EP1025923A1 - Production method for double-structure container - Google Patents
Production method for double-structure container Download PDFInfo
- Publication number
- EP1025923A1 EP1025923A1 EP99944778A EP99944778A EP1025923A1 EP 1025923 A1 EP1025923 A1 EP 1025923A1 EP 99944778 A EP99944778 A EP 99944778A EP 99944778 A EP99944778 A EP 99944778A EP 1025923 A1 EP1025923 A1 EP 1025923A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- tube
- workpiece
- axis
- spinning
- double
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/18—Construction facilitating manufacture, assembly, or disassembly
- F01N13/1872—Construction facilitating manufacture, assembly, or disassembly the assembly using stamp-formed parts or otherwise deformed sheet-metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/14—Spinning
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/14—Spinning
- B21D22/18—Spinning using tools guided to produce the required profile
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N1/00—Silencing apparatus characterised by method of silencing
- F01N1/02—Silencing apparatus characterised by method of silencing by using resonance
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/14—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having thermal insulation
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/18—Construction facilitating manufacture, assembly, or disassembly
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
- F01N3/2842—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration specially adapted for monolithic supports, e.g. of honeycomb type
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2882—Catalytic reactors combined or associated with other devices, e.g. exhaust silencers or other exhaust purification devices
- F01N3/2885—Catalytic reactors combined or associated with other devices, e.g. exhaust silencers or other exhaust purification devices with exhaust silencers in a single housing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2470/00—Structure or shape of gas passages, pipes or tubes
- F01N2470/24—Concentric tubes or tubes being concentric to housing, e.g. telescopically assembled
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2470/00—Structure or shape of gas passages, pipes or tubes
- F01N2470/26—Tubes being formed by extrusion, drawing or rolling
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2490/00—Structure, disposition or shape of gas-chambers
- F01N2490/15—Plurality of resonance or dead chambers
- F01N2490/155—Plurality of resonance or dead chambers being disposed one after the other in flow direction
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2490/00—Structure, disposition or shape of gas-chambers
- F01N2490/20—Chambers being formed inside the exhaust pipe without enlargement of the cross section of the pipe, e.g. resonance chambers
Definitions
- This invention relates to a method of producing a double-walled container, and more particularly to a production method in which a double-walled container is obtained by changing the cross-sectional shapes of inner and outer tubes simultaneously.
- a heat-insulating tube structure in which an inner tube of an integral construction, continuously varying axially a cross-sectional shape, and an outer tube of an integral construction, decreasing in diameter in a tapering manner at its opposite ends, are arranged in concentric relation to each other, with a space formed therebetween.
- an inner tube 104 of metal which contains a catalyst carrier 101 therein, and has tapering diameter-decreasing portions 102 and 103 formed respectively at opposite ends thereof, with an outer tube 107 of metal, having tapering diameter-decreasing portions 105 and 106 formed respectively at opposite ends thereof, so that a space 108 is formed between the inner tube 104 and the outer tube 105, as shown in Fig. 15.
- This construction is disclosed, for example, in JP-A-6-101465.
- One method of producing the catalytic converter is to apply a diameter-decreasing processing to the outer tube 107 held around the inner tube 104, beforehand subjected to a diameter-decreasing processing, with the predetermined space 108 formed therebetween. With this method, however, the production is difficult, and besides the production cost is high.
- thermos bottle There is known a method of producing a thermos bottle, in which an inner tube, which is open only at one end thereof, and an outer tube, which is open only at one end thereof, are separately formed respectively into desired cross-sections by spinning processing, and these tubes are combined together. This is disclosed, for example, in JP-A-10-15631 and JP-A-7-284452.
- a production method of a first aspect of the invention is characterized in that an inner tube is arranged in an outer tube, with a space formed therebetween; a solid interposition material is held between the tubes at least in one region of said space extending in a direction of a tube axis; and in this condition, a spinning processing is applied to said outer tube, thereby changing cross-sections of said inner and outer tubes simultaneously.
- the inner and outer tubes, holding the solid interposition material therebetween are rotated about the tube axis, and spinning rollers are pressed against the outer tube to effect the spinning processing, so that the cross-section of the outer tube is changed by its pressing force, and further the pressing force is transmitted from the outer tube to the inner tube through the deformable solid interposition material, held in the space, so that the cross-section of the inner tube is changed simultaneously. Therefore, one end portions of the inner and outer tubes can be simultaneously formed into a desired shape with one spinning step.
- the inner and outer tubes are held stationary, and the spinning rollers are revolved, so as to press the spinning rollers against the outer tube, thereby effecting the spinning processing.
- the revolving spinning rollers are pressed against the stationary outer tube to effect the spinning processing, so that the cross-section of the outer tube is changed by its pressing force, and further the pressing force is transmitted from the outer tube to the inner tube through the deformable solid interposition material, held in the space, so that the cross-section of the inner tube can be changed simultaneously.
- one end portions of the inner and outer tubes can be simultaneously formed into a desired shape with one spinning step.
- a production method of a second aspect of the invention is characterized in that an inner tube is arranged in an outer tube, with a space formed therebetween; a solid interposition material is held between the tubes at least in one region of the space extending in a direction of a tube axis; and in this condition, spinning rollers are revolved to apply a spinning processing to the outer tube, thereby simultaneously changing cross-sections of the inner and outer tubes in eccentric relation to a tube axis of a workpiece of the inner and outer tubes.
- one end portions of the inner and outer tubes, changed in eccentric relation to the tube axis of the workpiece, can be formed simultaneously with one spinning step.
- a production method of a third aspect of the invention is characterized in that an inner tube is arranged in an outer tube, with a space formed therebetween; a solid interposition material is held between the tubes at least in one region of said space extending in a direction of a tube axis; a tube axis of a workpiece of said inner and outer tubes is inclined with respect to an axis of spinning rollers, and said spinning rollers are revolved to apply a spinning processing to said outer tube, thereby changing cross-sections of said inner and outer tubes in slantingly-bending relation to the tube axis of the workpiece of said inner and outer tubes.
- one end portions of the inner and outer tubes, changed in bending relation to the tube axis of the workpiece, can be formed with one spinning step.
- a mandrel may be inserted into at least one of the inner and outer tubes at least at one region thereof.
- the mandrel is inserted between the inner and outer tubes or in the inner tube, and therefore excessive deformation of the inner and outer tubes during the spinning operation can be prevented.
- the solid interposition material may be one of hot-melt resin , thermoplastic resin and molten salt in a solidified condition.
- this solid interposition material By heating this solid interposition material so as to soften and molt it, the charging of the solid interposition material into the space before the shaping of the inner and outer tubes, as well as the removal of the solid interposition material to the outside of the space after the shaping, can be easily effected.
- Fig. 1 is a partly-broken, side-elevational view of a spinning machine
- Fig. 2 is a partly-broken, plan view of the spinning machine of Fig. 1.
- a workpiece drive portion 2 is mounted on one side portion of a fixed base 1
- a roller drive portion 3 is mounted on the other side portion thereof.
- Two parallel X-direction slide rails 5 are fixedly mounted on a side of the base 1, on which the workpiece drive portion 2 is mounted, and extend in a direction (referred to as "X direction") parallel to an axis X5 of revolution of rollers 28 (described later).
- An X-direction slider 6 is mounted on the X-direction slide rails 5 for sliding movement in the X-direction, and a ball spline shaft 8 is threadedly engaged with a boss 7 formed on the X-direction slider 6.
- the X-direction slider 6 can be moved forward and backward in the X-direction in a desired distance by rotating the ball spline shaft 8 in normal and reverse directions in a desired amount by drive means 9 such as a motor.
- Two parallel Y-direction slide rails 10 are fixedly mounted on the X-direction slider 6, and extend in a horizontal direction (referred to as "Y-direction") perpendicular to the X-direction.
- a Y-direction slider 11 is mounted on the Y-direction slide rails 10 for sliding movement in the Y-direction.
- a bed 30 is fixedly mounted on the Y-direction slider 11, and a ball spline shaft 15 is threadedly engaged with a boss 14 fixedly mounted on a lower surface of the bed 30.
- the bed 30 can be moved forward and backward in the Y-direction in a desired distance by rotating the ball spline shaft 15 in normal and reverse directions in a desired amount by drive means 16 such as a motor.
- Angular-movement drive means 31 such as a motor is mounted on the bed 30, and an angular-movement drive shaft 31a of this angular-movement drive means 31 projects vertically from the upper surface of the bed 30.
- the angular-movement drive means 31 and the angular-movement drive shaft 31a jointly form means for inclining a workpiece 4.
- a lower clamp 13, constituting a clamp device 12, is slidably mounted on the upper surface of the bed 30, and the drive shaft 31a is fixed to the lower clamp 13, and when the angular-movement drive shaft 31a is rotated in normal and reverses directions, the lower clamp 13 is angularly moved about the angular-movement drive shaft 31a in normal and reverse directions in a horizontal plane.
- the angular-movement drive shaft 31a is disposed such that its axis perpendicularly intersects a tube axis X4 of the workpiece 4 placed on the lower clamp 13 (described later), as shown in Fig. 2.
- a clamp surface 13a of a semi-circular shape for supporting a lower half surface of the workpiece 4 is formed on the upper surface of the lower clamp 13 in such a manner that when the workpiece 4 is placed on this clamp surface, the tube axis X4 of the workpiece 4 is disposed at the same level as that of the axis X5 of a rotation shaft 21 of the roller drive portion 3 (described later).
- drive means 18 such as a hydraulic cylinder
- a stopper 19 is provided on a rear side of the clamp device 12, and the positioning of the workpiece 4 in the axial direction can be easily effected by abutting a rear end of the workpiece 4 against the stopper 19.
- the stopper 19 is provided on the lower clamp 13, and is moved with the clamp device 12, and the position of this stopper can be adjusted in the direction of the tube axis X4 of the workpiece 4.
- roller drive portion 3 on the base 1 will be described.
- a rotation facility portion 20 is mounted on the base 1, and the rotation shaft 21 is rotatably provided on this portion 20, with its axis directed in the X-direction.
- the rotation shaft 21 can be rotated in one direction by a motor 22, serving as rotation drive means, through a belt 23.
- a roller holder 24 is fixed to the rotation shaft 21 on a side of the workpiece drive portion 2, and when the rotation shaft 21 is rotated, the roller holder 24 is rotated about the axis X5 of the rotation shaft 21.
- Path changing means for changing a drive path of the rollers is provided on the rotation facility means 20.
- This means comprises a cylinder 25, serving as drive means, and a ring plate 26 which is mounted at a distal end of a rod 25a of the cylinder 25, and is disposed within the roller holder 24 so that it will not interfere with the rotation of the roller holder 24.
- the ring plate 26 is formed into an annular shape coaxial with the rotation shaft 21, and an outwardly-spreading, tapering surface 26a is formed on an inner surface of this ring plate at its distal end.
