Welded components

Abstract

To provide a technology which makes improper welding of a welding member less likely to occur.SOLUTION: A welding member is attached to a welding surface of a body member included in an on-vehicle component mounted on a vehicle by resistance-welding and includes a welding end and a non-welding end. The welding end is an end to be welded to the welding surface. The non-welding end is an end opposite to the welding end. The non-welding end has a pressing surface and a non-pressing surface. The pressing surface is a surface pressed during resistance-welding. The pressing surface faces the welding surface in a pressing direction in which pressing is performed. The non-pressing surface is a surface other than the pressing surface. The welding member has a shape in which an axis extending from the welding end to the non-pressing surface inclines relative to the welding surface or the axis bends.SELECTED DRAWING: Figure 4

Description

[[Technical Field]]

[0001] The present disclosure relates to a welding member attached to a main body member of an in-vehicle component by resistance welding. [[Background Art]]

[0002] Patent Document 1 discloses a welding method in which an exhaust pipe having a projection formed thereon and another member are mounted on a joining jig provided in a ring projection welding machine, and the exhaust pipe and the other member are joined by ring projection welding. In this welding method, pressing and energization are performed in a state where the exhaust pipe and the other member are sandwiched from above and below by the joining jig. [[Prior Art Literature]] [[Patent Literature]]

[0003] [[Patent Document 1]] Japanese Patent Laid-Open No. 2006-150397 [[Summary of the Invention]] [[Problem to be Solved by the Invention]]

[0004] Meanwhile, welding members attached to a main body member by resistance welding have various shapes and configurations, and the selected welding member differs depending on the application, usage environment, and the like. In the welding method of Patent Document 1, depending on the shape and configuration of the welding member, it is difficult to apply uniform pressure to the welding member or it is difficult for a uniform current to flow through the welding member, so there has been a problem that poor welding of the welding member to the main body member may occur.

[0005] One aspect of the present disclosure aims to provide a technique that makes it difficult for poor welding of a welding member to occur. [[Means for Solving the Problem]]

[0006] One aspect of the present disclosure is a welded member that is attached by resistance welding to a welded surface of a main body member of an on-board component mounted on a vehicle, and comprises a welded end and a non-welded end. The welded end is the end that is welded to the welded surface. The non-welded end has a pressing surface and a non-pressed surface. The pressing surface is the surface that is pressed during resistance welding. The pressing surface faces the welded surface in the direction of the applied pressure. The non-pressed surface is the surface other than the pressing surface. The welded member has a shape in which the axis extending from the welded end to the non-pressed surface is inclined with respect to the welded surface, or the axis is bent.

[0007] In this configuration, since the welded member has a pressing surface, even if the welded member has a shape in which the shaft does not extend straight from the welded surface in the direction of pressing, it is easy to apply uniform pressure to the welded member during resistance welding. Therefore, it is possible to reduce the likelihood of welding defects in the welded member to the main body member.

[0008] In one aspect of this disclosure, the non-pressing surface may be located between the pressing surface and the weld end in the pressing direction. In this configuration, a space is formed between the contact surface of the fixing base that contacts the pressing surface of the welded member in the pressing direction and the non-pressing surface. Therefore, when welding resistance occurs, for example, by housing the receiving jig that contacts the contact surface and non-pressing surface of the fixing device in this space, the welded member is held stably, making it easier to apply uniform pressure to the welded member through the pressing surface and the receiving jig.

[0009] In one aspect of this disclosure, the in-vehicle component may be an exhaust system component for passing exhaust gas through. With such a configuration, welding defects in welded members of the exhaust system component can be made less likely.

[0010] In one aspect of this disclosure, the resistance welding may be projection welding. With such a configuration, it is possible to apply uniform pressure to one or more projections provided on the welding member or main body member. As a result, welding defects in the welding member of the automotive component can be reduced.

[0011] In one aspect of the present disclosure, the outer circumferential surface of the welded member, extending from the welded end to the non-welded end, may have at least two holding surfaces facing each other for gripping and holding the welded member during resistance welding. With such a configuration, the welded member can be stably held during resistance welding by, for example, gripping the two holding surfaces, making it easier to apply uniform pressure to the welded member through the pressing surface. [Brief explanation of the drawing]

