JPH0336710B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a reservoir device for a master cylinder.

Conventionally, as a manufacturing method of this type, a pair of synthetic resin members having welded portions facing the periphery of the opening end are fitted into the recesses of a pair of opposing molds, with the recesses of the members facing each other. After a float movable across a plane including the welded portion is previously installed in a recess of one of the pair of members, the welded portion is heated and melted, and the pair of molds is used to press the welded portion to melt the float. A method is known in which a reservoir body is formed by crimping the members of the reservoir body, and a space for storing liquid is formed inside the reservoir body.

However, in this method, since the float is not fixed in one of the recesses, vibrations caused when the pair of molds move to heat the welded part of the pair of members may cause the float to be placed inside the recess beforehand. It may move from the position to the open end side. In such a case, the float may also be heated and partially melted during the process of heating and melting the welded part, causing the float to become deformed or stuck in one of the recesses, making it impossible to move within the reservoir body. This will cause problems.

For this reason, a method has been proposed in which the outer periphery of the float is held between a plurality of claws provided in one of the recesses to mechanically fix the float in one of the recesses. However, in this method, after forming the reservoir body, an external force is mechanically applied to the float through a hole provided in the reservoir body.
Since the float must be removed from the claw and made movable, the process and work for releasing the fixation of the float are complicated, and problems such as the risk of the float being damaged by external force arise.

The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a method for manufacturing a reservoir device for a master cylinder, which prevents the float from melting and damage, and also allows the float to be released extremely easily. The object of the present invention is that the float is magnetically fixed within the one recess.

By doing this, while the magnetic attraction force is acting on the float, the float is fixed in one of the recesses and will not move toward the open end due to vibrations, etc., thereby preventing the float from melting. When the magnetic attraction force is no longer applied to the float, the fixation is automatically released and the float can be moved inside the reservoir body. There is no need to apply external force, and the work of releasing the fixation of the float becomes extremely simple, and damage to the float due to external force can be prevented.

Hereinafter, the present invention will be explained in detail based on the illustrated embodiments.

The figure is a plan cross-sectional view showing one embodiment of the present invention, and shows a heating and melting process during production of a reservoir device. In the following explanation, the "up and down" direction of the reservoir device refers to the "left and right" directions in the drawings.
direction.

In the figure, reference numerals 1 and 2 denote a pair of upper and lower bodies made of synthetic resin, which can form a reservoir body having a substantially rectangular parallelepiped shape of a reservoir device for a tandem master cylinder, and have openings facing each other. The upper body 1 has an upper recess formed by an upper wall 3 and a peripheral wall 4, and the lower body 2 has a lower wall 5 and a peripheral wall 4'.
A lower recess is formed by. The upper recess has a depth that can accommodate the entire float 25,
Three recesses 10,
11 and 12, the lower recess extends parallel to the peripheral wall 4' from the lower wall 5 toward the opening,
It is further divided into three recesses 13, 14, and 15 by partition walls 6, 7 and partition walls 8, 9, which are opposite to each other. In addition, a recess 1 is provided in the upper wall 3 of the upper body 1.
A cylindrical liquid inlet portion 16 having an opening communicating with the liquid inlet 1 and into which a cap (not shown) can be attached is integrally formed. Cylindrical liquid connecting parts 17 and 18 integrally protrude from the lower wall 5 of the lower body 2 and have passages communicating with recesses 13 and 15, respectively, and are connected to a tandem master cylinder (not shown) so as to be able to supply liquid. Furthermore, a bulge 19 is integrally formed on the lower surface facing the recess 14 and extends along the lower wall 5 in a direction perpendicular to the direction connecting the centers of the liquid connecting parts 17 and 18. The hole 2 of the bulge 19 is formed.
0 is provided.

At the open end of each of the upper body 1 and the lower body 2, there are flanges 2 facing each other over the entire circumference of the peripheral walls 4, 4'.
1 and 22 are integrally provided, and welding parts 23 and 2 for welding the upper body 1 and the lower body 2 by the end faces of the peripheral walls 4 and 4' and the opposing faces of the flanges 21 and 22.
4 is formed. Note that the partition walls 6 and 7 are formed to such a length that their lower end surfaces are positioned inward of the upper recess than the opening end surface of the upper body 1, and the partition walls 8 and 9 have their upper end surfaces slightly longer than the opening end surface of the lower body 2. A passageway is formed between the partition walls 6 and 8 and between the partition walls 7 and 9 to allow liquid communication therebetween.