- a plurality of (three in this embodiment) brackets 27 are mounted on the roller holder 24 at equal intervals in the circumferential direction, with their axes extending in the X-axis. Further, the brackets 27 are movable radially with respect to the axis X5 of the roller holder 24.
- a tapering surface 27a is formed, along the tapering surface 26a of the ring plate 26, at one side of each bracket 27 corresponding to the inner side of the roller holder 24, and the roller 28 is freely rotatably mounted at the outer end of each bracket 27.
- each bracket 27 is pushed toward the axis through the two tapering surfaces 26a and 27a, so that each of rollers 28 is moved the same amount toward the axis of the rotation shaft 21, respectively.
- each bracket 27 is returned radially outwardly through the two tapering surfaces 26a and 27a, so that each of rollers 28 is moved the same amount radially outwardly of the roller holder, respectively.
- Figs. 4A to 4D show a first embodiment according to a production method of the present invention.
- Fig. 4A shows a first step, and shows a condition in which a cylindrical outer tube 4B of metal, which is larger in diameter than a cylindrical inner tube 4A of metal, is arranged around the inner tube 4A in concentric relation thereto, and a solid interposition material 4D is filled in an annular space 4C of a predetermined width formed between the two tubes 4A and 4B.
- the product in this condition is the workpiece 4.
- a hot-melt resin is used as the solid interposition material 4D, and for filling it, the inner and outer tubes 4A and 4B are held by suitable means in such a manner that the predetermine space 4C is formed therebetween, and one end of this space 4C is closed, and a resin in a heat-molten state is poured into the space 4C through the other end thereof, and is cooled and solidified, and is interposed as the solid interposition material 4D between the inner and outer tubes 4A and 4B.
- the solid interposition material 4D has good filling and discharging abilities, and can be deformed to a certain degree when it is filled and formed into a solid state, and further has low compressibility (it may have non-compressibility), and preferably the solid interposition material is the above-mentioned hot-melt resin, but may be other material than this resin.
- a melting point of the hot-melt resin is higher than a temperature of the workpiece 4 which is raised by the spinning.
- a resin, marketed under the trade name "Seal Peal Hot” can be used as the above hot-melt resin.
- the process shifts to a second step in which the workpiece 4 is held by the clamp device 12 of the spinning machine, and the end portions of the workpiece 4 are decreased in diameter, as shown in Fig. 4B.
- the ring plate 26 of the spinning machine is located at a position spaced right from its position shown in Fig. 1, and the rollers 28 are retracted outwardly of the outer periphery of the workpiece 4 prior to the processing, and are held in an open condition.
- the workpiece 4 is fitted in and placed on the clamp surface 13a of the lower clamp 13, with its rear end abutted against the stopper 19 set at a predetermined position, and thereafter the drive means 18 is operated to move the upper clamp 17 downward, so that the workpiece 4 is held between the upper and lower clamps 17 and 13 so as to prevent it from rotating.
- the position of the clamp device 12 in the Y-direction is set by the drive means 16 to a position where an extension line of the axis of the angular-movement drive shaft 31a intersects an extension line of the axis X5 of the rotation shaft 21.
- a mandrel 51 is inserted into that end of the inner tube 4A to be subjected to the spinning operation, as shown in Fig. 4B.
- the mandrel 51 includes a decreased-diameter portion 51a, corresponding to the decreased diameter of the inner tube 4A, a tapering portion 51b, which extends from this decreased-diameter portion, and is slanting radially outwardly, and a larger-diameter portion 51c which is continuous with this tapering portion, and extends parallel to the axial direction, the larger-diameter portion 51c having an outer diameter substantially equal to the inner diameter of the workpiece 4.
- the ball spline shaft 8 is rotated in one direction by the drive means 9, thereby moving the clamp device 12 right (in Fig. 1) in the X-direction parallel to the axis X5 of the rotation shaft 21, so that the rollers 28 are located at a diameter-decrease starting point A of the workpiece 4, as shown in Fig. 4B.
- the motor 22, serving as the drive means is driven to rotate the roller holder 24 in one direction, and also the drive means 25 is operated to advance the ring plate 26 to move the path of revolution of the rollers 28 in the closing direction toward the center of the roller holder 24, and also the drive means 9 is driven to rotate the ball spline shaft 8 in a direction reverse to the above-mentioned direction, thereby moving the clamp device 12, together with the workpiece 4, backward left (in Fig. 1) in the X-direction.
- rollers 28 while freely rotating in press-contact with the outer peripheral surface of the outer tube 4B in the workpiece 4, revolves about the tube axis X5, and also the diameter of the path of revolution of these rollers gradually decreases, thereby effecting the spinning operation starting from the diameter-decrease starting point A, as shown in Fig. 4B.
- the outer tube 4B is deformed to be decreased in diameter, and also this deforming force is transmitted to the inner tube 4A through the solid interposition material 4D, so that the inner and outer tubes 4A and 4B and the solid interposition material 4D are simultaneously deformed.
- a tapering portion 4b decreased in diameter from a stock tube portion 4a of the inner and outer tubes 4A and 4B, and a neck portion 4c, extending from a distal end of this tapering portion 4b, are sequentially formed, with the solid interposition material 4D held between the inner and outer tubes 4A and 4B.
- the step of the above spinning operation may be effected with one pass or a plurality of passes of the rollers.
- the diameter-decreasing processing of the neck portion 4c is accurately effected by the decreased-diameter portion 51a of the mandrel 51.
- the spinning rollers 28 move along the tapering portion 51b of the mandrel 51 as indicated by an arrow in the drawing, and are moved away outwardly from the larger-diameter portion 51c of the mandrel 51.
- the inner and outer tubes 4A and 4B are cut at a portion C shown in Fig. 4B, and a discard portion 4e is removed.
- the workpiece 4, shaped in the second step is removed from the clamp device 12, and is inverted in the axial direction, and is again held by the clamp device 12, and as shown in Fig. 4C, the other tube end portion of the workpiece 4, opposite to that processed in the second step, is decreased in diameter by spinning process as in the second step.
- the mandrel 51 may be used if necessary as in the second step.
- the inner and outer tubes 4A and 4B are cut at a portion D shown in Fig. 4C, and a discard portion 4f is removed.
- the cutting of the inner and outer tubes 4A and 4B in the second step and the cutting of these tubes in the third step may be effected at a time after the third step.
- discard portions 4e and 4f are not always necessary, it is preferred to form these discard portions 4e and 4f and to remove them by cutting in order to accurately form the shape of the tube end portions.
- each of the opposite end portions of the workpiece 4 has been decreased in diameter by one spinning process.
- the shaped product is removed from the clamp device 12, and this product, obtained in the third step, and having the solid interposition material 4D remaining in the space 3C, may be provided as a final product.
- the solid interposition material 4D may be removed in a fourth step so as to provide a final product having the space 4C formed between the inner and outer tubes 4A and 4B.
- the solid interposition material 4D is hot-melt resin
- the solid interposition material 4 can be easily flowed away and removed by heating the product in the fourth step.
- the solid interposition material 4D In the case where a member with excellent heat-insulating properties, such as a heat-insulating mat, it is preferred that this solid interposition material should be left as it is. However, generally, when this container is used as an exhaust-system container of an automobile, a high heat-resistance is required, and therefore the solid interposition material 4D is removed.
- Fig. 5 shows a second embodiment of a production method according to the present invention.
- This second embodiment is directed to an embodiment, in which an interior member is contained in the inner tube 4A of the first embodiment, and shows an example in which it is applied to a catalytic converter of an exhaust system of an automobile.
- a catalyst carrier 50 is inserted or press-fitted in the first step of the first embodiment shown in Fig. 4A.
- a second step (Fig. 5B), a third step (Fig. 5C) and a fourth step (Fig. 5D) as described above in the first embodiment are effected, thereby producing a double-walled pipe as shown in Fig. 5D which contains the catalyst carrier 50 therein, and has a space 4C formed between the inner and outer tubes 4A and 4B.
- the mandrel 51 is not always necessary, and may be used if necessary.
- Fig. 6 shows a third embodiment of a production method according to the present invention.
- This third embodiment is directed to an embodiment in which an interior member, such for example as a catalyst carrier 50 as described above in the second embodiment, is contained, and one ends of inner and outer tubes 4A and 4B are extended long, with a space 4C formed therebetween, and for example, a resonant-type muffler is formed integrally on the rear side of the catalytic converter 50 of the second embodiment.
- a resonant-type muffler is formed integrally on the rear side of the catalytic converter 50 of the second embodiment.
- that portion, designated by reference numeral 54 is the resonant-type muffler.
- the production process of this third embodiment is basically similar to the production process of the second embodiment, and resonance holes 52 are beforehand formed in the inner tube 4A, and a mandrel, which is similar to the mandrel 51 described in the second embodiment, but has an extended insertion portion, is used during the spinning operation, and the resonance holes 52 are closed by this extension portion from the inside of the inner tube 4A.
- One ends (for example, left ends in Fig. 6) of the inner and outer tubes 4A and 4B, shaped in this third embodiment, are fixed to other connection pipe whereas a wire net ring 53 for holding the inner and outer tubes 4A and 4B in a manner to allow them to move relative to each other is held between the other ends (for example, the right end in Fig. 6), so that a relative movement between the inner tube 4A and the outer tube 4B due to thermal expansion can be allowed.
- the space 4C on the left side (side A) of the catalyst carrier 50 has a gradually decreasing thickness (the distance of the gap between the inner and outer tubes), and for shaping this left-side portion, the inner tube 4A and the outer tube 4B are beforehand decreased in diameter into tapering portions and neck portions as shown in the drawing, and then this inner tube 4A is inserted into the outer tube 4B, and the diameter-decreased portion of the inner tube 4A is held by holding means (not shown), and a solid interposition material 4D is filled into the space 4C between the inner tube 4A and the outer tube 4B on the right side (side B) of the catalyst carrier 50, and a spinning operation as described above is applied to the outer tube 4B.
- exhaust gas is purified by the catalyst carrier 50, and also exhaust sounds flow through the resonance holes 52 into the gap 4C in the resonant-type muffler 54, so that the sounds are deadened by the gap 4C serving as a resonance space.
- This gap 4C also achieves an originally-intended, heat-insulating effect.
- the range of use of the mandrel 51 and the shape of this mandrel, the inner and outer tubes 4A and 4B, having the space 4C therebetween, can be formed in a desired manner.
- Fig. 7 shows a fourth embodiment of a production method according to the present invention.
- This fourth embodiment shows an example in which a double-walled pipe, in which the axes of the inner and outer tubes 4A and 4B are eccentric with respect to each other, is produced.
- the inner tube 4A and the outer tube 4B are suitably made eccentric with respect to each other, and a solid interposition material 4D is filled in a gap 4C between the two tubes, and then the similar steps as described above in the first and second embodiments are effected, thereby producing the product.
