GB2356662A - Roll forming tool for securing an edge trim or seal on a flange - Google Patents

Description

2356662 ROLL FORMING TOOL FOR SECURING AN EDGE TRIM OR SEAL ON A FLANGE

The present invention relates to a roll forming tool for securing or clinching an edge trim 5 or seal on a flange on a motor vehicle.

In the motor industry, the doors and boot of a vehicle are provided with an edge trim and/or a seal which forms a largely air and water tight barrier between the opening member, i.e. door or boot lid, and the aperture in which the opening member is located.

Traditionally, these edge trims or seals have a U-shaped Range gripping portion and, in the case of a seal, a resiliently deformable sealing portion extending from or secured to the Ushaped flange gripping portion. Normally, the U-shaped flange gripping portion is extruded from a polymeric material and incorporates therein a metallic carrier formed of knitted wire or slotted or slit metal which imparts rigidity to the edge trim and, due to the nature of the carrier, allows the edge trim to grip onto a flange around the periphery of the opening member or aperture on the vehicle.

In the past, such edge trims or seals were applied to the metal flange (which is normally of non-uniform cross-section, e.g. of 1, 2 or 3 thicknesses of metal) by hand with the aid of a harnmer or mallet. Obviously, for such application, the U-shaped flange gripping portion of the edge trim or seal must be able to grip the flange and traditionally therefore it has been provided with one or more gripper fins which collapse during application of the flange gripping portion to the flange but which resist pulling off of the edge trim or seal from the flange. One of the problems with such an arrangement is that the gap between the limbs of the U-shaped flange gripping portion has to be largely of uniform dimension so as to grip the flange regardless of its thickness and while the gripper fins may be able to accommodate very thin flanges, e.g. of only a single layer thickness, there is always a problem in applying the edge trim or seal to flanges of above average thickness, e.g. of 3layer thickness. Usually, therefore, the fitter has to apply excessive force to the back of the flange gripping portion, i.e. to the base of the U so as to fit it onto the flange and this can have the disadvantage that it causes the U-shaped flange gripping portion to splay open, thus damaging the edge trim and reducing its flange gripping properties.

2 The above problems have been overcome recently by using a roll forming tool in conjunction with a modified edge trim or seal for applying the modified edge trim or seal to the flange. Instead of using a traditional flange gripping portion on the edge trim or seal of U-shaped cross section, the flange gripping portion is of open U-shape, i.e. the arms of the U are splayed apart, thus allowing the flange gripping portion of the edge trim or seal to be offered up onto the flange but without gripping it.

The roll forming tool incorporates a pair of crimping rollers rotatable in opposite directions about spaced axes which may be parallel to one another or alternatively one of which may be adjustable relative to the other, e.g. by pivoting relative to the other against the bias of a spring force. The rollers are rotated by means of a motor which is air driven or electrically driven, there being suitable gearing between drive shafts for the crimping rollers so that they will rotate at the same speed but in opposite directions. The roll forming tool, in use, is applied to the flange gripping portion of the edge trim or seal which has been offered up onto the flange to which it is being fitted and when the rollers are rotating, light pressure applied to the tool will cause the rollers to drive themselves onto the flange gripping portion of the edge trim or seal and by virtue of the parallel or generally parallel relationship between the rolling surfaces of the two rollers will cause the edge trim to be crimped into clamping engagement on the flange, this crimping operation deforming the splayed apart arms of the U-shaped flange gripping portion and hence the carrier located within the arms into gripping engagement with the flange.

The roll forming tool will normally be fitted to an air line and have a cylindrical or barrel shaped gripping portion incorporating a drive motor therein with which is associated an on/off gripper and from the end of the gripping portion remote from the air line (or power supply lead in the case of an electrical tool), a drive shaft will extend generally coaxial with the longitudinal axis of the hand gripping portion. A crimping head incorporating the two crimping rollers is then fitted to the end of the tool remote from the power supply line, e.g. with a snap fit arrangement or, alternatively, by means of one or more locking pins, screws, bolts or the like. In its simplest arrangement, the drive shaft terminates in a hexagonal head which engages within a matching hexagonal socket located in a proximal end of one of the drive shafts for the crimping rollers.