25 is molded from foamable synthetic resin,
It is a float that can float on the liquid stored in the reservoir body. This float 25 is prevented from rotating by fitting the vertical grooves 26, 27 provided on its side surface with the guide portions 28, 29, 30, 31 provided on the partition walls 6, 7, 8, 9. being guided,
It is movable within the float chamber formed by the recesses 11 and 14 across the plane containing the welds 23 and 24 of the reservoir body. A rectangular parallelepiped permanent magnet 32 is integrally molded in the lower part of the float 25 so that one surface of the permanent magnet 32 faces the inner surface of the lower wall 5 of the lower body 2 and is prevented from coming off. The permanent magnet 32 has different magnetic poles on both ends of the hole 20 in the axial direction, and when the reservoir device is used, when the float 25 moves downward by a predetermined amount due to a drop in the liquid level, the lower body 2 bulges. A magnetically sensitive element such as a reed switch installed in the hole 20 of 19 can be operated.

A plate-shaped attraction member 33 made of a magnetic material is integrally molded on the upper part of the float 25 so that one side of the attraction member 33 can come into contact with the inner surface of the upper wall 3 of the upper body 1. A permanent magnet 40 provided in
The magnetic force allows the float 25 to be magnetically fixed within the recess 11. Specifically, the suction member 33 is a plate member having a hole in the center made by punching an iron plate, and uses the slope (sagging) of the inner and outer circumferential surfaces that occurs during the punching process to prevent the float 25 from coming off. It has been subjected.

34 and 35 are pressing surfaces 38 and 3 facing each other.
9 are a pair of press molds vertically arranged. On one of the pressing molds 34, from the pressing surface 38 toward the inside,
A recess 36 is provided in which the upper body 1 can be fitted by bringing the flange 21 and the pressing surface 38 into contact. Further, when the upper body 1 is fitted into the recess 36, the upper wall 3
A float 2 is placed in a portion facing the recess 11 via the
A permanent magnet 40 capable of applying a magnetic force is fitted onto the attraction member 33 provided at 5. The other pressing die 35 is provided with a recess 37 extending inward from the pressing surface 39 into which the lower body 2 can be fitted by bringing the flange 22 and the pressing surface 39 into contact. Such a pair of press molds 34 and 35 are formed by forming the upper body 1 and the lower body 2 so that the welded parts 23 and 24 face each other, and the recesses 36 respectively.
and 37, the pressing surfaces 38 and 39
It is possible to move in the horizontal direction between a position where the welded parts 23 and 24 are sufficiently separated from each other and a position where the welded parts 23 and 24 can be brought into contact and pressed. In the figure, the paper surface is a horizontal plane, and the direction passing through the paper surface at right angles is the vertical direction.

Reference numeral 41 denotes a heating plate that incorporates heating wires (none of which are shown) that are supplied with power from an external power source. This heating plate 41 is connected to the press molds 34 and 3.
5 in a direction along the pressing surfaces 38, 39, in other words, in a direction orthogonal to the moving direction of the pair of pressing molds 34, 35, both pressing molds, 3
On the 4 and 35 sides, heating surfaces 42 and 43 capable of applying high heat to the entire surfaces of the welded parts 23 and 24 of the upper body 1 and lower body 2 that are fitted into the press molds 34 and 35, respectively, are formed.

The pair of press molds 34, 35 and the heating plate 41 are assembled into a single device in which a predetermined movement is performed by pneumatic or hydraulically actuated equipment, and a predetermined electric power is supplied to the heating wire of the heating plate 41. It shall be controlled by the operator's switch operation.

The operation will be explained step by step below.

First, the heating plate 41 moves upward in the figure to a position where it comes out from between the press molds 34 and 35 and then stops, the press die 34 moves to the left in the figure, and the press die 35 moves to the right in the figure. , the pressing surfaces 38 and 39 are stopped with a wide gap between them. In this state, the preformed upper body 1 is fitted into the recess 36 with its upper wall 3 side facing the mold 34 side, and brought into contact with the pressing surface 38 of the flange 21. In addition, the pre-formed lower body 2
into the recess 37 with its lower wall 5 side facing the mold 36 side.
The flange portion 22 and the pressing surface 39 are brought into contact with each other. Next, the float 25, in which the permanent magnet 32 and the attraction member 33 have been integrally molded in advance, is placed in the vertical groove 2 with the surface of the attraction member 33 facing the upper wall 3.
6 and 27 are fitted into the recess 11 in alignment with the guide portions 28 and 29, respectively. These floats 2
5 into the recess 11, the suction member 33
As the float approaches the permanent magnet 40 provided on the mold 34, the magnetic force of the permanent magnet 40 acts on the attraction member 33, creating a force that draws the entire float 25 toward the upper wall 3. When the suction member 33 comes into contact with the inner surface of the upper wall 3, the permanent magnet 4 is strong enough to prevent the suction member 33 from moving toward the opening of the float 25.
The float 25 is magnetically fixed in the recess 11 by a magnetic force of zero.