- Fig. 8 shows a fifth embodiment of a production method according to the present invention.
- This fifth embodiment shows an example in which one diameter-decreased portion of the double-walled tube (container) is offset respect to the other diameter-decreased portion.
- a workpiece 4 as shown above in Fig. 5A, in which a solid interposition material 4D is interposed between an inner tube 4A and an outer tube 4B, and an interior member (for example, a catalyst carrier 50) is contained in the inner tube 4A.
- an interior member for example, a catalyst carrier 50
- the ring plate 26 is located at a position spaced right from its position shown in Fig. 1, and the rollers 28 are retracted outwardly of the outer diameter of the workpiece 4 prior to the processing, and are held in an open condition.
- the unprocessed workpiece 4 is fitted in and placed on the clamp surface 13a of the lower clamp 13, with its rear end abutted against the stopper 19 set at a predetermined position, and thereafter the drive means 18 is operated to move the upper clamp 17 downward, so that the workpiece 4 is held between the upper and lower clamps 17 and 13 against rotation.
- the angular-movement drive means 31 is operated to angularly move the clamp device 12, so that the tube axis X4 of the workpiece 4, held by this clamp device, is parallel to the axis X5 of the rotation shaft 21.
- the drive means 16 is operated to adjustably move the clamp device 12 in the Y-direction, so that the tube axis X4 of the workpiece 4 is parallel to and is offset a predetermined amount OF1 (see Fig. 9A) from the axis X5 of the rotation shaft 21.
- the ball spline shaft 8 is rotated in one direction by the drive means 9, thereby moving the clamp device 12 right (in Fig. 1) in the X-direction to move the workpiece 4 forward (right in Fig. 1) toward the roller holder 24 by a predetermined amount in a direction parallel to the tube axis thereof, so that the rollers 28 are located at a diameter-decrease starting point A (see Fig. 9A) of the workpiece 4.
- the motor 22, serving as the drive means is driven to rotate the roller holder 24 in one direction, and also the drive means 25 is operated to advance the ring plate 26 to move the path of revolution of the rollers 28 in the closing direction toward the center of the roller holder 24, and also the drive means 9 is reversely driven to rotate the ball spline shaft 8 in a direction reverse to the above-mentioned direction, thereby moving the clamp device 12, together with the workpiece 4, backward left (in Fig. 1) in the X-direction.
- the workpiece 4 is continued to be moved backward, with the rollers 28 held in the closed position, and by doing so, a cylindrical neck portion 4c, having its axis coinciding with the revolution axis X5 and being parallel to the tube axis X4 of the workpiece 4, is formed at the distal end of the tapering portion 4b by plastic deformation.
- the workpiece 4, as well as the rollers 28, is moved backward in a direction opposite to that of the forward movement (that is, the diameter-decreasing movement), and the first spinning operation is finished with this one reciprocation (forward-backward movement).
- the rollers 28 are returned to the open position, and also the drive means 9 is operated to rotate the ball spline shaft 8 in one direction to further advance the workpiece 4, together with the clamp device 12, by a predetermined amount in a direction parallel to the tube axis thereof, so that the rollers 28 are located at a point B in Fig. 9C.
- the drive means 16 is operated to rotate the ball spline shaft 15 in one direction to further move the workpiece 4, together with the clamp device 12, by a predetermined amount in the Y-direction, so that the amount OF2 of offset of the tube axis X4 of the workpiece 4 from the axis of the rotation shaft 21, that is, the axis X5 of revolution of the rollers 28, is made larger than the above offset amount OF1, as shown in Fig. 9C.
- a spinning operation similar to the above spinning operation, is effected in such a manner that the amount of closing movement of the rollers 28 is larger than that in the above first process.
- the tapering portion 4b is plastically deformed into the tapering portion 4b of a truncated cone-shape which has a larger tapering angle, and has its axis disposed on the revolution axis X5 offset an amount OF2 from the tube axis X4 of the stock tube portion (barrel portion) 4a of the workpiece 4.
- the workpiece 4 is continued to be moved backward with the rollers 28 held in the closed position, and by doing so, the neck portion 4c, smaller in diameter than the neck portion of Fig. 9B, is formed at the distal end of the tapering portion 4b.
- a diameter-decreased portion 4d having the offset tapering portion 4b and the offset tapering neck portion 4c which are integrally formed with each other, is formed at the end portion (right end portion in Fig. 8).
- the outer tube 4B is deformed to be decreased in diameter, and also this deforming force is transmitted to the inner tube 4B through the solid interposition material 4D, so that the inner and outer tubes 4A and 4B and the solid interposition material 4D are simultaneously deformed.
- the tapering portion 4b decreasing in diameter from the stock tube portion 4a of the inner and outer tubes 4A and 4B, and the neck portion 4c, extending from the distal end of this tapering portion 4b, are sequentially formed, with the solid interposition material 4D held between the inner and outer tubes 4A and 4B.
- the workpiece 4, shaped in the above process is removed from the clamp device 12, and is inverted in the axial direction, and is again held by the clamp device 12, and the other tube end portion of the workpiece 4, opposite to that processed in the above process, is decreased in diameter by spinning process in a manner as described above.
- the shaped product is removed from the clamp device 12, and this product, obtained in the third step, and having the solid interposition material 4D remaining in the space 4C, may be provided as a final product.
- the solid interposition material 4D may be removed so as to provide a final product having the space 4C formed between the inner and outer tubes 4A and 4B.
- Fig. 10 shows a sixth embodiment according to the present invention.
- This sixth embodiment shows an example in which diameter-decreased portions and neck portions at opposite end portions are processed by bend-spinning.
- the workpiece 4 similar to that of Fig. 4A, is fitted in and placed on the clamp surface 13a of the lower clamp 13, with its rear end abutted against the stopper 19 set at a predetermined position, and thereafter the drive means 18 is operated to move the upper clamp 17 downward, so that the workpiece 4 is held between the upper and lower clamps 17 and 13 against rotation.
- the position of the clamp device 12 in the Y-direction is so set by the drive means 16 that an extension line of the axis of the angular-movement drive shaft 31a intersects an extension line of the axis X5 of the rotation shaft 21, as shown in Fig. 11A.
- the angular-movement drive means 31 is operated to incline the clamp device 12 horizontally, so that the tube axis X4 of the workpiece 4 is horizontally inclined at a predetermined angle ⁇ 1 with respect to the axis X5 of the rotation shaft 21, as shown in Fig. 11A.
- the ball spline shaft 8 is rotated in one direction by the drive means 9, thereby moving the clamp device 12 right (in Fig. 1) in the X-direction parallel to the axis X5 of the rotation shaft 21, so that the rollers 28 are located at a diameter-decrease starting point A of the workpiece 4, as shown in Fig. 11A.
- the motor 22, serving as the drive means is driven to rotate the roller holder 24 in one direction, and also the drive means 25 is operated to advance the ring plate 26 to move the path of revolution of the rollers 28 in the closing direction toward the center of the roller holder 24, and also the drive means 9 is driven to rotate the ball spline shaft 8 in a direction reverse to the above-mentioned direction, thereby moving the clamp device 12, together with the workpiece 4, backward left (in Fig. 1) in the X-direction.
- the rolls 28, while freely rotating in press-contact with the outer peripheral surface of the workpiece 4, revolves about the tube axis X5, and also the diameter of the path of revolution of these rollers gradually decreases, thereby effecting the spinning operation starting from the diameter-decrease starting point A, as shown in Fig. 11B.
- the workpiece 4 is continued to be moved backward, with the rollers 28 held in the closed position, and by doing so, a cylindrical neck portion 4c, having its axis coinciding with the revolution axis X5 inclined at the angle ⁇ 1 with respect to the tube axis X4 of the workpiece 4, is formed at the distal end of the tapering portion 4b by plastic deformation.
- the workpiece 4, as well as the rollers 28, is moved backward in a direction opposite to that of the forward movement (that is, the diameter-decreasing movement), and the first spinning operation is finished with this one reciprocation (forward-backward movement).
- the rollers 28 are returned to the open position, and the drive means 9 is operated to rotate the ball spline shaft 8 in one direction to further advance the workpiece 4, together with the clamp device 12, by a predetermined amount in the X-direction, so that the rollers 28 are located at a point B in Fig. 11C, and also the angular-movement means 31 is operated to further incline the workpiece 4, together with the clamp device 12, by a predetermined amount, so that the angle ⁇ 2 between the tube axis X4 of the workpiece 4 and the axis of the rotation shaft 21, that is, the axis X5 of revolution of the rollers 28, is made larger than the angle ⁇ 1 in the above first step, as shown in Fig. 11C.
- a spinning operation similar to the above spinning operation, is effected in such a manner that the amount of closing movement of the rollers 28 is larger than that during the above first process.
- the tapering portion 4b shaped in the first process, is plastically deformed into the tapering portion 4b of a truncated cone-shape which has a larger tapering angle, and has its axis disposed on the revolution axis X5 inclined at the angle ⁇ 2 with respect to the tube axis X4 of the stock tube portion (barrel portion) 4a of the workpiece 4.
- the workpiece 4 is continued to be moved backward in the X-direction with the rollers 28 held in the closed position, and by doing so, the neck portion 4c, having its axis disposed on the above axis X5 and smaller in diameter than the neck portion of the first process, is formed at the distal end of the tapering portion 4b.
- a diameter-decreased portion 4d having the tapering portion 4b and the tapering neck portion 4c having its axis coinciding with the axis X5 inclined with respect to the axis X4, which are integrally formed with each other, is formed at the end portion of the barrel portion 4a having its axis coinciding with the axis X4, the as shown in Fig. 12. It is not always necessary to effect the inclining movement only about the angular-movement drive shaft 31, and when the inclining movement about the angular-movement drive shaft 31 and the movement in the X- and/or Y-direction are used in combination, the degree of freedom of the shaping further increases.
- the workpiece 4, decreased in diameter, is inverted in the forward-backward direction, and is again held by the clamp device 12, and a spinning operation, similar to the above spinning operation, is effected, and by doing so, the tapering portions 4d, 4d, as well as the neck portions 4c, 4c, subjected to bend spinning, are formed at the opposite ends, respectively, as shown in Fig. 13.
- the product is removed from the clamp device 12, and this product, having the solid interposition material 4D remaining in the space 3C, may be provided as a final product.
- the solid interposition material 4D may be removed so as to provide a final product having the space 4C formed between the inner and outer tubes 4A and 4B.
- thermoplastic resin may be used as the solid interposition material 4D.
- a heat-insulating member may be used. In the case of using this heat-insulating member, it is preferred that the inner tube 4A of the workpiece 4 be press-fitted into the outer tube 4B, with the heat-insulating member wound around the outer periphery of the inner tube.
- a muffler and a catalytic converter originally require a heat-insulating material, and therefore there is no need to remove the solid interposition material 4D after the shaping operation. In such a case, the step of removing the solid interposition material 4D can be omitted.
