JP2004174974A

JP2004174974A - Manufacturing process for long material

Info

Publication number: JP2004174974A
Application number: JP2002345183A
Authority: JP
Inventors: Tatsuya Tamura; 達也田村; Tomohiro Sakagami; 智博坂神
Original assignee: Tokai Kogyo Co Ltd
Current assignee: Tokai Kogyo Co Ltd
Priority date: 2002-11-28
Filing date: 2002-11-28
Publication date: 2004-06-24
Anticipated expiration: 2022-11-28
Also published as: JP4112349B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a process for manufacturing a long-size material which permits, compared with a conventional manufacturing process, reducing the generation of unnecessary portions discarded and so on after shaping. <P>SOLUTION: The process is that for manufacturing a bumper spoiler S<SB>1</SB>that has a spoiler main unit 11 of longer form and a plurality of mounting plate portions 12 which project laterally from the spoiler main unit 11 along its longitudinal direction at a predetermined interval. The process has a step of forming the intermediate member S<SB>1</SB>' having the first and second portions 11a', 11b' predetermined for forming the main unit which are disposed symmetrically away from each other and have an identical cross-section and having the portion 12' of a given width predetermined for forming the mounting plate portions which integrally joins the above first and second portions 11a' and 11b', and a step of cutting the portion 12' predetermined for forming the mounting plate portions of the intermediate member S<SB>1</SB>' along the longitudinal direction by a line of cut SL and separating so that the mounting plate portions 12 of each bumper spoiler S<SB>1</SB>may be formed alternately in the longitudinal direction. The above intermediate member S<SB>1</SB>' is cut into a predetermined length to simultaneously obtain substantially a plurality of, identical or symmetrical bumper spoilers S<SB>1</SB>. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、長尺状の本体部と、その長手方向に沿って所定間隔をおいて前記本体部から側方に突出する複数個の取付部とを有する長尺材の製造方法に関するものである。
【０００２】
【従来の技術】