3 Instead of extending from the end of the cylindrical or barrel shaped gripping portion of the roll forming tool, generally coaxially with the longitudinal axis of the gripping portion, a right-angled drive may be provided in the tool body, so that the output or drive shaft thereof extends radially from the cylindrical or barrel shaped hand gripping portion, at the 5 end thereof remote from the power input line.

If desired, the crimping head, instead of being provided with only two rotatable crimping rollers, may be provided with a third roller, the rotational axis of which is generally at right angles to that of the two crimping rollers, the third roller being arranged to locate on the back of the flange gripping portion of the edge trim or seal (i.e. on the external surface of the base of the U), thus allowing the operator to swivel the tool about this roller and the roller acting as a guide which controls the precise location of the two crimping rollers on the Range gripping portion of the edge trim or seal.

When a fitter is fitting edge trims or seals to a closure member, e.g. door or boot lid or tile opening therefor, on a motor vehicle, he takes one of the edge trims or seals of the correct length, and fits it loosely onto the flange surrounding the closure member or opening, and then crimps it in place by applying the roll forming tool to the flange gripping portion of the edge trim or seal by running the tool all the way round the opening member or opening, thus crimping the flange gripping portion of the edge trim or seal onto the flange. This involves the fitter running the tool over the top, down the side, along the bottom and back up the other side of the closure member or opening, while keeping the crimping rollers in crimping engagement with the flange gripping portion of the edge trim or seal. This means that the fitter has to twist his arms or body effectively through 360' each time he fits the edge trim or seal to a vehicle. Bearing in mind that a fitter is expected to fit a large number of edge trims or seals to all the closure members or openings of quite a large nwnber of vehicles per hour, this imposes substantial strain on the fitter due to the twisting motions required. Such twisting is, of course, necessary since the crimping head is fixedly secured to the roll forming tool.

The present invention has been designed to overcome the above problem and reduce the strain on the fitter of using a roll forming tool all day. Because the fitter does not have to 4 swap hands when fitting an edge trim or seal, he is able to fit more edge trims or seals than would otherwise be the case.

According to the present invention, we provide a roll forming tool for securing an edge trim or seal on a flange around a closure member or opening therefor on a motor vehicle, the roll forming tool having a gripping portion, a driven output or drive shaft, and a crimping head carrying a pair of crimping rollers, at least one of which is driven by the drive shaft, wherein the crimping head and the gripping portion are articulatable relative to one another.

Preferably, the crimping head articulates relative to the gripping portion.

Preferably, the crimping head is supported on a body portion of the tool, which also supports the gripping portion, for rotation through any angle up to 360' (or beyond if required) relative to the body portion.

Preferably, the body portion has a distal end portion which forms a mating engagement with a circumferential flange or locking collar on the crimping head, there being a circumferential groove on the distal end portion of the body portion which is engaged by two locking pins located in parallel passageways in the crimping head, thereby permitting relative rotation of crimping head relative to the body portion, but maintaining the crimping head on the body portion.

Preferably, the crimping head articulates relative to the body portion under the control of spring means; friction means may be provided between the body portion and crimping head to control relative movement between the two.

Two roll forming tools according to the present invention are now described by way of example with reference to the accompanying drawings, in which:

FIGURE 1 is a side elevation, partly in section and partly schematic, of a right angle drive tool in accordance with a first embodiment of the invention; FIGURE 2 is a view looking in the direction of the arrow A in Figure 1 showing the tool with the right-angle drive; FIGURE 3 is a plan view of the crimping head of the tool of Figures I and 2; 5 FIGURE 4 is a view similar to Figure 2 of a second embodiment of tool; FIGURE 5 is a partial view of the crimping head of the tool of Figure 4, looking in the direction of the arrow A in Figure 4; and FIGURE 6 is a vertical cross-sectional view through the crimping head of Figure 4 but to an enlarged scale.