[0012] [Figure 1] This is a schematic diagram showing some of the components used in a vehicle. [Figure 2] This is a perspective view of the workpiece. [Figure 3] A bottom view showing the workpiece. [Figure 4] This is a schematic cross-sectional view illustrating the state of the main body component and workpiece before ring projection welding, and the ring projection welding process. [Figure 5] This diagram schematically illustrates how current flows uniformly from the outer surface of the workpiece to the second electrode. [Figure 6] As a modified example, this is a schematic cross-sectional view showing the state of the workpiece and main body member held by a clamp before ring projection welding. [Figure 7] This is a view from above of a workpiece held in place by a clamp. [Modes for carrying out the invention]

[0013] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings. [1. Configuration of in-vehicle components] The vehicle component 100 shown in Figure 1 is used when mounted on a vehicle. The vehicle component 100 in this embodiment is an exhaust system component. An exhaust system component is a component that constitutes at least a part of the passage for passing exhaust gas from an internal combustion engine mounted on a vehicle. Examples of exhaust system components include an exhaust manifold, exhaust pipe, catalytic converter, muffler, etc.

[0014] As shown in Figure 1, the in-vehicle component 100 comprises a main body member 1 and a workpiece 2. The in-vehicle component 100 is a component in which the main body member 1 and the workpiece 2 are welded by resistance welding. In resistance welding, electric current is passed while pressing the main body member 1 and the workpiece 2, whereby a pressed portion having a smaller current cross-sectional area than other portions generates heat and melts, thus performing welding. Although details will be described later, in the present embodiment, the workpiece 2 is welded to the main body member 1 by ring projection welding, which is a type of resistance welding. Note that in Figures 1, 4 and 6, only a part of the main body member 1 is schematically shown.

[0015] <Main Body Member> The main body member 1 forms a flow passage for allowing exhaust gas to pass through. The main body member 1 is made of metal and configured as a plate-shaped member. For example, a cylindrical main body member 1 is formed by rolling a plate-shaped metal member. The main body member 1 has a welding surface 11, a non-welding surface 12, and an insertion hole 13.

[0016] The welding surface 11 is a surface to which the workpiece 2 is welded, and is an outer surface of the main body member 1, that is, a surface opposite to the flow passage. In the present embodiment, the region of the welding surface 11 to which the workpiece 2 is welded is planar. The non-welding surface 12 is a surface opposite to the welding surface 11, and is an inner surface of the main body member 1.

[0017] The insertion hole 13 is a through hole formed in the main body member 1, and penetrates the welding surface 11 and the non-welding surface 12. The insertion hole 13 is a hole that allows a predetermined object 3 to be inserted from the outside of the main body member 1 into the flow passage formed by the main body member 1.

[0018] <Workpiece> The workpiece 2 is a joining member for attaching a predetermined object 3 to the in-vehicle component 100. In the present embodiment, the workpiece 2 is a sensor boss for attaching a sensor as the predetermined object 3 to the in-vehicle component 100. The sensor boss is a member configured to hold the sensor inserted into the insertion hole 13 of the main body member 1. The workpiece 2 is attached to the welding surface 11 of the main body member 1.

[0019] The workpiece 2 is made of metal and has a cylindrical shape. In the present embodiment, the workpiece 2 has a shape in which a central axis A extending from a welded end 21 described later to a non-pressing surface 222 of a non-welded end 22 is curved. As shown in FIGS. 1 to 3, the workpiece 2 includes the welded end 21, the non-welded end 22, an outer peripheral surface 23, a communication path 24, and a protruding portion 25.

[0020] The welded end 21 is an end welded to the welding surface 11 of the main body member 1. The end surface of the welded end 21 is planar and intersects the central axis A substantially perpendicularly. The non-welded end 22 is an end on the opposite side from the welded end 21. The non-welded end 22 includes a pressing surface 221 and a non-pressing surface 222.

[0021] The pressing surface 221 is a surface pressed during ring projection welding, and is a surface that abuts against a fixing base 6 described later. The pressing surface 221 faces the welding surface 11 of the main body member 1 in the pressing direction shown in FIG. 4, which is the direction in which pressing is applied during ring projection welding. In the present embodiment, the pressing direction is the vertical direction in FIG. 4, in other words, a direction substantially perpendicular to the pressing surface 221. In the present embodiment, the pressing surface 221 is planar and extends parallel to the welding surface 11 of the main body member 1. The pressing surface 221 is an end surface in the pressing direction at the non-welded end 22 of the workpiece 2.

[0022] The non-pressing surface 222 is the surface that contacts the receiving jig 7, which will be described later. In this embodiment, the non-pressing surface 222 is located between the pressing surface 221 and the end face of the welded end 21 in the pressing direction. Specifically, the non-pressing surface 222 is planar and extends with an inclination relative to the welded surface 11 of the main body member 1. The non-pressing surface 222 extends from the pressing surface 221 toward the welded end 21 and intersects with the central axis A approximately perpendicularly. The non-pressing surface 222 is the end face in the direction of the central axis A at the non-welded end 22 of the workpiece 2.