Then, by operating the switch, the pair of press molds 3
4 and 35 are moved to bring the pressing surfaces 38 and 39 closer to each other, and the heating plate 41 is pressed against the pressing mold 34.
and 35. Then, each of the heating surfaces 42 and 43 of the heating plate 41 comes into a state in which it closely opposes the welded part 23 of the upper body 1 and the welded part 24 of the lower body 2, that is, the state shown in the drawing.
In this way, the welded parts 23 and 24 are connected to the heating surfaces 42 and 43.
It is heated and melted by the high heat radiated from.
However, the float 25 is fixed inside the recess 11 by the magnetic action of the permanent magnet 40 and the attraction member 33, and the lower surface on which the permanent magnet 32 is provided is sufficiently separated from the heating surface 42. Because there are
The synthetic resin part is never melted. Note that the welded parts 23 and 24 may be melted by contacting the heating surfaces 42 and 43, respectively.

When the welding parts 23 and 24 are heated and melted, the heating plate 41 is moved upward in the figure to a position where it comes out from between the pressing surfaces 38 and 39, and the pair of pressing molds 34 and 3
5 is moved to bring the pressing surfaces 38 and 39 closer together. Finally, the melted welded parts 23 and 24 come into contact with each other, and the flanges 21 and 23 are pressed between the pressing surfaces 38 and 39. In this way, the welded parts 23 and 24 are integrally connected,
The upper body 1 and the lower body 2 form one reservoir body, in which a first liquid chamber is formed by recesses 10 and 13 and a second liquid chamber is formed by recesses 12 and 15. A float chamber is formed by the liquid chamber and the recesses 11 and 14, respectively.

After this, the pair of press molds 34 and 35 are pressed against the press surface 38.
The space between and 39 opens wide, and the reservoir body is moved to a position where it can be taken out from the recesses 36 and 37, and then stopped. Then, the upper body 1 side of the reservoir body,
By pulling out the suction member 33 of the float 25 from the recess 36 of the press mold 34 with enough force to overcome the magnetic force (attractive force) of the permanent magnet 40 acting on the suction member 33 of the float 25, the suction member 33 of the float 25 is permanently attached. magnet 4
move away from 0. In this way, when the upper body 1 side of the reservoir body is completely pulled out from the recess 36, the magnetic fixation that prevents the float 25 from moving on the welded part 23 side is automatically released, and the float 25 is moved to the guide part 23. , 29, 30, and 31, and can move within the float chamber.

After forming the reservoir body, the hole 2 of the bulge 19 is
A reservoir device for a tandem master cylinder is completed by assembling a magnetic sensing element into the tank 0 and attaching a cap to the liquid inlet 16.

Here, the functions when this reservoir device is connected to a tandem master cylinder will be briefly explained. When brake fluid is injected from the opening of the fluid inlet 16, it flows into the first fluid chamber, the float chamber through the partitions 6 and 7, and the second fluid chamber through the partitions 7 and 9. Brake fluid is stored in the
In this way, a predetermined amount of brake fluid is stored in each chamber inside the reservoir main body, and the brake fluid can be supplied to the tandem master cylinder side through each passage of the fluid connection parts 17 and 18.

The float 25 moves along the guide portion 28, as the level of brake fluid injected into the reservoir body rises.
It is guided by 29, 30, and 31 and moves toward the upper body 1 side without rotating. By storing a predetermined amount of brake fluid in the reservoir body,
The permanent magnet 32 provided on the float 25 and the magnetically sensitive element provided in the hole 20 of the lower body 2 are sufficiently separated, and the magnetically sensitive element does not operate due to the magnetic force of the permanent magnet 32 in normal use. When the brake fluid in the reservoir body decreases due to fluid leakage or the like, the float 25 moves toward the lower body 2 side. When the level of the brake fluid drops to the upper end surfaces of the partition walls 8 and 9, the magnetic force of the permanent magnet 32 activates the magnetically sensitive element, and an alarm circuit connected to the magnetically sensitive element prevents the brake fluid from decreasing. be notified.

