JP5808192B2 - Resin container, method for manufacturing resin container, and method for detecting defective welding of resin container - Google Patents

Description

The present invention relates to a resin container , a method for manufacturing a resin container, and a method for detecting poor welding of a resin container.

2. Description of the Related Art Resin containers that are formed using a resin material and store or contain gas or liquid are known.
The resin container is formed by injection molding of a resin material or is formed by joining resin plate materials by resin welding (hereinafter simply referred to as welding).
An example of the latter is the resin container 110 shown in the perspective sectional view of FIG.

The resin container 110 is formed in a box shape by joining the top plate 101, the bottom plate 102, and the plurality of side plates 103 by welding. The joining between the side plates 103 and the welding for joining the bottom plate 102 and the side plate 103 are performed as a welded portion Y101 at the corner of the inner surface of the container.
The liquid injection hole 104 is provided with a small diameter at a position near the end of the top plate 101 so that the stored liquid does not easily spill out, and in consideration of convenience during discharge, particularly in the case of storage applications. There are many.
If a resin container made by joining a plurality of resin plates into a container is defective such as pinholes or cracks in the welded part, the contained liquid may leak from the defective part. .
For this reason, it is common to perform non-destructive detection of welded parts before use.

As a defect detection method for a welded portion in a resin container, a so-called penetrant inspection method is known.
In addition, there is a method for detecting defects in a welded part by checking the state of water leakage when water is injected into the water channel at a predetermined pressure, assuming that the container structure has a water channel at a position corresponding to the welded part. It is disclosed in Patent Document 1.

JP 2001-66217 A

The penetrant inspection method includes an operation of applying a liquid agent such as a penetrant or a developer to the welded portion, and an operation of visually observing the presence or absence of the penetrant remaining in the welded portion.
This method is suitable for a container in which the opening is sufficiently large and each liquid can be easily applied to the welded part and visually observed.
However, in a container having a narrow inlet and a deep interior as shown in FIG. 8, it is very difficult to perform these operations, and depending on the shape of the container, the inspection itself may not be performed.

Further, the method disclosed in Patent Document 1 is, for example, a water channel as shown in FIG. 9 which is an enlargement of the portion A in FIG. 8 when the defect inspection of the welded portion Y101 shown in FIG. Sharpening is required to form 105.
Furthermore, it is necessary to provide the welded portion Y102 with no defects at the lower corner of the bottom plate 102 so that there is no water leakage from other than the welded portion Y101.
In addition, since the strength of the resin container 110 is reduced by providing the water channel 105, in order to obtain the same strength as the case without the water channel 105, it is necessary to take care such as increasing the plate thickness.
Therefore, the manufacturing cost of the resin container 110 and the cost of the container itself are significantly increased.

Therefore, the problem to be solved by the present invention is that a resin-made container , a method for producing a resin-made container , and a weld-like defect in a resin-made container , which can easily detect a welding defect and suppress the cost of the container production and the container itself. It is to provide a detection method.

In order to solve the above problems, the present invention has the following configuration or procedure as means.
1) A resin container provided with an accommodating portion for accommodating a gas or a liquid formed by joining a plurality of resin plate materials by welding, wherein the accommodating portion has an end face of one of the resin plate materials other than the above The resin plate material is abutted against the surface of the resin plate material with a conductive layer formed of a conductive paint, and covers the one resin plate material, the end of the conductive layer, and the other resin plate material. Is formed in a box shape by the welded portion
A through hole provided at a position corresponding to the one resin plate material in the other resin plate material;
A conductive rod-shaped member, one end of which is inserted into the through-hole and connected to the conductive layer and attached so that the other end protrudes outward ;
A resin container, characterized that you have provided a.
2) The one resin plate member has a hole opened in the end face;
The connection part is provided with the one end side entering the hole, and the conductive layer is also filled in the hole so that the conductive layer and the connection part are in conductive contact. The resin container according to 1).
3) A method for producing a resin container comprising a resin container having an accommodating part for containing gas or liquid, wherein a plurality of resin plate materials are welded to form a resin container,
A conductive layer forming step of forming a conductive layer by applying a conductive paint to an end face of one of the resin plate members to be joined; and
A through hole forming step of forming a through hole in the other resin plate material to be joined;
The end face of the one resin plate material and the conductive layer is abutted against the end surface of the one resin plate material with the conductive layer interposed at a position corresponding to the through hole on the surface of the other resin plate material. A joining step of forming a welded portion by fillet welding so as to straddle the portion and the other resin plate material,
Prior to the joining step, a conductive rod-shaped member is inserted into the through-hole formed in the through-hole forming step, and the leading end of the rod-shaped member is abutted against the end surface in the joining step to form the conductive layer. Conductive contact with the rod-shaped member, and after the joining step, a conductive rod-shaped member is inserted into the through-hole formed in the through-hole forming step, and the leading end of the rod-shaped member is conductively contacted with the conductive layer. Any one of the rod-shaped member conduction | electrical_connection steps to be made is the manufacturing method of the resin-made containers characterized by the above-mentioned.
4) A method for detecting poor welding of a resin container provided with a housing portion that houses a gas or liquid formed by joining a plurality of resin plate materials by welding,
The resin container is
The housing portion is abutted against the surface of the other resin plate material with an end face of the other resin plate material interposed with a conductive layer formed of a conductive paint, and the one resin plate material and the While being formed in a box shape by a welded portion provided to cover the end portion of the conductive layer and the other resin plate material,
A through hole provided at a position corresponding to the one resin plate material in the other resin plate material;
A conductive rod-shaped member that is inserted into the through-hole and attached so that one end side is in conductive contact with the conductive layer and the other end side protrudes outward;
With
A liquid having conductivity is stored in the storage portion,
Immerse the electrode in the liquid,
Apply a voltage between the electrode and the connection portion to measure leakage current or insulation resistance,
A defect detection method for a resin container, wherein a defect is determined based on the measured leakage current or the value of the insulation resistance.