In the drawings, like parts are identified by the same reference numerals.

Referring to Figures 1-3 of the drawings, the roll forming tool 1 shown therein has a body portion 3 incorporating a drive motor M therein, which may either be air driven or electrically driven, there being a power supply line (not shown) extending axially out of a proximal end of the body portion. It will be appreciated, of course, that the power supply line may extend from a different location. The body portion 3 is cylindrical or barrel shaped (although it could be of a different cross-section) and at least a portion of the outer surface of the body 3 may be serrated or formed in some other manner so as to provide a gripping portion 11, the overall dimension of the body portion being such as to allow a fitter easily to hold it in one hand. Optionally, adjacent one or other end of the body a radially extending handle or knob 13 may be provided which optionally may have a rotatable gripping portion 15 thereon. Also secured to the body portion 3 is an on/off trigger (not shown). This trigger could be replaced with an on/off switch or some such other control arrangement. The body portion incorporates a right angle drive mechanism at 18 and extending from a distal end 19 of the body portion is an output or drive shaft 21 on a free end of which a hexagonal socket (not shown) is provided.

A crimping head 25 is mounted on the distal end portion of the body portion 3 for articulating movement relative thereto. The crimping head 25 can rotate relative to the 6 body portion 3 in either sense through any angle up to 360' (or beyond if required). To enable this to be achieved, a circumferentially extending groove 27 shown in broken lines in Figure 3 is formed in the outer surface of the body portion 3 adjacent the distal. end 19, which groove is of semi-circular cross-section, and the crimping head is provided with a proximal portion 28 having a circular Range 29 with an offset socket 30 therein, the inner diameter of which is sized to form a close fit on the distal end portion 19 of the body portion 3. The crimping head 25 is held in position on the body portion 3 by means of a pair of parallel extending locking pins 33, which pass through parallel extending passageways 31 provided in the portion 28 of the crimping head 25 and extend parallel to a tangent to the groove 27, so that at a diametrically opposed location in the groove 27, the locking pins 31 engage the groove 27. In this way, the crimping head 25 can rotate in either sense relative to the body portion 3, the pins 33 acting both to hold the crimping head on the body portion 3 and also allowing relative rotation between the two. The portion 28 is connected to the remainder of the crimping head 25 by a plurality of screws which locate in apertures 32, there being a suitable oil seal at 34. A through-aperture 36 containing a shaft seal 44 is provided in the portion 28 to accommodate a proximal end portion of a drive shaft 47 for one of the crimping rollers. Articulation between the body portion 3 and crimping head 25 is under the control of a coil spring 40, one upturned end 42 of which is located in an aperture in the end face of the distal. end portion 19 of the body portion 3, and the other downturned end 45 of which is located in an aperture in the portion 28. The spring is located so as to be co-axial with a distal end of the output drive shaft 21, i.e. the axis about which the spring 40 is coiled is co-axial with the axis of the shaft 21.

The crimping tool 25 supports the drive shaft 47 and a parallel spaced roller drive shaft 49. 25 The drive shaft 47 is driven directly by the output drive shaft 21 driven by the drive motor M and, for this purpose, has at one end thereof a hexagonal nut 51 thereon which forms a mating engagement with a hexagonal socket on the drive shaft 21. It will of course be appreciated that alternative means of drive between the shaft 21 and the shaft 47 such as splines or the like may be provided.

Mounted for rotation on and with the drive shaft 47 is a first gear 52 which meshes with a second gear 53 mounted for rotation on and with the shaft 49. So that the shafts 47 and 49 rotate at the same speed but in opposite senses, the two gears 52 and 53 are of the same 7 size and have the same number of drive teeth. On the output end of each of the shafts 47 and 49, a crimping roller 55 is provided and extending at right angles thereto is a steadying or guide roller 57 which is supported for rotation about an axis 59 extending at right angles to the rotational axes of the two rollers 55. As can be seen from Figures I and 2, the steadying or guide roller 57 is supported for rotation on a pair of support arms 63 extending outwardly from the lower end of the head 25. In some instances, different sized crimping rollers 55 may be provided. In these instances, the gearing and/or size of the gears 51,53 would normally be designed to ensure that the circumferential speed of the different sized rollers 55 was the same.

