JP2000202530A - Manufacture of three-dimensional curved surface mirror and its manufacturing device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a three-dimensional curved surface mirror with an excellent productivity by plastically deforming a metal sheet with one passing. SOLUTION: A stainless steel sheet 14 is bent around an axis parallel to a first axial direction 15 with a C bending roll device 11 having C bending projected rolls 20, 22 and C bending recessed rolls 21, 23. Further, it is bent around an axis parallel to a second axial direction 16 with an L bending roll device 12 provided with an L bending projected roll 24 and L bending recessed roll devices 25, 26 and its shape is adjusted with an adjusting bending roll device 13. A plastic deformation required as a three-dimensional curved surface mirror is executed with one passing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a three-dimensional curved mirror used as a rearview mirror of a vehicle.

[0002]

2. Description of the Related Art Conventionally, glass mirrors having a three-dimensional curved surface shape such as a spherical surface have been used for rearview mirrors for vehicles including automobiles and motorcycles so that a wide field of view can be obtained. ing. These glass mirrors may break when subjected to a large impact, so if a glass sheet is attached to the back of the glass, or if multiple sheets of glass are attached with a sheet adhesive, the glass The debris is kept from scattering.

The inventor of the present invention has proposed a method of manufacturing a three-dimensional curved mirror by forming a stainless steel plate having a mirror-polished surface into a three-dimensional curved surface by pressing in order to eliminate cracks, which is a drawback of a glass mirror. For example, Japanese Patent Application Hei 10-
7484 and Japanese Patent Application No. 10-101760. FIG. 7 shows an outline of a manufacturing process of a three-dimensional curved mirror proposed in Japanese Patent Application No. 10-7484. As shown in (1), the stainless steel large plate 1 is two-dimensionally bent around the first axis 1a in a state where the surface is mirror-polished.
As shown in (2), the mirror piece 2 is cut off along the cutting lines 3 and 4 by shearing from the stainless steel large plate 1 that has been subjected to the two-dimensional bending. The separated rectangular mirror piece 2 is bent around the first axis 1a and has a two-dimensional curved surface shape. As shown in (3), when the mirror piece 2 is adhered to the three-dimensional curved surface 6 on the surface of the mirror fixing mounting member 5, the mirror piece 2 is elastically deformed also around the second axis 2a, and is curved. In this state, it is attached to the surface of the mirror fixing mounting member 5.

In the manufacturing method proposed in Japanese Patent Application No. 10-101760, a large stainless steel plate 1 is polished with a curved surface and then bent around a first axis 1a as in FIG. However, when the large stainless steel plate 1 is rectangular, the first axis 1a is in the long side direction. Next, the large stainless steel plate 1 is cut along a cutting line 3 parallel to the first axis 1a, and is further bent around a second axis perpendicular to the first axis to obtain a final three-dimensional structure. It is plastically deformed so as to obtain a curved surface, and is punched out to have a final external shape as a three-dimensional curved mirror.

[0005]

In the manufacturing method of Japanese Patent Application Laid-Open No. 10-7484 proposed by the present applicant, a three-dimensional curved surface is formed by elastically deforming a two-dimensionally bent metal plate. Manufacturing may be difficult depending on the shape of the three-dimensional curved mirror to be manufactured. For example, even when the external shape of the three-dimensional curved mirror is substantially rectangular, the ratio of the long side to the short side is close to 1: 1, or the thickness of the metal plate is 1.6 mm or more. In such a case, a large force is required to bend elastically, and even if the elastic bending state is to be maintained with an adhesive or the like, the adhesive force is insufficient and the shape tends to return to the shape before bending deformation. Further, when the external shape of the three-dimensional curved mirror has a curved external shape on at least one or more sides, simply bending and elastically deforming the three-dimensional curved mirror may provide a necessary curvature as the three-dimensional curved mirror. May be insufficient.

In the manufacturing method proposed in Japanese Patent Application No. 10-101760, a metal plate is cut once along a cutting line parallel to the first axis after bending around a first axis, and the cutting is performed again. In order to perform bending processing around the second axis, it is put into a forming roll. That is, the large stainless steel plate 1
After processing in the first pass for bending around the first axis, cutting of banding by shearing is performed, and as a second pass forming, bending around the second axis perpendicular to the first axis is performed. Processing is performed so that a shape required as a three-dimensional curved mirror is obtained by two-pass bending. However, between the bending around the first axis in the first pass and the bending around the second axis in the second pass,
Since the shearing step or the like is included, the productivity is not always good, and the metal plate may be deformed at the stage of moving the metal plate of the intermediate shape.