  According to the present invention, it is possible to easily detect welding defects and to suppress the production of the container and the cost increase of the container itself.

It is an external appearance perspective view for demonstrating the Example of the resin-made containers of this invention. It is S1-S1 sectional drawing in FIG. It is S2-S2 sectional drawing in FIG. It is a schematic diagram for demonstrating the welding defect detection method of the resin-made containers of this invention. It is a fragmentary sectional view for demonstrating the modification 1 in the Example of the resin-made containers of this invention. It is a fragmentary sectional view for demonstrating the modification 2 in the Example of the resin-made containers of this invention. It is a fragmentary perspective view for demonstrating the modification 2 in the Example of the resin-made containers of this invention. It is a perspective sectional view showing a conventional resin container. It is a perspective fragmentary sectional view which shows a part of conventional resin containers.

  The preferred embodiments of the present invention will be described with reference to FIGS.

The resin container according to the embodiment is a container 51 that stores a chemical solution used in a surface treatment apparatus such as plating.
1 is an external perspective view of the container 51, and FIG. 2 is a cross-sectional view taken along line S1-S1 in FIG. In FIG. 2, the container 51 is shown installed on the floor surface FL.

As shown in FIGS. 1 and 2, the container 51 is formed in a box shape with the top side open by welding and joining the left side plate 1L, the right side plate 1R, the front side plate 1M, the rear side plate 1U, and the bottom plate 1B. Yes.
Specifically, the left side plate 1L and the right side plate 1R are formed of resin plates of the same size and shape and arranged in parallel, and the front side plate 1M and the rear side plate 1U are formed of resin plates of the same size and shape. They are arranged in parallel.
The bottom plate 1B is joined to each side plate 1L, 1R, 1M, 1U at a position separated from the floor surface FL by a predetermined distance H1.
The directions “left, right, front, back” shown here are determined for convenience based on the posture shown in FIG.

Adjacent side plates 1L, 1R, 1M, and 1U are welded together at weld corners at welds Y1 to Y4.
Each of the side plates 1L, 1R, 1M, 1U and the bottom plate 1B are welded and joined at weld corners at welded portions Y5 to Y8 (Y6 is not shown for the hidden position).

  The container 51 includes the side plates 1L, 1R, 1M, and 1U and the bottom plate 1B, and a storage portion SY that stores gas or liquid is formed. The interior of the housing part SY is a space V corresponding to a rectangular parallelepiped. The liquid chemical LQ, which is a liquid, is accommodated in the accommodating portion SY, for example, with the position of the one-dot chain line in FIG. 2 as the upper limit of the liquid level.

The right side plate 1R is provided with a through hole 1Rh. The connecting portion 2 is inserted and attached to the through hole 1Rh so that a part thereof protrudes outward.
The connection part 2 is a conductive member and is formed in a rod shape. An example of the material of the connecting portion 2 is copper.
The position in the top-and-bottom direction where the connection part 2 is provided corresponds to the position of the bottom plate 1B.

  FIG. 3 is a partial cross-sectional view of the S2-S2 cross section in FIG. In detail, it is sectional drawing for demonstrating the butting part of the baseplate 1B and the right side board 1R including the connection part 2. FIG.