The gears 51 and 53 are located within an upper housing area 39 formed within a distal portion 38 of the crimping head 25, in which area 39 two bronze thrust plates 60 and 62 are located. These prevent scouring of the head itself. Immediately below the area 39, recesses are formed in the housing area for upper bearings 64 for the shafts 47 and 49 which extend through passageways in the portion 38. At the base of the distal portion 38, the passageways open into further recesses which are provided for lower bearings 66.

Referrin g now to the embodiment shown in Figures 4 to 6, the body portion 3 is of generally the same construction as in the previous embodiment, with power being led to the motor M of the tool through a supply line 17A controlled by an on/off trigger 17 pivotally supported on the body portion 3.

The crimping head 25 has a generally rectangular body formed of an upper or proximal bearing housing 39 and a lower or distal bearing housing 41. The upper bearing housing is secured to the distal end of the body portion 3 in the same manner as in the first embodiment of the invention using locking pins 33 and, in this construction, the upper portion of the upper bearing housing 39 and its locking collar 29 are co-axial with the distal. end portion of the body portion 3. However, the lower portion of the upper bearing housing 39 is stepped outwardly so as to accommodate two upper bearings 43 for the two drive shafts 47 and 49 for the crimping rollers 55. As in the previous embodiment, the drive shaft 47 is co-axial with the output shaft 21 from the drive motor M and the crimping head 25 incorporates a lower bearing and gear housing 41 which supports the two gears 52 and 53, and lower bearings 46 for the two drive shafts 47 and 49.

Articulation of the crimping head 25 relative to the body portion 3, instead of being under the control of a coil spring 40, which will return the crimping head to a position of rest when not in use, is under the control of a crimped or disc-like preload spring 65 located between an end face 67 of the distal end 19 of the body portion 3 and an internal face 69 of the head 25 so as to provide a friction force between the body portion 3 and the crimping head 25 so as to prevent the head 25 from rotating inadvertently relative to the body 3.

This preload spring 65 may be provided by a spring washer, a BELLEVILLE type washer or the like.

In this embodiment of the invention, the articulatable crimping head does not return automatically to a position of rest after use but the user can twist the head relative to the body portion 3 so as to enable the crimping rollers 55 to be applied to an edge trim to fit the edge trim to a flange at any location selected by the user. On the other hand, with the embodiment of the invention shown in Figures 1 to 3, the crimping head will always return under the action of the coil spring 40 to a predetermined position, meaning that a particular user will always normally apply the tool to an edge trim to be fitted to a flange at a particular location.

Obviously, certain features of the first embodiment of the invention could be replaced by equivalent features of the second embodiment of the invention and vice versa, and/or certain features of one embodiment could be incorporated into the construction, the subject of the other embodiment.

It will be appreciated that the arrangement of the crimping rollers 55, their method of mounting within the crimping head, the design of the crimping head, the design of the crimping head and other details thereof are unimportant and it is envisaged, for example, that at least one of the drive shafts may be of a floating construction, i.e. able to pivot relative to the other. What is important, however, is that the whole of the crimping head 25 can articulate and preferably rotate relative to the body portion 3 of the roll forming tool.

By providing a crimping head 25 which can rotate relative to the body portion 3 of the tool, it is possible for the fitter to take the tool around a closure member, e.g. a door or boot lid 9 or an opening therefor in about 10 seconds, with the rotating head reducing the amount by which the fitter has to twist his arms or body to go the whole way round the door or opening. Over a day's work, this considerably reduces the strain on the fitter.

The pins, instead of being solid, could be formed of rolled spring steel, e.g. of a generally C-shaped cross section, or in the form of a coil.

Of course, the roll forming tool, instead of having the illustrated shapes with a right angle drive, could be of "in-line" construction without a right angle drive.

