Toyota Jidosha Kabushiki Kaisha

Toyota Jidosha K.k.

Fumio Nomizo

Yasuhiro Ueno

Toru Sugiyama

Hideo Nakamura

Masao Yasukawa

Shoichi Tsuchiya

Kenta Watanabe

Tatsuya Kitagawa

Yutaroh Gotoh

Takashi Nagase

Natuhiko Katahira

A pack case includes: a first wall pressing a battery stack toward a second side in a stacking direction; and a second wall pressing the battery stack toward a first side in the stacking direction. At least one of the first wall and the second wall is a panel structure wall including a first metal plate, a second metal plate located outward of the first metal plate in the stacking direction and faces the first metal plate, and an interposed member interposed between and fixed to the first metal plate and the second metal plate. The interposed member has a lower density than a metal forming the first metal plate and the second metal plate.

Pack case, battery pack, and method for manufacturing pack case

A battery pack includes a plurality of secondary batteries, and a binding band made of fiber reinforced plastic. The binding band has a braid member formed into a braided state with use of a plurality of bundled bodies, and a reinforcing part made of resin impregnated in the braid member. Each of the bundled bodies includes a plurality of fiber materials that have been bundled together.

Battery pack and manufacturing method for battery pack

A member joining method includes: a placement process of arranging a first member and a second member inserted into the first member so that a gap surrounding the second member is provided between the first member and the second member; a filling process of filling a molten resin into the gap and applying pressure to the resin so as to cause at least one member of the first member or the second member to undergo elastic deformation; and a pressure maintaining process of maintaining the pressure until the resin that has been filled into the gap has cured.

Member joining method

A reactor comprises a reactor core in which two U-shaped core members are connected in a ring shape with a gap section therebetween, a primary insert-molded resin part provided covering at least an outer peripheral surface of a leg part of the core member other than an adhesion surface of the core member, a coil placed around the gap section and the leg part of the core member, and a secondary insert-molded resin part made of a thermoplastic resin and which is insert-molded around the coil to fix the coil on the reactor core and fix the leg parts of the core members in a connected state. A positioning section which determines a relative position of opposing leg parts and a window section which allows a melted thermoplastic resin for forming the secondary insert-molded resin part to flow into the gap section are formed on an end of the primary insert-molded resin part connected in a state where core members are placed connected in a ring shape.

Reactor and manufacturing method thereof

An inductor that has the following: an inductor core comprising a plurality of core members arranged in a ring with gaps therebetween; primary insert-molded resin parts comprising a thermoplastic resin covering the outside surface of the inductor core, excluding the surfaces of the core members that face each other; coils disposed around the aforementioned gaps and the primary insert-molded resin parts on the inductor core; and secondary insert-molded resin parts comprising a thermoplastic resin insert-molded around the coils to affix said coils to the inductor core. This allows high-cycle manufacturing of inductors without a thermosetting-resin potting step in a vacuum furnace or a heat curing treatment in a heating furnace.

Inductor and manufacturing method therefor

A reactor comprises a reactor core in which two U-shaped core members are connected in a ring shape with gap sections including adhesive layers therebetween, a primary insert-molded resin part which is provided covering leg parts of the core member and which includes joint sections formed around end surfaces of the leg parts a coil placed around the gap sections and the leg parts of the core members, and a secondary insert-molded resin part which is made of a thermoplastic resin and which is insert-molded around the coil to fix the coil on the reactor core and fix the leg parts of the two core members in a connected state, wherein the joint sections of the primary insert-molded resin parts are fitted to each other in a state where the core members are placed connected in a ring shape, to form a peripheral wall surrounding the gap section.

Reactor

A valve body of an intake controlling valve, which is selectively opened and closed to communicate and interrupt communications between chambers which are divided by a partition wall in a resin surge tank, may be used for internal combustion engines. A variable intake device for an internal combustion engine is manufactured such that the valve unit is integrally assembled to a resin surge tank body by installing the valve unit into an opening of an outer wall of the resin surge tank and an opening of the partition wall formed at the partition wall and fixing the valve unit. Between the frame and the opening of the partition wall, and the valve unit and the opening of the outer wall are integrally fixed at their contact portions through adhesion with an adhesive or by welding.

Variable intake device for internal combustion engines and method for manufacturing the device

A composite intake manifold includes a first outer member, an inner member fitted within the first outer member, and a second outer member fixed to the first outer member. An intake port of the manifold includes a curved portion. The curved portion is defined by the inner member and at least one of the first outer member and the second outer member. The curved portion of the intake port is divided at a seam parallel to an axis of the curved portion of the intake port so that the respective members can be molded without using a molding core.

Composite intake manifold for an internal combustion engine

A method of manufacturing a cushion material including steps of: a mixed fiber manufacturing process in which main fibers and a plurality of types of heat-fusible fibers, which are formed of main fibers and sheath portions and whose sheath portions have different melting points, are mixed so as to make mixed fibers; a supplying process in which the mixed fibers are spread at a substantially uniform density at an entire one forming mold of a plurality of forming molds; and a heating process in which the mixed fibers spread at the entire one forming mold are heated such that a heating temperature of portions of a cushion material which are to be formed hard differs from a heating temperature of portions of the cushion material which are to be formed soft so that a number of types of the heat-fusible fibers which melt at the portions of the cushion material which are to be formed hard is greater than a number of types of the heat-fusible fibers which melt at the portions of the cushion material which are to be formed soft.

Method of manufacturing cushion material

A method of manufacturing a cushion material for seat pads comprises a step for filling a mold part that will form the cushion material with a mixed fiber containing a thermofusible fiber, a step for engaging this mold part with another mold part, and a step for applying heat to a specific region of the mixed fiber that will form a bottom surface so that the thermofusible fiber in the specific region melts before the thermofusible fiber in the other region of the mixed fiber that will form a sitting surface of the cushion material.

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Toyota, Japan

Fumio Nomizo