Case manufacturing method

Abstract

To provide a case manufacturing method which can accurately align members with each other during manufacturing of a case.SOLUTION: In a case manufacturing method, a plurality of divided plate materials 1 formed by dividing a peripheral wall 10 of a case in a peripheral direction are formed, and at least one protrusion 1c is formed on a surface of one divided plate material 1a of adjacent divided plate materials 1 in the vicinity of an end edge of the one divided plate material. The plurality of divided plate materials 1 are housed in a jig 2 which guides the divided plate materials 1 to a combining position of the peripheral wall 10. By moving the jig 2 is to the combining position and bringing the end edge into contact with the protrusion 1c on the one divided plate material 1a of the adjacent divided plate materials 1, the plurality of divided plate materials 1 are temporarily held. The end edges of the adjacent divided plate materials 1 of the plurality of divided plate materials 1 which are being temporarily held are joined to each other, thus forming the peripheral wall 10.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a case.

Background Art

[0002] There are various methods for manufacturing a case. When press-forming a metal case with a large aspect ratio (i.e., a deep depth relative to the opening area), so-called "deep drawing" is required. In the case of "deep drawing", it is necessary to use a metal with good stretchability, a large pressing pressure, and a mold with a long stroke. Also, in the case of injection-molding a resin case with a large aspect ratio, a mold with a long ejection stroke corresponding to the depth of the case is required. That is, regardless of the material of the case, a large mold is required. For this reason, as disclosed in Patent Document 1 below, there are cases where a case is manufactured by dividing the case into a plurality of members and then joining the members together.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in order to manufacture a case from a plurality of members, it is necessary to join the members while accurately aligning them. When airtightness or liquid tightness is required for the case, if the joining of the members is insufficient, the airtightness or liquid tightness will be insufficient. For this reason, the positioning of the members during joining is important. If the members can be accurately positioned, the members can be firmly joined together.

Means for Solving the Problems

[0005] In the case manufacturing method according to one aspect of the present invention, a plurality of divided plate materials formed by dividing the peripheral wall of the case in the circumferential direction are formed, at least one protrusion is formed on the surface near one edge of the adjacent divided plate materials, and the plurality of divided plate materials are respectively stored in a jig for guiding the divided plate materials to the synthetic position of the peripheral wall, and the jig is moved to the synthetic position to bring the other edge into contact with the protrusion of the one of the adjacent divided plate materials, temporarily holding the plurality of divided plate materials, and joining the edges of the adjacent divided plate materials of the plurality of temporarily held divided plate materials to form the peripheral wall.

[0006] When joining the divided plate materials constituting the peripheral wall of the case and moving the jig storing the divided plate materials to the above-described synthetic position, the adjacent divided plate materials are accurately positioned and temporarily held by receiving the other edge with the protrusion formed on one of the adjacent divided plate materials. This positioning is performed for all adjacent divided plate materials. Since the plurality of divided plate materials are joined in a temporarily held state with accurate positioning, a firmly joined peripheral wall is formed.

Effect of the Invention

[0007] According to the case manufacturing method of one aspect of the present invention, members can be accurately aligned with each other during case manufacturing, and the members can be firmly joined.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Mode for Carrying Out the Invention

[0009] While referring to the drawings, a case manufacturing method according to an embodiment will be described. First, the outline of the manufacturing method of the embodiment will be described with reference to FIG. 1. FIG. 1 is a schematic perspective view showing a case manufacturing method according to the embodiment.

[0010] In the case manufacturing method, a plurality of divided plate materials 1 (1a, 1b) formed by dividing the peripheral wall 10 of the case in the circumferential direction are formed, at least one protrusion 1c is formed on the surface near the edge of one 1a (1b) of the adjacent divided plate materials 1, and the plurality of divided plate materials 1 are respectively stored in a jig 2 that guides the divided plate materials 1 to the synthesis position of the peripheral wall 10. The jig 2 is moved to the synthesis position, and the edge of the other 1b (1a) is brought into contact with the protrusion 1c of the one 1a (1b) of the adjacent divided plate materials 1 to temporarily hold the plurality of divided plate materials 1, and the edges of the adjacent divided plate materials of the plurality of temporarily held divided plate materials 1 are joined to form the peripheral wall 10.

[0011] Hereinafter, it will be described in more detail. As shown in FIGS. 1(a) and 1(b), first, a plurality of divided plate materials 1 formed by dividing the peripheral wall 10 (see FIG. 1(d)) of the case in the circumferential direction are formed. In this embodiment, the case has a rectangular parallelepiped shape, and its peripheral wall is bisected to form two divided plate materials 1 (divided plate materials 1a, 1b). The divided plate materials 1 have the same shape and are metal plates bent at 90 degrees.

[0012] First, a plate material 1x is punched out from a metal plate by pressing (Fig. 1(a)), and then it is bent by 90 degrees by pressing to form a divided plate material 1. In addition, at least one protrusion 1c is formed on the surface near one edge of adjacent divided plate materials 1. In this embodiment, two protrusions 1c are formed near the edge of the divided plate material 1. Note that the protrusion 1c is formed simultaneously when the plate material 1x is punched out from the metal plate by pressing.

