Masking jig, masking jig unit, thermal spraying method

Abstract

To provide a technology that can perform thermal spray while an object to be thermally sprayed is stabilized, in a masking jig that is used for thermal spray with respect to an object to be thermally sprayed.SOLUTION: A masking jig used for thermal spray with respect to an object to be thermally sprayed includes: a first surface facing an object to be thermally sprayed; a second surface located on an opposite side to the first surface; a jig through-hole penetrating from the first surface to the second surface; and a support projection provided in a position overlapping on an object to be thermally sprayed at the first surface, projecting from the first surface and supporting an object to be thermally sprayed.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present disclosure relates to a masking jig, a masking jig unit, and a thermal spraying method. [Background technology]

[0002] A technique is known in which an object to be sprayed is placed in a masking jig with through holes, and a spray material is sprayed from the through holes toward the object to be sprayed on a fixed member to fix the object to the fixed member (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2015-112534 A Summary of the Invention [Problem to be solved by the invention]

[0004] When spraying using a masking jig, if the spray material collides with the object to be sprayed, vibrations of the object may occur, and it may not be possible to deposit a sufficient amount of spray material on the object. [Means for solving the problem]

[0005] The present disclosure can be realized in the following forms.

[0006] (1) According to one aspect of the present disclosure, there is provided a masking jig for use in thermal spraying of a body to be thermally sprayed, the masking jig comprising a first surface for facing the body to be thermally sprayed, a second surface opposite to the first surface, a jig through-hole penetrating from the first surface to the second surface, and a support protrusion provided on the first surface at a position overlapping the body to be thermally sprayed and protruding from the first surface for supporting the body to be thermally sprayed. According to the masking jig of this embodiment, the object to be sprayed can be supported by the supporting protrusions in a state where it protrudes from the first surface. By spraying the object to be sprayed while being supported by the supporting protrusions, the object to be sprayed can be sprayed in a stable state, and the spray material can be sufficiently deposited on the object to be sprayed. (2) In the masking jig of the above embodiment, the support protrusion may be arranged at a position including at least a first position near the jig through hole and a second position on the opposite side of the jig through hole from the first position. With this type of masking jig, the object to be sprayed can be supported by the support protrusions on both sides of the jig through hole, which results in the object to be sprayed being sprayed in a more stable state, and the spray material can be sufficiently deposited on the object to be sprayed. (3) In the masking jig of the above aspect, the supporting protrusion may include a first supporting protrusion arranged at the first position and a second supporting protrusion arranged at the second position. With this form of masking jig, the object to be sprayed can be supported by the support protrusions on both sides of the jig through hole, while the area occupied by the support protrusions on the first surface can be reduced, and the support protrusions can be efficiently arranged on the first surface. (4) In the masking jig of the above embodiment, the first support convex portion may have a first apex that is furthest from the first surface in a direction from the first surface toward the second surface, and the second support convex portion may have a second apex that is furthest from the first surface in a direction from the first surface toward the second surface. With this form of masking jig, the object to be sprayed can be supported in a linear manner near the jig through hole, and when the masking jig is fixed onto the object during thermal spraying, the object to be sprayed is more easily pressed against the surface of the object, allowing the object to be sprayed in a more stable state. (5) In the masking jig of the above aspect, the supporting protrusion may have a tip surface of the supporting protrusion having a surface shape corresponding to a surface shape of a fixed member which is an object to which the sprayed body is fixed by thermal spraying. With this type of masking jig, the contact area between the supporting protrusions and the surface of the object to be fixed is increased, allowing thermal spraying to be carried out with improved adhesion between the body to be sprayed and the object to be fixed. (6) In the masking jig of the above aspect, the first surface may be provided with an alignment mechanism for positioning the object to be sprayed at a predetermined position on the first surface at a position corresponding to the outer shape of the object to be sprayed. With this type of masking jig, the object to be sprayed can be easily positioned at a predetermined position on the first surface. (7) According to another aspect of the present disclosure, there is provided a masking jig unit. The masking jig unit includes the masking jig of the above aspect, and a three-dimensional forming jig that is used by pressing it against the first surface, the three-dimensional forming jig having a masking jig facing surface that faces the first surface and an accommodating recess that can accommodate the support protrusion. The accommodating recess may be formed in the masking jig facing surface over a range that includes the support protrusion and the jig through hole in a plan view when the three-dimensional forming jig is disposed on the first surface. According to this embodiment of the masking jig unit, by accommodating the supporting protrusion in the accommodating recess, a three-dimensional shape protruding from the first surface can be easily formed in the object to be sprayed, thereby reducing or preventing contact of parts of the object to be sprayed other than the three-dimensional shape with members other than the masking jig unit, such as the fixed member. (8) In the masking jig unit of the above embodiment, the masking jig facing surface may be a curved surface. According to this form of masking jig unit, it is possible to reduce or suppress the occurrence of wrinkles and the like on the object to be sprayed when forming a three-dimensional shape on the object to be sprayed. (9) In the masking jig unit of the above aspect, the masking jig may include an alignment mechanism that fits with a part of the three-dimensional forming jig. According to this form of masking jig unit, the three-dimensional forming jig can be easily disposed at a predetermined position on the first surface. (10) According to another aspect of the present disclosure, there is provided a thermal spraying method, which includes preparing a masking jig having a first surface and a support protrusion disposed in the vicinity of a jig through hole on the first surface, and an object to be sprayed, disposing the object to be sprayed facing the first surface so that at least a portion of the object to be sprayed overlaps with the support protrusion, pressing the object to be sprayed disposed on the first surface toward the first surface to form a three-dimensional shape on the object to be sprayed in which a position where the thermal spray material is to be sprayed protrudes from the object to be sprayed, and spraying the thermal spray material through the jig through hole toward the object to be sprayed that is disposed on the first surface and has the three-dimensional shape formed thereon. According to the thermal spraying method of this embodiment, the object to be sprayed can be sprayed while being supported by the supporting protrusions, and the object to be sprayed can be sprayed in a stable state. Since the object to be sprayed has a three-dimensional shape, it is possible to reduce or prevent contact of parts of the object to be sprayed other than the three-dimensional shape with the masking jig or members other than the object to be sprayed. (11) In the thermal spraying method of the above aspect, the three-dimensional shape may be formed on the body to be sprayed by pressing at least a portion of the body to be sprayed against the first surface while pulling the body to be sprayed along the surface direction of the masking jig. According to this form of thermal spraying method, a three-dimensional shape is formed in the body to be sprayed while tension is being generated, thereby reducing or suppressing the occurrence of wrinkles, etc. in the body to be sprayed when forming the three-dimensional shape in the body to be sprayed. The present disclosure can also be realized in various forms other than the masking jig, the masking jig unit, and the thermal spraying method, for example, in the form of a three-dimensional forming jig, an electrically heated catalyst, a vehicle part, a method for manufacturing a vehicle part, a processing method for a vehicle part, a surface treatment method, a construction method, a method for forming a thermal sprayed film, a method for manufacturing a masking jig, a method for manufacturing a masking jig unit, a method for manufacturing an electrically heated catalyst, a method for manufacturing a vehicle part, etc. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a perspective view showing an external configuration of a masking jig according to a first embodiment of the present disclosure. [Diagram 2]FIG. 4 is a perspective view showing the configuration of an electrode member as an object to be sprayed. [Diagram 3] FIG. 4 is a perspective view showing the structure of a surface of a masking jig. [Figure 4] FIG. 4 is an explanatory diagram showing the structure of the back surface of the masking jig. [Diagram 5] 5 is a cross-sectional view of the VV position in FIG. 3 and FIG. 4 . [Figure 6] FIG. 4 is an explanatory diagram showing the external configuration of a three-dimensional forming jig. [Figure 7] FIG. 7 is a cross-sectional view taken along line VII-VII in FIG. [Figure 8] FIG. 2 is a flow diagram showing the thermal spraying method of the present embodiment. [Figure 9] FIG. 4 is a flow chart showing in detail a method for forming a three-dimensional shape on an electrode member. [Figure 10] FIG. 4 is an explanatory diagram showing an electrode member in a state where it is arranged on the back surface of a masking jig. [Figure 11] FIG. 13 is an explanatory diagram showing a state in which a three-dimensional forming jig is placed on a masking jig with an electrode member placed on the back surface thereof. [Figure 12] FIG. 11 is an explanatory diagram showing how a three-dimensional shape is formed on an electrode member by a three-dimensional forming jig. [Figure 13] FIG. 4 is an explanatory diagram showing a cross section of an electrode member in a state in which a three-dimensional shape is formed. [Figure 14] FIG. 2 is an explanatory diagram illustrating a thermal spraying method using the masking jig of the present embodiment. [Figure 15] FIG. 11 is a perspective view showing a masking jig according to a second embodiment. [Figure 16] FIG. 13 is a perspective view showing a supporting protrusion included in a masking jig according to a third embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] A. First embodiment: 1 is a perspective view showing an external configuration of a masking jig 200 according to a first embodiment of the present disclosure. The masking jig 200 is a flat plate-shaped member made of, for example, aluminum or an aluminum alloy. The masking jig 200 is used when spraying a thermal spray material onto a target body. The target body means an object onto which the thermal spray material is sprayed. The masking jig 200 is not limited to aluminum-based materials, and may be made of various metal materials such as iron-based materials, ceramic materials, and composite materials thereof.