- ice may be used, in which case water is poured into the space 4C, and then is frozen into ice.
- metal shots may be used.
- Other materials, which can be changed into a solid or a liquid upon application of heat, can be used, and examples thereof includes a molten salt, such as nitrate and nitrite, a metal of a low melting point, and a compound thereof.
- a mandrel may be inserted in the outer tube 4B.
- the workpiece 4 may be fixed whereas the spinning rollers 28 are moved in the direction of the tube axis, or both may be moved.
- the drive path that is, the means for continuously controlling the rollers in the deforming direction, is arbitrary.
- the workpiece 4 is fixed while the spinning rollers 28 is revolved.
- the axis X5 of the roller drive portion 3 and the axis X4 of the workpiece drive portion 2 are parallel to each other, and are disposed on a common line
- each of the above embodiments is directed to the containers of the exhaust-system parts of an automobile
- the present invention can be applied to other articles such as a general-purpose container and an article for daily use such as a pot, and the invention is not limited to the above use.
- a first step of Fig. 14A an inner tube 4A is inserted into an outer tube 4B. Then, a solid interposition material 4D is filled into a space 4C formed between the inner and outer tubes as shown in Fig. 14B, thereby forming a workpiece 4 shown in Fig. 4C.
- this workpiece 4 is held by the clamp device 12 of the spinning machine, and one end portion of this workpiece 4 is decreased in diameter as shown in Fig. 14D.
- the outer tube 4B is deformed to be decreased in diameter, and this deforming force is transmitted to the inner tube 4A through the solid interposition material 4D, so that the inner and outer tubes 4A and 4B and the solid interposition material 4D are simultaneously deformed.
- a tapering portion 4b decreased in diameter from a stock tube portion 4a of the inner and outer tubes 4A and 4B, and a neck portion 4c, extending from a distal end of this tapering portion 4b, are sequentially formed, with the solid interposition material 4D held between the inner and outer tubes 4A and 4B.
- the inner and outer tubes 4A and 4B are cut at a portion C shown in Fig. 14D, and a discard portion 4e is removed.
- the step of the above spinning operation may be effected with one pass or a plurality of passes of the rollers.
- the diameter-decreasing processing of the neck portion 4c is accurately effected by the decreased-diameter portion 51a of the mandrel 51.
- the spinning rollers 28 move along the tapering portion 51b of the mandrel 51 as indicated by an arrow in the drawing, and are moved away outwardly from the larger-diameter portion 51c of the mandrel 51.
- the one end portion of the workpiece 4 is decreased in diameter by spinning operation.
- the shaped product is removed from the clamp device 12, and this product, obtained in the third step, and having the solid interposition material 4D remaining in the space 4C, may be provided as a final product.
- the solid interposition material 4D may be removed in a fourth step so as to provide a final product having the space 4C formed between the inner and outer tubes 4A and 4B.
- the container having one closed end thereof, is formed.
- the inner and outer tubes of the double-walled container having the space between the inner and outer tubes, can be simultaneously deformed and shaped into desired cross-sections by applying the spinning processing simultaneously to the inner and outer tube, and therefore as compared with the conventional method, the facilitation of the processing and the reduction of the processing time can be achieved, and the processing cost can be greatly reduced.
- the inner tube is arranged in the outer tube, with the space formed therebetween, and the solid interposition material is held between the tubes at least in one region of the space extending in the direction of the tube axis, and in this condition, the spinning rollers are revolved to apply a spinning processing to the outer tube, thereby simultaneously changing the cross-sections of the inner and outer tubes in eccentric relation to the tube axis of the workpiece of the inner and outer tubes. Therefore, the inner and outer tubes, changed in eccentric relation to the tube axis of the workpiece, can be produced while securing the above effects.
- the inner tube is arranged in the outer tube, with the space formed therebetween, and the solid interposition material is held between the tubes at least in one region of the space extending in the direction of the tube axis, and the tube axis of the workpiece of said inner and outer tubes is inclined with respect to the axis of the spinning rollers, and the spinning rollers are revolved to apply a spinning processing to the outer tube, thereby changing the cross-sections of the inner and outer tubes in slantingly-bending relation to the tube axis of the workpiece. Therefore, the inner and outer tubes, changed in bending relation to the tube axis of the workpiece, can be produced while securing the above effects.
- the inner and outer tubes can be prevented by the mandrel, and the desired cross-sectional shape can be positively obtained. Further, by selecting the position of the mandrel, the inner and outer tubes can be deformed into different cross-sectional shapes, respectively, in such a manner that the amount of deformation of the inner tube is different from that of the outer tube, and the cross-sectional shapes of the inner and outer tubes can be made different from each other by simultaneously spinning the inner and outer tubes.
- the mandrel is inserted into at least one of the inner and outer tubes at least at one region thereof, and by doing so, the charging and removal of the solid interposition material, can be effected easily and rapidly, and therefore the efficiency of the operation can be enhanced.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
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- Toxicology (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
- Exhaust Silencers (AREA)
- Exhaust Gas After Treatment (AREA)
Abstract
In a method of producing a double-walled container
having a space between an inner tube and an outer tube, in
order to facilitate its production and to reduce its cost,
the inner tube 4A is arranged in the outer tube 4B, with
the space 4C formed therebetween, and a solid interposition
material 4D is held between the tubes at least in one region
of the space 4C extending in a direction of a tube axis, and
in this condition, a spinning processing is applied to the
outer tube 4B, thereby changing cross-sections of the inner
and outer tubes 4A and 4B simultaneously.
Description
This invention relates to a method of producing a
double-walled container, and more particularly to a production
method in which a double-walled container is obtained
by changing the cross-sectional shapes of inner and outer
tubes simultaneously.
In exhaust-system parts of an automobile, such as
a muffler and a catalytic converter, there is often used a
heat-insulating tube structure in which an inner tube of an
integral construction, continuously varying axially a cross-sectional
shape, and an outer tube of an integral construction,
decreasing in diameter in a tapering manner at its
opposite ends, are arranged in concentric relation to each
other, with a space formed therebetween.
Particularly, in a catalytic converter, it is a
common practice to combine an inner tube 104 of metal, which
contains a catalyst carrier 101 therein, and has tapering
diameter-decreasing portions 102 and 103 formed respectively
at opposite ends thereof, with an outer tube 107 of metal,
having tapering diameter-decreasing portions 105 and 106
formed respectively at opposite ends thereof, so that a
space 108 is formed between the inner tube 104 and the
outer tube 105, as shown in Fig. 15. This construction is
disclosed, for example, in JP-A-6-101465.
One method of producing the catalytic converter,
shown in Fig. 15, is to apply a diameter-decreasing processing
to the outer tube 107 held around the inner tube 104,
beforehand subjected to a diameter-decreasing processing,
with the predetermined space 108 formed therebetween. With
this method, however, the production is difficult, and
besides the production cost is high.
Particularly, there is a significant problem
that is the shaping of the outer tube 107. Namely, in the
formation of the outer tube 107 having a cross-sectional
shape that generally conforms to a change of the cross-section
of the inner tube 104 in the axial direction, and
has the desired space 108 therebetween, it has been extremely
difficult to shape the integral outer tube 107 while
forming the desired space 108 over the entire axial length
thereof.
Therefore, as a convenient production method, it
is a common technique to arrange an outer tube, axially
split into halves, around an inner tube, beforehand shaped,
with a space formed therebetween, and to join the halves
together by welding or the like. With this method, however,
costly equipments, such as pressing dies and a welding
apparatus, are needed, and much time and labor are required
for the pressing process and the welding process.
Therefore, instead of the above production method,
there has been proposed a technique as shown in Fig. 16,
in which an increased-diameter portion 202 is formed at
a proximal end of an inner tube 201, and a decreased-diameter
portion 204 is formed at a proximal end of an outer
tube 203, and the two tubes 201 and 203 are fitted together
as shown in Fig. 16, thereby producing a double-walled
catalytic converter having a predetermined space 205. This
is disclosed, for example, in JP-A-9-108576.
In this production method of Fig. 16, however, the
contact of the increased-diameter portion 202 of the inner
tube 201 with the outer tube 203, as well as the contact of
the decreased-diameter portion 204 of the outer tube 203
with the inner tube 201, is inevitable, and heat transfer
occurs at these contact portions, and therefore, although
the double-walled catalytic convertor has the heat-insulat-ing
structure with the space 205, there is encountered a
problem that its heat-insulating effect is reduced.
There is known a method of producing a thermos
bottle, in which an inner tube, which is open only at one
end thereof, and an outer tube, which is open only at one
end thereof, are separately formed respectively into desired
cross-sections by spinning processing, and these tubes are
combined together. This is disclosed, for example, in JP-A-10-15631
and JP-A-7-284452.
In this production method, however, the spinning
operations are required for the inner tube and the outer
tube, respectively, so that the process becomes complicated,
and besides there is required the additional step of
decreasing the diameter of the mouth in the outer tube after
the inner tube is inserted thereinto, and therefore the
facilitation of the processing and the reduction of the
processing cost can not be achieved also with this method.
Under the above circumstances, it has been desired
to provide a method for easily producing at low costs a
double-walled container, which has a predetermined space
between an inner tube and an outer tube and in which each
of the inner tube and the outer tube is integrally formed
and has a varied cross-section in an axial direction,
respectively.
It is an object of this invention to provide a
double-walled container-producing method which meets the
above requirement.
Therefore, a production method of a first aspect
of the invention is characterized in that an inner tube is
arranged in an outer tube, with a space formed therebetween;
a solid interposition material is held between the tubes at
least in one region of said space extending in a direction
of a tube axis; and in this condition, a spinning processing
is applied to said outer tube, thereby changing cross-sections
of said inner and outer tubes simultaneously.
Therefore, in the production method of the first
aspect, the inner and outer tubes, holding the solid
interposition material therebetween, are rotated about the
tube axis, and spinning rollers are pressed against the
outer tube to effect the spinning processing, so that the
cross-section of the outer tube is changed by its pressing
force, and further the pressing force is transmitted from
the outer tube to the inner tube through the deformable
solid interposition material, held in the space, so that the
cross-section of the inner tube is changed simultaneously.
Therefore, one end portions of the inner and outer tubes can
be simultaneously formed into a desired shape with one
spinning step.
In contrast, the inner and outer tubes are held
stationary, and the spinning rollers are revolved, so as to
press the spinning rollers against the outer tube, thereby
effecting the spinning processing.
In this case, also, as in the case where the inner
and outer tubes are rotated, the revolving spinning rollers
are pressed against the stationary outer tube to effect the
spinning processing, so that the cross-section of the outer
tube is changed by its pressing force, and further the
pressing force is transmitted from the outer tube to the
inner tube through the deformable solid interposition
material, held in the space, so that the cross-section of
the inner tube can be changed simultaneously.