[0013] In this embodiment, the peripheral wall 10 is bisected into L-shaped plates, but it may be divided into three or more parts, and does not necessarily have to be equally divided. Also, the divided shape is not limited to an L shape, and may be a simple flat plate, a curved plate, an angular U shape (C shape), etc. Also, the dividing direction may be vertical or diagonal. Also, the aspect ratio of the formed case (peripheral wall 10) is not limited. Also, for convenience, the term "case" is used in this embodiment, but the "case" mentioned here includes containers called tanks, bottles, etc.

[0014] A protrusion 1c is formed on one of the adjacent divided plate materials 1 (1a, 1b), and as will be described later, the edge of the other divided plate material 1b will come into contact with this protrusion 1c. Conversely, if one of the adjacent divided plate materials 1 is considered to be the divided plate material 1b, a protrusion 1c is also formed on the divided plate material 1b, and the edge of the other divided plate material 1a will come into contact with this protrusion 1c. That is, the protrusion 1c is formed on both of the divided plate materials 1a and 1b. In this embodiment, in this way, two divided plate materials 1 (1a, 1b) of the same shape including the protrusion 1c are formed.

[0015] Next, as shown in FIG. 1(c), the divided plates 1 are respectively stored in the jigs 2. The jigs 2 guide the stored divided plates 1 to the joining position of the peripheral wall 10. The jigs 2 have an inner surface that conforms to the designed shape of the divided plates 1, and also have a holding mechanism 3 for bringing the divided plates 1 into surface contact with the inner surface. Although the holding mechanism 3 will be described in detail later (see FIG. 8), the jigs 2 are formed with insertion holes 20 through which the suction portions 30 of the holding mechanism 3 are inserted. Since the two divided plates 1 have the same shape, the two jigs 2 for storing them also have the same shape. In the present embodiment, since the peripheral wall 10 of the rectangular parallelepiped-shaped case is formed, each jig 2 also has a rectangular parallelepiped-shaped box form, and a part of it is opened for storing the divided plates 1. Also, an opening 21 for exposing the joint portion between the divided plates 1 is formed in the jig 2.

[0016] As shown in FIG. 1(d), the jig 2 storing the divided plates 1 is moved to the above-described joining position. Note that the two jigs 2 (divided plates 1) may be relatively moved with respect to all the jigs 2 so as to be moved to the joining position. For example, the two jigs 2 may be moved in the same manner facing each other, or one of the two jigs 2 may be stationary and only the other may be moved. Note that the relative movement of the jig 2 may be linear or curvilinear. Also, the same applies when the peripheral wall 10 is divided into three or more divided plates 1. In this case, the respective movement amounts of the jigs 2 do not have to be equal. The same also applies when the plurality of divided plates 1 do not have the same shape.

[0017] By moving the jig 2 described above, the edge of one 1a (1b) of the adjacent divided plates 1 contacts the protrusion 1c of the other 1b (1a), and the plurality of divided plates 1 are temporarily held in the shape of the peripheral wall 10. The position of the jig 2 for temporarily holding the divided plates 1 is the above-described combined position of the jig 2. That is, the edge of the divided plate 1a is contacted and positioned by the protrusion 1c of the divided plate 1b, and the edge of the divided plate 1b is contacted and positioned by the protrusion 1c of the divided plate 1a. As a result, all adjacent divided plates 1 that make up the peripheral wall 10 are accurately positioned, and the divided plates 1 are temporarily held in the combined state of the peripheral wall 10. This temporary holding is the same even when the peripheral wall 10 is divided into three or more divided plates 1, and is also the same when the plurality of divided plates 1 have different shapes.

[0018] In the temporarily held state, the joint between the divided plates 1, that is, the edge in contact with the protrusion 1c, is exposed from the opening 21 of the jig 2. Next, in this temporarily held state, the edges of the divided plates 1 are joined to form the peripheral wall 10. In this embodiment, the joint of the metal divided plates 1 is joined by laser welding. When the divided plates 1 are formed of resin, they are joined by an adhesive or the like. When the divided plates 1 are formed of resin, it is also possible to weld the joints, and it is also possible to perform the welding using a laser.

[0019] As shown in Fig. 1(e), the peripheral wall 10 formed by joining the joints of the divided plates 1 is taken out from the jig 2. Finally, the bottom plate 11 is joined to the peripheral wall 10. In this embodiment, the bottom plate 11 is also a metal plate punched by press working, and protrusions 11c similar to the protrusions 1c are formed at the four corners of the bottom plate 11 by press working. Alignment of the bottom plate 11 with the peripheral wall 10 is performed by the protrusions 11c. The bottom plate 11 is also laser welded to the peripheral wall 10. In this way, the case is manufactured. Although not shown in the figure, after a predetermined content is accommodated in the case, a cover plate is also joined in the same manner as the bottom plate 11 as appropriate. Depending on the use of the case, a detachable cover is used.