[0009] As the thermal spray material, various materials such as metal, ceramics, plastic, and cermet can be used. In this embodiment, a powdered composite material in which a metal and a ceramic are mixed is used as the thermal spray material. The material of the thermal spray material is not limited to a powder, and may be a wire or a rod.

[0010] 1 shows a state in which the masking jig 200 is removed from the electrode member 60 serving as the body to be sprayed, in order to facilitate understanding of the technique. When spraying a thermal spray material onto the body to be sprayed, the masking jig 200 covers the surface of the body to be sprayed, thereby allowing the thermal spray material to pass through the jig through hole 242 while preventing the thermal spray material from adhering to unintended positions on the body to be sprayed. The masking jig 200 is used as a part of a masking jig unit together with a three-dimensional forming jig 100, which will be described later.

[0011] In this embodiment, the object to be sprayed is an electrode member 60 shown in Fig. 1. The electrode member 60 as the object to be sprayed is electrically connected to an electric surface electrode 460 provided on an electrically heated catalyst (EHC) 400. The electrically heated catalyst 400 is used, for example, to forcibly activate the catalyst by electrically heating, thereby improving the purification efficiency of exhaust gas. As the electrically heated catalyst 400, for example, a substantially cylindrical carrier having a honeycomb structure on which a catalyst such as platinum or palladium is supported is used.

[0012] The surface electrode 460 has a substantially rectangular planar shape, for example, as shown in FIG. 1. Although only one surface electrode 460 is shown in FIG. 1, a pair of surface electrodes 460 corresponding to an anode and a cathode are arranged on the outer surface of the electrically heated catalyst 400 so as to face each other. The electrode member 60 is fixed to the surface electrode 460 by a thermal spraying material. The object to which the sprayed body is fixed is also called a "fixed member". In this embodiment, the electrically heated catalyst 400 and the surface electrode 460 are examples of the fixed member. The electrode member 60 supplies power supplied from a power source (not shown) to the electrically heated catalyst 400 via the surface electrode 460. The electrically heated catalyst 400 may be the fixed member without using the surface electrode 460. In this case, the electrode member 60 may be fixed on the surface TP of the electrically heated catalyst 400. The shape of the surface electrode 460 is not limited to a rectangular shape and may be various shapes.

[0013] FIG. 2 is a perspective view showing the configuration of an electrode member 60 as a sprayed body. In this embodiment, the electrode member 60 functions as an anode of a pair of electrodes provided in the electrically heated catalyst 400. FIG. 2 shows the electrode member 60 in a manufactured state. The manufactured electrode member 60 has an approximately flat plate-like external shape, for example, as shown in FIG. 2. The thickness of the electrode member 60 is about 0.1 mm. The electrode member 60 is formed by die molding using a metal material such as a stainless steel alloy. The electrode member 60 is not limited to a stainless steel alloy, and may be formed using various metals, for example, various alloys such as a Ni alloy and a Co alloy. The electrode member 60 is not limited to an anode, and may be used as a cathode, or may be used as both an anode and a cathode.

[0014] 2, the electrode member 60 includes a first wiring 61 and a second wiring 62. The electrode member 60 has an elongated shape along one direction, and the first wiring 61 and the second wiring 62 are arranged in order along the extending direction. The first wiring 61 is a portion of the electrode member 60 that is directly or indirectly connected to a power source (not shown), such as a battery.

[0015] The second wiring 62 is a portion fixed to and electrically connected to the surface electrode 460 of the electrically heated catalyst 400. The second wiring 62 is formed continuously with the first wiring 61, and supplies power supplied from a power source (not shown), such as a battery, via the first wiring 61 to the surface electrode 460 of the electrically heated catalyst 400. In this embodiment, the second wiring 62 has 15 straight wirings 621 and has a so-called comb teeth-like external shape. The width of each wiring 621 of the second wiring 62 is, for example, about 0.5 to 1.0 mm.

[0016] In FIG. 2, the sprayed position PT is conceptually shown to facilitate understanding of the technique. The sprayed position means a planned position where the spray material is sprayed on the sprayed body. The sprayed position is set in advance. In this embodiment, the sprayed position PT is arranged on the second wiring 62. When the sprayed body is fixed to the fixed member by the sprayed material, the sprayed position includes a part of the fixed member. In this embodiment, the sprayed position PT includes a part of each wiring 621 of the second wiring 62 arranged on the surface electrode 460 and the surface electrode 460 around each wiring 621. The sprayed material is arranged over a part of each wiring 621 of the second wiring 62 and the surface electrode 460 around each wiring 621, so that the electrode member 60 is fixed to the surface electrode 460. The second wiring 62 and the wiring 621 are included in the sprayed body.

[0017] The positions of the sprayed positions PT are determined by the jig through holes 242 of the masking jig 200. That is, the number of the sprayed positions PT and their positions can be set arbitrarily depending on the number and arrangement of the jig through holes 242. In this embodiment, the number of the sprayed positions PT is 15, which is the same as the number of the wirings 621 of the second wiring 62. In other words, each of the 15 wirings 621 of the second wiring 62 is fixed on the surface electrode 460 by the spraying material. The sprayed positions PT are linearly arranged in the first row PL1 and the second row PL2. The first row PL1 has eight sprayed positions PT, and the second row PL2 has seven sprayed positions PT. The sprayed positions PT are arranged in a so-called staggered array, in which the sprayed positions PT are alternately arranged in the first row PL1 and the second row PL2.