As shown in FIG. 3, the conductive layer 3 is interposed between the bottom plate 1 </ b> B and the right side plate 1 </ b> R at the butted portion that is a joint portion between the bottom plate 1 </ b> B and the right side plate 1 </ b> R.
The conductive layer 3 is formed of a conductive material. As this material, a material having such a viscosity that it can be adhered to the entire end face of the plate material by application is suitable, and a commercially available conductive paint can be used.
The conductive layer 3 is provided at least at a joint portion (a butting portion on which the welded portions Y1 to Y8 are formed) facing the housing portion SY.

The connecting portion 2 passes through the right side plate 1R, and the tip portion is attached in contact with the conductive layer 3. That is, the conductive layer 3 and the connection portion 2 are in a conductive state.
The other end protrudes outward from the right side plate 1R and is exposed.
The connection portion 2 is exposed to the outside from a portion (for example, the outer surface) other than the housing portion SY in the right side plate 1R.
Welding is so-called fillet welding.
Accordingly, the welded portion 7 covers the range AR1 in the vicinity of the entering corner on the inner surface of the bottom plate 1B, the range AR2 in the vicinity of the entering corner on the inner surface of the right side plate 1R, and the end AR3 of the conductive layer 3 in the entering corner. In this way, the cross section is provided in a substantially triangular shape.

The plate thickness of the bottom plate 1B and the right side plate 1R is, for example, 5 to 10 mm.
The height Hy and width Wy of the weld Y7 are both 2 to 3 mm, and are about 5 mm at the maximum. The same applies to the other welds Y1 to Y6 and Y8.
The thickness td of the conductive layer 3 is assumed to be, for example, about 0.5 mm at the maximum. However, when the end surface of each plate is abutted against the surface of the mating plate, there is no problem even if the thickness is smaller than this. It is enough to intervene.

In FIG. 3, when the container 51 is manufactured, the conductive layer 3 is provided in advance on the end surface 1Bt of the bottom plate 1B by coating or the like, and the end surface 1Bt is projected to the inner surface 1Rs of the right side plate 1R serving as the inner surface of the space V. It welds so that the welding part Y7 may be formed in the applied state.
Similarly, the other welded portions Y1 to Y6 and Y8 are provided with the conductive layer 3 corresponding to the welded portions.
That is, the conductive layer 3 is provided at the abutting portion between the side plates 1L, 1R, 1M, and 1U and the abutting portion between the side plates 1L, 1R, 1M, and 1U and the bottom plate 1B.
The connecting portion 2 is inserted in advance into a through hole 1Rh provided in the right side plate 1R, and a bottom plate 1B coated with the conductive layer 3 on the end surface 1Bt is abutted and welded.
The connection part 2 may be inserted into the through-hole 1Rh even after welding.
It is preferable to fix the connecting portion 2 to the through hole 1Rh with an adhesive or the like so that the position of the connecting portion 2 does not shift after welding.

The conductive layer 3 at the corner KS of the bottom plate 1B in FIG. 1 is in a conductive state by crossing the conductive layer 3 on three sides corresponding to the vertical welded portion Y1 and the horizontal welded portions Y5 and Y8. It is provided as follows. The same applies to the remaining three corners of the bottom plate 1B.
Therefore, the conductive layers 3 corresponding to all the corners of the container 51 that form the accommodating portion SY, that is, the portions where the welded portions Y1 to Y8 are provided are in a conductive state with each other, and the connecting portion 2 is also in a conductive state. is there.

The above-described welding failure detection of the container 51 can be performed by the following method.
FIG. 4 is a schematic diagram for explaining a method for detecting a welding failure of the container 51.
The container 51 is filled with a volume of water WT that exceeds the capacity required to detect defective welding. That is, an amount of water WT exceeding the upper limit position of the set liquid level is put.
The electrode 4 is immersed in the added water WT, and a DC voltage is applied between the electrode 4 and the connecting portion 2 by the power source 5. The applied voltage may be alternating current.
As a result, the conductive layer 3 in conduction with the connection portion 2 functions as an electrode, and a voltage is applied between the electrode 4 and the entire conductive layer 3 provided in the container 51.
Leakage current is measured with a voltage applied, and if the current value is equal to or greater than a predetermined value, the container 51 is determined to be defective. This is because if there is a defective portion such as a pinhole or a crack in the welded portions Y1 to Y8, water enters the defective portion and leakage current increases.