[0020] Note that, in the example of FIG. 1, due to the shape of the jig 2, after joining the joint portions of the temporarily held split plates 1 shown in FIG. 1(d), the bottom plate 11 cannot be joined to the peripheral wall 10. However, depending on the shape of the jig 2, there may be cases where the bottom plate 11 can be joined while the peripheral wall 10 is held by the jig 2 (see the second embodiment described later). In such cases, the case is removed from the jig 2 after the bottom plate 11 is joined to the peripheral wall 10.

[0021] Next, the shape of the protrusion 1c will be described with reference to FIG. 2. FIG. 2 is an enlarged side view showing the contact state of the edge of the split plate 1. The protrusion 1c shown in FIG. 2(a) has a shape obtained by bisecting a teardrop shape with a plane passing through its central axis. The surface on the edge side of the protrusion 1c is an inclined convex curved surface. The protrusion 1c shown in FIG. 2(b) has a conical or polygonal pyramid shape (alternatively, it has a shape in which a triangular prism extends along the edge). The surface on the edge side of the protrusion 1c is an inclined curved surface or an inclined plane. The protrusion 1c shown in FIG. 2(c) has a shape obtained by cutting a part of a rectangular parallelepiped shape. The cut surface is an inclined plane directed toward the edge side.

[0022] The protrusion 1c shown in FIG. 2(d) has a hemispherical shape (alternatively, it has a shape in which a bisected cylinder extends along the edge). The surface on the edge side of the protrusion 1c is an inclined convex curved surface. The protrusion 1c shown in FIG. 2(e) has a shape obtained by quartering a sphere with two planes perpendicular to each other passing through its center (alternatively, it has a shape in which a quartered cylinder extends along the edge). The surface on the edge side of the protrusion 1c is a plane perpendicular to the inner surface of the split plate 1. The protrusion 1c shown in FIG. 2(f) has a cube shape with rounded corners. The surface on the edge side of the protrusion 1c is a plane perpendicular to the inner surface of the split plate 1. Also, although not shown, the protrusion 1c may have a shape that is a part of a sphere or a part of a cylinder, and it is sufficient if the protrusion 1c at the edge has a shape that can position the split plate 1.

[0023] Note that the width of the protrusion 1c in the edge direction shown in FIGS. 2(a) to 2(f) described above is small. However, the protrusion 1c may have a cross-section of the shape shown in FIGS. 2(a) to 2(f) described above and may be formed long along the edge. Further, when a plurality of protrusions 1c are formed along the edge, not all of the protrusions 1c need to have the same shape. In this way, the protrusion 1c is formed in a shape that can position the edge of the other split plate 1 between the inner surface of the split plate 1 and itself.

[0024] Further, as shown in FIGS. 2(a) to 2(f), it is preferable that the edges of the split plates 1 are joined (temporarily held) so as to be in a so-called "half-pull" state. In the "half-pull" state, one end face of the split plate 1 is positioned in the middle of the other end face. When laser welding the metal split plate 1, by adopting such a "half-pull", the edges of the split plates 1 can be surely joined over their entire lengths by irradiating the laser toward the end faces where the split plates 1 are in contact (temporarily held). At this time, if the laser is irradiated from above (or upper right) in FIG. 2, the molten metal will not enter the inside of the peripheral wall 10 (case). When manufacturing cases for food or medical use, the entry of molten metal into the inside of the peripheral wall 10 (case) is a quality problem. Also, increasing the process of removing the intruded metal will reduce the manufacturing efficiency.

[0025] Even when the split plate 1 is formed of another material such as resin, the edges of the split plate 1 can be surely joined over their entire lengths by filling an adhesive into the end faces where the split plate 1 is joined (temporarily held). Also in this case, since the "half-pull" is adopted, while securing the surface for filling the adhesive, the entry of the adhesive into the inside of the peripheral wall 10 (case) can be prevented. The molten metal and the adhesive are located on two perpendicular end faces and can firmly join the edges of the split plate 1 without soiling the outer surface of the split plate 1.

[0026] Consider the case of so-called "single-sided pulling" instead of "half pulling". In "single-sided pulling", one end face of the divided plate material 1 is flush with the other outer surface. Taking Figure 2 as an example, in "single-sided pulling", the end face of the upper horizontal divided plate material 1 reaches up to the outer surface of the lower vertical divided plate material 1. In the case of laser welding in "single-sided pulling", the case of irradiating the laser from above Figure 2 and the case of irradiating the laser from the right side of Figure 2 can be considered. In any case, since laser marks remain on the outer surface of the divided plate material 1, the appearance quality deteriorates. If the process of removing the laser marks is increased, the manufacturing efficiency decreases. Also, when irradiating the laser from the right side of Figure 2, there is a possibility that the molten metal may penetrate into the interior of the formed peripheral wall 10 (case). However, when irradiating the laser from above Figure 2, high joint strength can be obtained.