[0023] For example, the central axis A extends from the center of the welded end 21 to the center of the non-pressed surface 222. In this embodiment, as shown in Figure 1, the central axis A extends linearly from the welded end 21, curves, and then extends linearly to the non-pressed surface 222 while being inclined with respect to the end face of the welded end 21. Therefore, the workpiece 2 is fixed to the main body member 1 with the central axis A in a curved state. Furthermore, since the central axis A has a portion that extends inclined with respect to the end face of the welded end 21, it can also be said that the workpiece 2 is fixed to the main body member 1 with the central axis A inclined with respect to the welded surface 11 of the main body member 1. Note that the state in which the central axis A is inclined with respect to the welded surface 11 of the main body member 1 can also be rephrased as the central axis A having an angle with respect to a line that extends substantially perpendicular to the welded surface 11.

[0024] As a result, the welded surface 11 of the main body member 1, the end face of the welded end 21 of the workpiece 2, and the pressing surface 221 of the unwelded end 22 of the workpiece 2 are arranged substantially parallel to each other. In addition, the unpressed surface 222 of the unwelded end 22 of the workpiece 2 is arranged to intersect with the welded surface 11 of the main body member 1, the end face of the welded end 21 of the workpiece 2, and the pressing surface 221 of the unwelded end 22 of the workpiece 2.

[0025] The outer circumferential surface 23 is a surface that extends from the welded end 21 to the unwelded end 22. In other words, in this embodiment, all surfaces other than the end face of the welded end 21, the pressing surface 221, and the unpressed surface 222 are referred to as the outer circumferential surface 23. Near the welded end 21 of the workpiece 2, a straight section 20 is provided that extends from the welded end 21 substantially perpendicular to the end face of the welded end 21. The straight section 20 is part of the outer circumferential surface 23. In this embodiment, as shown in Figures 2 and 3, the outer circumferential surface 23 has two planar sections 231 that extend planarly in the direction in which the pressing surface 221 and the unpressed surface 222 are aligned, and along the pressing direction. The two planar sections 231 are arranged to face each other. Specifically, the two planar sections 231 are arranged parallel to each other with the unpressed surface 222 in between. Note that, for example, two or more planar sections may be formed on the outer circumferential surface, or no planar sections may be formed thereon.

[0026] The communication passage 24 is a through-hole formed in the workpiece 2, passing through the end face of the welded end 21 and the non-pressed surface 222. In this embodiment, as shown in Figure 1, the communication passage 24 extends linearly from the welded end 21 to the non-pressed surface 222 and is inclined with respect to the end face of the welded end 21. The tip of a predetermined object 3 can be inserted through the communication passage 24. In this embodiment, the communication passage 24 has a small-diameter portion 241 and a large-diameter portion 242. The small-diameter portion 241 has a first opening located at the welded end 21 and a second opening communicating with the large-diameter portion 242. The large-diameter portion 242 has a larger diameter than the small-diameter portion 241. The large-diameter portion 242 has an opening located on the non-pressed surface 222 that does not communicate with the small-diameter portion 241. In addition, the predetermined object 3 may have threads formed on it, and the large-diameter portion 242 may have threads that screw into the threads of the predetermined object 3.

[0027] As shown in Figure 2, the projection 25 is provided on the welded end 21 and protrudes from the end face of the welded end 21. In this embodiment, the projection 25 is formed in an annular shape so as to surround the opening of the communication passage 24 on the welded end 21 side. In other words, the projection 25 is provided so as to circle around the edge of the welded end 21. In this embodiment, the projection 25 has a trapezoidal cross-sectional shape perpendicular to the direction of circulation. Also, in this embodiment, the projection 25 is positioned approximately in the middle between the edge of the welded end 21 and the opening on the welded end 21 side.

[0028] The shape and arrangement of the projection may be other shapes and arrangements as long as the pressure is concentrated on the main body member. For example, the projection may have a triangular, square, or square cross-sectional shape perpendicular to the circumferential direction, with a recess in the center of the upper surface. Also, for example, the projection may be positioned near the edge of the welded end 21, or near the opening on the welded end 21 side. Pressure is applied to the projection 25 by ring projection welding, and electricity is passed through it. As a result, the projection 25 is melted by the current, and the workpiece 2 is welded to the main body member 1.