[0018] 3 is a perspective view showing the structure of the front surface TP of the masking jig 200. The front surface TP of the masking jig 200 is the surface opposite to the surface facing the body to be sprayed, and is the surface facing the supply source of the thermal spray material (in this embodiment, the thermal spray nozzle 80 described later) when the thermal spray material is sprayed. In the masking jig 200, the surface facing the body to be sprayed, i.e., the back surface BP described later, is also called the "first surface," and the surface opposite to the surface facing the body to be sprayed, i.e., the front surface TP, is also called the "second surface."

[0019] The masking jig 200 has a jig through hole 242 and a recess 261. The jig through hole 242 is a through hole for passing a thermal spray material during thermal spraying. The jig through hole 242 penetrates the masking jig 200 from the front surface TP to the back surface BP of the masking jig 200, i.e., in the thickness direction. The thermal spray material passes through the jig through hole 242 and collides with the position to be thermal sprayed PT.

[0020] As shown in Fig. 3, the jig through holes 242 are provided in a number corresponding to the number of sprayed positions PT. In this embodiment, there are 15 jig through holes 242, which are linearly arranged in a first row JL1 corresponding to the first row PL1 of the sprayed positions PT and a second row JL2 corresponding to the second row PL2 of the sprayed positions PT. The first row JL1 has eight jig through holes 242, and the second row JL2 has seven jig through holes 242. The jig through holes 242 are arranged in a so-called staggered arrangement, in which the first row JL1 and the second row JL2 are alternately arranged in this order.

[0021] The recess 261 has an external shape that is concave from the outer edge toward the center of the masking jig 200. The width of the recess 261 is approximately the same as the width of the first wiring 61 of the electrode member 60. The recess 261 functions as a guide when bending the first wiring 61 in a direction away from the fixed member in order to connect the first wiring 61 to a power source after the electrode member 60 is fixed to the surface electrode 460 by a thermal spray material, for example.

[0022] 4 is an explanatory diagram showing the structure of the back surface BP of the masking jig 200. The back surface BP of the masking jig 200 is a surface on which the electrode member 60 is placed during thermal spraying, and is the surface facing the electrode member 60. A masking jig fitting portion 270, a sprayed object fixing portion 280, and a supporting protrusion 250 are formed on the back surface BP of the masking jig 200.

[0023] As described later, the masking jig fitting portion 270 is a recess that can fit into a part of the three-dimensional forming jig 100. In this embodiment, the masking jig fitting portion 270 is a recess that corresponds to the outer shape of the three-dimensional forming jig fitting portion 170 formed in the three-dimensional forming jig 100. When the three-dimensional forming jig 100 is used, the masking jig fitting portion 270 fits into the three-dimensional forming jig fitting portion 170 and functions as an alignment mechanism for locating the three-dimensional forming jig 100 in an initial position of the back surface BP of the masking jig 200.

[0024] The sprayed object fixing parts 280 function as an alignment mechanism for arranging the electrode member 60 at a predetermined position on the back surface BP of the masking jig 200 when placing the electrode member 60 on the back surface BP. In this embodiment, as shown in Fig. 4, the back surface BP is provided with four sprayed object fixing parts 280 corresponding to the four corners of the second wiring 62. If the electrode member 60 can be easily placed at a predetermined position on the back surface BP, the sprayed object fixing parts 280 do not need to be provided.

[0025] The support protrusion 250 formed on the back surface BP of the masking jig 200 will be described with reference to Fig. 5 together with Fig. 4. Fig. 5 is a cross-sectional view of the VV position in Fig. 3 and Fig. 4. In Fig. 5, the outer surface 400S of the electrically heated catalyst 400 is indicated by a solid line, and the position of the outer surface of the electrically heated catalyst 400 in contact with the masking jig 200 is indicated by a dashed line 400F. Note that the electrode member 60 and the surface electrode 460 are omitted from Fig. 5.

[0026] As shown in FIG. 4 and FIG. 5, the support protrusion 250 is a portion of the masking jig 200 that protrudes from the back surface BP of the masking jig 200 as the first surface. The support protrusion 250 is provided in the vicinity of the jig through hole 242, and supports a portion of the electrode member 60 in the vicinity of the jig through hole 242 when the thermal spray material is sprayed onto the electrode member 60. In this embodiment, a plurality of support protrusions 250 are provided. The plurality of support protrusions 250 are provided individually for each of the plurality of jig through holes 242 of the masking jig 200. The support protrusions 250 are provided in the same number as the number of the jig through holes 242 and the number of the wires 621 in order to support each of the wirings 621 of the second wiring 62 in the vicinity of each of the plurality of jig through holes 242.

[0027] In order to facilitate understanding of the technique, in Fig. 4, among the planned arrangement positions of the electrode member 60 on the back surface BP of the masking jig 200, the planned arrangement positions AP of the second wiring 62 are diagrammatically shown by dashed lines. The arrangement positions of the support protrusions 250 are included in these planned arrangement positions AP. More specifically, each of the support protrusions 250 is arranged at the planned arrangement positions of each wiring 621 of the second wiring 62 among the planned arrangement positions AP. As a result, the support protrusions 250 can support, at their tips, each wiring 621 arranged at the planned arrangement positions AP.

[0028] In this embodiment, the support protrusion 250 is disposed at a second position PT2 near the jig through hole 242 and on the center side of the back surface BP, and a first position PT1 near the jig through hole 242 and on the opposite side of the second position PT2 with the jig through hole 242 in between, among the planned arrangement positions AP of the second wiring 62. The first position PT1 and the second position PT2 are included in the range of the planned arrangement position AP. In this embodiment, the first position PT1 and the second position PT2 are equidistant from the jig through hole 242. The support protrusion 250 disposed at the first position PT1 is also called the "first support protrusion 251," and the support protrusion 250 disposed at the second position PT2 is also called the "second support protrusion 252." "Disposed at the first position PT1" means that the center of the first support protrusion 251 in a plan view is disposed at the first position PT1, and "disposed at the second position PT2" means that the center of the second support protrusion 252 in a plan view is disposed at the second position PT2. This allows the supporting protrusions 250 to support each of the wirings 621 included in the second wiring 62 at two points on either side of the jig through hole 242 .

[0029] 5, the first support protrusion 251 has a first support protrusion tip surface 251S at the tip, an inner wall surface 251F facing the jig through hole 242, and an outer wall surface 251E on the opposite side to the inner wall surface 251F. The second support protrusion 252 has a second support protrusion tip surface 252S at the tip, an inner wall surface 252F facing the jig through hole 242, and an outer wall surface 252E on the opposite side to the inner wall surface 252F. The inner wall surface 251F of the first support protrusion 251 and the inner wall surface 252F of the second support protrusion 252 face each other.

[0030] The positions where the first support protrusion 251 and the second support protrusion 252 are disposed relative to the jig through hole 242, i.e., the first position PT1 and the second position PT2, can be set arbitrarily. The positions of the first support protrusion 251 and the second support protrusion 252 relative to the jig through hole 242 can be set based on conditions such as the rigidity of the wiring 621, the type of spray material, the areas of the first support protrusion tip surface 251S and the second support protrusion tip surface 252S, and the spray amount and spray speed of the spray material, on the premise that the support protrusion 250 can adequately support the wiring 621. "The support protrusion 250 can adequately support the wiring 621" means that the support protrusion 250 can support the wiring 621 to an extent that it does not bend during spraying. "The supporting protrusion 250 can adequately support the wiring 621" includes the fact that the wiring 621 can be supported to the extent that it does not bend by being sandwiched between the supporting protrusion 250 and the electrically heated catalyst 400 during thermal spraying.