[0027] In the case of "single-sided pulling" where the divided plate material 1 is formed of another material such as resin, for example, it will be joined using an adhesive. However, still, since the adhesive remains on the outer surface of the divided plate material 1, the appearance quality deteriorates. In order not to leave the adhesive on the outer surface, the adhesive must be applied to the end face with a narrow area before the edges of the divided plate material 1 are brought into contact with each other, which complicates the process and reduces the manufacturing efficiency. In addition, although it is also conceivable to use welding or an adhesive at the inner corner part of the peripheral wall 10, there remains the possibility of the molten metal or the adhesive penetrating into the case interior, and it causes a reduction in the volume inside the case.

[0028] Consider the case of "double-sided pulling" instead of "half pulling" or "single-sided pulling". In "double-sided pulling", one edge of the divided plate material 1 is in line contact with the other edge. Taking Figure 2 as an example, in "double-sided pulling", the end face of the upper horizontal divided plate material 1 only reaches up to the inner surface of the lower vertical divided plate material 1. In the case of laser welding in "double-sided pulling", since it is necessary to build up fillets on the end faces arranged at right angles, a welding rod or welding wire is required. When using an adhesive, sufficient joint strength cannot be obtained. Also, in both laser welding and adhesive bonding, there is a possibility that the molten metal or the adhesive may penetrate into the interior of the formed peripheral wall 10 (case).

[0029] In addition, in this embodiment, laser bonding and adhesive bonding are described as examples, but the edges of the divided plates 1 may be joined by other methods. For example, other joining methods include mechanical joining and metallurgical joining. More specifically, examples of mechanical joining include joining with bolts and nuts, caulking, riveting, press-fitting, etc. More specifically, examples of metallurgical joining include laser welding, as well as fusion welding, pressure welding (resistance welding), and brazing (soldering and soldering with solder).

[0030] Next, the movement trajectory of the divided plate 1 when one protrusion 1c of the divided plate 1 contacts the other edge will be described with reference to FIG. 3. FIG. 3 is an enlarged side view showing the contact method of the edge of the divided plate 1. In FIG. 3, the protrusion 1c shown in FIG. 2(a) is used for explanation. As described above, by moving the plurality of jigs 2 to the synthesis position, the edges of the divided plates 1 are brought into contact with each other, but the movement trajectory of the edges at that time is not limited either. Also, in FIG. 3, only the movement trajectory immediately before contact is shown.

[0031] In FIG. 3(a), the edge of the divided plate 1 is brought into contact with the divided plate 1 having the protrusion 1c formed thereon perpendicularly. In FIG. 3(b), the edge of the divided plate 1 is brought into contact with the divided plate 1 having the protrusion 1c formed thereon in the surface direction of the divided plate 1 having the protrusion 1c formed thereon. In FIG. 3(c), the edge of the divided plate 1 is brought into contact with the divided plate 1 having the protrusion 1c formed thereon obliquely. FIG. 3(d) shows a trajectory according to FIG. 3(a), and the edge of the divided plate 1 is guided by the inclined convex curved surface of the protrusion 1c. As a result, the edges of the divided plates 1 are positioned more accurately. Such a guiding effect can also be realized with the shapes of the protrusions 1c shown in FIGS. 2(b) to (d).

[0032] In FIG. 3(e), with respect to the divided plate material 1 having the protrusion 1c formed thereon, the divided plate material 1 rotates, and its edge is brought into contact in the above-described surface direction. In FIG. 3(f), with the divided plate material 1 rotating, the edge of the divided plate material 1 having the protrusion 1c formed thereon is brought into contact vertically. In the cases of FIG. 3(b) and FIG. 3(e), the above-described guiding effect cannot be obtained, but the shape of the protrusion 1c that receives the edge with a surface as shown in FIG. 2(e) and FIG. 2(f) is preferable for the protrusion 1c. Also, in the case of FIG. 3(f), in order to obtain the above-described guiding effect, a shape like that in FIG. 2(a) to (d) is preferable.

[0033] In FIG. 3, the upper horizontal divided plate material 1 was described as being stationary and the lower vertical divided plate material 1 as being moved. However, as described above, this shows a relative movement, and it may be that the upper horizontal divided plate material 1 is moved and the lower vertical divided plate material 1 is stationary. Or, by moving both divided plate materials 1, a movement locus as shown in FIG. 3 may be realized.

[0034] Next, the form of the peripheral wall 10 to be formed will be described with reference to FIG. 4. FIG. 4 is a schematic side view showing the contact form between the divided plate materials 1. Note that FIG. 4 is a schematically shown figure and does not accurately show the size and aspect ratio of the peripheral wall 10 formed by the divided plate materials 1. Also in FIG. 4, the protrusion 1c shown in FIG. 2(a) is used for the description. FIG. 4(a) shows the form shown in FIG. 1. A rectangular parallelepiped-shaped case (peripheral wall 10) is formed by a plurality of divided plate materials 1. FIG. 4(b) shows a form in which the corners of the case in FIG. 4(a) are rounded. By changing the radius of curvature of such corners, the shape of the case can also be changed.