An object of the present invention is to efficiently produce a three-dimensional curved mirror by performing plastic working so that a three-dimensional curved shape is formed by bending with one-pass passing of a metal plate. An object of the present invention is to provide a manufacturing method and a manufacturing apparatus of a three-dimensional curved mirror that can be manufactured.

[0008]

SUMMARY OF THE INVENTION The present invention relates to a method for manufacturing a three-dimensional curved mirror by plastic working of a mirror-finished metal plate, the width of which corresponds to the short side of the shape of the three-dimensional curved mirror. While passing a metal plate having a longitudinal direction parallel to the first axial direction, between the C bending rolls having a second axial direction perpendicular to the first axial direction. And a metal plate bent between the C-bending rolls is formed on the convex roll having a shape corresponding to the two-dimensional curved surface and the two-dimensional curved surface. An L bending roll device comprising two concave rolls having corresponding shapes, wherein the first concave roll sandwiches the metal plate that has passed between the C bending rolls with the convex roll,
The second concave roll passes through an L bending roll device that is arranged at a position where the metal plate is bent around the second axis along the outer periphery of the convex roll, and the second concave roll is rotated around the second axis. Forming a three-dimensional curved surface by bending the metal plate along the longitudinal direction by a length corresponding to the long side of the three-dimensional curved mirror. is there.

According to the present invention, a substantially rectangular three-dimensional curved mirror can be manufactured from a mirror-finished metal plate by plastic working with one-pass passing. The metal plate is mirror-finished and passed between the C bending rolls so that the longitudinal direction is parallel to the first axial direction in a state having a width corresponding to the short side of the shape of the three-dimensional curved mirror. C bending roll
The metal plate rotates around a second axis perpendicular to the first axis, and performs bending around the first axis parallel to the transport direction while transporting the metal plate. The metal plate bent between the C bending rolls is a L bending roll device including a convex roll having a shape corresponding to a two-dimensional curved surface and two concave rolls. Between the concave roll and the convex roll, and the second concave roll and the convex roll disposed at a position where the metal plate is bent around the second axis along the outer periphery of the convex roll. A bending process is performed around the second axis to form a three-dimensional curved surface. The metal plate on which the three-dimensional curved surface is formed by the three-dimensional bending roll device can be cut along the longitudinal direction by a length corresponding to the long side of the three-dimensional curved surface mirror to manufacture the three-dimensional curved surface mirror.

According to the present invention, the metal plate having the three-dimensional curved surface formed by passing through the L-bending roll device further has a shape adapted to a curved surface shape around the first axis.
The separation is performed after passing the metal plate from the bending roll to the L bending roll device through an adjustment bending roll disposed at a position shifted inward of the three-dimensional curved surface from the passing path of the metal plate. Features.

According to the present invention, after the metal plate is bent around the second axis by the L bending roll device, the metal plate is passed through the adjusting bending roll to cause the curvature around the first axis and the curvature around the second axis. The curvature can be adjusted.

Further, in the present invention, the metal plate is a stainless steel plate.

According to the present invention, since the mirror-polished metal plate is a stainless steel plate, the mirror-polished surface state can be maintained for a long time, and the plate thickness can be reduced to reduce the weight. is there. Further, since there is no possibility of breaking like a glass mirror, durability can be improved.

In the present invention, the metal plate has a Vickers (Hv) hardness of 330 or more as a surface hardness.

According to the present invention, since the surface hardness of the metal plate is not less than 330 in Vickers (Hv) hardness, the mirror-polished surface state is less likely to be scratched, and a good mirror function is maintained for a long period of time. be able to.