[0029] [2. Manufacturing methods for automotive parts] Next, the manufacturing method of the in-vehicle component 100 will be described using Figure 4. Specifically, the welding method of the workpiece 2 included in the manufacturing method of the in-vehicle component 100 will be described. The manufacturing method of the in-vehicle component 100 comprises a contact step and a welding step. In the manufacturing method of the in-vehicle component 100 of this embodiment, the workpiece 2 is welded to the main body member 1 by ring projection welding using a welding apparatus comprising a first electrode 4, a second electrode 5, a fixed base 6, and a receiving jig 7.

[0030] <First electrode and second electrode> As shown in Figure 4, the first electrode 4 is positioned above the main body member 1 so as to be in contact with the non-welded surface 12.

[0031] The second electrode 5 contacts the vicinity of the weld end 21 on the outer circumferential surface 23 of the workpiece 2. Specifically, the second electrode 5 contacts the straight portion 20 of the workpiece 2 and is positioned to circle the straight portion 20, as shown in Figure 5. That is, the straight portion 20 of the workpiece 2 is covered by the second electrode 5 in the circumferential direction around the central axis A of the workpiece 2.

[0032] In this embodiment, the second electrode 5 has a first portion 5a located on the left side in Figure 5, and a second portion 5b located on the right side in Figure 5. The first portion 5a and the second portion 5b are arranged to sandwich the workpiece 2 from the left and right sides. Notches are formed on the mutually opposing end faces of the first portion 5a and the second portion 5b, with a shape that follows the curvature of the outer circumferential surface 23 of the workpiece 2. The first portion 5a and the second portion 5b are brought together with their notches facing each other and their respective end faces on both sides of the notches in contact with each other. As a result, the outer circumferential surface 23 of the workpiece 2 is sandwiched between the first portion 5a and the second portion 5b, covering the entire circumference.

[0033] The surface of the first electrode 4 facing the main body member 1 and the surface of the second electrode 5 facing the main body member 1 extend substantially parallel to each other. Due to the arrangement of the first electrode 4 and the second electrode 5 described above, the distance from the first electrode 4 to the second electrode 5 is approximately the same as the sum of the thickness of the main body member 1 and the height of the projection 25.

[0034] <Fixed stand> The fixing base 6 is a component that is fixed in place so as not to move, and to which the receiving jig 7, described later, can be positioned above it. The upper surface 61 of the fixing base 6 is flat. The fixing base 6 is insulated by an insulating material such as nylon.

[0035] <Support jig> The support jig 7 is a member that holds the workpiece 2 described above. In this embodiment, as shown in Figure 4, it is configured to support a portion of the non-welded end 22 of the workpiece 2 from below. Specifically, when the pressing surface 221 of the workpiece 2 is in contact with the upper surface 61 of the fixed base 6, a space is formed between the upper surface 61 of the fixed base 6 and the non-pressed surface 222 of the workpiece 2 in the pressing direction. The support jig 7 is then housed in this space, and the workpiece 2 is supported from below by the support jig 7 coming into contact with the upper surface 61 of the fixed base 6 and the non-pressed surface 222 of the workpiece 2. The support jig 7 is made of an insulating material. Examples of insulating materials include nylon, plastic, and insulating metal. The support jig 7 has a bottom surface 71, an upper surface 72, a side surface 73, and an insertion portion 74.

[0036] The bottom surface 71 is the surface that contacts the upper surface 61 of the fixed base 6 and is pressed against during ring projection welding. In this embodiment, the bottom surface 71 is planar and extends parallel to the welding surface 11 of the main body member 1.

[0037] The upper surface 72 is located above the bottom surface 71 and is in contact with the non-pressed surface 222 of the workpiece 2. The upper surface 72 is planar and extends inclined with respect to the upper surface 61 of the fixed base 6 when the receiving jig 7 is placed on the fixed base 6. The upper surface 72 intersects the central axis A approximately perpendicularly when the non-pressed surface 222 of the workpiece 2 is in contact with it.

[0038] The side surface 73 is a surface that extends from the bottom surface 71 to the top surface 72. The insertion portion 74 is a part that protrudes from the upper surface 72, substantially perpendicular to the upper surface 72. Specifically, the insertion portion 74 has substantially the same shape as the large-diameter portion 242 and is insertable into the large-diameter portion 242. In other words, the outer diameter of the insertion portion 74 is substantially the same as the inner diameter of the large-diameter portion 242, and the central axis of the insertion portion 74 coincides with the central axis of the large-diameter portion 242 when the insertion portion 74 is inserted into the large-diameter portion 242 in the communication passage 24 of the workpiece 2. From the viewpoint of inserting the insertion portion 74 into the large-diameter portion 242, the outer diameter of the insertion portion 74 may be formed to be slightly smaller than the inner diameter of the large-diameter portion 242.