[0035] In the form shown in Fig. 4(c), the joining form of the split plate 1 at the upper right joint is different from the forms described so far. In this joining form, the edges of the split plate 1 are not joined at right angles, but are joined in the above-described plane direction. By adopting such a joining form, it becomes possible to realize the shapes of various cases (the peripheral wall 10). In the form shown in Fig. 4(d), the corners of the case are rounded, and the joining form at the lower left is also the same as that at the upper right in Fig. 4(c). Considering the form of Fig. 4(d), it is also possible to form a cylindrical or conical case (the peripheral wall 10) by changing the radius of curvature of the split plate 1.

[0036] Next, the manufacturing method of the first embodiment will be described with reference to Figs. 5 and 6. Fig. 5 is a schematic perspective view showing a case manufacturing apparatus according to the first embodiment (the first half of the manufacturing process). Fig. 6 is a schematic perspective view showing the case manufacturing apparatus (the second half of the manufacturing process). Since the split plate 1 and the jig 2 have been described with reference to Fig. 1, detailed descriptions thereof are omitted here.

[0037] As shown in Fig. 5(a), in the present embodiment, the jig 2 is slidably attached to the moving mechanism 4. The moving mechanism 4 of the present embodiment is a frame rail (hereinafter simply referred to as the rail 4). A plurality of jigs 2 are slidably provided on the radially extending rail 4. In the present embodiment, since there are two jigs 2, the rail 4 is provided on a straight line passing through the radiation center. Further, the rail 4 is configured to be rotatable around a rotation axis (right angle line) that is perpendicular to the extending direction thereof and passes through the radiation center.

[0038] First, the divided plate material 1 shown in FIG. 1(b) is formed as described above. Next, the divided plate material 1 is stored in the jig 2. For this purpose, the jigs 2 are respectively positioned at both ends of the rail 4 as shown in FIG. 5(a). In this state, the divided plate materials 1 are respectively stored in the jigs 2. The divided plate materials 1 stored in the jigs 2 are held in the jigs 2 such that their outer surfaces are pressed against the inner surfaces of the jigs 2 by a holding mechanism 3 described later. As a result, even if there is some deformation in the divided plate material 1, by being pressed against the inner surface of the jig 2, the divided plate material 1 is held so as to maintain a design shape suitable for joining.

[0039] From that state, as shown in FIG. 5(b), the pair of jigs 2 are slid along the rail 4 toward each other. By this sliding, the jigs 2 are moved to the joining position, and the divided plate materials 1 come into contact with each other. That is, as shown in FIG. 6(a), one edge of an adjacent divided plate material 1 contacts the other projection 1c, and the plurality of divided plate materials 1 are temporarily held. The edges of the temporarily held divided plate materials 1 are accurately positioned by the projections 1c as described above. In this state, one of the two joining portions is laser welded. For example, a laser is irradiated onto the joining portion from above (or upper right in FIG. 6(a)) to join the edges together.

[0040] Next, as shown in FIG. 6(b), the rail 4 is rotated 180 degrees around the above-described rotation axis (right-angle line). In the present embodiment, the peripheral wall 10 is bisected to form the divided plate material 1. Also, the divided plate materials 1 temporarily held by the jigs 2 are arranged point-symmetrically with respect to the radiation center when viewed from the direction of the right-angle line (rotation axis) passing through the above-described radiation center perpendicular to the extending direction of the rail 4. Therefore, by rotating 180 degrees, the other of the two joining portions can be arranged at the position where one was laser welded.

[0041] Therefore, similar to laser welding one side of the joint, the other side can be directly laser welded. In this embodiment, the peripheral wall 10 is bisected. However, even when equally divided into three or more parts, if the rails are extended radially, the jig (divided plate material) and the rails can be rotated by a predetermined angle around the radiation center, and the edges of adjacent divided plate materials can be sequentially laser welded. In this way, all joints can be sequentially joined with only a single laser processing machine, simplifying the device configuration and improving the manufacturing efficiency.

[0042] FIG. 7 is a schematic perspective view showing a manufacturing apparatus according to a modification of the first embodiment described above. In this modification, as shown in FIG. 7(a), the jig 2 is divided into two parts that are each slidable in the width direction. Since the other configurations are the same as those of the first embodiment described above, detailed descriptions thereof are omitted. Each jig 2 of this modification is divided into a first divided jig 2a and a second divided jig 2b in the width direction. The first divided jig 2a and the second divided jig 2b are configured to be slidable parallel to the above-described straight line (rotation axis). Since a known mechanism can be used for the slide mechanism of the first divided jig 2a and the second divided jig 2b, detailed descriptions thereof are omitted.

[0043] In this modification, when storing the divided plate material 1 in the jig 2, the first divided jig 2a and the second divided jig 2b are spaced slightly wider than the width of the divided plate material 1. Then, while or after storing the divided plate material 1 in the jig 2, the first divided jig 2a and the second divided jig 2b are slid toward each other as shown in FIG. 7(b). As a result, the divided plate material 1 is accurately positioned in the width direction with respect to the jig 2. The subsequent joining method of the divided plate materials 1 is the same as the joining method of the first embodiment described above. According to this modification, the divided plate materials 1 can be joined more accurately.