According to the above embodiment, the recess 3 of one of the molds 34
When the float 25 is inserted into the recess 11 of the upper body 1 that has been fitted in advance into the upper body 1 , the attraction member 33 is attracted by the magnetic force of the permanent magnet 40 provided on the mold 34 , and the float 25 is magnetically inserted into the recess 11 . This state is maintained as long as the upper body 1 is fitted into the recess 36. After welding the upper body 1 and the lower body 2, the upper body 1 side of the reservoir body is attached to the permanent magnet 40 acting on the suction member 33 of the float 25.
By pulling the float 25 out of the recess 36 with enough force to overcome the magnetic force of the float 25, the magnetic fixation of the float 25 is automatically released. Therefore, the welded parts 23, 24
When heated and melted, the float 25 can be prevented from moving toward the open end welding part 23 and being melted. Furthermore, compared to a method of mechanically fixing the float, the work of releasing the fixation of the float 25 is easier. can be done extremely easily. In addition, in order to release the fixation of the float 25, there is no need to apply mechanical external force to the float 25 from the outside through the opening provided in the reservoir body, so damage to the float 25 due to external force can be prevented. Regardless of the location of the opening, such as the inlet 16, the float 25 can be centrally located within the reservoir body.

The suction member 33 is formed by punching out an iron plate, so its processing is easy.Since the inner and outer circumferences are inclined with respect to the plate surface, the large diameter plate surface should be directed toward the float 25 as shown in the figure. Or, conversely, even if the small-diameter plate surface is molded toward the float 25 side, the float 25 is prevented from coming off. Therefore, the suction member 33 can be molded onto the float 25 without any consideration of the orientation of its plate surface.

Although the illustrated embodiments have been described above, the present invention is not limited to the above-mentioned embodiments.
It can be implemented in various ways.

For example, the attraction member 33 may be a permanent magnet having magnetic poles capable of attracting each other to the permanent magnet 40 provided on the press die 34. If the entire press die 34 is made of a magnetic material, only the attraction member 33 may be a permanent magnet. Good too. In addition, a permanent magnet 4 provided on the mold 34
An electromagnet may be used instead of 0. In addition, if the recess formed in the lower body 2 has a depth that can accommodate the entire float 25, after fitting the lower body into the recess 37 of the mold 35, the hole in the bulge 19 is 2
If the shaft member made of a magnetic material is automatically inserted into the magnet 0, the attraction member 33 and the permanent magnet 40
The permanent magnet 32 of the float 25
can also be used as a suction member to magnetically fix the float 25 within the recess 14 of the lower body 2.

In short, when a float is fitted into the recess of either one of the pair of members forming the reservoir body, the float is suctioned and fixed into the one recess between the outside of the one recess and the float. It is sufficient that magnetic action is generated.

In the embodiment, the lower wall 5 of the lower body 2 is moved by the magnetic force of the permanent magnet 32 provided on the lower surface of the float 25.
Although a description has been given of a reservoir device operated by a magnetically sensitive element provided on the outside, the present invention has a cylindrical portion formed from the upper or lower wall of the reservoir body toward the inside of the main body, and a magnetically sensitive element provided inside the cylindrical portion. The present invention can also be applied to a reservoir device having a cylindrical shape in which a float is fitted and guided in a cylindrical portion, and a permanent magnet that can actuate a magnetically sensitive element is molded on the inner circumferential side. Furthermore, it goes without saying that the present invention is not limited to use in tandem master cylinders, but can also be applied to reservoir devices for single master cylinders.

As is clear from the above description, according to the present invention, by magnetically fixing the float in a location of either one of the pair of members forming the reservoir body, magnetic attraction is applied to the float. As long as the float is acting, the float does not move, and when the magnetic attraction disappears, the float automatically moves within the reservoir body, which prevents the float from melting when a pair of members are welded. , unfixing the float is an extremely simple task.
Furthermore, this can be done without damaging the float due to mechanical external force.

[Brief explanation of drawings]

The drawing is a plan cross-sectional view showing one embodiment of the present invention.
This shows the process of heating and melting the welded part. 1... Upper body, 2... Lower body, 10, 11, 1
2, 13, 14 and 15... recess, 23, 24...
... Welded part, 25 ... Float, 33 ... Suction member, 34, 35 ... Press mold, 36, 37 ... Recessed part,
40...Permanent magnet, 41...Heating plate.

Claims (1)

[Claims] 1 A pair of synthetic resin members having welded portions facing the periphery of the opening end are respectively fitted into the recessed portions of the pair of opposing molds, with the recesses of the members facing each other, so as to include the welded portions. After a float movable across a plane is previously installed in the recess of one of the pair of members, the welded portion is heated and melted, and the pair of members are crimped with the pair of press molds to form a reservoir. A method for manufacturing a reservoir device for a master cylinder, which forms a main body and forms a space for storing liquid inside the reservoir main body, wherein the float is magnetically fixed in one of the recesses. A method for manufacturing a reservoir device.