このような長尺材としては、本体部から側方に突出する部分を被取付体への取付部として使用でき、前記長尺材の一例としては、車両のバンパに取り付けるバンパスポイラを挙げることができる。このようなバンパスポイラを製造するには、本体部と取付部との各形成予定部を一体的に一定断面形状に高分子可塑材料で押出成形し、この押出成形品を所定の長さに切断して中間材を形成し、更にこの中間材に後加工を施して目的のスポイラを得る製造方法が考えられる。中間材は、その取付部形成予定部を複数箇所で部分的に除去され、残余の取付部形成予定部を取付部として形成されて、長手方向に所定間隔を保って取付部を有するスポイラが得られる。上記のようにして製造されたスポイラは、バンパの幅方向に沿って形成した挿入孔に前記取付部を差し込んで取り付けられた状態で使用に供される。
【０００３】
しかしながら、上記の製法においては、取付部形成予定部を複数箇所で部分的に除去する際に発生する不要部が、必然的に端材として発生するという問題を有していた。
【０００４】
【発明が解決しようとする課題】本発明は、上記不要部の発生量が従来製法よりも少なくてすむ長尺材の製造方法を提供することを課題としている。
【０００５】
【課題を解決するための手段】
上記の課題を解決するために請求項１に記載の発明は、長尺状の本体部と、その長手方向に沿って所定間隔をおいて前記本体部から側方に突出する複数個の取付部とを有する長尺材の製造方法であって、互いに離れて対称に配置されて同一又は略同一横断面形状の第１及び第２の本体部形成予定部と、前記第１及び第２の本体部形成予定部を一体に連結する一定幅の取付部形成予定部とを有する中間材を準備する工程と、各長尺材の取付部が長手方向でそれぞれ交互に形成されるように、前記中間材の取付部形成予定部を長手方向に沿って切断して分離する工程とを有し、前記中間材を所定長さに切断して、実質的に複数の同一の又は対称の長尺材を同時に得ることを特徴としている。
【０００６】
請求項１の発明によれば、前記中間材から切断によって長尺材を得る際に発生する長尺材一本当たりの不要部（端材）の発生量を減少させることができる。更に、一本の中間材の切断分離により、複数の互いに同一形状の、又は互いに対称形状の長尺材が得られるので、長尺材の製造能率が高まる。
【０００７】
また、請求項２の発明は、長尺状の本体部と、その長手方向に沿って所定間隔をおいて前記本体部から側方に突出する複数個の取付部とを有する長尺材の製造方法であって、互いに離れて対称に配置されて同一又は略同一横断面形状の第１及び第２の本体部形成予定部と、前記第１及び第２の本体部形成予定部を一体に連結する一定幅の取付部形成予定部とを有する中間材を形成する工程と、各長尺材の取付部が長手方向でそれぞれ交互に形成されるように、前記中間材の取付部形成予定部を長手方向に沿って切断して分離する工程とを有し、前記中間材を所定長さに切断して、実質的に複数の同一の又は対称の長尺材を同時に得ることを特徴としている。
【０００８】
請求項２の発明によれば、中間材の横断面形状は対称に配置されて形成されるので、中間材形成の際にバランスのとれたで成形が可能で、容易に行えることに加えて、前記中間材から切断によって長尺材を得る際に発生する長尺材一本当たりの不要部（端材）の発生量を減少させることができる。更に、一本の中間材の切断分離により、複数の互いに同一形状の、又は互いに対称形状の長尺材が得られるので、長尺材の製造能率が高まる。
【０００９】
また、請求項３の発明は、請求項１又は２の発明において、前記中間材は、長尺材の整数倍の長さを有していて、前記中間材を取付部形成予定部で長手方向に沿って切断して二分した後に、二分された長尺材予定部を所定長さに切断するか、又は長尺材予定部を所定長さに切断した後に、前記中間材を取付部形成予定部で長手方向に沿って切断して二分することを特徴としている。
【００１０】
請求項３の発明によれば、請求項１又は２の発明の効果に加えて、一つの前記中間材から二本の長尺材を前記整数組形成できるので、製造能率が高められる。
【００１１】
また、請求項４の発明は、請求項１ないし３のいずれかの発明において、中間材を分離する工程において、二つの各本体部形成予定部は、その長さを同一に保持して、長手方向に沿って互いに端末位置をずらして幅方向に切断することを特徴としている。
【００１２】
請求項４の発明によれば、請求項１ないし３のいずれかの発明の効果に加えて、前記中間材から長尺材を形成する際に発生する不要部（端材）の発生量が更に減少する。
【００１３】
また、請求項５の発明は、請求項１ないし４のいずれかの発明において、前記中間材は、その横断面視において、取付部形成予定部の幅方向中心線に対して線対称であることを特徴としている。
【００１４】
例えば長尺材を車両の両側部に取り付けられる各種トリム材として用いる時等は、左右線対称形状の一対の長尺材を必要とする。請求項５の発明によれば、請求項１ないし４のいずれかの発明の効果に加えて、ここで前記分離工程において、前記横断面視が線対称（折返し対称）な中間材の取付部形成予定部を長手方向に沿って切断して二分すると、左右線対称の一対の長尺材を容易に形成できる。そして、左右に対応した後加工や仕分け等に備えて、例えばそれぞれの長尺材を双方が対向するのと反対方向に平行移動させ、個別に取り扱うことが容易となる。
【００１５】