[0044] Next, with reference to FIG. 8, the holding mechanism 3 will be described. FIG. 8 is a partial cross-sectional side view showing the operation of the holding mechanism 3 in the manufacturing apparatus according to the first embodiment (and its modification). In FIG. 8, only the jig 2 is shown as a cross-section at the position of the insertion hole 20. As shown in FIG. 8(a), the holding mechanism 3 includes a plurality of suction portions 30 that adsorb the divided plate material 1 using negative pressure. Each suction portion 30 is inserted into the insertion hole 20 of the jig 2, and the suction cup at its tip is located inside the jig 2. The bellows portion with a suction cup formed at its tip can be bent. Therefore, when the first divided jig 2a and the second divided jig 2b slide in the above-described modification, the bellows portion bends and the adsorption of the divided plate material 1 by the suction cup does not come off.

[0045] As shown in FIG. 8(b), the divided plate material 1 is held by the suction portion 30 of the holding mechanism 3, and its outer surface is pressed (attracted) against the inner surface of the jig 2. The divided plate material 1 of the present embodiment is a bent plate material, but even if the bending angle (90 degrees) is slightly larger or smaller than the design value, it is pressed against the inner surface of the jig 2 and maintained in a design shape suitable for temporary holding. From the state shown in FIG. 8(b), the jig 2 is moved, and as shown in FIG. 8(c), the divided plate materials 1 are brought into contact with each other, and the divided plate material 1 is temporarily held while being held by the holding mechanism 3.

[0046] At this time, the edge of the divided plate material 1 is positioned by the protrusion 1c. In the present embodiment, the positioning of the edge at this time is in the form shown in FIG. 3(a) or FIG. 3(d). Here, even if the edge of the divided plate material 1 is slightly deformed inward, since there is a guiding effect by the protrusion 1c as shown in FIG. 3(d), the divided plate materials 1 are accurately positioned. When the peripheral wall 10 is removed from the jig 2 after the divided plate materials 1 are joined, the suction using negative pressure by the holding mechanism 3 is released.

[0047] Next, the manufacturing method of the second embodiment will be described with reference to FIG. 9. FIG. 9 is a schematic perspective view showing a case manufacturing apparatus according to the second embodiment. Since the divided plate material 1 is the same as that of the first embodiment, detailed description thereof is omitted here.

[0048] In this embodiment, the jig 2X is moved in the horizontal direction. The moving mechanism 4X of this embodiment includes a rotary table 40 and a pair of rails 41 provided on the upper surface of the rotary table 40. The jig 2X is slidably provided on the rails 41. Also in this embodiment, the jig 2X is moved to the joining position, and the divided plate materials 1 are brought into contact with each other.

[0049] The jig 2X has a shape bent at 90 degrees, and a recess for accommodating the divided plate material 1 is formed on its inner surface. A right-angle step 22 on which the lower edge of the divided plate material 1 is placed is formed at the lower edge of the recess. On the other hand, an inclined step 23 for guiding the accommodation of the divided plate material 1 into the recess is formed at the upper edge of the recess. Further, the holding mechanism 3X of this embodiment is a magnet embedded in the inner surface of the jig 2X (hereinafter simply referred to as the magnet 3X). The surface of the magnet 3X is flush with the inner surface of the jig 2X.

[0050] When the divided plate material 1 is accommodated in the jig 2X, the jig 2X is positioned at the outer end of each rail 41. In this state, the lower edge of the divided plate material 1 is placed on the right-angle step 22, and the metal divided plate material 1 is attracted by the magnet 3X. However, when the metal divided plate material 1 is not magnetic, an elastic body may be used to provide an attracting force instead of the magnetic force. By the attracting force of the magnet 3X, the upper edge of the divided plate material 1 is guided by the inclined step 23, and the outer surface of the divided plate material 1 is pressed (attracted) against the inner surface of the jig 2X and held in the recess of the jig 2X. As a result, even if the divided plate material 1 has some deformation, the divided plate material 1 is held so as to maintain a design shape suitable for joining by being pressed against the inner surface of the jig 2.

[0051] From that state, a pair of jigs 2X are slid along the rail 41 toward each other. By this sliding, the jigs 2X are moved to the combined position, and the divided plates 1 come into contact with each other. That is, one edge of an adjacent divided plate 1 contacts the other projection 1c, and a plurality of divided plates 1 are temporarily held. The edges of the temporarily held divided plates 1 are accurately positioned by the projections 1c. In this state, one of the two joints is laser welded. For example, a laser is irradiated from the side of the rotary table 40 to the joint to join the edges together.