Further, the present invention provides a roll having a second axial direction perpendicular to the first axial direction while passing a strip-shaped metal plate so that the longitudinal direction is parallel to the first axial direction. A C-bending roll device for performing bending processing around the first axis between the metal plate and the metal plate, which has an axis parallel to the second axis direction, disposed on an exit side of the C-bending roll device;
An outer peripheral surface includes a convex roll and first and second concave rolls formed in accordance with a shape of a bent surface around the first axis, and the convex roll and the first concave roll are provided between the rolls. The metal plate that has passed through the C bending roll device is disposed at a position where it is guided as it is, and the second concave roll is disposed at an interval from the first concave roll in the first axial direction. And an L-bending roll device capable of adjusting the relative position of the three-dimensional curved mirror.

According to the present invention, the apparatus for manufacturing a three-dimensional curved mirror includes a C bending roll device and an L bending roll device. The C bending roll device is configured to pass a first metal sheet between rolls having a second axis direction perpendicular to the first axis direction while passing a band-shaped metal plate so that the longitudinal direction is parallel to the first axis direction. Bending around the axis of. The metal plate is subjected to a bending process around a first axis parallel to the passing direction while passing the C bending roll device to form a two-dimensional curved surface. The metal sheet bent around the first axis by the C bending roll device is sandwiched between the convex roll and the first concave roll of the L bending roll device, and is moved in the first axial direction from the first concave roll. The second concave roll arranged at an interval performs bending around the second axis.
The convex roll and the first and second concave rolls provided in the L bending roll device can adjust the relative position of each roll. Therefore, the relative position adjustment allows the curvature in the bending process around the second axis to be adjusted. The radius can be easily adjusted.

[0018]

FIG. 1 shows a schematic configuration of a three-dimensional curved mirror manufacturing apparatus 10 according to an embodiment of the present invention. The three-dimensional curved mirror manufacturing apparatus 10 includes a C bending roll device 11, an L bending roll device 12
And an adjusting bending roll device 13 are arranged in order, while bending a belt-shaped stainless steel plate 14 along the first axis direction 15 around the first axis 15 and perpendicularly to the first axis direction 15. Bending around a second axial direction 16 parallel to the width direction of the stainless steel plate 14
Performs plastic deformation necessary for a three-dimensional curved mirror.

The C-bending roll device 11 includes a bending stand composed of a combination of a C-bending convex roll 20 and a C-bending concave roll 21, a C-bending convex roll 22 and a C-bending concave roll 2.
And a bending stand with a combination of the three. Each of the C-bending convex rolls 20 and 22 and the C-bending concave rolls 21 and 23
While holding the stainless steel plate 14 in the first axial direction 1
Perform bending around 5. In order to perform bending, C
The bending convex rolls 20 and 22 have a convex outer periphery with a profile having a large radius at the center and a small radius at both ends along the second axis 16. The C-bent concave rolls 21 and 23 have a concave outer shape with a profile along the second axial direction 16 such that the radius is large at both ends and the radius is minimum at the center. The curved surface shape along the second axial direction 16 is a C-bending convex roll 20 on the front stand side.
And the C-bent concave roll 23 and the C-bent concave roll 23 on the stand side,
Are arranged such that the radius of curvature is smaller. Although the number of stands of the C-bending convex rolls 20 and 22 and the C-bending concave rolls 21 and 23 is two in the present embodiment, it can be reduced to one or increased to three or more. Also, the C-bending convex rolls 20 at each stand,
The distance between the C-shaped concave rolls 21 and 23 can be adjusted.

In the L-bending roll device 12, an L-bending convex roll 24 is disposed inside the curvature bent by the C-bending roll device 11 around the first axial direction 15, and the L-bending concave roll is placed outside the curvature. Rolls 25 and 26 are arranged. Two L
The stainless steel plate 14 that has passed through the C-bending roll device 11 enters between the first L-bending concave roll 25 and the L-bending convex roll 24 on the former stage of the bending concave rolls 25 and 26. The second L-bent concave roll 26 is arranged at a distance from the first L-bent concave roll 25 in the first axial direction 15. The two L-bent concave rolls 25 and 26 are the first
Can be moved in the axial direction 15 and the opposite direction, and the distance between them can be adjusted. L-bending convex roll 24
And the L-bent concave roll 26 can be displaced in a direction perpendicular to both the first axial direction 15 and the second axial direction 16. By adjusting the position of the second L-bend concave roll 26 and the position of the L-bend convex roll 24, the stainless steel plate 14 sandwiched and passed between the L-bend convex roll 24 and the L-bend concave roll 26 can be formed by the second step. It can be bent around the second axial direction 16.