また、請求項６の発明は、請求項１ないし４のいずれかの発明において前記中間材は、その横断面視において、取付部形成予定部の幅方向中心に対して点対称であることを特徴としている。
【００１６】
請求項６の発明によれば、請求項１ないし４のいずれかの発明の効果に加えて、前記分離工程において、前記横断面視が点対称（反転対称）な中間材の取付部形成予定部を長手方向に沿って切断することにより二分される片側の長尺材を、その長手方向に沿った軸を中心にして１８０°半回転させる作業を行い、２本の同一の長尺材の突出方向を揃えた状態で、まとめて取り扱うことが容易となる。この場合、分離後の片側の長尺材を、同一平面内で回転移動させる作業を考慮する必要がないので、製造ラインの作業面積を縮小したり、生産効率を維持できる。
【００１７】
また、請求項７の発明は、請求項１ないし６のいずれかの発明において、前記中間材は、ゴム、樹脂、エラストマー等の高分子可塑材料から、押出成形型を用いて押出成形されることを特徴としている。
【００１８】
請求項７の発明によれば、請求項１ないし６のいずれかの発明の効果に加えて、一つの中間材から少なくとも二本の長尺材が形成されるので、従来方法と比較すると、単位時間あたりの生産量が少なくともほぼ倍増する。即ち、押出成形するのに、ほぼ倍の時間を掛け、その成形速度を遅くしても、従来方法と同等の生産量を維持できる。こうすると、押出成形時の中間材の形状の変動が小さくなり、正確な形状の中間材が得易くなる。更に、ゴム又は樹脂の押出成形において、押出後の加硫又は冷却の各装置の長さを長大化させず、それら各装置の設置面積を小さくできるばかりでなく、熱効率も向上する。
【００１９】
また、請求項８の発明は、請求項１ないし６のいずれかの発明において、前記中間材は、軽金属材料から、押出成形型を用いて押出成形されることを特徴としている。
【００２０】
請求項８の発明によれば、請求項１ないし６のいずれかの発明の効果に加えて、前記高分子可塑材料の代わりに、軽金属を中間材の形成材料とすることでのみ、請求項７の発明と異なっており、押出後の伸長、直線化工程の装置の長大化を防げる。
【００２１】
また、請求項９の発明は、請求項１ないし６のいずれかの発明において、前記中間材は、所定幅の帯板状材料から、所定の横断面形状にロール成形されることを特徴としている
【００２２】
請求項９の発明によれば、請求項１ないし６のいずれかの発明の効果に加えて、請求項７の発明の作用効果と同じ理由で、従来方法と同等の生産量を維持しながら、ロール成形速度を遅くできる。よって、ロール成形時の中間材の形状のバランスが保たれた正確な形状の中間材が得易くなり、成形機等の各装置の設置面積を小さくできる。
【００２３】
また、請求項１０の発明は、請求項１ないし６のいずれかの発明において、前記中間材は、硬質材料からなる所定断面形状の芯材と、該芯材の上に押出成形される高分子可塑材料との両材料からなることを特徴としている。
【００２４】
請求項１０の発明によれば、請求項１ないし６のいずれかの発明の効果に加えて、請求項７及び９の場合と同じ理由で、中間材の形状の変動やバランスを、小さく又は維持できて、正確な形状の中間材が得易くなり、成形機等の各装置の設置面積を小さくできる。
【００２５】
また、請求項１１の発明は、請求項１ないし１０のいずれかの発明において、前記取付部形成予定部を分離する工程は、プレス型によって、又は集中エネルギー手段によって切断する方法で行われることを特徴としている。
【００２６】
請求項１１の発明によれば、請求項１ないし１０のいずれかの発明の効果に加えて、プレス型によって切断する方法では、短時間で効率良く中間材を分離できる。またレーザー光線による溶断やウォータージェットによる切断のような集中エネルギー手段による切断方法では、取付部形成予定部の切断形状の自由度を大きくでき、多種類少量生産に好適である。
【００２７】
また、請求項１２の発明は、請求項１ないし１１のいずれかの発明において、前記長尺材は被取付体への取付部材であって、前記中間材の取付部形成予定部には、長手方向に沿って連続する突条が一体に形成されていて、取付部形成予定部が分離された後に、長尺材の前記突条が被取付体の係合部に係止する係止部となることを特徴としている。
【００２８】
請求項１２の発明によれば、請求項１ないし１１のいずれかの発明の効果に加えて、前記取付部形成予定部を分離することによって、別途の係止部形成工程を要せずに、係止部が形成される。
【００２９】
【発明の実施の形態】
以下、複数の実施形態を挙げて、本発明について更に詳細に説明する。最初に、本発明の方法によって製造される第１実施形態のバンパスポイラ（以下、単に「スポイラ」と略すこともある）Ｓ_１の構成、及びフロントバンパＢに対するスポイラＳ_１の取付構造について簡単に説明し、その後に、本発明に係るスポイラＳ_１の製造方法について説明する。図１は、本発明の方法により製造されたスポイラＳ_１と、これが取付けられるフロントバンパＢの左側半分を示す部分斜視図であり、図２は、スポイラＳ_１の平面図であり、図３は、バンパＢとスポイラＳ_１との関係を示す部分平面図であり、図４及び図５は、バンパＢにスポイラＳ_１が取付けられた状態における図２のＸ_１−Ｘ_１線及びＸ_２−Ｘ_２線拡大断面図である。