[0031] The first position PT1 and the second position PT2 may be set individually using the distance from the jig through hole 242 to the first position PT1 and the distance from the jig through hole 242 to the second position PT2, or may be set using the distance from the first position PT1 to the second position PT2. The distance from the first position PT1 to the second position PT2 is preferably close enough to sufficiently support the wiring 621. For example, as shown in FIG. 5, the first position PT1 and the second position PT2 are preferably arranged at positions included in a distance L1 that is three times the width W1 of the jig through hole 242 from the outer edge E1 of the jig through hole 242, and more preferably arranged at positions included in a distance L2 that is 1.5 times the width W1 of the jig through hole 242 from the outer edge E1 of the jig through hole 242. However, it is preferable that the distance L3 from the jig through hole 242 to the inner wall surface 251F of the first support convex portion 251 and the distance from the jig through hole 242 to the inner wall surface 252F of the second support convex portion 252 are far enough to prevent the thermal spray material from adhering to the support convex portion 250. The arrangement position of the second support convex portion 252 is similar to the arrangement position of the first support convex portion 251, and therefore a description thereof will be omitted. The first position PT1 and the second position PT2 are not limited to being equidistant from the jig through hole 242, and may be set at different distances from each other.

[0032] The first support protrusion tip surface 251S and the second support protrusion tip surface 252S are surfaces for supporting the wiring 621. As shown in FIG. 5, the first support protrusion tip surface 251S and the second support protrusion tip surface 252S have a surface shape corresponding to the surface shape of the outer surface 400S of the substantially cylindrical electrically heated catalyst 400. Specifically, the first support protrusion tip surface 251S and the second support protrusion tip surface 252S are formed as curved surfaces having substantially the same curvature as the curvature of the outer surface 400S. This is configured so that the contact area between the first support protrusion tip surface 251S and the outer surface 400S and the contact area between the second support protrusion tip surface 252S and the outer surface 400S are large. Note that the first support protrusion tip surface 251S and the second support protrusion tip surface 252S are not limited to curved surfaces and may be flat surfaces. When the first supporting protrusion tip surface 251S and the second supporting protrusion tip surface 252S are flat surfaces, it is preferable that the surface direction is arranged along the outer surface 400S from the viewpoint of increasing the contact area with the outer surface 400S. The first supporting protrusion 251 and the second supporting protrusion 252 may have various shapes such as a columnar shape, a flat plate shape, a cone shape, etc., and the first supporting protrusion tip surface 251S and the second supporting protrusion tip surface 252S may not be provided.

[0033] An outer wall surface 251E of the first support protrusion 251 is inclined with respect to a first support protrusion tip surface 251S. An outer wall surface 252E of the second support protrusion 252 is inclined with respect to a second support protrusion tip surface 252S. The outer wall surfaces 251E and 252E are also inclined with respect to the back surface BP. This configuration makes it easier for the wiring 621 to form a shape that conforms to the surfaces of the first support protrusion 251 and the second support protrusion 252 when a three-dimensional shape is formed, which will be described later.

[0034] When the position of the electrically heated catalyst 400 where the distance from the back surface BP of the masking jig 200 is the smallest is the top 400T shown in FIG. 5, the back surface recess 260 is provided at a position on the back surface BP facing the top 400T. The back surface recess 260 is omitted in FIG. 4. The back surface recess 260 is a recess formed on the back surface BP, and is formed continuously from the outer wall surface 252E of the second support protrusion 252. In a state where the electrode member 60 is fixed to the front surface electrode 460 by the thermal spray material, it is preferable that the electrode member 60 is separated from the outer surface 400S from the viewpoint of reducing or preventing an electrical short circuit between the electrode member 60 and the front surface electrode 460. In order to reduce or suppress contact between the wiring 621 when it has formed a three-dimensional shape, which will be described later, and the outer surface 400S near the top 400T, the distance from the tip surface 252S of the second support convex portion to the back surface BP is increased by the back surface recess 260, as shown as distance L4 in Figure 5.

[0035] The configuration of a three-dimensional forming jig 100 used in the thermal spraying method of this embodiment will be described with reference to Figures 6 and 7. Figure 6 is an explanatory diagram showing the external configuration of the three-dimensional forming jig 100. Figure 7 is a cross-sectional view taken along line VII-VII in Figure 6. The three-dimensional forming jig 100 includes a gripping portion 110 and a main body portion 120 having a masking jig facing surface 100S. As shown in Figure 7, the masking jig facing surface 100S is a curved surface having a predetermined curvature.

[0036] The three-dimensional forming jig 100 is used by pressing it against the back surface BP of the masking jig 200, and forms a three-dimensional shape on the electrode member 60 arranged on the back surface BP of the masking jig 200, more specifically, on the wiring 621 of the electrode member 60. The position where the three-dimensional shape is formed on the wiring 621 is a position near the sprayed position PT. The three-dimensional forming jig 100 is pressed against the back surface BP of the masking jig 200 so that the masking jig facing surface 100S faces the back surface BP of the masking jig 200. The three-dimensional forming jig 100 is used as a part of the masking jig unit together with the masking jig 200. Note that, for example, when the three-dimensional shape of the electrode member 60 is formed manually by an operator, the three-dimensional forming jig 100 may be omitted.

[0037] The gripping portion 110 is used to operate the three-dimensional forming jig 100 when forming a three-dimensional shape of the electrode member 60 on the back surface BP. By operating the gripping portion 110, the masking jig facing surface 100S rolls on the back surface BP of the masking jig 200 and comes into contact with the object to be sprayed on the back surface BP, thereby forming a three-dimensional shape in the electrode member 60.

[0038] As shown in FIG. 6 and FIG. 7, the masking jig facing surface 100S is provided with an accommodating recess 150, a three-dimensional forming jig protrusion 160, and a three-dimensional forming jig fitting portion 170. The accommodating recess 150 is a recess capable of accommodating the supporting protrusion 250. In this embodiment, the accommodating recess 150 is formed over a range including the first supporting protrusion 251, the second supporting protrusion 252, and the jig through hole 242 in a plan view. The accommodating recess 150 forms a three-dimensional shape in the wiring 621 by accommodating the supporting protrusion 250 in a state in which the supporting protrusion 250 supports the wiring 621. The accommodating recess 150 accommodates both the first supporting protrusion 251 and the second supporting protrusion 252 included in the supporting protrusion 250.

[0039] The three-dimensional forming jig protrusion 160 is a portion having approximately the same shape as the rear surface recess 260. The three-dimensional forming jig protrusion 160 fits into the rear surface recess 260 in a state in which the wiring 621 is supported, thereby forming the wiring 621 in a three-dimensional shape whose height is approximately the same as the separation distance L4.

[0040] The three-dimensional forming jig fitting portion 170 is a portion having a shape corresponding to the outer shape of the concave masking jig fitting portion 270 shown in FIG. 4. In this embodiment, the three-dimensional forming jig fitting portion 170 is a substantially cylindrical member. The three-dimensional forming jig fitting portion 170 is disposed at a position corresponding to the arrangement position of the masking jig fitting portion 270 on the masking jig facing surface 100S. The three-dimensional forming jig fitting portion 170 functions as a positioning mechanism when disposing the three-dimensional forming jig 100 at the initial position on the back surface BP of the masking jig 200 by fitting with the masking jig fitting portion 270. The three-dimensional forming jig fitting portion 170 is not limited to a cylindrical shape, and may be a sphere, a disk, an annular shape, or various shapes such as a prism or a polyhedron. In a case where the three-dimensional forming jig 100 can be easily disposed at the initial position on the back surface BP, the three-dimensional forming jig fitting portion 170 and the masking jig fitting portion 270 may be omitted.