Instead of leakage current, the insulation resistance may be measured with an insulation resistance meter.
When there is no defective portion in the welded portions Y1 to Y8, the insulation resistance value usually indicates an infinite value or 100 MΩ or more. Therefore, if a predetermined value is set to less than 100 MΩ and the predetermined value is used as a threshold value, an inspection is performed. Good.
The predetermined value may be arbitrarily set according to the quality required for the container 51, the liquid to be stored, the environment to be used, and the like. As a setting example, the applied voltage is DC500V and the predetermined value is 4MΩ. A container having an insulation resistance value of less than 4 MΩ when a direct current of 500 V is applied between the electrode 4 and the connection portion 2 is determined as a defective product.

  According to the container 51 and the welding failure detection method for the container 51 described above, the work is performed by putting a conductive liquid (for example, water) in the container 51 and immersing the electrode 4 in the liquid and the connecting portion provided in the container 51. The voltage is simply applied between the two and can be easily performed regardless of the shape of the container. For example, the welding failure can be detected even in the container 110 shown in FIG.

The processing of the plate material (for example, the bottom plate 1B and the side plates 1L, 1R, 1M, and 1U) constituting the container 51 is only easy to open the through-hole 1Rh through which the connecting portion 2 is passed. Cost increase is suppressed.
Since the groove part is not formed in the plate material constituting the container 51 and only the through hole 1Rh through which the connection part 2 is passed is opened, a decrease in strength of the container 51 can be almost ignored.
Accordingly, since it is not necessary to use a thick plate for maintaining the strength, an increase in the cost of the container itself is suppressed.

  If a commercially available conductive paint is used as the material of the conductive layer 3, it is a general-purpose agent, so that the cost is not significantly increased. Also, the coating operation is extremely easy because it can be performed before the side plates 1L, 1R, 1M, 1U and the bottom plate 1B are assembled.

  Since the bottom plate 1B and the side plates 1L, 1R, 1M, and 1U are welded only to the corners on the receiving portion SY (space V) side, defects can be detected. Is done.

  FIG. 5 shows a first modification of the above-described embodiment, and is shown in a diagram corresponding to FIG.

In FIG. 5, a hole 1Bh is formed in the end surface 1Bt of the bottom plate 1B.
The connection part 2 is provided with its tip entering the hole 1Bh.
After forming the hole 1Bh, the conductive paint to be the conductive layer 3 is applied, so that the hole 1Bh is filled with the conductive paint.
When the distance from the inner surface 1Rs of the right side plate 1R to the tip of the connection portion 2 is Dt, the contact area where the connection portion 2 and the conductive layer 3 are in contact with each other is different from that of the above-described embodiment (see FIG. 3). Example 1 is increased by at least the peripheral surface in the range of the distance Dt.
Therefore, electrical connection between the connecting portion 2 and the conductive layer 3 can be ensured more reliably.
Moreover, since the arrangement position of the connecting portion 2 (the position in the left-right direction in FIG. 5) does not have to be determined with high accuracy, the assembly work of the container 51 is facilitated.

  FIG. 6 shows a second modification of the above-described embodiment, and is a diagram corresponding to FIG. FIG. 7 is a partial perspective view in which the vicinity of the joint portion of the front plate 1M, the right plate 1R, and the bottom plate 1B of the container 51 is looked up from the lower front side in the second modification.

As shown in FIG. 6 and FIG. 7, in the second modification, the container 51 is not provided with the connection portion 2, and the conductive layer 3 is disposed on the inner surface of the right side plate 1 </ b> R from between the joint portions of the right side plate 1 </ b> R and the bottom plate 1 </ b> B. The bottom plate 1B is partially extended downward and exposed to the outside. A portion exposed to the outside is referred to as an electrode portion 3a.
Moreover, it is better to form the notch 1Rk in the range corresponding to the electrode 3a at the lower end of the right side plate 1R.
Further, a hole 1Rk2 may be formed in the vicinity of the electrode portion 3a.
According to the modified example 2, it is possible to obtain electrical connection by directly sandwiching the electrode portion 3a between, for example, clip-shaped electrodes without providing the connection portion 2.
Therefore, the container 51 is reduced in cost by reducing the number of components.
Moreover, it becomes easy to attach a clip-shaped electrode by providing the notch 1Rk.
When the notch 1Rk or the hole 1Rk2 is provided, when a cord is directly connected to the electrode portion 3a by solder or the like, it becomes a path for drawing the cord to the outside of the right side plate 1R, and the cord drawing operation becomes easy.

  The embodiment and each modification of the present invention are not limited to the above-described configuration and procedure, and it goes without saying that other modifications may be made without departing from the gist of the present invention.

