes a fabrication step of fabricating multiple wiring fasteners 100 on a base plate 600, and a product separation step of separating the wiring fasteners 100 fabricated in the fabrication step by wire electrical discharge machining, the wiring fasteners 100 are fabricated such that the bottom surface of the base plate 600 and the axial direction of the wiring material 400 when the wiring material 400 is placed on the wiring fastener 100 are perpendicular. Furthermore, the wiring fasteners 100 can be fabricated in a stacked manner perpendicular to the bottom surface of the base plate 600. This increases the number of parts that can be manufactured in one batch, resulting in the effect of reducing manufacturing costs.

[0047] Furthermore, in the product separation process, the spacing in the X direction between adjacent wiring fasteners 100 in the Z direction is set so that the wiring fastener 100 located vertically downward is separated first. As a result, the wiring fasteners 100 located vertically downward fall one by one. Consequently, the manufacturing method of the wiring fasteners 100 of this disclosure has the effect of preventing processing stoppages and processing defects caused by interference between parts, without the wiring fasteners 100 interfering with each other.

[0048] Furthermore, in the product separation process, the spacing in the Z direction between adjacent wiring fasteners 100 in the Z direction is set so that, before one wiring fastener 100 is separated, no other wiring fastener 100 is caught between that wiring fastener 100 and other wiring fasteners 100 adjacent to it in the Z direction. As a result, the manufacturing method of the wiring fastener 100 of this disclosure can prevent processing stoppages and processing defects caused by separated and fallen wiring fasteners 100 getting caught.

[0049] In addition, by fabricating the wiring fixture 100 using a 3D printer, the height of the space-saving portion 20 can be easily changed. As a result, the manufacturing method of the wiring fixture 100 of this disclosure can produce wiring fixtures 100 with different heights of the space-saving portion 20 in a single batch, thereby reducing manufacturing costs.

[0050] Furthermore, when using a metal 3D printer for fabrication, compared to fabricating each part individually using cutting or other methods, there is no need to prepare extrusions, castings, or sheet metal parts to accommodate differences in the height of the space-saving section 20, resulting in the advantage of lower manufacturing costs.

[0051] Furthermore, when using a metal 3D printer, complex shapes such as the R-shape of the cable tie fastening portion of the wiring fastener 100 can be easily manufactured using conductive materials, compared to machining or other manufacturing methods.

[0052] In the embodiments described herein, the materials and relative arrangements of the components may be described, but these are illustrative examples in all respects and are not limited to those described in each embodiment. Therefore, countless variations not illustrated are conceivable within the scope of each embodiment. For example, this includes modifying, adding, or omitting any component, or even extracting at least one component from at least one embodiment and combining it with a component from another embodiment. In other words, it is possible to freely combine each embodiment or modify or omit each embodiment as appropriate.

[0053] Furthermore, to the extent that it does not create a contradiction, a component described as being provided as "one" in each of the above embodiments may be provided as "one or more." In addition, each component is a conceptual unit, including cases where one component is composed of multiple structures, and cases where one component corresponds to a part of a structure.

[0054] The various aspects of this disclosure are summarized below as an appendix.

[0055] (Note 1) The bottom plate section, A space-securing portion that rises from the side edge of the bottom plate portion and has an opening, A connecting part that connects the upper end of the space-securing part, A wiring fixture equipped with this is manufactured by addition manufacturing, which involves sintering conductive metal powder. A method for manufacturing wiring fasteners. (Note 2) A fabrication process for creating multiple wiring fixtures having opposing planes on a base plate, A product separation process in which the wiring fixture formed in the molding process is separated by wire electrical discharge machining, A method for manufacturing a wiring fastener having the following characteristics. (Note 3) The manufacturing method according to Appendix 2, wherein the spacing of the wiring fasteners in the direction of wire travel during the product separation process is set such that the wiring fasteners located vertically downward are separated first. (Note 4) A method for manufacturing a wiring fastener according to Appendix 2 or 3, wherein in the product separation step, the distance between the wiring fastener and other vertically adjacent wiring fasteners is set such that the other wiring fasteners are not sandwiched between the wiring fastener and the other wiring fasteners. (Note 5) The method for manufacturing a wiring fastener according to any one of the appendices 2 to 4, wherein the molding step involves forming the wiring fastener by stacking materials in a direction perpendicular to the opposing planes. (Note 6) A method for manufacturing a wiring fastener according to any one of the appendices 2 to 5, wherein in the molding step, a plurality of wiring fasteners having a pair of space-saving portions with openings and different heights are molded on a single base plate. (Note 7) A process for creating multiple three-dimensional objects on a base plate, wherein one arrangement direction is inclined in the other arrangement direction that intersects with one arrangement direction, and the three-dimensional objects are created such that adjacent three-dimensional objects are arranged with gaps between them in one direction and the other direction. A product separation process in which the molded object formed in the molding process is separated by wire electrical discharge machining, A method for manufacturing a three-dimensional object having [a specific characteristic]. [Explanation of symbols]

[0056] 100 Wiring fasteners, 200 Structural members, 300 Adhesive, 400 Wiring material, 500 Cable ties, 600 Base plate, 10 Adhesive parts, (20, 20a, 20b) Space-saving parts, 21 Openings, (211, 211a, 211b) Straight parts, (212, 212a, 212b) Beam parts, 22 Weight-reducing parts, 30 Connection parts, 31 Adhesive surfaces

Claims

1. The bottom plate section, A space-securing portion that rises from the side edge of the bottom plate portion and has an opening, A connecting part that connects the upper end of the space-securing part, A wiring fixture equipped with this is manufactured by addition manufacturing, which involves sintering conductive metal powder. A method for manufacturing wiring fasteners.

2. A fabrication process for creating multiple wiring fixtures having opposing planes on a base plate, A product separation process in which the wiring fixture formed in the molding process is separated by wire electrical discharge machining, A method for manufacturing a wiring fastener having the following characteristics.

3. The manufacturing method according to claim 2, wherein the spacing of the wiring fasteners in the direction of wire travel during the product separation process is set such that the wiring fasteners located vertically downward are separated first.

4. The method for manufacturing a wiring fastener according to claim 2, wherein in the product separation step, the distance between the wiring fastener and other vertically adjacent wiring fasteners is set such that the other wiring fasteners are not sandwiched between the wiring fastener and the other wiring fasteners.

5. The method for manufacturing a wiring fastener according to claim 2, wherein the molding step involves forming the wiring fastener by stacking materials in a direction perpendicular to the opposing planes.

6. The method for manufacturing a wiring fastener according to claim 2, wherein in the molding step, a plurality of wiring fasteners having openings and space-saving portions of different heights are molded on a single base plate.

7. A process for creating multiple three-dimensional objects on a base plate, wherein one arrangement direction is inclined in the other arrangement direction that intersects with one arrangement direction, and the three-dimensional objects are created such that adjacent three-dimensional objects are arranged with gaps between them in one direction and the other direction. A product separation process in which the molded object formed in the molding process is separated by wire electrical discharge machining, A method for manufacturing a three-dimensional object having [a specific characteristic].

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