[0039] When the insertion portion 74 is inserted into the large-diameter portion 242, the tip of the insertion portion 74 abuts against the stepped portion formed by the connection between the large-diameter portion 242 and the small-diameter portion 241. As a result, the movement of the workpiece 2 is restricted by the insertion portion 74. Consequently, the workpiece 2 is stably held by the receiving jig 7.

[0040] <Abutting process> As shown in Figure 4, in the contact process, the projection 25 formed on the welded end 21 of the workpiece 2 is brought into contact with the welded surface 11 of the main body member 1.

[0041] Specifically, first, the workpiece 2 is positioned on the fixed base 6 and the receiving jig 7 so that the insertion portion 74 of the receiving jig 7, which is placed on the fixed base 6, is inserted into the large-diameter portion 242 of the communication passage 24 of the workpiece 2. At this time, the pressing surface 221 of the workpiece 2 comes into contact with the upper surface 61 of the fixed base 6, the non-pressing surface 222 of the workpiece 2 comes into contact with the upper surface 72 of the receiving jig 7, and the tip of the insertion portion 74 comes into contact with the stepped portion formed by the connection between the large-diameter portion 242 and the small-diameter portion 241. As a result, the workpiece 2 is held by the receiving jig 7 with the welded end 21 facing upward.

[0042] Next, the second electrode 5 is positioned so as to contact the straight portion 20 of the workpiece 2. Specifically, the first portion 5a and the second portion 5b sandwich the straight portion 20 of the workpiece 2 from the left and right directions, covering its entire circumference.

[0043] Next, the main body member 1 is positioned above the welded end 21 of the workpiece 2 so that the communication passage 24 of the workpiece 2 and the insertion hole 13 of the main body member 1 overlap, and the projection 25 formed on the welded end 21 of the workpiece 2 is brought into contact with the welded surface 11 of the main body member 1.

[0044] Then, the first electrode 4 is positioned above the main body member 1, and the first electrode 4 is brought into contact with the non-welded surface 12 of the main body member 1.

[0045] <Welding Process> In the welding process, the workpiece 2 held in the receiving jig 7 and the main body member 1 come into contact, the first electrode 4 is in contact with the non-welded surface 12 of the main body member 1, and the second electrode 5 is in contact with the straight portion 20 of the workpiece 2, and ring projection welding is performed. As a result, the workpiece 2 is welded to the main body member 1.

[0046] Specifically, first, the first electrode 4 is moved downward, and pressure is applied to the main body member 1 and the workpiece 2 in the direction of arrow X shown in Figure 4, so as to press the main body member 1 against the workpiece 2. At this time, the pressing surface 221 of the workpiece 2 comes into contact with the upper surface 61 of the fixed base 6, and the workpiece 2 is stably held by the receiving jig 7. The pressing surface 221 of the workpiece 2 and the bottom surface 71 of the receiving jig 7 are pressed along the pressing direction by a force opposite to the direction of arrow X. For this reason, even with a workpiece 2 that has a curved shape with a central axis A, as in this embodiment, the pressure is easily applied uniformly to the workpiece 2 along the pressing direction. That is, since the pressing direction by the first electrode 4 is substantially perpendicular to the main body member 1, the second electrode 5, the receiving jig 7, and the fixed base 6, the pressure is easily applied uniformly to the workpiece 2.

[0047] Along with applying pressure to the main body member 1 and workpiece 2 as described above, current is passed between the first electrode 4 and the second electrode 5. As a result, current flows from the first electrode 4 to the second electrode 5 via the projection 25 of the workpiece 2 and the outer circumferential surface 23 of the workpiece 2, as shown by arrow Y in Figure 4. In this embodiment, the second electrode 5 is positioned on the straight portion 20 of the workpiece 2. Therefore, even with a workpiece 2 that has a curved shape with a central axis A as in this embodiment, the distance from the first electrode 4 to the second electrode 5 is approximately the same, so current flows more uniformly through the projection 25 of the workpiece 2, as shown in Figure 5.