Therefore, as in the above method, one end
portions of the inner and outer tubes can be simultaneously
formed into a desired shape with one spinning step.
A production method of a second aspect of the
invention is characterized in that an inner tube is arranged
in an outer tube, with a space formed therebetween; a solid
interposition material is held between the tubes at least in
one region of the space extending in a direction of a tube
axis; and in this condition, spinning rollers are revolved
to apply a spinning processing to the outer tube, thereby
simultaneously changing cross-sections of the inner and
outer tubes in eccentric relation to a tube axis of a
workpiece of the inner and outer tubes.
In the production method of the second aspect, by
a similar function as described in the production method of
the first aspect in which the spinning rollers are revolved,
one end portions of the inner and outer tubes, changed in
eccentric relation to the tube axis of the workpiece, can be
formed simultaneously with one spinning step.
A production method of a third aspect of the
invention is characterized in that an inner tube is arranged
in an outer tube, with a space formed therebetween; a solid
interposition material is held between the tubes at least in
one region of said space extending in a direction of a tube
axis; a tube axis of a workpiece of said inner and outer
tubes is inclined with respect to an axis of spinning
rollers, and said spinning rollers are revolved to apply a
spinning processing to said outer tube, thereby changing
cross-sections of said inner and outer tubes in slantingly-bending
relation to the tube axis of the workpiece of said
inner and outer tubes.
In the production method of the third aspect, by a
similar function as described in the production method of
the first aspect in which the spinning rollers are revolved,
one end portions of the inner and outer tubes, changed in
bending relation to the tube axis of the workpiece, can be
formed with one spinning step.
In the production method of the present invention,
before said spinning processing, a mandrel may be inserted
into at least one of the inner and outer tubes at least at
one region thereof.
Thus, the mandrel is inserted between the inner
and outer tubes or in the inner tube, and therefore excessive
deformation of the inner and outer tubes during the
spinning operation can be prevented.
In the production method of the present invention,
the solid interposition material may be one of hot-melt
resin, thermoplastic resin and molten salt in a solidified
condition.
By heating this solid interposition material so
as to soften and molt it, the charging of the solid
interposition material into the space before the shaping of
the inner and outer tubes, as well as the removal of the
solid interposition material to the outside of the space
after the shaping, can be easily effected.
The mode for carrying out the present invention
will be described with reference to embodiments shown in
Figs. 1 to 14.
First, a spinning machine for performing a
production method of the invention will be described.
Fig. 1 is a partly-broken, side-elevational view
of a spinning machine , and Fig. 2 is a partly-broken, plan
view of the spinning machine of Fig. 1. A workpiece drive
portion 2 is mounted on one side portion of a fixed base 1,
and a roller drive portion 3 is mounted on the other side
portion thereof.
Two parallel X-direction slide rails 5 are fixedly
mounted on a side of the base 1, on which the workpiece
drive portion 2 is mounted, and extend in a direction
(referred to as "X direction") parallel to an axis X5 of
revolution of rollers 28 (described later). An X-direction
slider 6 is mounted on the X-direction slide rails 5 for
sliding movement in the X-direction, and a ball spline
shaft 8 is threadedly engaged with a boss 7 formed on the
X-direction slider 6. The X-direction slider 6 can be
moved forward and backward in the X-direction in a desired
distance by rotating the ball spline shaft 8 in normal and
reverse directions in a desired amount by drive means 9 such
as a motor.
Two parallel Y-direction slide rails 10 are
fixedly mounted on the X-direction slider 6, and extend
in a horizontal direction (referred to as "Y-direction")
perpendicular to the X-direction. A Y-direction slider 11
is mounted on the Y-direction slide rails 10 for sliding
movement in the Y-direction. A bed 30 is fixedly mounted on
the Y-direction slider 11, and a ball spline shaft 15 is
threadedly engaged with a boss 14 fixedly mounted on a lower
surface of the bed 30. The bed 30 can be moved forward
and backward in the Y-direction in a desired distance by
rotating the ball spline shaft 15 in normal and reverse
directions in a desired amount by drive means 16 such as a
motor.
Angular-movement drive means 31 such as a motor
is mounted on the bed 30, and an angular-movement drive
shaft 31a of this angular-movement drive means 31 projects
vertically from the upper surface of the bed 30. The
angular-movement drive means 31 and the angular-movement
drive shaft 31a jointly form means for inclining a workpiece
4.
A lower clamp 13, constituting a clamp device 12,
is slidably mounted on the upper surface of the bed 30, and
the drive shaft 31a is fixed to the lower clamp 13, and when
the angular-movement drive shaft 31a is rotated in normal
and reverses directions, the lower clamp 13 is angularly
moved about the angular-movement drive shaft 31a in normal
and reverse directions in a horizontal plane.
A guide groove 32 of an arcuate shape, having a
center disposed at the angular-movement drive shaft 31a, is
formed in the bed 30, and a guide roller 33, formed on and
projecting from a lower surface of the lower clamp 13, is
rotatably fitted in the guide groove 32. The angular-movement
drive shaft 31a is disposed such that its axis
perpendicularly intersects a tube axis X4 of the workpiece 4
placed on the lower clamp 13 (described later), as shown in
Fig. 2.
A clamp surface 13a of a semi-circular shape for
supporting a lower half surface of the workpiece 4 is formed
on the upper surface of the lower clamp 13 in such a manner
that when the workpiece 4 is placed on this clamp surface,
the tube axis X4 of the workpiece 4 is disposed at the same
level as that of the axis X5 of a rotation shaft 21 of the
roller drive portion 3 (described later). Further, an upper
clamp 17, having at its lower surface a clamp surface 17a
for pressing and holding an upper half circle portion of the
workpiece 4, is upwardly and downwardly movably provided
above the lower clamp 13, and the upper clamp 17 can be
driven upward and downward by drive means 18 such as a
hydraulic cylinder, and when the upper clamp 17 is moved
downward, the upper clamp 17 and the lower clamp 13 hold the
workpiece 4 therebetween at a predetermined position against
rotation, and when the upper clamp 17 is moved upward, the
workpiece 4 can be attached and removed.
A stopper 19 is provided on a rear side of the
clamp device 12, and the positioning of the workpiece 4 in
the axial direction can be easily effected by abutting a
rear end of the workpiece 4 against the stopper 19. For
example, the stopper 19 is provided on the lower clamp 13,
and is moved with the clamp device 12, and the position of
this stopper can be adjusted in the direction of the tube
axis X4 of the workpiece 4.
Next, the roller drive portion 3 on the base 1
will be described.
A rotation facility portion 20 is mounted on the
base 1, and the rotation shaft 21 is rotatably provided on
this portion 20, with its axis directed in the X-direction.
The rotation shaft 21 can be rotated in one direction by a
motor 22, serving as rotation drive means, through a belt
23. A roller holder 24 is fixed to the rotation shaft 21
on a side of the workpiece drive portion 2, and when the
rotation shaft 21 is rotated, the roller holder 24 is
rotated about the axis X5 of the rotation shaft 21.
Path changing means for changing a drive path of
the rollers is provided on the rotation facility means 20.
This means comprises a cylinder 25, serving as drive means,
and a ring plate 26 which is mounted at a distal end of a
rod 25a of the cylinder 25, and is disposed within the
roller holder 24 so that it will not interfere with the
rotation of the roller holder 24. The ring plate 26 is
formed into an annular shape coaxial with the rotation shaft
21, and an outwardly-spreading, tapering surface 26a is
formed on an inner surface of this ring plate at its distal
end.
A plurality of (three in this embodiment) brackets
27 are mounted on the roller holder 24 at equal intervals in
the circumferential direction, with their axes extending in
the X-axis. Further, the brackets 27 are movable radially
with respect to the axis X5 of the roller holder 24. A
tapering surface 27a is formed, along the tapering surface
26a of the ring plate 26, at one side of each bracket 27
corresponding to the inner side of the roller holder 24, and
the roller 28 is freely rotatably mounted at the outer end
of each bracket 27.
Although not shown, means, which normally urges
the bracket 27 toward the outer periphery of the roller
holder 24, such for example as a return spring, is provided
on each bracket 27, and when the ring plate 26 is moved
forward (left in Fig. 1) by the cylinder 25, each bracket 27
is pushed toward the axis through the two tapering surfaces
26a and 27a, so that each of rollers 28 is moved the same
amount toward the axis of the rotation shaft 21, respectively.
When the ring plate 26 is moved backward (right in
Fig. 1), each bracket 27 is returned radially outwardly
through the two tapering surfaces 26a and 27a, so that each
of rollers 28 is moved the same amount radially outwardly of
the roller holder, respectively.
Next, a method of producing a double-walled
container by deforming cross-sections of inner and outer
tubes simultaneously by the use of the spinning machine will
be described.
Figs. 4A to 4D show a first embodiment according
to a production method of the present invention.
Fig. 4A shows a first step, and shows a condition
in which a cylindrical outer tube 4B of metal, which is
larger in diameter than a cylindrical inner tube 4A of
metal, is arranged around the inner tube 4A in concentric
relation thereto, and a solid interposition material 4D is
filled in an annular space 4C of a predetermined width
formed between the two tubes 4A and 4B. The product in this
condition is the workpiece 4.
For example, a hot-melt resin is used as the
solid interposition material 4D, and for filling it, the
inner and outer tubes 4A and 4B are held by suitable means
in such a manner that the predetermine space 4C is formed
therebetween, and one end of this space 4C is closed, and a
resin in a heat-molten state is poured into the space 4C
through the other end thereof, and is cooled and solidified,
and is interposed as the solid interposition material 4D
between the inner and outer tubes 4A and 4B.
Preferably, the solid interposition material 4D
has good filling and discharging abilities, and can be
deformed to a certain degree when it is filled and formed
into a solid state, and further has low compressibility (it
may have non-compressibility), and preferably the solid
interposition material is the above-mentioned hot-melt
resin, but may be other material than this resin. Preferably,
a melting point of the hot-melt resin is higher than
a temperature of the workpiece 4 which is raised by the
spinning. For example, a resin, marketed under the trade
name "Seal Peal Hot" can be used as the above hot-melt
resin.
Then, the process shifts to a second step in
which the workpiece 4 is held by the clamp device 12 of the
spinning machine, and the end portions of the workpiece 4
are decreased in diameter, as shown in Fig. 4B.
Before the diameter-decreasing operation, the ring
plate 26 of the spinning machine is located at a position
spaced right from its position shown in Fig. 1, and the
rollers 28 are retracted outwardly of the outer periphery of
the workpiece 4 prior to the processing, and are held in an
open condition.
Then, the workpiece 4 is fitted in and placed on
the clamp surface 13a of the lower clamp 13, with its rear
end abutted against the stopper 19 set at a predetermined
position, and thereafter the drive means 18 is operated to
move the upper clamp 17 downward, so that the workpiece 4 is
held between the upper and lower clamps 17 and 13 so as to
prevent it from rotating. The position of the clamp device
12 in the Y-direction is set by the drive means 16 to a
position where an extension line of the axis of the angular-movement
drive shaft 31a intersects an extension line of the
axis X5 of the rotation shaft 21.