[0052] Next, the rotary table 40 is rotated 180 degrees around a rotation axis (right angle line) perpendicular to the extending direction of the rail 41. Also in this embodiment, the peripheral wall 10 is bisected to form the divided plates 1. Further, the divided plates 1 temporarily held by the jigs 2X are arranged point-symmetrically with respect to the radiation center when viewed from the direction of the right angle line (rotation axis). Therefore, also in this embodiment, by rotating 180 degrees, the other of the two joints can be arranged at the position where one was laser welded.

[0053] Accordingly, similar to laser welding one of the joints, the other can be laser welded as it is. As described in the first embodiment, even when the peripheral wall 10 is equally divided into three or more parts, if the rails are extended radially, the jigs (divided plates) and the rails can be rotated by a predetermined angle around the radiation center, and the edges of adjacent divided plates can be sequentially laser welded. In this way, all the joints can be sequentially joined with only a single laser processing machine, the equipment configuration can be simplified, and the manufacturing efficiency can be improved.

[0054] FIG. 10 is a schematic partial perspective view showing a manufacturing apparatus according to a modified example of the above-described second embodiment. In this modified example, like the modified example of the first embodiment (see FIG. 7), the jig 2X is divided into two parts that are slidable in the width direction. Since the other configurations are the same as those of the above-described second embodiment, detailed descriptions thereof are omitted. Further, the moving mechanism 4 is not shown in FIG. 10. Each jig 2X of this modified example is divided into a first divided jig 2Xa and a second divided jig 2Xb in the width direction (the vertical direction in FIG. 10). The first divided jig 2Xa and the second divided jig 2Xb are configured to be slidable in parallel with the above-described right-angle line (rotation axis). Since a known mechanism can be used for the slide mechanisms of the first divided jig 2Xa and the second divided jig 2Xb, detailed descriptions thereof are omitted.

[0055] Further, each divided jig 2Xa, 2Xb has triangular side walls (upper wall or lower wall). The right-angle step 22 in the second embodiment is formed by the inner surfaces of these side walls. That is, in this modified example, the inclined step 23 in the second embodiment is not formed.

[0056] In this modified example, when storing the divided plate material 1 in the jig 2X, the first divided jig 2Xa and the second divided jig 2Xb are spaced slightly wider than the width of the divided plate material 1. Then, when the divided plate material 1 is placed on the lower divided jig 2Xa or 2xb, the divided plate material 1 is attracted by the magnet 3X. Thereafter, the first divided jig 2Xa and the second divided jig 2Xb are slid relatively toward each other. Specifically, in this modified example, the lower divided jig 2Xa or 2xb is stationary, and only the upper divided jig 2Xb or 2xa is moved downward. As a result, the divided plate material 1 is positioned by the right-angle step 22 from above and below, and is also accurately positioned in the width direction with respect to the jig 2X.

[0057] Regarding the method of joining the subsequent split plates 1, it is the same as the joining method of the second embodiment described above. Therefore, also according to this modification example, the split plates 1 can be joined to each other more accurately. In addition, in this embodiment, since the split plates 1 are held by the magnets 3X, the split plates 1 can slide with respect to the first split jig 2Xa and the second split jig 2Xb even in the state of being held by the magnets 3X. For this reason, the adsorption of the split plates 1 does not come off when the first split jig 2Xa and the second split jig 2Xb slide.

[0058] According to the above embodiment (including the modification example), [1] a plurality of split plates 1 are formed by dividing the peripheral wall 10 of the case in the circumferential direction, [2] at least one protrusion 1c is formed on the surface near one edge of the adjacent split plates 1, [3] the plurality of split plates 1 are respectively housed in a jig 2 (2X) that guides the split plates 1 to the synthesis position of the peripheral wall 10, [4] the jig 2 (2X) is moved to the synthesis position and the other edge is brought into contact with one protrusion 1c of the adjacent split plates 1 to temporarily hold the plurality of split plates 1, and [5] the edges of the adjacent split plates 1 of the plurality of split plates 1 in the temporarily held state are joined to form the peripheral wall 10.

[0059] Therefore, it is possible to temporarily hold the adjacent split plates 1 in a state where they are accurately positioned, and it is possible to firmly join the split plates 1 in the temporarily held state. That is, when manufacturing the case, the members can be accurately aligned with each other and firmly joined. In addition, since the peripheral wall 10 of the case is formed by a plurality of split plates 1, it is not necessary to use a mold having a long stroke, so a large press device or resin molding machine is not required, and the manufacture of the case becomes easy.

[0060] In addition, in the above-described embodiments (including modified examples), the plurality of divided plate members 1 are formed by equally dividing the peripheral wall 10, and each has the same shape including the protrusion 1c. Therefore, since the plurality of divided plate members 1 can be formed by the same apparatus and process, the manufacturing cost can be reduced and the manufacturing efficiency can be improved. Further, since all the jigs 2 for storing the divided plate members 1 can be formed in the same shape, the manufacturing cost of the jigs 2 can also be reduced. Furthermore, since the moving mechanism of the jigs 2 can be configured in the same manner, the configuration of the manufacturing apparatus can be simplified.