[0041] FIG. 8 is a flow diagram showing the thermal spraying method of this embodiment. In step S10, the masking jig 200, the electrode member 60 as the object to be thermally sprayed, and the three-dimensional forming jig 100 are prepared. In step S20, the electrode member 60 is placed on the back surface BP of the masking jig 200. In step S30, the three-dimensional forming jig 100 is used to form a three-dimensional shape on the electrode member 60 placed on the back surface BP. In step S40, the masking jig 200 in a state in which the electrode member 60 with the three-dimensional shape formed is placed on the back surface BP is placed on the front surface electrode 460 of the electrically heated catalyst 400 as the fixed member. In step S50, the thermal spray material is sprayed from the front surface TP side of the masking jig 200 through the jig through hole 242 toward the electrode member 60. In step S60, when the thermal spray material solidifies and the electrode member 60 is fixed to the front surface electrode 460, the masking jig 200 is removed from the electrode member 60 fixed to the electrically heated catalyst 400. With the above, the thermal spraying method of this embodiment is completed.

[0042] FIG. 9 is a flow diagram showing in detail the method of forming a three-dimensional shape on the electrode member 60 as the object to be sprayed in step S30. In step S32, the three-dimensional forming jig 100 is placed on the back surface BP of the masking jig 200 with the electrode member 60 placed on the back surface BP. In step S34, tension is generated in the second wiring 62 of the electrode member 60 placed on the back surface BP along the surface direction of the masking jig 200. In step S36, the gripping portion 110 of the three-dimensional forming jig 100 is operated to press the electrode member 60 on the back surface BP so that the masking jig facing surface 100S rolls on the back surface BP of the masking jig 200. As a result, a three-dimensional shape is formed on the electrode member 60 as the object to be sprayed. These processes may be performed using a robot or a dedicated device, or may be performed by an operator.

[0043] 10 is an explanatory diagram showing the electrode member 60 in a state where it is arranged on the back surface BP of the masking jig 200. The electrode member 60 is in a state before a three-dimensional shape is formed by the three-dimensional forming jig 100, and each wire of the second wiring 62 is in a bent state while being supported by the first supporting protrusion 251 and the second supporting protrusion 252 due to its own weight.

[0044] In this embodiment, as shown in FIG. 10, the back surface BP is provided with four sprayed object fixing parts 280. The four sprayed object fixing parts 280 are arranged at positions corresponding to the four corners of the second wiring 62. When the electrode member 60 is arranged on the back surface BP of the masking jig 200, the sprayed object fixing parts 280 abut against the outer peripheral ends of the four corners of the second wiring 62. This configuration makes it possible to easily align the electrode member 60 with the back surface BP of the masking jig 200. As a result, it is possible to easily align the sprayed position PT of the electrode member 60 with the jig through hole 242 of the masking jig 200.

[0045] 11 is an explanatory diagram showing a state in which the three-dimensional forming jig 100 is placed on the masking jig 200 in a state in which the electrode member 60 is placed on the back surface BP. FIG. 11 shows a cross section of the masking jig 200 at the XI-XI position in FIG. 10 and a cross section of the three-dimensional forming jig 100 at a position corresponding to the position. The three-dimensional forming jig 100 is moved in a direction D1 toward the back surface BP of the masking jig 200 and pressed onto the back surface BP. At this time, the three-dimensional forming jig fitting portion 170 of the three-dimensional forming jig 100 is fitted into the masking jig fitting portion 270 of the masking jig 200, so that the three-dimensional forming jig 100 can be placed at a predetermined initial position on the back surface BP.

[0046] Fig. 12 is an explanatory diagram showing a state in which a three-dimensional shape is formed on the electrode member 60 by operating the three-dimensional forming jig 100. Similar to Fig. 11, Fig. 12 shows a cross section of the masking jig 200 at the XI-XI position in Fig. 10 and a cross section of the three-dimensional forming jig 100 at a position corresponding to that position. In Fig. 12, the three-dimensional forming jig 100 arranged at the initial position is shown by a dashed line, and the three-dimensional forming jig 100 in a state in which formation of a three-dimensional shape on the electrode member 60 has been completed is shown typically by a solid line.

[0047] In this embodiment, after the three-dimensional forming jig 100 is placed at the initial position, tension is generated in the second wiring 62 of the electrode member 60 along the surface direction of the masking jig 200. Specifically, the tension in the second wiring 62 can be generated, for example, by pulling the first wiring 61 of the electrode member 60 along the surface direction D2 of the masking jig 200 shown in Fig. 12 with the electrode member 60 fixed to the back surface BP. By forming a three-dimensional shape in the wiring 621 in this state, it is possible to reduce or suppress the formation of a three-dimensional shape in a wavy or wrinkled state for the wiring 621.

[0048] While tension is generated in the electrode member 60, the gripping portion 110 of the three-dimensional forming jig 100 arranged at the initial position is operated to form a three-dimensional shape in the electrode member 60. Specifically, while pressing the back surface BP with the masking jig facing surface 100S, for example, as shown by the arrow D3 in FIG. 12, the gripping portion 110 is rotated around the central axis AX near the masking jig facing surface 100S. The wiring 621 of the second wiring 62 is pressed toward the back surface BP, and a three-dimensional shape is formed in the electrode member 60 due to the ductility of the metal. Since the masking jig facing surface 100S is a curved surface, when the wiring 621 is pressed, the wiring 621 is easily extended in a direction away from the starting position of the pressing. The direction away from the starting position of the pressing includes the surface direction D2 as a directional component. By forming a three-dimensional shape in the wiring 621 in this state, it is possible to reduce or suppress the formation of a three-dimensional shape in which the wiring 621 is wavy or wrinkled. The gripping unit 110 may be operated manually by an operator, or a robot or a dedicated device may be used.

[0049] Fig. 13 is an explanatory diagram showing a cross section of the electrode member 60 in a state where a three-dimensional shape is formed. In Fig. 13, the outer surface 400S of the electrically heated catalyst 400 is indicated by a solid line, and the position of the outer surface 400S of the electrically heated catalyst 400 in a state where it is in contact with the masking jig 200 is indicated by a dashed line 400F. In Fig. 13, the illustration of the surface electrode 460 is omitted.

[0050] As illustrated as the wiring 62B in FIG. 13, the wiring 621 of the electrode member 60 is pressed toward the back surface BP by the three-dimensional forming jig 100, so that a three-dimensional shape is formed that protrudes from the back surface BP toward the electrically heated catalyst 400. The three-dimensional shape is determined by the outer shape of the support protrusion 250 and the outer shape of the accommodation recess 150. In this embodiment, the wiring 62B is formed from the first support protrusion 251 to the second support protrusion 252 by the accommodation recess 150 of the three-dimensional forming jig 100 accommodating the first support protrusion 251 and the second support protrusion 252 of the masking jig 200. As a result, as shown in FIG. 13, the wiring 621 of the second wiring 62 is formed into a three-dimensional shape in which the vicinity of the jig through hole 242 protrudes from the back surface BP toward the electrically heated catalyst 400.