【００３０】
図１及び図２に示されるように、スポイラＳ_１は、これが取付けられる車両のバンパＢに対応する長さを有し、車両の正面の幅方向の左右中心線Ｃ_１１（図１及び図２参照）に対して左右対称な長尺形状であって、バンパＢに取付けられた状態で、ほぼ上下方向に向いて配置される略板状をしたスポイラ本体部１１と、ほぼ板状をなしていて、前記スポイラ本体部１１の上端部寄りから裏面側（車両の後方）に向けて突出する複数の略板状の取付板部１２，１２とから構成される。複数の取付板部１２は、スポイラ本体部１１の長手方向に沿って所定間隔を保って一体に設けられている。また、スポイラ本体部１１の裏面側には、バンパＢのスポイラ取付溝１に嵌合される嵌合支持部１３が長手方向の全長に亘って設けられ、各取付板部１２は、前記嵌合支持部１３の裏面側に一体に形成されている。この嵌合支持部１３は各取付板部１２よりも厚肉であって、スポイラ本体部１１から離れる側の肉厚が小さくなるような横断面台形状（テーパー状）に形成されている。また、温度変化によるスポイラＳ_１の長手方向の伸縮を防止するためのテープ状の芯材１４（図４及び図５参照）が、その全長に亘って埋設されている。この芯材１４は、スポイラ本体部１１及び取付板部１２の各材質よりも剛性が高くて、しかも伸縮性の小さな材質、例えば、スチールストリップ（金属帯板）等を使用することが好ましい。
【００３１】
バンパＢのスポイラ取付溝１を構成する取付溝底壁部２には、長手方向に所定間隔をおいて複数の取付板部挿通孔３が形成されており、スポイラＳ_１の各取付板部１２は、前記各取付板部挿通孔３に挿通されて、バンパ底壁板部４の上面に重ね合わさった状態となる。スポイラＳ_１の取付板部１２の形状は、その基端部の首部１２ａは、一定幅となっていて、この首部１２ａから先端（自由端）に向けて徐々に幅広となって中間で最大幅の部分が形成され、この最大幅部から先端に向けて徐々に幅狭となった形状である。また、取付板部１２の幅方向の両端部には、この取付板部１２をバンパＢの取付板部挿通孔３に挿通する際の変形を助けると共に抜け出しを防止する変形補助溝１２ｂが前後方向に沿って形成されている。また、取付板部１２の先端部には、バンパＢに対してスポイラＳ_１を取付けて、スポイラＳ_１の取付板部１２をバンパＢの取付板部挿通孔３に挿通した状態で、バンパＢの底壁板部４の固着具挿通孔５と合致する固着具挿通孔１２ｃが形成されている。なお、スポイラＳ_１の取付板部１２の最大幅部、先端部（自由端部）、及び首部１２ａの幅をそれぞれＷ_１１，Ｗ_１２，Ｗ_１３とし、バンパＢの取付板部挿通孔３の内幅をＷ_１４とすると、これらの間には、（Ｗ_１４＞Ｗ_１２，Ｗ_１４＜Ｗ_１１，Ｗ_１４≦Ｗ_１３）の関係を満たすように設定されている。また、バンパＢの取付溝底壁部２の板厚、及び取付板部１２の首部１２ａの厚さをそれぞれｔ_１，ｔ_２とすると、（ｔ_１≒ｔ_２）の関係を満たすように設定されている。なお、長手方向に沿う隣りの取付板部同士の間の間隙は、他方のスポイラの取付板部が形成できるだけの間隙を必要とし、この間隙は最大幅部Ｗ_１１を下回らないように設定されている。
【００３２】
スポイラ本体部１１は、取付板部１２及び嵌合支持部１３よりも軟質で弾性変形可能な材料、例えば、軟質のＴＰＥ樹脂（好ましくはＪＩＳＫ７２１５デュロメーター硬度ＨＤＡ７０°以下）等で成形され、取付板部１２及び嵌合支持部１３は、スポイラ本体部１１よりも硬質で剛性を有する弾性変形可能なゴムや合成樹脂材料、例えば、ＰＰ樹脂、硬質のＴＰＥ樹脂（好ましくはＪＩＳＫ７２１５デュロメーター硬度ＨＤＤ５０°以上）等で成形され、両部の接合部１５（図４参照）は、両部の共押出成形時において、溶着で一体複合化されている。前述のＴＰＥ（熱可塑性エラストマー）の材質は特に限定されるものではなく、例えば、ビニル系ＴＰＥ、オレフィン系ＴＰＥ（以下、単に「ＴＰＯ」と称する）、スチレン系ＴＰＥ等が適用可能であるが、軽量化、環境保護の観点からＴＰＯを使用することが好ましい。即ち、スポイラＳ_１の本体部１１、取付板部１２、及び嵌合支持部１３をそれぞれＴＰＯで成形すると、スポイラＳ_１が不要になって廃棄処分される際においても、焼却処理が可能で、有毒ガスも発生しない利点もある。更に、ＴＰＥ以外の材料としては、スポイラ本体部１１としては軟質のゴム、取付板部１２及び嵌合支持部１３としては本体部１１よりも硬質のゴム材料とし、ゴムとしては特にＥＰＤＭも好ましい材料の一つである。
【００３３】