There are many optional features, none of which is illustrated in the drawings, which can be provided on the roll forming tool. Some of these are listed below:

a) It is envisaged that only one of the crimping rollers need be driven.

b) The surface of the crimping rollers may be contoured to match the contour of the edge trim or seal being fitted to the flange. This allows the closing or crimping forces to be applied in a controlled manner to optimise the deformation of the metallic carrier within the edge trim. The profiled rollers may be designed to form a positive location onto a particular part of the edge trim or seal to improve accuracy and control of the roll forming tool. It may also be advisable within the profile of the rollers to provide free space to accommodate a sealing portion or flip forming part of the edge trim or seal to avoid deformation thereof during application of the edge trim or seal to the flange. Furthermore, or alternatively, the steadying or guide roller 57 may be contoured, e.g. of concave construction for the purpose of providing guidance to the crimping head and crimping rollers 55. The concave roller surface provides a means of "tracking" such that the crimping rollers 55 and concave roller 57 maintain a unifonn contact with the edge trim/seal being applied to a flange.

c) The crimping rollers may be formed in more than one rolling part, which are rotatable relative to one another, but which have a common axis of rotation. For example, one part of the roller may be free running whereas another part may be driven so as to reduce frictional forces which would occur during application of an edge trim or seal to a flange resulting, for example, from the particular external contour of the edge trim or flange, thus requiring different surface speeds across the surface of the edge trim or seal.

d) The surface of the crimping rollers may be ribbed or otherwise contoured to 5 improve their grip upon the edge trim or seal to be applied to the flange. The ribs may be in the form of castellations or alternatively dimples or the like, i.e. serrations may be provided and, if desired, the ribs may be inclined or of helical nature so as to assist in feeding the crimping head onto the edge trim or seal to be applied to the flange. By providing a particular surface construction to the crimping rollers, it may be possible to provide a sequenced and concentrated closing pressure on the edge trim or seal to be applied to the flange. If the ribs or the like are inclined or of a helical arrangement, rotation of the rollers in one direction would assist in applying the crimping head to the edge trim or seal but if the drive to the rollers was then reversed, it would be simple to remove the crimping head from the applied edge trim or seal.

e) It is envisaged that the axis of rotation or articulation of the crimping head relative to the body of the tool could be varied. It is also envisaged that the frictional force provided by the spring 65 may be combined with another type of spring system, e.g. the type shown in Figures 1-3, of sufficient strength to overcome the frictional force and return the crimping head 25 to a neutral position relative to the body portion 3 when the roll forming tool is not in use.

0 It is envisaged that around the periphery of the crimping head, rolling members or pads or strips or the like may be discretely positioned which provide a low friction contact surface with the body of the vehicle adjacent the edge trim or seal to be applied to a flange to avoid scuffing damage due to componentry on the vehicle and adjacent to the edge trim or seal being roll formed.

g) Adjacent to the crimping rollers 55 or the steadying or guide roller 57, an auxiliary 30 member or roller which may either precede or trail the rollers may be provided, the purpose of which is to displace and/or replace any of the functional or cosmetic sealing members or flips on the edge trim or seal, thus aiding the clinching of the edge trim or seal onto the flange and fitting the edge trim around or over other adjacent components on the motor vehicle, e.g. a vehicle interior trim or the like. Alternatively, a pair of counter rotating rollers, which may be suitably profiled, are provided adjacent to the crimping rollers 55. These would provide location and stability for the crimping head/crimping rollers 55. The counter rotating rollers would be free to rotate independently at a speed 5 dependent on seal/edge him fitting circumstances.

One of the advantages of the embodiment of Figures 1-3 over the embodiment of Figures 4-6 is the slim nature of the distal end of the crimping head 25. This allows the tool to be used in confined locations.

It will of course be understood that the present invention has been described above purely by way of example, and modifications of detail can be made within the scope of the invention.