[0051] FIG. 13 shows a first apex 251P of the first support protrusion 251 and a second apex 252P of the second support protrusion 252. The first apex 251P is a portion of the first support protrusion 251 that is farthest from the back surface BP in the direction from the front surface TP to the back surface BP, i.e., in the protruding direction of the first support protrusion 251, and the second apex 252P is a portion of the second support protrusion 252 that is farthest from the back surface BP in the direction from the front surface TP to the back surface BP, i.e., in the protruding direction of the second support protrusion 252. As shown in FIG. 13, the wiring 62B is in a tensioned state and is formed in a substantially straight line connecting the first apex 251P to the second apex 252P. This straight wiring 62B is formed by pressing the electrode member 60 in a state in which tension is generated in the electrode member 60 when forming a three-dimensional shape using the three-dimensional forming jig 100, as described above.

[0052] When the masking jig 200 with the electrode member 60 arranged thereon is placed on the electrically heated catalyst 400, the electrically heated catalyst 400 moves relatively in the direction D4 shown in Fig. 13 to come into contact with the first supporting protrusion tip surface 251S and the second supporting protrusion tip surface 252S. At this time, the electrically heated catalyst 400 comes into contact with the linear wiring 62B connecting the first apex 251P to the second apex 252P before coming into contact with the first supporting protrusion tip surface 251S and the second supporting protrusion tip surface 252S.

[0053] The electrically heated catalyst 400 in contact with the wiring 62B moves to the position of the broken line 400F. The straight wiring 62B is pushed up by the outer surface 400S of the electrically heated catalyst 400, and moves along the direction D5 approaching the jig through hole 242 as shown in FIG. 13. The wiring 62B pushed up by the electrically heated catalyst 400 is sandwiched between the first support protrusion tip surface 251S and the second support protrusion tip surface 252S together with the outer surface 400S. As a result, the straight wiring 62B is deformed into an arc-shaped wiring 62F along the outer surface 400S. In this way, by making the wiring 621 straight between the first apex 251P and the second apex 252P, i.e., in the vicinity of the sprayed position PT of the second wiring 62, as in the wiring 62B, a force pressing the wiring 621 against the outer surface 400S is obtained when the masking jig 200 is placed on the electrically heated catalyst 400. As a result, it is possible to improve the adhesion and contact area between the wiring 621 and the outer surface 400S. When sufficient adhesion between the wiring 621 and the outer surface 400S can be obtained, the first top portion 251P and the second top portion 252P may be omitted.

[0054] Fig. 14 is an explanatory diagram that shows a thermal spraying method using the masking jig 200 of this embodiment. In Fig. 14, in order to facilitate understanding of the technique, the masking jig 200 in a state in which the electrode member 60 is arranged is shown in an exploded perspective view of the electrode member 60 and the masking jig 200.

[0055] FIG. 14 shows a schematic diagram of a thermal spray nozzle 80. The thermal spray nozzle 80 is connected to a thermal spraying device (not shown) and sprays a thermal spray material from a nozzle at the tip. In this embodiment, the thermal spraying device is a plasma thermal spraying type thermal spraying device. The thermal spraying device applies thermal energy to the thermal spraying material to make the thermal spraying material semi-molten, and sprays the semi-molten thermal spraying material to which kinetic energy has been applied from the thermal spraying nozzle 80. The thermal spraying device is not limited to plasma thermal spraying, and may be a thermal spraying device of various types such as flame thermal spraying, arc thermal spraying, high-velocity flame thermal spraying, and laser thermal spraying.

[0056] 14 is a schematic diagram showing a jet 82 of the spray material sprayed from the spray nozzle 80. The spray material sprayed from the spray nozzle 80 passes through the jig through hole 242 as the jet 82 and collides with the sprayed position PT including a part of the wiring 621 and a part of the front surface electrode 460. At this time, the wiring 621 in the vicinity of the sprayed position PT has a three-dimensional shape in which the vicinity of the jig through hole 242 protrudes from the back surface BP toward the electrically heated catalyst 400. In this three-dimensional shape, the wiring 621 in the vicinity of the sprayed position PT is supported by the first supporting protrusion 251 and the second supporting protrusion 252, and is pressed against the outer surface 400S by the first supporting protrusion tip surface 251S and the second supporting protrusion tip surface 252S. In this embodiment, the wiring 621 in the vicinity of the sprayed position PT is further deformed from a tensile wiring 62B state to an arc-shaped wiring 62F by being pushed up by the electrically heated catalyst 400, as shown in Figure 13.

[0057] The sprayed material is deposited on the electrode member 60 and the surface electrode 460 at the sprayed position PT. The deposited sprayed material solidifies to form a sprayed film 70, also called a splat. The sprayed film 70 solidifies on the second wiring 62 and the surface electrode 460, and fixes the electrode member 60 to the surface electrode 460 by the adhesive force with the surface electrode 460, and electrically connects the electrode member 60 and the surface electrode 460.

[0058] If spraying is performed in a state where there is a gap between the wiring 621 and the outer surface 400S, the sprayed material jet 82 may collide with the wiring 621 in a state separated from the outer surface 400S, causing the wiring 621 to vibrate. In a state where the wiring 621 vibrates, the sprayed material may not be sufficiently deposited on the wiring 621. In addition, if the sprayed material is deposited on the wiring 621 in a state separated from the outer surface 400S, problems such as a decrease in the adhesive strength of the sprayed film 70 to the wiring 621 and the front electrode 460 and an insufficient electrical connection between the electrode member 60 and the front electrode 460 may occur. In this embodiment, the vicinity of the jig through hole 242 is formed into a three-dimensional shape that protrudes from the back surface BP toward the electrically heated catalyst 400, and is pressed against the outer surface 400S by the first support protrusion 251 and the second support protrusion 252, thereby improving the adhesion and contact area between the wiring 621 and the outer surface 400S. As a result, it is possible to reduce or prevent the occurrence of a gap between the wiring 621 and the outer surface 400S, and by sufficiently depositing the spray material on the wiring 621, the wiring 621 can be sufficiently fixed to the surface electrode 460. In addition, by deforming the straight wiring 62B into the arc-shaped wiring 62F pushed up by the electrically heated catalyst 400, a force is obtained to press the second wiring 62 against the outer surface 400S, and the adhesion and contact area between the wiring 621 and the outer surface 400S can be improved. As a result, it is possible to reduce or prevent the vibration of the wiring 621 caused by the spray material sprayed during spraying colliding with the wiring 621, and the occurrence of a gap between the wiring 621 and the outer surface 400S.

[0059] As described above, the masking jig 200 of this embodiment includes a back surface BP facing the electrode member 60 as the object to be sprayed, a jig through hole 242, and a support protrusion 250 protruding from the back surface BP. The support protrusion 250 is provided at a position overlapping with the intended arrangement position AP of the electrode member 60, and supports the electrode member 60. By spraying the electrode member 60 while being supported by the support protrusion 250, the electrode member 60 can be sprayed in a stable state, and the spray material can be sufficiently deposited on the electrode member 60. By pressing the electrode member 60 supported by the support protrusion 250 against the outer surface 400S by the support protrusion 250, the electrode member 60 can be sprayed in a state in which the adhesion and contact area between the wiring 621 and the outer surface 400S are improved. Therefore, it is possible to reduce or prevent the occurrence of a gap between the wiring 621 and the outer surface 400S at the sprayed position PT, and the wiring 621 can be sufficiently fixed to the surface electrode 460. Since the electrode member 60 can be formed with a three-dimensional shape protruding from the back surface BP, it is possible to reduce or prevent contact of the portion of the electrode member 60 other than the three-dimensional shape with the front surface electrode 460 as the fixed member.