[0048] [3. Effects] According to the embodiments described in detail above, the following effects can be obtained. (3a) In this embodiment, the workpiece 2 has a pressing surface 221 and a non-pressing surface 222, the non-pressing surface 222 is located between the pressing surface 221 and the end face of the weld end 21 in the pressing direction. The receiving jig 7 is housed in the space formed between the upper surface 61 of the fixed base 6 that abuts against the pressing surface 221 of the workpiece 2 and the non-pressing surface 222. As a result, the workpiece 2 is held by the receiving jig 7, and during ring projection welding, the pressing surface 221 and the bottom surface 71 of the receiving jig 7 are pressed in the pressing direction.

[0049] Therefore, as in this embodiment, even if the central axis A of the workpiece 2 is bent or tilted relative to the welding surface 11 of the main body member 1, the workpiece 2 is held stably. In other words, even if the workpiece 2 has a shape in which the central axis A does not extend straight from the welding surface 11 of the main body member 1 in the direction of pressure, the workpiece 2 is held stably. Therefore, the center of gravity of the workpiece 2 is less likely to be biased by the pressure applied during ring projection welding. Consequently, it is easier to apply pressure uniformly to the workpiece 2. As a result, welding defects of the workpiece 2 to the main body member 1 can be reduced.

[0050] Furthermore, in this embodiment, since the workpiece 2 has a pressing surface 221 and a non-pressing surface 222, the non-pressing surface 222 can be used to hold the workpiece 2 with the receiving jig 7. For this reason, the receiving jig 7 may not have a shape that covers the entire workpiece 2. Therefore, the size of the receiving jig 7 can be reduced compared to a receiving jig that covers the entire workpiece 2. Also, the workpiece 2 can be held even if the shape precision of the receiving jig 7 is lower compared to a receiving jig that covers the entire workpiece 2.

[0051] (3b) In this embodiment, the workpiece 2 is fixed to the main body member 1 with its central axis A bent (in other words, the central axis A of the workpiece 2 is inclined with respect to the welding surface 11 of the main body member 1). Then, during ring projection welding, the first electrode 4 is positioned on the non-welded surface 12 of the main body member 1, and the second electrode 5 is positioned on the straight portion 20 of the workpiece 2 (i.e., near the welding end 21 on the outer peripheral surface 23). As a result, the length of the current path from the first electrode 4 through the main body member 1 and the outer peripheral surface 23 of the workpiece 2 to the second electrode 5 (i.e., the length of the current path in the workpiece 2) tends to be shorter compared to a configuration in which the second electrode 5 is positioned on the non-welded end 22 of the workpiece 2. In contrast, in a configuration in which the second electrode 5 is positioned on the non-welded end 22 of the workpiece 2, the length of the current path in the workpiece 2 is also longer, so the way the current flows is more easily affected by the shape of the workpiece 2. For this reason, in the case of a workpiece 2 with a bent central axis A, as in this embodiment, the way the current flows tends to vary throughout the workpiece 2.

[0052] On the other hand, in this embodiment, as described above, even in the case of a workpiece 2 with a curved central axis A, the length of the current path in the workpiece 2 is also shortened, so variations in the length of the current path throughout the workpiece 2 can be suppressed. As a result, the way the current flows becomes less likely to vary throughout the workpiece 2.

[0053] Therefore, even in the case of workpiece 2 with a curved central axis A, as shown in Figure 5, the current flows more uniformly through the projection 25 of workpiece 2 during ring projection welding. Consequently, welding defects of workpiece 2 to the main body member 1 can be reduced. Furthermore, ring projection welding allows for gap-free welding between workpiece 2 and the main body member 1.

[0054] (3c) In this embodiment, the vehicle component 100 is an exhaust system component, and the workpiece 2 is a sensor boss for mounting a sensor. Therefore, welding defects of the sensor boss in the exhaust system component can be made less likely.

[0055] (3d) In this embodiment, the workpiece 2 is welded to the main body member 1 with the weld end 21 of the workpiece 2 facing upward. This makes it possible to perform ring projection welding by applying pressure to the main body member 1 positioned above the workpiece 2 with the first electrode 4. Therefore, it is possible to suppress the complexity of the structure of the device used for ring projection welding.

[0056] In this embodiment, workpiece 2 corresponds to an example of a welded member, the central axis A of workpiece 2 corresponds to an example of an axis, and the two planar portions 231 correspond to two holding surfaces.

[0057] [4. Other Embodiments] While embodiments of this disclosure have been described above, it goes without saying that this disclosure is not limited to the embodiments described above and can take various forms.

