Metal working – Method of mechanical manufacture – Combined manufacture including applying or shaping of fluent...
Reexamination Certificate
1998-02-18
2001-01-23
Echols, P. W. (Department: 3726)
Metal working
Method of mechanical manufacture
Combined manufacture including applying or shaping of fluent...
C264S171140, C264S171150, C425S381000, C425S465000, C425S466000
Reexamination Certificate
active
06176003
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a method and an apparatus for manufacturing a molding comprising a core metal and synthetic resin coating the core metal and having a varied sectional configuration.
BACKGROUND ART
Generally, moldings such as a window molding, a door outer molding, and the like are installed on a vehicle. The window molding is installed along the boundary between a pillar and a window glass. Likewise, the door outer molding is installed along the boundary between a door and a door glass.
In recent years, in order to improve rainwater-removing performance and appearance, a molding whose sectional configuration is changed lengthwise has been used.
As an example of the above-described molding, as shown in
FIG. 4
, a molding
9
comprising a core metal
90
and synthetic resin
19
coating a surface of the core metal
90
is known. The core metal
90
comprises an installing portion
11
; an outer strip
13
whose height is changed lengthwise; and a ceiling portion
12
connecting both with each other.
Conventionally, the molding is manufactured as described below. First, the core metal
90
whose sectional configuration is uniform is formed.
Then, synthetic resin is extruded onto the surface of the core metal
90
to obtain a coated material
99
whose sectional configuration is uniform, as shown in FIG.
5
. Then, using a cutter, the coated material
99
is cut to obtain the molding
9
. At this time, in conformity to the configuration of the molding
9
, a part of the outer strip
13
of the core metal
90
and the synthetic resin
19
coating the surface of core metal
90
are cut off from the molding
9
.
In this manner, the molding
9
as shown in
FIG. 4
is obtained.
Reference numeral
909
shown in
FIG. 4
denotes a cut portion formed as a result of the above-described cut-off.
However, the above-described conventional manufacturing method has problems which are described below.
First, in the above-described cut-off, the core metal
90
is cut off together with the synthetic resin
19
coating the surface of the core metal
90
. Therefore, it is difficult to obtain a smoothed cut portion
909
.
Further, heat is generated in the cut-off and the synthetic resin
19
may attach to the cutter. Due to the attachment of the synthetic resin
19
to the cutter, the cutting performance of the cutter deteriorates and it is more and more difficult to obtain the smoothed cut portion
909
.
Further, in the cut-off, the synthetic resin
19
may separate from the core metal
90
in the cutting portion
909
.
Furthermore, the cut-off is carried out only after the synthetic resin
19
is completely hardened on the surface of the core metal
90
. Thus, it takes long to manufacture the molding
9
and hence the productivity is unfavorable.
In view of the above-described problems, it is an object of the present invention to provide a method and an apparatus, for manufacturing a molding, capable of securing the adhesion of synthetic resin to a core metal and having a superior productivity.
DISCLOSURE OF THE INVENTION
According to the invention of claim
1
, a method for manufacturing a molding comprising synthetic resin and a core metal whose periphery is coated with the synthetic resin by extrusion and having a varied sectional configuration, comprising:
a forming process of preparing a molded material which is used as a core metal and has a uniform sectional configuration by forming a material of the core metal into a predetermined configuration;
a cut-off process of cutting off a part of the molded material to prepare the core metal whose sectional configuration is varied; and
an extrusion process of variably extruding the synthetic resin onto a surface of the core metal by moving a movable die installed on an extruding die body according to a sectional configuration of the core metal, using the extruding die body and the movable die.
The operation of the present invention is described below.
In the manufacturing method and the manufacturing apparatus of the present invention, the molded material which is used as the core metal and has the uniform sectional configuration is partly cut according to the configuration of a molding to form the core metal, and then, the synthetic resin is extruded onto the core metal, according to the sectional configuration of the metal core by using the movable die.
Therefore, the cut-off process consists of an operation of cutting off an unrequited portion from the molded material to be used as the core metal, and thus the removal of the unrequired portion is facilitated.
Further, after the unrequited portion is cut off from the molded material to be used as the core metal, the synthetic resin is extruded onto the core metal. Therefore, the adherence of the synthetic resin to the core metal can be reliably accomplished.
Furthermore, the forming of the molded material to be used as the core metal, the removal of a part thereof, and the extrusion of the synthetic resin can be consecutively carried out. Thus, the manufacturing method of the present invention is highly productive and effective.
Further, because the molded material which is used as the core metal has the uniform sectional configuration, the forming thereof can be accomplished easily. Therefore, according to the present invention, the molded material which is used as the core metal and has a high size accuracy can be obtained. In addition, in forming the molded material to be used as the core metal, few defective goods are produced.
Furthermore, the core metal having the predetermined sectional configuration is obtained by cutting the unrequited portion from the molded material to be used as the core metal. Thus, the degree of the design freedom of the sectional configuration of the core metal is high, and hence the molding having a desired configuration can be easily manufactured.
As described above, according to the present invention, the adherence of the synthetic resin to the core metal can be reliably accomplished and thus a molding-manufacturing method having a high productivity can be provided.
As the synthetic resin, polyvinyl chloride, ionomer resin, synthetic rubber, and the like can be used.
As the material of the core metal, steel plates, stainless steel plates, aluminum plates, and the like can be used.
As described in claim
2
, it is preferable that the unrequired portion is cut off from the molded material to be used as the core metal by using a laser.
This method allows the core metal to be processed with high accuracy.
As the laser beam oscillator, the use of a gas laser and a solid laser are conceivable, but it is preferable to utilize the solid laser which is compact.
As described in claim
3
, it is preferable that the molded material to be used as the core metal comprises an installing portion, an outer strip, and a ceiling portion connecting both with each other; and in the cut-off process, a part of the molded material to be used as the core metal is cut off such that the height of the outer strip is varied.
This method and construction allows the provision of the molding whose configuration is varied according to the layout of a vehicle body or a window glass or the like and the change in the configuration thereof and which can be installed thereon easily and has a fine appearance.
The molded material to be used as the core metal is formed according to the configuration of the core metal to be obtained, and a portion which is cut off from the molded material to be used as the core metal is selected according to the configuration of the core metal.
As described in claim
4
, it is preferable that in the extrusion process, the synthetic resin is applied to the surface of a cut end of the core metal as well as the surface of the entire core metal.
This method prevents the cut end from being exposed to the outside. Thus, the core metal can be prevented from being corroded and rusted.
The cut end means a sectional surface formed as a result of the cutting of the molded material to be used as the core metal in the cut-off process (see FIG.
1
)
Echols P. W.
Oblon & Spivak, McClelland, Maier & Neustadt P.C.
Tokai Kogyo Kabushiki Kaisha
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