If necessary, a mandrel 51 is inserted into that
end of the inner tube 4A to be subjected to the spinning
operation, as shown in Fig. 4B. The mandrel 51 includes
a decreased-diameter portion 51a, corresponding to the
decreased diameter of the inner tube 4A, a tapering portion
51b, which extends from this decreased-diameter portion,
and is slanting radially outwardly, and a larger-diameter
portion 51c which is continuous with this tapering portion,
and extends parallel to the axial direction, the larger-diameter
portion 51c having an outer diameter substantially
equal to the inner diameter of the workpiece 4.
Then, the ball spline shaft 8 is rotated in one
direction by the drive means 9, thereby moving the clamp
device 12 right (in Fig. 1) in the X-direction parallel to
the axis X5 of the rotation shaft 21, so that the rollers 28
are located at a diameter-decrease starting point A of the
workpiece 4, as shown in Fig. 4B.
In this condition, the motor 22, serving as the
drive means, is driven to rotate the roller holder 24 in
one direction, and also the drive means 25 is operated to
advance the ring plate 26 to move the path of revolution of
the rollers 28 in the closing direction toward the center of
the roller holder 24, and also the drive means 9 is driven
to rotate the ball spline shaft 8 in a direction reverse to
the above-mentioned direction, thereby moving the clamp
device 12, together with the workpiece 4, backward left (in
Fig. 1) in the X-direction.
As a result, the rollers 28, while freely rotating
in press-contact with the outer peripheral surface of the
outer tube 4B in the workpiece 4, revolves about the tube
axis X5, and also the diameter of the path of revolution of
these rollers gradually decreases, thereby effecting the
spinning operation starting from the diameter-decrease
starting point A, as shown in Fig. 4B.
As a result of this spinning operation, the outer
tube 4B is deformed to be decreased in diameter, and also
this deforming force is transmitted to the inner tube 4A
through the solid interposition material 4D, so that the
inner and outer tubes 4A and 4B and the solid interposition
material 4D are simultaneously deformed.
Namely, a tapering portion 4b, decreased in
diameter from a stock tube portion 4a of the inner and outer
tubes 4A and 4B, and a neck portion 4c, extending from a
distal end of this tapering portion 4b, are sequentially
formed, with the solid interposition material 4D held
between the inner and outer tubes 4A and 4B.
If necessary, the step of the above spinning
operation may be effected with one pass or a plurality of
passes of the rollers.
In the case where the mandrel 51 is inserted in
this spinning operation, the diameter-decreasing processing
of the neck portion 4c is accurately effected by the
decreased-diameter portion 51a of the mandrel 51. Further,
as shown in Fig. 4B, the spinning rollers 28 move along the
tapering portion 51b of the mandrel 51 as indicated by an
arrow in the drawing, and are moved away outwardly from the
larger-diameter portion 51c of the mandrel 51.
Then, the inner and outer tubes 4A and 4B are cut
at a portion C shown in Fig. 4B, and a discard portion 4e is
removed.
Then, in a third step, the workpiece 4, shaped in
the second step, is removed from the clamp device 12, and is
inverted in the axial direction, and is again held by the
clamp device 12, and as shown in Fig. 4C, the other tube
end portion of the workpiece 4, opposite to that processed
in the second step, is decreased in diameter by spinning
process as in the second step. At this time, the mandrel 51
may be used if necessary as in the second step.
Then, the inner and outer tubes 4A and 4B are cut
at a portion D shown in Fig. 4C, and a discard portion 4f is
removed.
The cutting of the inner and outer tubes 4A and 4B
in the second step and the cutting of these tubes in the
third step may be effected at a time after the third step.
Although the discard portions 4e and 4f are not
always necessary, it is preferred to form these discard
portions 4e and 4f and to remove them by cutting in order to
accurately form the shape of the tube end portions.
Thus, each of the opposite end portions of the
workpiece 4 has been decreased in diameter by one spinning
process.
Then, after the above shaping processing, the
shaped product is removed from the clamp device 12, and this
product, obtained in the third step, and having the solid
interposition material 4D remaining in the space 3C, may be
provided as a final product. Alternatively, as shown in
Fig. 4D, the solid interposition material 4D may be removed
in a fourth step so as to provide a final product having the
space 4C formed between the inner and outer tubes 4A and 4B.
In the case where the solid interposition material
4D is hot-melt resin, the solid interposition material 4 can
be easily flowed away and removed by heating the product in
the fourth step.
In the case where a member with excellent heat-insulating
properties, such as a heat-insulating mat, is
used as the solid interposition material 4D, it is preferred
that this solid interposition material should be left as it
is. However, generally, when this container is used as an
exhaust-system container of an automobile, a high heat-resistance
is required, and therefore the solid interposition
material 4D is removed.
In the thus shaped product of Fig. 4D, the
opposite ends of the inner and outer tubes 4A and 4B are
connected to other connection pipes or the like, with the
space 4C held therebetween.
Fig. 5 shows a second embodiment of a production
method according to the present invention.
This second embodiment is directed to an embodiment,
in which an interior member is contained in the inner
tube 4A of the first embodiment, and shows an example in
which it is applied to a catalytic converter of an exhaust
system of an automobile.
In a first step of Fig. 5A, a catalyst carrier 50
is inserted or press-fitted in the first step of the first
embodiment shown in Fig. 4A.
Then, a second step (Fig. 5B), a third step (Fig.
5C) and a fourth step (Fig. 5D) as described above in the
first embodiment are effected, thereby producing a double-walled
pipe as shown in Fig. 5D which contains the catalyst
carrier 50 therein, and has a space 4C formed between the
inner and outer tubes 4A and 4B.
In this embodiment, also, the mandrel 51 is not
always necessary, and may be used if necessary.
Fig. 6 shows a third embodiment of a production
method according to the present invention.
This third embodiment is directed to an embodiment
in which an interior member, such for example as a catalyst
carrier 50 as described above in the second embodiment, is
contained, and one ends of inner and outer tubes 4A and 4B
are extended long, with a space 4C formed therebetween, and
for example, a resonant-type muffler is formed integrally on
the rear side of the catalytic converter 50 of the second
embodiment. In Fig. 6, that portion, designated by reference
numeral 54, is the resonant-type muffler.
The production process of this third embodiment is
basically similar to the production process of the second
embodiment, and resonance holes 52 are beforehand formed in
the inner tube 4A, and a mandrel, which is similar to the
mandrel 51 described in the second embodiment, but has an
extended insertion portion, is used during the spinning
operation, and the resonance holes 52 are closed by this
extension portion from the inside of the inner tube 4A.
One ends (for example, left ends in Fig. 6) of
the inner and outer tubes 4A and 4B, shaped in this third
embodiment, are fixed to other connection pipe whereas a
wire net ring 53 for holding the inner and outer tubes 4A
and 4B in a manner to allow them to move relative to each
other is held between the other ends (for example, the right
end in Fig. 6), so that a relative movement between the
inner tube 4A and the outer tube 4B due to thermal expansion
can be allowed.
In the embodiment of Fig. 6, the space 4C on
the left side (side A) of the catalyst carrier 50 has a
gradually decreasing thickness (the distance of the gap
between the inner and outer tubes), and for shaping this
left-side portion, the inner tube 4A and the outer tube 4B
are beforehand decreased in diameter into tapering portions
and neck portions as shown in the drawing, and then this
inner tube 4A is inserted into the outer tube 4B, and the
diameter-decreased portion of the inner tube 4A is held
by holding means (not shown), and a solid interposition
material 4D is filled into the space 4C between the inner
tube 4A and the outer tube 4B on the right side (side B)
of the catalyst carrier 50, and a spinning operation as
described above is applied to the outer tube 4B.
In the product produced in this third embodiment,
exhaust gas is purified by the catalyst carrier 50, and also
exhaust sounds flow through the resonance holes 52 into the
gap 4C in the resonant-type muffler 54, so that the sounds
are deadened by the gap 4C serving as a resonance space.
This gap 4C also achieves an originally-intended, heat-insulating
effect.
As described above, by arbitrarily determining
the range of filling of the solid interposition material 4D,
the range of use of the mandrel 51 and the shape of this
mandrel, the inner and outer tubes 4A and 4B, having the
space 4C therebetween, can be formed in a desired manner.
Fig. 7 shows a fourth embodiment of a production
method according to the present invention.
This fourth embodiment shows an example in which a
double-walled pipe, in which the axes of the inner and outer
tubes 4A and 4B are eccentric with respect to each other, is
produced.
Referring to the production method of this embodiment,
in the first step of the first and second embodiments,
the inner tube 4A and the outer tube 4B are suitably made
eccentric with respect to each other, and a solid interposition
material 4D is filled in a gap 4C between the two
tubes, and then the similar steps as described above in the
first and second embodiments are effected, thereby producing
the product.
Fig. 8 shows a fifth embodiment of a production
method according to the present invention.
This fifth embodiment shows an example in which
one diameter-decreased portion of the double-walled tube
(container) is offset respect to the other diameter-decreased
portion.
This production process will be described.
First, there is used a workpiece 4 as shown above
in Fig. 5A, in which a solid interposition material 4D is
interposed between an inner tube 4A and an outer tube 4B,
and an interior member (for example, a catalyst carrier 50)
is contained in the inner tube 4A.
In Fig. 1, before the diameter-decreasing
operation, the ring plate 26 is located at a position spaced
right from its position shown in Fig. 1, and the rollers 28
are retracted outwardly of the outer diameter of the workpiece
4 prior to the processing, and are held in an open
condition.
Then, the unprocessed workpiece 4 is fitted in
and placed on the clamp surface 13a of the lower clamp 13,
with its rear end abutted against the stopper 19 set at a
predetermined position, and thereafter the drive means 18 is
operated to move the upper clamp 17 downward, so that the
workpiece 4 is held between the upper and lower clamps 17
and 13 against rotation. The angular-movement drive means
31 is operated to angularly move the clamp device 12, so
that the tube axis X4 of the workpiece 4, held by this clamp
device, is parallel to the axis X5 of the rotation shaft 21.
Further, the drive means 16 is operated to adjustably move
the clamp device 12 in the Y-direction, so that the tube
axis X4 of the workpiece 4 is parallel to and is offset a
predetermined amount OF1 (see Fig. 9A) from the axis X5 of
the rotation shaft 21.
Then, the ball spline shaft 8 is rotated in one
direction by the drive means 9, thereby moving the clamp
device 12 right (in Fig. 1) in the X-direction to move the
workpiece 4 forward (right in Fig. 1) toward the roller
holder 24 by a predetermined amount in a direction parallel
to the tube axis thereof, so that the rollers 28 are located
at a diameter-decrease starting point A (see Fig. 9A) of the
workpiece 4.