バンパＢに対してスポイラＳ_１を取付けるには、以下のようにして行われる。まず、スポイラ本体部１１の裏面側に一体に設けられた各取付板部１２を、バンパＢのスポイラ取付溝１の奥部に設けられた各取付板部挿通孔３にそれぞれ挿通すると共に、スポイラＳ_１の全長に亘って設けられた嵌合支持部１３をバンパＢのスポイラ取付溝１に嵌合させる。スポイラＳ_１の各取付板部１２は、その挿通途中において変形補助溝１２ｂの作用によって、幅が狭くなるように弾性変形すると共に、挿通後には、原形状に復元するために、一旦バンパＢの取付板部挿通孔３に挿通されたスポイラＳ_１の取付板部１２は、抜け出なくなる。これにより、バンパＢに対してスポイラＳ_１が仮止めされる。なお、バンパＢのコーナー部の曲がった部分においては、この曲がりに沿ってスポイラＳ_１を曲げながら、その取付板部１２をバンパＢの取付板部挿通孔３に挿通することにより、スポイラＳ_１は、バンパＢの平面形状に倣って僅かにわん曲された状態で、その全長に亘ってバンパＢに仮止めされる。
【００３４】
最後に、図４に示されるように、クリップ等の固着具６を使用して、バンパＢの底壁板部４に対してスポイラＳ_１の各取付板部１２を固定する。即ち、互いに重なり合ったスポイラＳ_１及びバンパ底壁板部４の各固着具挿通孔１２ｃ，５に固着具６を挿通して、その頭部をかしめる等して行う。なお、スポイラＳ_１の取付状態では、スポイラ本体部１１の上端から斜前方に向けて一体に形成されている弾発リップ１６は、バンパＢの取付溝上側壁部７の下面に弾接してシール作用を果たす。
【００３５】
次に、本発明に係る前記スポイラＳ_１の製造方法について説明する。図６は、スポイラＳ_１となる前の中間材Ｓ_１’の斜視図であり、図７は、中間材Ｓ_１’の横断面図であり、図８は、中間材Ｓ_１’の切断線ＳＬを示す平面図であり、図９は、中間材Ｓ_１’を切断分離させて２本の同一のスポイラＳ_１が形成される状態を示す平面図であり、図１０は、形成された２本の同一のスポイラＳ_１の斜視図である。中間材Ｓ_１’は、図６及び図７に示されるように、互いに離れて反転対称（点対称）となるように配置された同一形状の第１及び第２の本体部形成予定部１１ａ’，１１ｂ’が、取付板部形成予定部１２’を介して一体に連結された長尺形状であって、後述の共押出成形により形成される。取付板部形成予定部１２’の幅Ｗ_１は、スポイラＳ_１を構成する各取付板部１２の突出長Ｌ_２１に、２つの嵌合支持部１３の突出長Ｌ_２２を加えた寸法〔Ｌ_２１＋（２×Ｌ_２２）〕と同一である（図３参照）。ここで、本体部形成予定部１１ａ’，１１ｂ’は、取付板部形成予定部１２’の幅方向の中心を通る反転対称線Ｃ_１を中心にして反転対称に配置されている。よって、図７において、本体部形成予定部１１ａ’，１１ｂ’を反転対称線Ｃ_１を中心にして相互に反転させると、互いに重なり合う関係にある。なお、図６及び図７において、１３ａ’，１３ｂ’は、取付板部形成予定部１２’に形成された嵌合支持部形成予定部、１６ａ’，１６ｂ’は、弾発リップ形成予定部であり、それぞれ前記反転対称線Ｃ_１を中心にして反転対称に配置されている。
【００３６】
そして、図８に示されるように、前記中間材Ｓ_１’をプレスブランク型（図示せず）により打ち抜いて切断分離することにより、２本の同一のスポイラＳ_１，Ｓ_１を形成する。即ち、スポイラＳ_１の全長（Ｌ_１）は、これが取付けられるバンパＢの長さに対応していて、その１本が独立使用され、その長手方向の中心の反転対称線Ｃ_１に対して同一形状となっている。このため、中間材Ｓ_１’を切断して２本の同一のスポイラＳ_１を形成する際の材料歩留りを高めるために、反転配置された本体部形成予定部１１ａ’，１１ｂ’は、その長手方向に沿って所定長（Ｌ_１１）だけずれて切断される。また、中間材Ｓ_１’は、これを切断して形成される２本の同一のスポイラＳ_１の同一位置に配置される各取付板部１２が互いに接触して隣接し、両者の間の不要部（端材）の発生が従来よりも少ない状態で切断される。
【００３７】
よって、中間材Ｓ_１’を図８に示される切断線ＳＬで切断して、その取付板部形成予定部１２’を長手方向に沿って切断して二分すると、図９に示されるように、前記切断線ＳＬで囲まれた部分において２種類の不要部Ｄ_１，Ｄ_２が発生した状態で（変形補助溝１２ｂと固着具挿通孔１２ｃは除く）、２本の独立したスポイラＳ_１が同時に形成される。なお、スポイラＳ_１の各取付板部１２に形成される変形補助溝１２ｂ及び固着具挿通孔１２ｃは、スポイラＳ_１の切断と同時に又は後工程で打ち抜かれて形成される。また、切断直後の２本のスポイラＳ_１は、いずれか一方をその位置で反転させることにより、２本のスポイラＳ_１の配置形状は、同一となるため、切断後におけるスポイラＳ_１の取扱いが容易となる。なお、スポイラＳ_１の取付板部１２に形成される変形補助溝１２ｂは、図３を除いて図示していない。
【００３８】
次に、スポイラＳ_１の中間材Ｓ_１’の製造方法について説明する。図１１は、中間材Ｓ_１’を製造する工程を示す図であって、中間材Ｓ_１’は、押出成形型２２において共押出成形される。押出成形型２２は、軟質及び硬質のＴＰＥの各溶融樹脂を所定の押出圧力を付加した状態で内部に供給する第１及び第２の各樹脂供給路２２ａ，２２ｂを備えている。前記軟質及び硬質のＴＰＥの各溶融樹脂は、中間材Ｓ_１’の前記第１及び第２の本体部形成予定部１１ａ’，１１ｂ’と弾発リップ形成予定部１６ａ’，１６ｂ’、及び取付板部形成予定部１２’と嵌合支持部形成予定部１３ａ’，１３ｂ’をそれぞれ形成する材料である。