[0061] Furthermore, in the above-described embodiments (including modified examples), the plurality of divided plate members 1 are made of metal. When manufacturing a metal case, since the peripheral wall 10 is formed by a plurality of metal divided plate members 1, there is no need for "deep drawing". Therefore, as described above, there is no need for a long-stroke mold, and no large pressing pressure is required. As a result, the configuration of the manufacturing apparatus can be further simplified. In addition, since there is no need for "deep drawing", there is no need to use a metal with good stretchability for the divided plate members 1, so the manufacturing cost can be reduced.

[0062] Furthermore, in the above-described embodiments (including modified examples), while one edge of an adjacent divided plate member 1 and the other said edge are in contact in a "semi-pull" state, the one edge and the other edge are laser-joined over the entire length. Therefore, while ensuring the joining strength, a case with excellent appearance quality can be manufactured without reducing the manufacturing efficiency. Furthermore, it is possible to prevent the intrusion of molten metal or molten resin during laser joining into the case interior. Moreover, a case having excellent airtightness and liquid tightness can be manufactured.

[0063] Furthermore, in the above-described embodiments (including modified examples), the jig 2 (2X) is slidably provided on a rail 4 (41) extending radially from the above-described combined position. Then, the jig 2 (2X) and the rail 4 (41) are rotated around the radiation center together with the plurality of temporarily held divided plate members 1, and one edge and the other edge are sequentially laser-welded. Therefore, all the joints can be sequentially joined by only a single laser processing machine, the equipment configuration can be simplified, and the manufacturing efficiency is improved.

[0064] Here, in the above-described embodiments (including modified examples), the peripheral wall 10 is bisected to form the divided plate material 1. And the divided plate material 1 temporarily held by the jig 2 (2X) is arranged symmetrically with respect to the radiation center when viewed from the direction of the perpendicular line passing through the radiation center and perpendicular to the extending direction of the rail 4 (41). By bisecting the peripheral wall 10, the number of parts can be minimized. Also, the number of jigs 2 (2X) can be minimized, so the number of joints to be welded can be reduced. Further, since the two jigs 2 (2X) are linearly moved, the moving mechanism can also be simplified. Moreover, the rotating mechanism of the divided plate material 1 in the temporarily held state, that is, the rotating mechanism of the jig 2 at the combining position can also be simplified. That is, the equipment configuration can be further simplified and the manufacturing efficiency can be further improved.

[0065] In the above-described embodiments (including modified examples), the jig 2 (2X) has a holding mechanism 3 (3X) that brings the divided plate material 1 into surface contact with the inner surface of the jig 2 (2X). Therefore, even if the divided plate material 1 is deformed, the divided plate material 1 can be maintained and held in the designed shape. As a result, the divided plate materials 1 can be temporarily held in a state where they are more accurately positioned with respect to each other.

[0066] The present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the gist of the present invention. For example, in the above-described embodiments, a rectangular parallelepiped-shaped case was manufactured, but by devising the divided shape of the peripheral wall, it is also possible to manufacture a polyhedral-shaped or spherical case.

Explanation of Reference Numerals

[0067] 1(1a,1b) Divided plate material 10 Peripheral wall 2 Jig 3,3X Holding mechanism 4,41 Rail

Claims

1. A method for manufacturing a case, comprising: forming a plurality of divided plate materials configured by dividing the peripheral wall of the case in the circumferential direction; forming at least one protrusion on the surface near one edge of the adjacent divided plate materials; accommodating each of the plurality of divided plate materials in a jig that guides the divided plate materials to the joining position of the peripheral wall; moving the jig to the joining position and bringing the other edge into contact with the one protrusion of the adjacent divided plate materials to temporarily hold the plurality of divided plate materials; A case manufacturing method, comprising joining the edges of the adjacent divided plate materials in the temporarily held state of the plurality of divided plate materials to form the peripheral wall.

2. The case manufacturing method according to claim 1, wherein the plurality of divided plate materials are formed by equally dividing the peripheral wall, and each has the same shape including the protrusion.

3. The case manufacturing method according to claim 2, wherein the plurality of divided plate materials are made of metal.

4. The case manufacturing method according to claim 2 or 3, wherein while the one edge of the adjacent divided plate materials and the other edge are in contact in a half-pulled state, the one edge and the other edge are laser-joined over the entire length.

5. The case manufacturing method according to claim 4, wherein the jig is slidably provided on a rail extending radially from the joining position, and the jig and the rail are rotated around the radiation center together with the plurality of temporarily held divided plate materials, and the one edge and the other edge are sequentially laser-welded.

6. The case manufacturing method according to claim 5, wherein the peripheral wall is bisected to form the divided plate materials, and the divided plate materials temporarily held by the jig are arranged symmetrically with respect to the radiation center when viewed from the direction of a perpendicular line passing through the radiation center perpendicular to the extending direction of the rail.

7. The case manufacturing method according to any one of claims 1 to 6, wherein the jig has a holding mechanism for bringing the divided plate material into surface contact with the inner surface of the jig.

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