In this condition of Fig. 9A, the motor 22,
serving as the drive means, is driven to rotate the roller
holder 24 in one direction, and also the drive means 25 is
operated to advance the ring plate 26 to move the path of
revolution of the rollers 28 in the closing direction toward
the center of the roller holder 24, and also the drive means
9 is reversely driven to rotate the ball spline shaft 8 in a
direction reverse to the above-mentioned direction, thereby
moving the clamp device 12, together with the workpiece 4,
backward left (in Fig. 1) in the X-direction.
As a result, the rolls 28, while freely rotating
in press-contact with the outer peripheral surface of the
outer tube 4B, revolves about the tube axis X5, and also the
diameter of the path of revolution of these rolls gradually
decreases, thereby effecting the spinning operation starting
from the diameter-decrease starting point A, as shown in
Fig. 9B. At this time, since the axis X5 of revolution of
the rollers 28 is offset a distance OF1 from the tube axis
X4 of the workpiece 5, the tube end, subjected to the
spinning operation, is plastically deformed into a tapering
portion 4b of a truncated cone-shape having its axis
coinciding with the revolution axis X5 offset a distance
OF1 from the tube axis X4 of a stock tube portion (barrel
portion) 4a of the workpiece 4, as shown in Fig. 9B.
After the tapering portion 4b is shaped, the
workpiece 4 is continued to be moved backward, with the
rollers 28 held in the closed position, and by doing so, a
cylindrical neck portion 4c, having its axis coinciding with
the revolution axis X5 and being parallel to the tube axis
X4 of the workpiece 4, is formed at the distal end of the
tapering portion 4b by plastic deformation.
Then, the workpiece 4, as well as the rollers
28, is moved backward in a direction opposite to that of
the forward movement (that is, the diameter-decreasing
movement), and the first spinning operation is finished with
this one reciprocation (forward-backward movement).
After the first spinning operation is finished,
the rollers 28 are returned to the open position, and also
the drive means 9 is operated to rotate the ball spline
shaft 8 in one direction to further advance the workpiece 4,
together with the clamp device 12, by a predetermined amount
in a direction parallel to the tube axis thereof, so that
the rollers 28 are located at a point B in Fig. 9C. The
drive means 16 is operated to rotate the ball spline shaft
15 in one direction to further move the workpiece 4,
together with the clamp device 12, by a predetermined amount
in the Y-direction, so that the amount OF2 of offset of
the tube axis X4 of the workpiece 4 from the axis of the
rotation shaft 21, that is, the axis X5 of revolution of the
rollers 28, is made larger than the above offset amount OF1,
as shown in Fig. 9C.
Then, in this condition, a spinning operation,
similar to the above spinning operation, is effected in such
a manner that the amount of closing movement of the rollers
28 is larger than that in the above first process. As a
result, the tapering portion 4b is plastically deformed into
the tapering portion 4b of a truncated cone-shape which has
a larger tapering angle, and has its axis disposed on the
revolution axis X5 offset an amount OF2 from the tube axis
X4 of the stock tube portion (barrel portion) 4a of the
workpiece 4. After this tapering portion 4b is shaped, the
workpiece 4 is continued to be moved backward with the
rollers 28 held in the closed position, and by doing so, the
neck portion 4c, smaller in diameter than the neck portion
of Fig. 9B, is formed at the distal end of the tapering
portion 4b.
With the above process, a diameter-decreased
portion 4d, having the offset tapering portion 4b and the
offset tapering neck portion 4c which are integrally formed
with each other, is formed at the end portion (right end
portion in Fig. 8).
In the above spinning operation, the outer tube 4B
is deformed to be decreased in diameter, and also this
deforming force is transmitted to the inner tube 4B through
the solid interposition material 4D, so that the inner and
outer tubes 4A and 4B and the solid interposition material
4D are simultaneously deformed.
Namely, the tapering portion 4b, decreasing in
diameter from the stock tube portion 4a of the inner and
outer tubes 4A and 4B, and the neck portion 4c, extending
from the distal end of this tapering portion 4b, are
sequentially formed, with the solid interposition material
4D held between the inner and outer tubes 4A and 4B.
Then, the workpiece 4, shaped in the above
process, is removed from the clamp device 12, and is
inverted in the axial direction, and is again held by the
clamp device 12, and the other tube end portion of the
workpiece 4, opposite to that processed in the above
process, is decreased in diameter by spinning process in a
manner as described above.
Incidentally, at this time, by effecting the
spinning operation in such a manner that the tube axis X4 of
the workpiece 4 and the axis X5 of the rotation shaft 21 are
disposed in coaxial relation to each other in Fig. 1, a
tapering portion 4b and a neck portion 4c, which are coaxial
with the stock tube portion 4a, are formed as the left end
portion in Fig. 8.
Then, after the above shaping operation, the
shaped product is removed from the clamp device 12, and this
product, obtained in the third step, and having the solid
interposition material 4D remaining in the space 4C, may be
provided as a final product. Alternatively, as shown in
Fig. 8, the solid interposition material 4D may be removed
so as to provide a final product having the space 4C formed
between the inner and outer tubes 4A and 4B.
Fig. 10 shows a sixth embodiment according to the
present invention.
This sixth embodiment shows an example in which
diameter-decreased portions and neck portions at opposite
end portions are processed by bend-spinning.
A production process of this embodiment will be
described.
In Figs. 1 and 2, before the diameter-decreasing
operation, the ring plate 26 is located at a position spaced
right from its position shown in Fig. 1, and the rollers 28
are retracted radially outwardly of the outer diameter of a
workpiece 4, as shown in Fig. 11A.
Then, the workpiece 4, similar to that of Fig. 4A,
is fitted in and placed on the clamp surface 13a of the
lower clamp 13, with its rear end abutted against the
stopper 19 set at a predetermined position, and thereafter
the drive means 18 is operated to move the upper clamp 17
downward, so that the workpiece 4 is held between the upper
and lower clamps 17 and 13 against rotation. The position
of the clamp device 12 in the Y-direction is so set by the
drive means 16 that an extension line of the axis of the
angular-movement drive shaft 31a intersects an extension
line of the axis X5 of the rotation shaft 21, as shown in
Fig. 11A. Further, the angular-movement drive means 31 is
operated to incline the clamp device 12 horizontally, so
that the tube axis X4 of the workpiece 4 is horizontally
inclined at a predetermined angle 1 with respect to the
axis X5 of the rotation shaft 21, as shown in Fig. 11A.
Then, the ball spline shaft 8 is rotated in one
direction by the drive means 9, thereby moving the clamp
device 12 right (in Fig. 1) in the X-direction parallel to
the axis X5 of the rotation shaft 21, so that the rollers 28
are located at a diameter-decrease starting point A of the
workpiece 4, as shown in Fig. 11A.
In this condition (the condition of Fig. 11A), the
motor 22, serving as the drive means, is driven to rotate
the roller holder 24 in one direction, and also the drive
means 25 is operated to advance the ring plate 26 to move
the path of revolution of the rollers 28 in the closing
direction toward the center of the roller holder 24, and
also the drive means 9 is driven to rotate the ball spline
shaft 8 in a direction reverse to the above-mentioned
direction, thereby moving the clamp device 12, together
with the workpiece 4, backward left (in Fig. 1) in the X-direction.
As a result, the rolls 28, while freely rotating
in press-contact with the outer peripheral surface of the
workpiece 4, revolves about the tube axis X5, and also the
diameter of the path of revolution of these rollers
gradually decreases, thereby effecting the spinning operation
starting from the diameter-decrease starting point A,
as shown in Fig. 11B. At this time, since the tube axis X4
of the workpiece 4 is inclined at the angle 1 with respect
to the axis X5 of revolution of the rollers 28, the tube
end, subjected to the spinning operation, is plastically
deformed into a tapering portion 4b of a truncated cone-shape
having its axis coinciding with the revolution axis X5
inclined at the angle 1 with respect to the tube axis X4
of a stock tube portion (barrel portion) 4a of the workpiece
4, as shown in Fig. 11B.
After the tapering portion 4b is shaped, the
workpiece 4 is continued to be moved backward, with the
rollers 28 held in the closed position, and by doing so, a
cylindrical neck portion 4c, having its axis coinciding
with the revolution axis X5 inclined at the angle 1 with
respect to the tube axis X4 of the workpiece 4, is formed
at the distal end of the tapering portion 4b by plastic
deformation.
Then, the workpiece 4, as well as the rollers 28,
is moved backward in a direction opposite to that of the
forward movement (that is, the diameter-decreasing movement),
and the first spinning operation is finished with
this one reciprocation (forward-backward movement).
After the first spinning operation is finished,
the rollers 28 are returned to the open position, and the
drive means 9 is operated to rotate the ball spline shaft
8 in one direction to further advance the workpiece 4,
together with the clamp device 12, by a predetermined amount
in the X-direction, so that the rollers 28 are located at a
point B in Fig. 11C, and also the angular-movement means 31
is operated to further incline the workpiece 4, together
with the clamp device 12, by a predetermined amount, so that
the angle 2 between the tube axis X4 of the workpiece 4
and the axis of the rotation shaft 21, that is, the axis X5
of revolution of the rollers 28, is made larger than the
angle 1 in the above first step, as shown in Fig. 11C.
Then, in this condition, a spinning operation,
similar to the above spinning operation, is effected in such
a manner that the amount of closing movement of the rollers
28 is larger than that during the above first process.
As a result, the tapering portion 4b, shaped in the first
process, is plastically deformed into the tapering portion
4b of a truncated cone-shape which has a larger tapering
angle, and has its axis disposed on the revolution axis X5
inclined at the angle 2 with respect to the tube axis X4
of the stock tube portion (barrel portion) 4a of the
workpiece 4. After this tapering portion 4b is shaped, the
workpiece 4 is continued to be moved backward in the X-direction
with the rollers 28 held in the closed position,
and by doing so, the neck portion 4c, having its axis
disposed on the above axis X5 and smaller in diameter than
the neck portion of the first process, is formed at the
distal end of the tapering portion 4b.
With the above process, a diameter-decreased
portion 4d, having the tapering portion 4b and the tapering
neck portion 4c having its axis coinciding with the axis X5
inclined with respect to the axis X4, which are integrally
formed with each other, is formed at the end portion of the
barrel portion 4a having its axis coinciding with the axis
X4, the as shown in Fig. 12. It is not always necessary to
effect the inclining movement only about the angular-movement
drive shaft 31, and when the inclining movement
about the angular-movement drive shaft 31 and the movement
in the X- and/or Y-direction are used in combination, the
degree of freedom of the shaping further increases.
Next, with the above process, the workpiece 4,
decreased in diameter, is inverted in the forward-backward
direction, and is again held by the clamp device 12, and a
spinning operation, similar to the above spinning operation,
is effected, and by doing so, the tapering portions 4d, 4d,
as well as the neck portions 4c, 4c, subjected to bend
spinning, are formed at the opposite ends, respectively, as
shown in Fig. 13.