L-bending convex roll 24 and L-bending concave roll 26
The stainless steel plate 14 bent around the second axial direction 16 is sandwiched between the adjusting bending convex roll 27 and the adjusting bending concave roll 28 constituting the adjusting bending roll device 13 to rotate around the first axial direction 15. And the bending deformation state around the second axial direction 16 are adjusted, and a three-dimensional curved surface required as a three-dimensional curved mirror is obtained. The position of the adjustment bending convex roll 27 and the position of the adjustment bending concave roll 28, as well as the distance between them, can be adjusted.

A three-dimensional curved mirror manufacturing apparatus 1 according to the present embodiment.
0, the C-bending convex rolls 20, 22, the C-bending concave rolls 21, 23, the L-bending convex roll 24, the L-bending concave roll 2
5, 26, the adjustment bending convex roll 27 and the adjustment bending concave roll 28 are all driven to rotate about a rotation axis parallel to the second axial direction 16. The motor for rotational driving is arranged for each stand that holds the stainless steel plate 14 and performs bending deformation. An outline of the specifications of the three-dimensional curved mirror manufacturing apparatus of the present embodiment is shown in Table 1 below.

[0023]

[Table 1]

FIG. 2 schematically shows an overall process of manufacturing a three-dimensional curved mirror using the three-dimensional curved mirror manufacturing apparatus 10 of FIG. The process starts from step s1, and in step s2, the surface of a metal plate such as the stainless steel plate 14 in FIG. 1 is mirror-polished. The mirror polishing is performed in a state of a large plate having a predetermined size. Next, in step s3, a mirror-polished large metal plate having a width required as a three-dimensional curved mirror is cut by shearing. In addition, the coil plate is continuously mirror-polished and the plate width is adjusted with a slitter,
A continuous stainless steel plate 14 can also be used.

From step s4, the sheet is passed through the three-dimensional curved mirror manufacturing apparatus 10 shown in FIG.
The bending is performed. In step s5, L bending is performed by the L bending roll device 12, and in step s6, the adjustment bending process is performed by the adjustment bending roll device 13. The metal plate that has been three-dimensionally bent by the three-dimensional mirror manufacturing apparatus 10 shown in FIG. 1 is punched out by blanking in step s7, cut off into a required outer shape as a three-dimensional curved mirror, and the procedure is performed in step s8. finish. At the time of these bending and punching, a film of vinyl chloride or the like having a thickness of several tens of μm is stuck on the mirror-polished surface to prevent scratches.

FIG. 3 shows a change in the shape of the stainless steel plate 14, which is a metal plate, changing along the manufacturing process of FIG.
2 shows a state in which the mirror polishing in step s2 and the shearing in step s3 in FIG. 2 have been performed. Is obtained by the C bending roll device 14 shown in FIG.
Shows the stainless steel plate 14 to which a two-dimensional curved surface has been applied in accordance with step s4. 2 by the L bending roll device 12 and the adjusting bending roll device 13 of FIG.
The stainless steel plate 14 in a state where the L-bending and the adjustment bending in the steps s5 and s6 of FIG. From the stainless steel plate 14 provided with the three-dimensional curved surface, the punching of step s7 in FIG.
A three-dimensional curved mirror 29 can be obtained. When punching is performed, a three-dimensional curved mirror 29 shown in FIG.

Table 2 below shows the material shape and surface hardness of the stainless steel plate 14 used for the three-dimensional curved mirror 29 prototyped by the present inventor. Such a material is a hard-strength stainless steel, for example, a work-hardening Cr-Ni-based austenitic stainless steel such as SUS301, or a metal structure having two of austenite and ferrite, and martensite and ferrite. Obtained from duplex stainless steel, martensitic stainless steel, and the like.

[0028]

[Table 2]

The following Table 3 shows that the three-dimensional curved mirror 2 manufactured in the shape shown in FIG. 3 by the manufacturing process shown in FIG.
9 shows the evaluation results. In a rearview mirror used for an automobile or the like, the three-dimensional curvature R is 1000 mm to 1500 mm. With the three-dimensional curved mirror 29 having various shapes, good results are obtained as indicated by the circles. Therefore, from Table 2, it can be seen that a good three-dimensional curved mirror 29 can be obtained from a stainless steel plate having a surface hardness of 330 or more in Vickers hardness (Hv).