[0058] (4a) In the above embodiment, ring projection welding was exemplified as resistance welding for welding the workpiece 2 to the main body member 1, but the method of welding the workpiece to the main body member is not limited to this. For example, the resistance welding may be projection welding other than ring projection welding. In the case of such projection welding, the workpiece has a plurality of protrusions at the welding end, and the plurality of protrusions are arranged at intervals. Pressure is applied to the plurality of protrusions and an electric current flows through them, and the plurality of protrusions are melted by the electric current and crushed by the pressure, thereby welding the workpiece to the main body member. Alternatively, for example, the resistance welding may be spot welding. In the case of spot welding, the workpiece does not have a protrusion at the welding end, and the first electrode, which is placed on the non-welded surface 12 of the main body member 1, has a tapered shape at the tip that contacts the non-welded surface 12. The tip of the first electrode pressurizes the main body member 1, and by passing an electric current through the pressurized portion whose resistance has increased due to the pressurization, the pressurized portion heats up and melts, thereby welding the workpiece to the main body member.

[0059] (4b) In the above embodiment, the projection 25 was provided on the welded end 21 of the workpiece 2, but the location where the projection is provided is not limited to this. For example, in a configuration in which the workpiece has a flange at the welded end, the projection may be provided on the flange. Also, for example, the projection may be provided around the insertion hole on the welded surface of the main body member. Furthermore, for example, in the case of spot welding, the projection may not be provided on either the workpiece or the main body member.

[0060] (4c) In the above embodiment, the second electrode 5 is shown as being divided into two parts in the left-right direction, but the direction in which the second electrode is divided, or the number of parts in which the second electrode is divided, is not limited thereto. For example, the second electrode may be divided into two parts in the front-back direction. Also, for example, the second electrode may be divided into three or more parts.

[0061] (4d) In the above embodiment, the receiving jig 7 is shown to have an insertion portion 74, and the workpiece 2 is held stably by the insertion portion 74 being inserted into the large diameter portion 242 of the communication passage 24 of the workpiece 2. However, the shape of the receiving jig is not limited to this. For example, the receiving jig may have a configuration that does not have an insertion portion 74. In this case, the workpiece 2 is held by the receiving jig only by the upper surface of the receiving jig contacting the non-pressing surface 222 of the workpiece 2 and the bottom surface of the receiving jig contacting the upper surface 61 of the fixed base 6.

[0062] (4e) In the above embodiment, a configuration in which the workpiece 2 is held using a receiving jig 7 has been illustrated, but the configuration for holding the workpiece 2 is not limited to this. For example, as shown in Figures 6 and 7, the workpiece 2 may be held by being clamped by a clamp 8. Specifically, during ring projection welding, the clamp 8 is brought into contact with the two planar portions 231 formed on the outer peripheral surface 23 of the workpiece 2, and the workpiece 2 is clamped by the clamp 8. In other words, in a configuration in which the workpiece 2 is held by a clamp 8, the two planar portions 231 function as surfaces for clamping and holding the workpiece 2 during ring projection welding. As a result, during ring projection welding, the workpiece 2 can be held stably by clamping the two planar portions 231 with the clamp 8, making it easier to apply uniform pressure to the workpiece via the pressing surface 221.

[0063] (4f) In the above embodiment, the workpiece 2 is shown as having a curved central axis A (in other words, having a portion where the central axis A is inclined with respect to the end face of the welded end 21), but the shape of the workpiece is not limited to this.

[0064] For example, the workpiece may have a central axis that is inclined with respect to the end face of the welded end of the workpiece, and extends linearly from the welded end to the non-pressed surface of the non-welded end. Specifically, the workpiece has a shape such that its outer circumferential surface is inclined with respect to the end face of the welded end, and extends linearly along the central axis from the welded end to the non-welded end. In this case, the workpiece is fixed to the main body member 1 with its central axis inclined with respect to the welded surface 11 of the main body member 1. Even with a workpiece of this shape, by positioning the second electrode near the welded end on the outer circumferential surface of the workpiece, the current can be more easily distributed uniformly at the joint between the workpiece and the main body member during resistance welding. Furthermore, because the workpiece has a pressing surface and is held by a receiving jig, the workpiece is held stably, making it easier to apply uniform pressure to the workpiece. Therefore, welding defects of the workpiece to the main body member 1 can be reduced.

[0065] (4g) In the above embodiment, pressure was applied by the downward movement of the first electrode 4 in the welding process of the manufacturing method of the in-vehicle component 100, but the direction in which the pressure is applied is not limited to this. For example, in a state in which the main body member 1 and the first electrode 4 placed on the non-welded surface 12 of the main body member 1 are fixed, pressure may be applied by the upward movement of the workpiece 2 and the receiving jig 7 that holds the workpiece 2, in a state in which the second electrode 5 is in contact with the straight portion 20 of the workpiece 2.