[0060] According to the masking jig 200 of this embodiment, the support protrusions 250 are disposed at a first position PT1 near the jig through hole 242 and a second position PT2 on the opposite side of the jig through hole 242 from the first position PT1. Therefore, the wiring 621 included in the second wiring 62 can be supported at two points on both sides of the jig through hole 242. As a result, the electrode member 60 can be sprayed in a more stable state, and the spray material can be sufficiently deposited on the electrode member 60. By pressing the electrode member 60 supported at two points against the outer surface 400S by the support protrusions 250, the electrode member 60 can be sprayed in a state in which the adhesion and contact area between the wiring 621 and the outer surface 400S are further improved.

[0061] According to the masking jig 200 of this embodiment, the supporting protrusion 250 includes a first supporting protrusion 251 arranged at a first position PT1 and a second supporting protrusion 252 arranged at a second position PT2. Therefore, while supporting the wiring 621 included in the second wiring 62 at two points on both sides of the jig through hole 242, it is possible to reduce the area occupied by the supporting protrusion 250 on the back surface BP, and the supporting protrusion 250 can be efficiently arranged on the back surface BP.

[0062] According to the masking jig 200 of this embodiment, the first support protrusion 251 has a first apex 251P that is the furthest from the back surface BP in the direction from the front surface TP to the back surface BP, and the second support protrusion 252 has a second apex 252P that is the furthest from the back surface BP in the direction from the front surface TP to the back surface BP. The three-dimensional shape of the wiring 621 in the vicinity of the sprayed position PT can be made linear, and a force that presses the wiring 621 against the outer surface 400S can be obtained when the masking jig 200 is placed on the electrically heated catalyst 400. Therefore, spraying can be performed in a state in which the adhesion and contact area between the wiring 621 and the outer surface 400S are further improved.

[0063] According to the masking jig 200 of this embodiment, the supporting protrusion 250 has a supporting protrusion tip surface having a surface shape corresponding to the surface shape of the outer surface 400S of the fixed member, the electrically heated catalyst 400. Therefore, the contact area between the supporting protrusion 250 and the outer surface 400S is increased, and thermal spraying can be performed in a state in which the adhesion and contact area between the wiring 621 and the outer surface 400S are further improved.

[0064] The masking jig 200 of this embodiment is provided with a sprayed object fixing portion 280 that functions as an alignment mechanism for arranging the second wiring 62 at a predetermined position on the back surface BP, at a position corresponding to the outer shape of the second wiring 62. Therefore, the electrode member 60 can be easily arranged at the predetermined position on the back surface BP.

[0065] The masking jig unit of this embodiment includes a masking jig 200 and a three-dimensional forming jig 100 that is pressed against the back surface BP. The three-dimensional forming jig 100 includes a masking jig facing surface 100S that faces the back surface BP, and a three-dimensional forming jig 100 having an accommodation recess 150 that can accommodate a support protrusion 250. The accommodation recess 150 is formed on the masking jig facing surface 100S over a range that includes the first support protrusion 251, the second support protrusion 252, and the jig through hole 242 in a plan view when the three-dimensional forming jig 100 is placed on the back surface BP. By accommodating the support protrusion 250 in the accommodation recess 150, the electrode member 60 can be formed into a three-dimensional shape that protrudes from the back surface BP. Therefore, a three-dimensional shape can be formed in the electrode member 60 by a simple method.

[0066] In the masking jig unit of this embodiment, the masking jig facing surface 100S of the 3D forming jig 100 is a curved surface. When the masking jig facing surface 100S presses the wiring 621 on the back surface BP, the wiring 621 is more easily extended in a direction away from the 3D forming jig 100 than when the masking jig facing surface 100S is flat. Therefore, it is possible to reduce or suppress the formation of a 3D shape in which the wiring 621 is wavy or wrinkled.

[0067] The masking jig 200 of this embodiment includes an alignment mechanism that fits with a part of the three-dimensional forming jig 100. Therefore, the three-dimensional forming jig 100 can be easily placed in the initial position of the back surface BP.

[0068] According to the thermal spraying method of this embodiment, the wiring 621 of the electrode member 60 as the object to be sprayed is arranged on the back surface BP so as to overlap with the support protrusion 250, the wiring 621 is pressed toward the back surface BP to form a three-dimensional shape in the wiring 621 with a protruding portion near the sprayed position PT, and the thermal spraying material is sprayed from the jig through hole 242 toward the wiring 621 with the three-dimensional shape formed. Therefore, the electrode member 60 is pressed against the outer surface 400S by the support protrusion 250, so that the adhesion and contact area between the wiring 621 and the outer surface 400S can be improved. While reducing or preventing the contact of the part of the electrode member 60 other than the three-dimensional shape with the surface electrode 460 as the fixed member, it is possible to reduce or prevent the occurrence of a gap between the wiring 621 and the outer surface 400S at the sprayed position PT, and the wiring 621 can be sufficiently fixed to the surface electrode 460.

[0069] According to the thermal spraying method of the present embodiment, a three-dimensional shape is formed in the wiring 621 while the electrode member 60 is pulled along the surface direction D2 of the masking jig 200. By forming a three-dimensional shape in the wiring 621 while generating tension, it is possible to reduce or suppress the formation of a three-dimensional shape in which the wiring 621 is wavy or wrinkled.

[0070] B. Second embodiment: 15 is a perspective view showing a masking jig 200b of the second embodiment. In the above-mentioned first embodiment, an example was shown in which a support protrusion 250 was provided for each jig through hole 242. In contrast, one support protrusion 250b may be provided for multiple jig through holes 242. The configuration of the masking jig 200b is different from that of the masking jig 200 of the first embodiment in that the jig through holes 242 are arranged only in the first row JL1 and in that one support protrusion 250b corresponding to the first row JL1 is provided instead of the multiple support protrusions 250, but the other configurations are the same.

[0071] In this embodiment, the support protrusion 250b includes a first support protrusion 251b at a first position PT1 and a second support protrusion 252b at a second position PT2. The first support protrusion 251b has an elongated shape in which the first support protrusion 251 in the first embodiment is extended along the arrangement direction of the jig through holes 242. The second support protrusion 252b has an elongated shape in which the second support protrusion 252 in the first embodiment is extended along the arrangement direction of the jig through holes 242. The first support protrusion 251b is arranged so as to include a first position PT1 for each jig through hole 242, and the second support protrusion 252b is arranged so as to include a second position PT2 for each jig through hole 242.

[0072] According to the masking jig 200b of the present embodiment, a three-dimensional shape can be formed with a simple configuration using one support protrusion 250b for multiple second wirings 62. Even with this form of masking jig 200b, a three-dimensional shape can be formed in which each wiring 621 included in the second wiring 62 is supported at two points on both sides of the jig through hole 242.

[0073] According to the masking jig 200b of the present embodiment, the first support protrusion 251b and the second support protrusion 252b have an elongated shape along the arrangement direction of the jig through holes 242. Therefore, it is possible to reduce or prevent the wiring 621 supported by the first support protrusion 251b and the second support protrusion 252b from falling off the first support protrusion 251b and the second support protrusion 252b.

[0074] C. Third embodiment: 16 is a perspective view showing a supporting protrusion 250c included in a masking jig 200c of the third embodiment. The masking jig 200c of this embodiment differs from the masking jig 200 of the first embodiment in that the masking jig 200c includes a supporting protrusion 250c having a different shape instead of the supporting protrusion 250, but otherwise has the same configuration.