[0030]

[Table 3]

FIG. 4 shows a schematic configuration of a three-dimensional curved mirror manufacturing apparatus 30 as another embodiment of the present invention.
In the three-dimensional curved mirror manufacturing apparatus 30 of the present embodiment, front rolls 31 and 32 are arranged in the first half of the three-dimensional curved mirror manufacturing apparatus 10 of the embodiment of FIG. In the present embodiment, parts corresponding to the embodiment of FIG.
A duplicate description will be omitted. The passing direction of the stainless steel plate 14 is changed by the front rolls 31 and 32 to the first axial direction 15 by the C-bent convex roll 20 and the C-bent concave roll 21 on the inlet side.
Instead of entering in the direction, it is changed so as to enter from an inclined direction. Thereby, the bending capacity of the C bending roll device 11 around the first axis can be improved. The following Table 4 shows the bending radius R1 around the first axis when the difference H between the center position of the C-bending convex roll 20 and the center position of the preceding roll 32 at the subsequent stage is changed. 2 shows a change with a bending radius R2 around the axis 2 of FIG.

[0032]

[Table 4]

FIG. 5 shows a configuration of a part of an L bending roll device of a three-dimensional curved mirror manufacturing apparatus 40 as still another embodiment of the present invention. The L-bending roll device of this embodiment includes an L-bending convex roll 41 and two L-bending concave rolls 42,
43. The second L-bent concave roll 43 of the present embodiment is disposed at an interval from the first L-bent concave roll 43 in the first axial direction 15, and furthermore, in the first axial direction 15 and the second axial direction. 16 are arranged at positions that also change in the vertical direction that is perpendicular to both. By changing the height difference h between the center of the L-bent concave roll 43 and the center of the L-bent convex roll 41, the bending state of the stainless steel plate 14 around the second axis can be adjusted.

FIG. 6 shows a three-dimensional curved mirror manufacturing apparatus 40 shown in FIG. 5, in which the bending material width is set to 70 mm, and the bending radius around the second axis is the same as the bending radius around the first axis. An example of the test results for the height of h obtained is shown. The thickness of the stainless steel plate 14 is 0.6 mm
It is. As in the present embodiment, in order to perform bending processing around the second axis, a convex roll and two concave rolls may be combined, but in the embodiment of FIGS. 1 and 4,
Further, an adjusting bending roll device 13 is arranged so that a desired three-dimensional curved surface shape can be reliably obtained.

[0035]

As described above, according to the present invention, a metal plate is bent around a first axis by a C bending roll, and is bent around a second axis perpendicular to the first axis by an L bending roll device. It can be bent and plastically deformed into a three-dimensional curved mirror in one pass. Since a three-dimensional curved mirror can be manufactured in a plastically deformed state, a high-quality three-dimensional curved mirror having a stable shape can be efficiently produced.

According to the present invention, the curvature of the manufactured three-dimensional curved mirror can be easily adjusted by providing the adjusting bending roll.

Further, according to the present invention, a stainless steel plate is used as the metal plate, and the plate thickness can be reduced to reduce the weight. Since there is no possibility of breaking as in the case of manufacturing a mirror using a glass plate, a highly reliable and safe three-dimensional curved mirror can be obtained.

Further, according to the present invention, since the surface hardness of the metal plate is not less than 330 in Vickers (Hv) hardness, the surface is hardly flawed, the mirror-polished state is kept stable for a long time, and the function as a mirror is maintained. Can be kept effective.

Further, according to the present invention, a metal plate is bent around a first axis by a C bending roll device, and bent around a second axis by an L bending roll device to form a three-dimensional curved mirror. It can be manufactured by one-pass threading. In the C bending roll device, since the position between the convex roll and the two concave rolls can be adjusted, the degree of bending around the second axis can be easily adjusted.

[Brief description of the drawings]

FIG. 1 is a simplified side view showing a schematic configuration of a three-dimensional curved mirror manufacturing apparatus 10 according to an embodiment of the present invention.