【００３９】
そして中間材を形成するには、まず、前記芯材１４を形成する２本のスチールストリップ２１ａを、芯材アンコイラ２１から巻き出して下流方向Ｐに向けて供給し、押出成形型２２の貫通孔（図示せず）からその内部に連続供給する。該スチールストリップ２１ａは、押出成形型２２の内部において、硬質のＴＰＥの溶融樹脂にその表面を覆われ、嵌合支持部形成予定部１３ａ’，１３ｂ’に対応する部分を形成されながら、取付板部形成予定部１２’に対応する部分の前記溶融樹脂と共に下流方向Ｐに押し出される。更に、硬質のＴＰＥ溶融樹脂は、共に押し出される軟質のＴＰＥ溶融樹脂と合流し、前記接合部１５に対応する部分が形成され、取付板部形成予定部１２’においてテーパー状に突出する嵌合支持部形成予定部１３ａ’，１３ｂ’と、一対の第１及び第２の本体部形成予定部１１ａ’，１１ｂ’とが接合された状態の溶融樹脂が押し出される。このようにして、中間材Ｓ_１’と同一の横断面形状であって、硬度の異なるＴＰＥの各樹脂材料で共押出成形された押出成形品Ｓ_１’’ が、押出成形型２２の出口である開口部から下流に向かって押し出される。
【００４０】
次に、前記押出成形品Ｓ_１’’ は、押出成形型２２から下流側に向けて更に引き取られ、冷却装置２３に供給されて冷却される。冷却されて常温近くに保持された押出成形品Ｓ_１’’ は、冷却装置２３の下流側の引取装置２４によって更に引き取られ、より下流側の切断機２５で所定長（≧スポイラＳ_１の全長Ｌ_１の整数倍）に切断され、前記中間材Ｓ_１’が形成される。
【００４１】
前述したように、本発明によって形成される１本の中間材からは、複数本の長尺材（スポイラ）が形成されるので、押出速度が同じ場合、単位時間あたりの生産量は２倍になり、従来の単位時間当たりの所定生産量を維持する場合には、共押出成形の速度を遅くできる。よって、上記した共押出成形工程では、押出成形型２２の内部での中間材Ｓ_１’の各部分に対応する形状をより精度良く保持できるので、形状の変動が押えられた押出成形品Ｓ_１’’ が得られる。しかも、中間材Ｓ_１’は、自身の重心と反転中心とが一致する反転対称な形状なので、押出成形型２２からバランス良く押し出して下流側に引き取ることができ、設計形状を一層正確に反映した中間材Ｓ_１’が得られる。更に、共押出成形を比較的ゆっくりと行えることにより、冷却装置２３の長さを長大化させず、設置面積を縮小できる。
【００４２】
次に、形成された中間材Ｓ_１’の取付板部形成予定部１２’を長手方向に沿って切断して分離する工程を行う。中間材Ｓ_１’は、前述したように取付板部形成予定部１２’において、前記切断線ＳＬに沿って切断され、二分されると共に、二つの各本体部形成予定部１１ａ’，１１ｂ’において、その長さを１本のスポイラＳ_１の全長Ｌ_１に保持し、長手方向に沿って互いに端末位置を所定長（Ｌ_１１）だけずらして幅方向に切断され（図９参照）、幅方向に対向する同一の二本のスポイラＳ_１が、一つの前記中間材Ｓ_１’から長手方向に沿って前記整数組得られる。前記取付板部形成予定部１２’には、テーパー状に突出する嵌合支持部形成予定部１３ａ’，１３ｂ’が長手方向に沿って連続して一体に形成されていたので、上記したように中間材が切断されるのと同時に、各スポイラＳ_１には、バンパＢのスポイラ取付溝１に嵌合して係止される前記嵌合支持部１３が形成されている。中間材Ｓ_１’は、プレスブランク型によって打ち抜いて切断されるので、この分離操作は短時間で効率良く行うことができ、同時にバンパＢへの係止部となるべき嵌合支持部１３を有する整数組の二本のスポイラＳ_１が得られるので、製造能率が高まっている。
【００４３】
中間材Ｓ_１’は、前記取付板部形成予定部１２’において、二本のスポイラＳ_１のそれぞれの各取付板部１２が互いに接触して隣接し、長手方向で交互に形成されるように切断されるので、従来の製造方法による一本のスポイラの隣合う取付板部の間に生じる不要部の発生量と比較すると、二本のスポイラＳ_１の同一位置に配置される取付板部１２の分だけ、不要部が減少する。更に、中間材Ｓ_１’は、前記各本体部形成予定部１１ａ’１１ｂ’において、幅方向に対向する二本のスポイラＳ_１のそれぞれの各本体部１１の端末が、長手方向に所定長（Ｌ_１１）だけずれて切断されるので、長手方向で隣接する次の二本のスポイラとの間に生じる不要部がより少なくなっている。なお、本実施形態においては、前記所定長（Ｌ_１１）は、二本のスポイラＳ_１の各両端に配置される取付板部１２が、交互に隣接して長手方向にずれた寸法に対応して定められている。
【００４４】
切断直後の片側のスポイラＳ_１は、その位置で上下反転され、相対向する他方側のスポイラＳ_１と取付板部１２の突出方向を揃え、同時に長手方向に隣接するスポイラＳ_１と共に収集される。この場合、前記片側の細長いスポイラＳ_１を、同一平面内で回転移動させる必要がないので、収集作業が容易に行える。収集されたスポイラＳ_１は、別の中間材から形成される同様のスポイラと共に収集され、それぞれ一本づつのスポイラＳ_１が、車両の組立工程においてバンパＢに取り付けられて使用される。