The shape of the container 51 is not limited to the above. A top plate may be provided. The shape of the container 110 shown in FIG. 8 may be used.
The plate material joined by welding may not be a flat plate but may be a curved plate.
The container may not always have an opening as shown in FIG. 1, and may be sealed in use, for example, for storing a gas lighter than air.
The position where the connection part 2 is provided is not limited as long as it can be connected to the conductive layer 3. A plurality of connection portions 2 may be provided.
The position where the electrode part 3a is provided is not limited. A plurality of electrode portions 3a may be provided.
The liquid stored in the space V at the time of detection does not have to be water, but may be a liquid having conductivity.

In the butting between the bottom plate 1B and the side plates 1L, 1R, 1M, and 1U or the butting between the side plates 1L, 1R, 1M, and 1U, the shape is limited to the mode in which the end surface of the other plate is butted against the surface of one plate. Instead, the end surfaces of both plates may be cut at 45 °, for example, and the cut surfaces may be abutted against each other.
Also in this case, the conductive layer 3 is interposed between the cut surfaces at the joint portion facing the housing portion SY.
In the case where the connection portion 2 is used to establish a conduction state with the conductive layer 3, the connection portion 2 penetrates the conductive layer 3 and passes through the conductive layer 3 as in Modification 2 in order to obtain conduction more reliably. It is preferable to adopt a configuration in which the tip enters the hole provided in.

1L left side plate, 1R right side plate, 1M front side plate, 1B bottom plate, 1U rear plate, 1Bh hole, 1Bt end face, 1Rh through hole, 1Rs inner surface 2 connection part 3 conductive layer 4 electrode 5 power supply 51 container (resin container)
Dt Distance FL Floor Hy (height of welded portion), Wy (welded portion) width LQ Liquid (chemical)
SY accommodation part td (conductive layer) thickness Y1 to Y8 welded part

Claims (4)

A resin container including a housing portion that houses a gas or a liquid formed by joining a plurality of resin plate materials by welding,
The accommodating portion is abutted against an end surface of the one resin plate material with a conductive layer formed of a conductive paint against the surface of the other resin plate material, and the one resin plate material and the It is formed in a box shape by a welded portion provided to cover the end portion of the conductive layer and the other resin plate material,
A through hole provided at a position corresponding to the one resin plate material in the other resin plate material;
A conductive rod-shaped member, one end of which is inserted into the through-hole and connected to the conductive layer and attached so that the other end protrudes outward ;
Resin container, characterized that you have provided a. The one resin plate material has a hole opened in the end face,
The connection part is provided with the one end side entering the hole, and the conductive layer is also filled in the hole so that the conductive layer and the connection part are in conductive contact. The resin container according to claim 1. A resin container having a housing portion for containing gas or liquid is a method for manufacturing a resin container, wherein a plurality of resin plate materials are welded to form a resin container,
A conductive layer forming step of forming a conductive layer by applying a conductive paint to an end face of one of the resin plate members to be joined; and
A through hole forming step of forming a through hole in the other resin plate material to be joined;
The end face of the one resin plate material and the conductive layer is abutted against the end surface of the one resin plate material with the conductive layer interposed at a position corresponding to the through hole on the surface of the other resin plate material. A joining step of forming a welded portion by fillet welding so as to straddle the portion and the other resin plate material,
Prior to the joining step, a conductive rod-shaped member is inserted into the through-hole formed in the through-hole forming step, and the leading end of the rod-shaped member is abutted against the end surface in the joining step to form the conductive layer. Conductive contact with the rod-shaped member, and after the joining step, a conductive rod-shaped member is inserted into the through-hole formed in the through-hole forming step, and the leading end of the rod-shaped member is conductively contacted with the conductive layer. Any one of the rod-shaped member conduction | electrical_connection steps to make it the manufacturing method of the resin-made containers characterized by the above-mentioned. A method for detecting defective welding of a resin container provided with an accommodating portion for accommodating a gas or a liquid formed by joining a plurality of resin plate materials by welding,
The resin container is
The housing portion is abutted against the surface of the other resin plate material with an end face of the other resin plate material interposed with a conductive layer formed of a conductive paint, and the one resin plate material and the While being formed in a box shape by a welded portion provided to cover the end portion of the conductive layer and the other resin plate material,
A through hole provided at a position corresponding to the one resin plate material in the other resin plate material;
A conductive rod-shaped member that is inserted into the through-hole and attached so that one end side is in conductive contact with the conductive layer and the other end side protrudes outward;
With
A liquid having conductivity is stored in the storage portion,
Immerse the electrode in the liquid,
Apply a voltage between the electrode and the connection portion to measure leakage current or insulation resistance,
A method for detecting a defective welding of a resin container, wherein a failure is determined based on the measured leakage current or the value of the insulation resistance.

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