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Claims (10)

1. A roll forming tool for securing an edge trim or seal on a flange around a closure member or opening therefor on a motor vehicle, the roll forming tool having a gripping portion, a driven output or drive shaft, and a crimping head carrying a pair of crimping rollers, at least one of which is driven by the drive shaft, wherein the crimping head and the gripping portion are articulatable relative to one another.

2. A roll forming tool according to claim 1, wherein the crimping head articulates relative to the gripping portion.

3. A roll forming tool according to claim I or claim 2, wherein the crimping head is supported on a body portion of the tool which also supports the gripping portion whereby said crimping head is rotatable relative to the body portion.

4. A roll forming tool according to claim 3, wherein the body portion has a distal end portion which forms a mating engagement with a circumferential flange or locking collar on the crimping head, there being a circumferential groove on the distal. end portion of the body portion which is engaged by two locating pins located in parallel passageways in the crimping head, thereby permitting relative rotation of the crimping head relative to the body portion but maintaining the crimping head on the body portion.

5. A roll forming tool according to any one of the preceding claims, wherein friction means are provided between the body portion and crimping head to control relative movement between the two.

6. A roll forming tool according to claim 4 wherein the friction means comprises a BELLEVILLE type washer located between facing surfaces provided, respectively, on the crimping head and body portion.

7. A roll forming tool according to any one of the preceding claims, wherein the crimping head rotates relative to the body portion under the influence of spring means.

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8. A roll forming tool according to claim 7, wherein the spring means is a coil spring, the coil spring being located such that the axis about which it is coiled is co-axial with a distal end of the output or drive shaft, with one end of the coil spring being connected to the body portion, and the other end being connected to the crimping head.

9. A roll forming tool according to claim 8, wherein upturned end portions of the coil spring are located, respectively, in apertures in the crimping head and body portion.

10. A roll forrriing tool for securing an edge trim or seal on a flange, said roll forining tool being substantially as hereinbefore described with reference to Figures 1-3 or Figures 4-6 of the accompanying drawings.

10. A roll forming tool for securing an edge trim or seal on a flange, said roll forming 10 tool being substantially as hereinbefore described with reference to Figures 1-3 or Figures 4-6 of the accompanying drawings.

14- Amendments to the claims have been filed as follows CLAIMS 1. A roll forming tool for securing an edge trim or seal on a flange around a closure member or opening therefor on a motor vehicle, the roll forming tool having a gripping portion, a driven output or drive shaft, and a crimping head carrying a pair of crimping rollers, at least one of which is driven by the drive shaft, wherein the crimping head and the gripping portion are articulatable relative to one another under the influence of spring means.

2. A roll forming tool according to claim 1, wherein the crimping head articulates relative to the gripping portion.

3. A roll forming tool according to claim I or claim 2, wherein the crimping head is supported on a body portion of the tool which also supports the gripping portion whereby said crimping head is rotatable relative to the body portion.

4. A roll forming tool according to claim 3, wherein the body portion has a distal end portion which forms a mating engagement with a circumferential flange or locking collar on the crimping head, there being a circumferential groove on the distal end portion of the body portion which is engaged by two locating pins located in parallel passageways in the crimping head, thereby permitting relative rotation of the crimping head relative to the body portion but maintaining the crimping head on the body portion.

5. A roll forming tool according to claim 3 or 4, wherein friction means are provided between the body portion and crimping head to control relative movement between the two.

6. A roll forming tool according to claim 5 wherein the friction means comprises a BELLEVILLE type washer located between facing surfaces provided, respectively, on the crimping head and body portion.

7. A roll forming tool according to any one of the preceding claims 3-6, wherein the crimping head rotates relative to the body portion under the influence of the spring means.

1.5 8. A roll forming tool according to any one of the preceding claims, wherein the spring means is a coil spring, the coil spring being located such that the axis about which it is coiled is co-axial with a distal end of the output or drive shaft, with one end of the coil spring being connected to the body portion, and the other end being connected to the crimping head.

9. A roll forming tool according to claim 8, wherein upturned end portions of the coil spring are located, respectively, in apertures in the crimping head and body portion.