【００４５】
次に、第２実施形態のバンパスポイラ及びその中間材Ｓ_２’の構成と、その製造方法について説明する。なお、以下に説明する第１実施形態の他の実施形態の各部分においては、既述の部分と同一の部分には、同一符号を付し、第１実施形態のそれらと異なっている点を中心に説明及び図示する。第２実施形態の「右」及び「左」の各用語は、車両の幅方向に沿った方向であって、乗員が進行方向を向いた時に相当する各方向として使用する。図１２は、第２実施形態のバンパスポイラを構成する右側及び左側の各スポイラＳ_２１，Ｓ_２２を示す平面図である。各スポイラＳ_２１，Ｓ_２２は、２本１組となってスポイラ（長尺材）として使用され、それぞれ取付けられる車両のバンパＢに対応する長さの約半分の全長を有していて、それぞれバンパＢの右側半分及び左側半分に取り付けられる。右側及び左側の各スポイラＳ_２１，Ｓ_２２の各スポイラ本体部１１には、同一間隔をおいてそれぞれ５つの前記取付板部１２が形成されている。各スポイラ本体部１１の長手方向に沿った両端に配置する各取付板部１２は、スポイラ本体部１１の各端面から起算した寸法が異なるように形成されている。図示されるとおり、右側及び左側の各スポイラＳ_２１，Ｓ_２２の各スポイラ本体部１１の片側（取付状態において右側に配置）及び他方側（取付状態において左側に配置）の各端面１７ａ_１，１７ｂ_２から起算した各取付板部１２の形成位置が同一で、同じく他方側及び片側の各端面１７ａ_２，１７ｂ_１から起算した各取付板部１２の形成位置が同一である。よって、両スポイラＳ_２１，Ｓ_２２は、互いの全体形状が異なるものの、折返し対称線（図示せず）に対して反転させると、スポイラ本体部１１に対する取付板部１２の長手方向に沿った形成位置が少しずつずれた左右対称な一対の長尺材になっている。両スポイラＳ_２１，Ｓ_２２は、右側スポイラＳ_２１の前記他方側の端面１７ａ_２と左側スポイラＳ_２２の前記片側の端面１７ｂ_１とを、バンパＢの前記左右中心線Ｃ_２１（図１参照）に対して対向させ、左右対称に配置するように取り付けて使用される。なお、バンパＢの中央部には車両のナンバプレート等が取り付けられ、実際の各スポイラＳ_２１，Ｓ_２２の全長は、対応するバンパＢの長さの半分より短いが、説明の便宜上、約半分（Ｌ_１／２）と仮定する。
【００４６】
次に、前記右側及び左側の各スポイラＳ_２１，Ｓ_２２を同時に製造する方法について説明する。前記各スポイラＳ_２１，Ｓ_２２の整数本分の全長を有する中間材Ｓ_２’の形状、及び中間材Ｓ_２’を形成する工程は、第１実施形態の中間材Ｓ_１’とほぼ同じであって（図６及び図１１参照）、第２実施形態においては、次の中間材Ｓ_２’を分離する工程における前記切断線のみが異なっている。図１３は、中間材Ｓ_２’を切断分離させて一対のスポイラＳ_２１，Ｓ_２２が形成される状態を示す平面図である。図示されるとおり、中間材Ｓ_２’の取付板部形成予定部１２’を長手方向に沿って切断することにより二分して、双方の各取付板部１２を形成すべき切断線（図示せず）は第１実施形態と同様であるが、中間材Ｓ_１’の第１及び第２の各本体部形成予定部１１ａ’，１１ｂ’の端末位置を前記所定長（Ｌ_１１）だけずらした切断線が無くなり、代わりに幅方向に平行な切断線となる。
即ち第２実施形態では、中間材Ｓ_２は、その取付板部形成予定部１２’を長手方向に沿って切断することにより二分されると共に、第１及び第２の各本体部形成予定部１１ａ’１１ｂ’の端末位置が長手方向に沿って揃うように、前記全長（Ｌ_１／２）毎に幅方向に切断される。切断分離すると、一対のスポイラ本体部１１の各片側の端面１７ａ_１，１７ｂ_１の端末位置と、同じく各他方側の端面１７ａ_２，１７ｂ_２の端末位置とが長手方向に沿った状態で、一対のスポイラＳ_２１，Ｓ_２２が得られる。得られる一対のスポイラＳ_２１，Ｓ_２２は、左右対称形状であって、切断後の左側のスポイラＳ_２２は、その位置で上下反転させて右側のスポイラＳ_２１と上下方向を揃え、双方個別に収集した後にそれぞれバンパＢに取り付けられる。
【００４７】
次に、第３実施形態では、第２実施形態のスポイラＳ_２１と同一形状であって、その一本が独立使用される二本のスポイラＳ_３を、前述の各実施形態の中間材Ｓ_１’と異なる形状の中間材Ｓ_３’から得る方法について例示する。図１４は、二本のスポイラＳ_３を製造するための中間材Ｓ_３’の斜視図である。図示されるとおり、中間材Ｓ_３’は、互いに離れて配置された同一形状の一対の第１及び第２の各本体部形成予定部１１ａ’，１１ｂ’が、取付板部形成予定部１２’の幅方向の中心を通る折返し対称面（図示せず）を中心にして反転対称に配置され、前述の各実施形態と同様に共押出成形で形成される。前記各本体部形成予定部１１ａ’，１１ｂ’は、中間材Ｓ_３’の横断面視において、自身を取付板部形成予定部１２’の折返し対称線Ｃ_３（幅方向中心線）に対して左右反転させると、各本体部形成予定部１１ａ’，１１ｂ’の端面１７’ 同士が重なり合うように配置している。図１５は、中間材Ｓ_３’を切断分離させて同一形状の２本のスポイラＳ_３が得られる状態を示す平面図である。図示されるとおり、中間材Ｓ_３’を分離する工程における前記切断線は、第２実施形態と同じであって、中間材Ｓ_３’は、その取付板部形成予定部１２’を長手方向に沿って切断することにより二分されると共に、スポイラＳ_３の全長Ｌ_１に対応して幅方向に切断され、同一形状の二本のスポイラＳ_３が製造される。