[0066] (4h) In the above embodiment, the vehicle component 100 was an exhaust system component, but for example, the vehicle component may be another component used in a heat exchanger or the like. (4i) In the above embodiment, the workpiece 2 was a sensor boss for holding the sensor, but it may be another joining member for attaching a predetermined object to the vehicle component 100.

[0067] (4j) In the above embodiment, the welded end 21 of the workpiece 2 was welded to the main body member 1 with the welded end 21 facing upward, but for example, the welded end 21 of the workpiece 2 may be welded to the main body member 1 with the welded end 21 facing downward.

[0068] (4k) The functions of one component in the above embodiment may be distributed among multiple components, or the functions of multiple components may be integrated into one component. Also, some parts of the configuration of the above embodiment may be omitted. Also, at least some parts of the configuration of the above embodiment may be added to, replaced with, etc., the configuration of other above embodiments.

[0069] [Technical concepts disclosed in this specification] [Item 1] A welding member that is attached by resistance welding to the welding surface of a main body component of an on-board component mounted on a vehicle, The welded end to be welded to the aforementioned welding surface, The non-welded end opposite to the welded end, Equipped with, The non-welded end has a pressing surface that is pressed during resistance welding and faces the welded surface in the pressing direction, which is the direction in which it is pressed, and a non-pressing surface other than the pressing surface. The welded member is a welded member having a shape in which the shaft extending from the welded end to the non-pressed surface is inclined with respect to the welded surface, or the shaft is bent.

[0070] [Item 2] The welded member described in item 1, The non-pressing surface is a welded member located between the pressing surface and the welded end in the pressing direction.

[0071] [Item 3] A welded member as described in item 1 or item 2, The aforementioned vehicle component is a welded member, which is an exhaust system component for passing exhaust gas through.

[0072] [Item 4] A welded member described in any one of items 1 to 3, The aforementioned resistance welding is projection welding, and the welded member is a projection weld.

[0073] [Item 5] A welded member described in any one of items 1 to 4, A welded member, wherein at least two holding surfaces are formed on the outer circumferential surface extending from the welded end to the non-welded end, facing each other, for gripping and holding the welded member during resistance welding. [Explanation of symbols]

[0074] 1...Main body component, 2...Workpiece, 3...Specified object, 4...First electrode, 5...Second electrode, 5a...First part, 5b...Second part, 6...Fixing base, 7...Receiving jig, 8...Clamp, 11...Welded surface, 12...Non-welded surface, 13...Insertion hole, 20...Straight section, 21...Welded end, 22...Non-welded end, 23...Outer circumferential surface, 24...Communication passage, 25...Protrusion, 71...Bottom surface, 61,72...Top surface, 73...Side surface, 74...Insertion section, 100...Vehicle-mounted component, 221...Pressing surface, 222...Non-pressing surface, 231...Flat section, 241...Small diameter section, 242...Large diameter section, A...Central axis.

Claims

1. A welding member that is attached by resistance welding to the welding surface of a main body component of an on-board component mounted on a vehicle, The welded end to be welded to the aforementioned welding surface, The non-welded end opposite to the welded end, Connecting passageway, Equipped with, The non-welded end is a pressing surface that is pressed during resistance welding and faces the weld surface in the pressing direction, which is the direction of pressing, and has a pressing surface that extends parallel to the weld surface, and a non-pressing surface other than the pressing surface that extends with respect to the weld surface, At least a portion of the non-pressing surface is located outside the outer edge of the end face of the welded end when viewed along the pressing direction, The welded member is a welded member in which the communication passage is a hole extending from the end face of the welded end to the non-pressed surface.

2. A welded member according to claim 1, The non-pressing surface is a welded member located between the pressing surface and the end face of the welded end in the pressing direction.

3. A welding member according to claim 1 or claim 2, The aforementioned vehicle component is a welded member, which is an exhaust system component for passing exhaust gas through.

4. A welding member according to claim 1 or claim 2, The aforementioned resistance welding is projection welding, and the welded member is a projection weld.

5. The welded member according to claim 4, A welded member further comprising a straight portion extending substantially perpendicular to the end face of the welded end toward the non-welded end from the welded end.

6. A welding member according to claim 1 or claim 2, A welded member, wherein at least two holding surfaces are formed on the outer circumferential surface extending from the welded end to the non-welded end, facing each other, for gripping and holding the welded member during resistance welding.

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