Then, after the above shaping operation, the
product is removed from the clamp device 12, and this
product, having the solid interposition material 4D
remaining in the space 3C, may be provided as a final
product. Alternatively, as shown in Fig. 10, the solid
interposition material 4D may be removed so as to provide a
final product having the space 4C formed between the inner
and outer tubes 4A and 4B.
In the above embodiment, thermoplastic resin may
be used as the solid interposition material 4D. Also,
instead of this resin, a heat-insulating member may be used.
In the case of using this heat-insulating member, it is
preferred that the inner tube 4A of the workpiece 4 be
press-fitted into the outer tube 4B, with the heat-insulating
member wound around the outer periphery of the inner
tube.
Furthermore, a muffler and a catalytic converter
originally require a heat-insulating material, and therefore
there is no need to remove the solid interposition material
4D after the shaping operation. In such a case, the step of
removing the solid interposition material 4D can be omitted.
Further, as the solid interposition material 4D,
ice may be used, in which case water is poured into the
space 4C, and then is frozen into ice. Further, metal shots
may be used. Other materials, which can be changed into a
solid or a liquid upon application of heat, can be used, and
examples thereof includes a molten salt, such as nitrate and
nitrite, a metal of a low melting point, and a compound
thereof.
In the above embodiments, although the mandrel 4A
is inserted in the inner tube 4A, a mandrel may be inserted
in the outer tube 4B.
In each of the above embodiments, although the
workpiece 4 is moved in the direction of the tube axis
during the spinning operation, the workpiece 4 may be fixed
whereas the spinning rollers 28 are moved in the direction
of the tube axis, or both may be moved. And, the drive
path, that is, the means for continuously controlling the
rollers in the deforming direction, is arbitrary.
In each of the above embodiments, the workpiece
4 is fixed while the spinning rollers 28 is revolved.
However, in the case where the axis X5 of the roller drive
portion 3 and the axis X4 of the workpiece drive portion 2
are parallel to each other, and are disposed on a common
line, there may be used an arrangement in which the
workpiece 4 is rotated about its axis, and also the mandrel
51 is rotated in the same manner, and the spinning rollers
28 are freely rotated without being revolved, and are moved
radially and in the direction of the tube axis.
Although each of the above embodiments is directed
to the containers of the exhaust-system parts of an
automobile, the present invention can be applied to other
articles such as a general-purpose container and an article
for daily use such as a pot, and the invention is not
limited to the above use.
As one such example, an eighth embodiment
according to the present invention will be described below
with reference to Figs. 14A to 14E.
This is an example in which the present invention
is applied to the workpiece 4 closed at one end thereof in
the first embodiment, and this can be applied to any
container such as a pot, a bomb and an accumulator.
In a first step of Fig. 14A, an inner tube 4A is
inserted into an outer tube 4B. Then, a solid interposition
material 4D is filled into a space 4C formed between the
inner and outer tubes as shown in Fig. 14B, thereby forming
a workpiece 4 shown in Fig. 4C.
Then, as in Fig. 4B of the first embodiment, in a
second step, this workpiece 4 is held by the clamp device
12 of the spinning machine, and one end portion of this
workpiece 4 is decreased in diameter as shown in Fig. 14D.
With this spinning operation, the outer tube 4B is
deformed to be decreased in diameter, and this deforming
force is transmitted to the inner tube 4A through the solid
interposition material 4D, so that the inner and outer tubes
4A and 4B and the solid interposition material 4D are
simultaneously deformed.
Namely, a tapering portion 4b, decreased in
diameter from a stock tube portion 4a of the inner and outer
tubes 4A and 4B, and a neck portion 4c, extending from a
distal end of this tapering portion 4b, are sequentially
formed, with the solid interposition material 4D held
between the inner and outer tubes 4A and 4B.
Then, the inner and outer tubes 4A and 4B are cut
at a portion C shown in Fig. 14D, and a discard portion 4e
is removed.
If necessary, the step of the above spinning
operation may be effected with one pass or a plurality of
passes of the rollers.
In the case where the mandrel 51 is inserted in
this spinning operation, the diameter-decreasing processing
of the neck portion 4c is accurately effected by the
decreased-diameter portion 51a of the mandrel 51. Further,
as shown in Fig. 14D, the spinning rollers 28 move along the
tapering portion 51b of the mandrel 51 as indicated by an
arrow in the drawing, and are moved away outwardly from the
larger-diameter portion 51c of the mandrel 51.
With the above operation, the one end portion of
the workpiece 4 is decreased in diameter by spinning
operation.
Then, after the above shaping processing, the
shaped product is removed from the clamp device 12, and this
product, obtained in the third step, and having the solid
interposition material 4D remaining in the space 4C, may be
provided as a final product. Alternatively, as shown in
Fig. 14E, the solid interposition material 4D may be removed
in a fourth step so as to provide a final product having the
space 4C formed between the inner and outer tubes 4A and 4B.
In this manner, the container, having one closed
end thereof, is formed.
As described above, in the first aspect of the
present invention, the inner and outer tubes of the double-walled
container, having the space between the inner and
outer tubes, can be simultaneously deformed and shaped into
desired cross-sections by applying the spinning processing
simultaneously to the inner and outer tube, and therefore as
compared with the conventional method, the facilitation of
the processing and the reduction of the processing time can
be achieved, and the processing cost can be greatly reduced.
In the second aspect of the invention, the inner
tube is arranged in the outer tube, with the space formed
therebetween, and the solid interposition material is held
between the tubes at least in one region of the space
extending in the direction of the tube axis, and in this
condition, the spinning rollers are revolved to apply a
spinning processing to the outer tube, thereby
simultaneously changing the cross-sections of the inner and
outer tubes in eccentric relation to the tube axis of the
workpiece of the inner and outer tubes. Therefore, the
inner and outer tubes, changed in eccentric relation to the
tube axis of the workpiece, can be produced while securing
the above effects.
In the third aspect of the invention, the inner
tube is arranged in the outer tube, with the space formed
therebetween, and the solid interposition material is held
between the tubes at least in one region of the space
extending in the direction of the tube axis, and the tube
axis of the workpiece of said inner and outer tubes is
inclined with respect to the axis of the spinning rollers,
and the spinning rollers are revolved to apply a spinning
processing to the outer tube, thereby changing the cross-sections
of the inner and outer tubes in slantingly-bending
relation to the tube axis of the workpiece. Therefore, the
inner and outer tubes, changed in bending relation to the
tube axis of the workpiece, can be produced while securing
the above effects.
Further, according to the present invention,
excessive deformation of the inner and outer tubes can be
prevented by the mandrel, and the desired cross-sectional
shape can be positively obtained. Further, by selecting the
position of the mandrel, the inner and outer tubes can be
deformed into different cross-sectional shapes, respectively,
in such a manner that the amount of deformation of the
inner tube is different from that of the outer tube, and the
cross-sectional shapes of the inner and outer tubes can be
made different from each other by simultaneously spinning
the inner and outer tubes.
Further, in the present invention, the mandrel is
inserted into at least one of the inner and outer tubes at
least at one region thereof, and by doing so, the charging
and removal of the solid interposition material, can be
effected easily and rapidly, and therefore the efficiency of
the operation can be enhanced.
Claims (12)
- A method of producing a double-walled container characterized in that an inner tube is arranged in an outer tube, with a space formed therebetween; and a solid interposition material is held between the tubes at least in one region of said space extending in a direction of a tube axis; and in this condition, a spinning processing is applied to said outer tube, thereby changing cross-sections of said inner and outer tubes simultaneously.
- A method of producing a double-walled container according to claim 1, in which before said spinning processing, a mandrel is inserted into at least one of said inner and outer tubes at least at one region thereof.
- A method of producing a double-walled container according to claim 2, characterized in that said solid interposition material is one of hot-melt resin, thermoplastic resin and molten salt in a solidified condition.
- A method of producing a double-walled container according to claim 1, characterized in that said solid interposition material is one of hot-melt resin, thermoplastic resin and molten salt in a solidified condition.
- A method of producing a double-walled container characterized in that an inner tube is arranged in an outer tube, with a space formed therebetween; and a solid interposition material is held between the tubes at least in one region of said space extending in a direction of a tube axis; and in this condition, spinning rollers are revolved to apply a spinning processing to said outer tube, thereby simultaneously changing cross-sections of said inner and outer tubes in eccentric relation to a tube axis of a workpiece of said inner and outer tubes.
- A method of producing a double-walled container according to claim 5, in which before said spinning processing, a mandrel is inserted into at least one of said inner and outer tubes at least at one region thereof.
- A method of producing a double-walled container according to claim 6, characterized in that said solid interposition material is one of hot-melt resin, thermoplastic resin and molten salt in a solidified condition.
- A method of producing a double-walled container according to claim 5, characterized in that said solid interposition material is one of hot-melt resin, thermoplastic resin and molten salt in a solidified condition.
- A method of producing a double-walled container characterized in that an inner tube is arranged in an outer tube, with a space formed therebetween; and a solid interposition material is held between the tubes at least in one region of said space extending in a direction of a tube axis; and a tube axis of a workpiece of said inner and outer tubes is inclined with respect to an axis of spinning rollers, and said spinning rollers are revolved to apply a spinning processing to said outer tube, thereby changing cross-sections of said inner and outer tubes in slantingly-bending relation to the tube axis of the workpiece of said inner and outer tubes.
- A method of producing a double-walled container according to claim 9, in which before said spinning processing, a mandrel is inserted into at least one of said inner and outer tubes at least at one region thereof.
- A method of producing a double-walled container according to claim 10, characterized in that said solid interposition material is one of hot-melt resin, thermoplastic resin and molten salt in a solidified condition.
- A method of producing a double-walled container according to claim 9, characterized in that said solid interposition material is one of hot-melt resin, thermoplastic resin and molten salt in a solidified condition.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP26944798 | 1998-09-24 | ||
JP10269447A JP2957176B1 (en) | 1998-09-24 | 1998-09-24 | Manufacturing method of double structure container |
PCT/JP1999/005184 WO2000016924A1 (en) | 1998-09-24 | 1999-09-22 | Production method for double-structure container |
Publications (1)
Publication Number | Publication Date |
---|---|
EP1025923A1 true EP1025923A1 (en) | 2000-08-09 |
Family
ID=17472565
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP99944778A Withdrawn EP1025923A1 (en) | 1998-09-24 | 1999-09-22 | Production method for double-structure container |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP1025923A1 (en) |
JP (1) | JP2957176B1 (en) |
WO (1) | WO2000016924A1 (en) |
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Also Published As
Publication number | Publication date |
---|---|
JP2000094050A (en) | 2000-04-04 |
JP2957176B1 (en) | 1999-10-04 |
WO2000016924A1 (en) | 2000-03-30 |
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