[0075] As shown in Fig. 16, the support protrusion 250c is a single protrusion having an annular shape protruding from the back surface BP. The support protrusion 250c is formed at a position including a first position PT1 and a second position PT2. In this manner, the support protrusion 250c may be formed such that a single protrusion includes the first position PT1 and the second position PT2.

[0076] According to the masking jig 200c of this embodiment, by arranging the support protrusions 250c surrounding the jig through hole 242, it is possible to increase the positions and area at which the sprayed body can be supported when forming a three-dimensional shape and during thermal spraying. Therefore, it becomes easy to support the sprayed body by the support protrusions 250c. Even with this form of masking jig 200c, it is possible to form a three-dimensional shape in which each wiring 621 included in the second wiring 62 is supported at two points on both sides of the jig through hole 242.

[0077] D. Other embodiments: (D1) In the above embodiment, the fixed member is the surface electrode 460 of the electrically heated catalyst, and the member to be sprayed is the electrode member 60 fixed to the surface electrode 460. In contrast, the fixed member is not limited to the electrically heated catalyst, and may be, for example, various vehicle parts such as a cylinder head, a cylinder block, a piston, etc., or various members such as machine parts, buildings, etc., structures. In this case, the member to be sprayed is not limited to the electrode member 60, and may be a member corresponding to various purposes such as a protective film or a heat shielding film for the various members described above, a coating for corrosion prevention or rust prevention of a structure, or a coating for improving wear resistance or heat resistance. In addition, there is no fixed member, and the member to be sprayed does not have to be fixed to the fixed member. In this case, only the member to be sprayed is included in the sprayed position, and the spray material is sprayed only on the member to be sprayed.

[0078] (D2) In each of the above embodiments, an example has been shown in which the first position PT1 and the second position PT2 are equidistant from the jig through hole 242. In contrast, the first position PT1 and the second position PT2 do not need to be disposed equidistant from the jig through hole 242, and may be set at any position on the premise that the second wiring 62 can be supported at two points.

[0079] (D3) In each of the above embodiments, the masking jig facing surface 100S is a curved surface. However, the masking jig facing surface 100S is not limited to a curved surface and may be a flat surface parallel to the back surface BP.

[0080] (D4) In the above first embodiment, the support convex portion 250 includes the first support convex portion 251 and the second support convex portion 252, and in the above second embodiment, an example was shown in which the support convex portion 250b includes the first support convex portion 251b and the second support convex portion 252b. In contrast, the support convex portion 250 may include only one of the first support convex portion 251 or the second support convex portion 252, and the support convex portion 250b may include only one of the first support convex portion 251b or the second support convex portion 252b.

[0081] The present disclosure is not limited to the above-mentioned embodiment, and can be realized in various configurations without departing from the spirit of the present disclosure. For example, the technical features in the embodiments corresponding to the technical features in each aspect described in the Summary of the Invention column can be appropriately replaced or combined to solve some or all of the above-mentioned problems or to achieve some or all of the above-mentioned effects. Furthermore, if the technical feature is not described as essential in this specification, it can be appropriately deleted. [Explanation of symbols]

[0082] 60...electrode member, 61...first wiring, 62...second wiring, 70...sprayed film, 80...spray nozzle, 82...jet, 100...three-dimensional forming jig, 100S...masking jig facing surface, 110...holding portion, 120...main body portion, 150...accommodating recess, 160...three-dimensional forming jig protrusion, 170...three-dimensional forming jig fitting portion, 200, 200b, 200c...masking jig, 242...jig through hole, 250, 250b, 250c...support protrusion, 251, 251b...first supporting protrusion, 251E...outer wall surface, 251F...inner wall surface, 251P... First top, 251S...first support protrusion tip surface, 252, 252b...second support protrusion, 252E...outer wall surface, 252F...inner wall surface, 252P...second top, 252S...second support protrusion tip surface, 260...rear surface recess, 261...recess, 270...masking jig fitting portion, 280...part for fixing body to be sprayed, 400...electrically heated catalyst, 400S...outer surface, 400T...top, 460...surface electrode, 621...wiring, AP...intended placement position, BP...rear surface, PT...position to be sprayed, PT1...first position, PT2...second position, TP...surface

Claims

1. A masking jig used for thermal spraying on a target body, comprising: A first surface for facing the object to be sprayed; A second surface opposite to the first surface; A jig through hole penetrating from the first surface to the second surface; a support protrusion provided on the first surface at a position overlapping the body to be sprayed and protruding from the first surface, the support protrusion being for supporting the body to be sprayed; The support protrusion has a support protrusion tip surface having a surface shape corresponding to a surface shape of a fixed member which is an object to which the sprayed body is fixed by thermal spraying. Masking fixture.

2. The masking jig according to claim 1, The support protrusion is disposed at a position including at least a first position in the vicinity of the jig through hole and a second position on an opposite side of the jig through hole from the first position. Masking fixture.

3. The masking jig according to claim 2, The support protrusion includes a first support protrusion disposed at the first position and a second support protrusion disposed at the second position. Masking fixture.

4. The masking jig according to claim 3, the first support protrusion includes a first apex portion that is furthest from the first surface in a direction from the first surface toward the second surface, The second support protrusion includes a second apex portion that is furthest from the first surface in a direction from the first surface toward the second surface. Masking fixture.

5. The masking jig according to any one of claims 1 to 4, the first surface is provided with an alignment mechanism for locating the object to be sprayed at a predetermined position on the first surface at a position corresponding to the outer shape of the object to be sprayed; Masking fixture.

6. A masking jig unit, comprising: A masking jig used for thermal spraying on a target body; A three-dimensional forming jig; The masking jig is A first surface for facing the object to be sprayed; A second surface opposite to the first surface; A jig through hole penetrating from the first surface to the second surface; a support protrusion provided on the first surface at a position overlapping the body to be sprayed and protruding from the first surface, the support protrusion being for supporting the body to be sprayed; The three-dimensional forming jig is used by being pressed against the first surface, and includes a masking jig facing surface facing the first surface, and an accommodating recess capable of accommodating the support protrusion, The accommodating recess is formed on the masking jig facing surface over a range including the support protrusion and the jig through hole in a plan view when the three-dimensional forming jig is disposed on the first surface. Masking jig unit.

7. The masking jig unit according to claim 6 , wherein the masking jig facing surface is a curved surface.

8. The masking jig unit according to claim 6 or 7, The masking jig has an alignment mechanism that fits with a part of the three-dimensional forming jig. Masking jig unit.

9. A thermal spraying method comprising: preparing a masking jig having a first surface and a support protrusion disposed in the vicinity of the jig through hole on the first surface, and an object to be sprayed; The object to be sprayed is disposed facing the first surface so that at least a portion of the object to be sprayed overlaps with the supporting protrusion; the object to be sprayed, which is placed on the first surface, is pressed against the first surface to form a three-dimensional shape on the object to be sprayed in which a position where the spray material is to be sprayed protrudes from the object to be sprayed; a thermal spray material is thermally sprayed from the jig through hole toward the object to be thermally sprayed, the object being disposed on the first surface and having the three-dimensional shape formed thereon; Thermal spraying method.

10. The thermal spray method according to claim 9, While pulling the object to be sprayed along a surface direction of the masking jig, at least a portion of the object to be sprayed is pressed against the first surface, thereby forming the three-dimensional shape on the object to be sprayed. Thermal spraying method.

Images