FIG. 2 is a flowchart showing a manufacturing process of a three-dimensional curved mirror in the embodiment of FIG.

FIG. 3 is a perspective view showing a shape of a three-dimensional curved mirror 29 manufactured in the manufacturing process of FIG. 2 including an intermediate stage.

FIG. 4 is a simplified side view showing a schematic configuration of a three-dimensional curved mirror manufacturing apparatus 30 according to another embodiment of the present invention.

FIG. 5 is a simplified side view showing a partial configuration of a three-dimensional curved mirror manufacturing apparatus 40 according to still another embodiment of the present invention.

FIG. 6 shows the embodiment of FIG. 5 in which the same curvature is obtained by bending the L-bent concave roll 43 up and down and bending around the first axis and bending around the second axis. It is a graph which shows a condition.

FIG. 7 is a simplified perspective view showing a three-dimensional curved mirror manufactured by the method of manufacturing a three-dimensional curved mirror previously proposed by the present applicant.

[Explanation of symbols]

 10, 30, 40 Three-dimensional curved mirror manufacturing device 11 C bending roll device 12 L bending roll device 13 Adjusting bending roll device 14 Stainless steel plate 15 First axial direction 16 Second axial direction 20, 22 C bending convex roll 21, 23 C bending concave roll 24, 41 L bending convex roll 25, 26, 42, 43 L bending concave roll 27 Adjusting bending convex roll 28 Adjusting bending concave roll 29 Three-dimensional curved mirror 31, 42 Front roll

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3D053 FF11 FF17 FF28 GG01 GG02 GG03 HH32 4E063 AA01 AA20 BB02 BB03 BB10 MA18

Claims (5)

[Claims] 1. A method for producing a three-dimensional curved mirror by plastic working of a mirror-finished metal plate, comprising: forming a metal plate having a width corresponding to a short side of the shape of the three-dimensional curved mirror in a longitudinal direction. Is bent around the first axis between C bending rolls having a second axis direction perpendicular to the first axis direction while passing the sheet so as to be parallel to the first axis direction. To form a two-dimensional curved surface, and further, the metal plate bent between the C bending rolls is
An L-bending roll device including a convex roll having a shape corresponding to the two-dimensional curved surface and two concave rolls having a shape corresponding to the two-dimensional curved surface, wherein a first concave roll is provided between the C bending rolls. The passed metal plate is sandwiched between the convex roll and the second concave roll, and the second concave roll is arranged at a position where the metal plate is bent around the second axis along the outer periphery of the convex roll. The metal plate is passed through an L-bending roll device, bent around the second axis to form a three-dimensional curved surface, and the metal plate is stretched along a longitudinal direction by a length corresponding to a long side of the three-dimensional curved mirror. And manufacturing the three-dimensional mirror. 2. After passing through the L bending roll device, the
The metal plate on which the three-dimensional curved surface is formed, further has a shape corresponding to the curved surface shape around the first axis, from the passing path of the metal plate from the C bending roll to the L bending roll device,
2. The method for manufacturing a three-dimensional curved mirror according to claim 1, wherein the separating is performed after the plate is passed through an adjusting bending roll disposed at a position shifted inward from the three-dimensional curved surface. 3. The method according to claim 1, wherein the metal plate is a stainless steel plate. 4. The method for manufacturing a three-dimensional curved mirror according to claim 1, wherein the metal plate has a surface hardness of 330 or more in Vickers (Hv) hardness. 5. A belt-shaped metal plate is passed between rolls having a second axis direction perpendicular to the first axis direction while passing the metal sheet so that the longitudinal direction is parallel to the first axis direction. First
A C-bending roll device for performing bending processing around the axis of, and disposed on the exit side of the metal plate from the C-bending roll device,
An axis parallel to the second axis direction is provided, and an outer peripheral surface is the first axis.
And a first and a second concave roll formed in conformity with the shape of the bending surface around the axis of the convex roll, and the convex roll and the first concave roll are provided with the C bending roll device between the rolls. The second concave roll is disposed at a position where the passed metal plate is guided as it is, and the second concave roll is disposed at an interval from the first concave roll in the first axial direction. An apparatus for manufacturing a three-dimensional curved mirror, comprising: an adjustable L bending roll device.