【００４８】
次に、第４ないし第６の各実施形態の長尺材Ｓ_４，Ｓ_５，Ｓ_６及びそれらの中間材Ｓ_４’，Ｓ_５’，Ｓ_６’と、その製造方法について説明する。図１６、図１８及び図２０は、それぞれ第４ないし第６の各実施形態における各切断線ＳＬ_４，ＳＬ_５，ＳＬ_６を図示した各中間材Ｓ_４’，Ｓ_５’，Ｓ_６’の各斜視図であって、図１７、図１９及び図２１は、それぞれ前記各中間材Ｓ_４’，Ｓ_５’，Ｓ_６’から得られる第４ないし第６の各実施形態の一対の各長尺材Ｓ_４，Ｓ_５，Ｓ_６の各斜視図である。各長尺材Ｓ_４，Ｓ_５，Ｓ_６は、全て高分子可塑材料で形成され、それらの中間材Ｓ_４’，Ｓ_５’，Ｓ_６’は、押出成形型を用いて一定の横断面形状に押出成形された各押出成形品（図示せず）を所定長に切断して形成される。前述の各実施形態では、長尺材がＴＰＥで形成されている場合について説明したが、ＴＰＥに代わる熱可塑性樹脂やゴム等のその他の高分子可塑材料でも、同様に中間材を形成おできる。
【００４９】
まず、第４実施形態の長尺材Ｓ_４は、中空部を有する帯板状の本体部４１の基端の部分に、鈍角をなして側方に突出する取付板部４２が所定間隔をおいて、長手方向に沿って形成された長尺材であって、車両のエンジンフードの縁部と車体の開口縁部との間に取り付けて使用され、エンジンルーム内への水やゴミの浸入や、エンジン音の漏れ等を防止するゴム成形品である。前記本体部４１は、中空弾接部４１ｃを有するように軟質のスポンジゴムで形成され、エンジンフードと対向配置する車両のボンネットの縁部に、中空弾接部４１ｃを弾接させて使用する部分である。前記取付板部４２は、自身の基端の部分が長手方向に沿って連続するように硬質のゴムで形成されており、エンジンフードの縁部に重ね合わせられ、固定具等を挿通して取り付ける部分である。一対の長尺材Ｓ_４を得るための中間材Ｓ_４’は、前記本体部４１と同一形状の第１及び第２の各本体部形成予定部４１ａ’，４１ｂ’が、取付板部形成予定部４２’を介して一体に形成された形状である。取付板部形成予定部４２’は、交互に隣接しながら対向する一対の前記取付板部４２の突出長に対応する幅寸法を有しており、各本体部形成予定部４１ａ’，４１ｂ’は、横断面視において、取付板部形成予定部４２’の幅方向の中心を通る折返し対称線Ｃ_４に対して折返し対称に配置するように形成されている。この中間材Ｓ_４’を分離する工程での切断線ＳＬ_４は、中間材Ｓ_４’を分離して得られる一対の長尺材Ｓ_４の同一位置に配置される各取付板部４２が、互いに隣接した状態に対応する線である。切断線ＳＬ_４に沿って中間材Ｓ_４’の取付板部形成予定部４２’を長手方向に沿って切断することにより二分すると、切断線ＳＬ_４で囲まれた部分において不可避である不要部Ｄ_４が発生し、一対の長尺材Ｓ_４が同時に形成される。なお、長尺材Ｓ_４はゴム材料で形成されているので、中間材Ｓ_４’の共押出工程においては、前記冷却装置の代わりに加硫装置が設置される。共押出成形は比較的ゆっくりと行えるので、加硫装置の長さは長大化しない。図１６及び図１７において、４１ｄは、本体部４１におけるボンネットの縁部と弾接する中空弾接部４１ｃから延設された延長部、４１ｃ’，４１ｄ’ は、前記中空弾接部４１ｃとその延長部４１ｄの形成予定部、４２ｃは、エンジンフードに取り付けるための固定具挿入孔、４５は、前記両ゴム材料の接合部である。
【００５０】
次に、第５実施形態の長尺材Ｓ_５は、丸みを有する略角柱形状の本体部５１の裏面に、側方に突出する取付挟持部５２が自身の幅間隔をおいて長手方向に沿って形成された長尺材である。取付挟持部５２は、横断面視において、高さの低い一対の二等辺三角形の底辺同士を対向させた二枚板状の突出部であって、本体部５１の形成方向と反対側に開口する開口部５２ａを有していて、車両の左右の両側面の被取付体である縁部を開口部５２ａで挟むことによって、長尺材Ｓ_５を取り付けて使用される。取付状態において表面に配置する本体部５１の大部分と、裏面に配置する本体部５１の一部分及び取付挟持部５２とは、それぞれ別の高分子可塑材料で形成されている。一対の長尺材Ｓ_５を得るための中間材Ｓ_５’は、前記本体部５１と同一形状の第１及び第２の各本体部形成予定部５１ａ’，５１ｂ’が、前記取付挟持部５２の突出長と同一幅の取付挟持部形成予定部５２’を介して一体に形成された形状であって、横断面視において、取付挟持部形成予定部５２’の幅方向の中心を通る折返し対称線Ｃ_５に対して折返し対称に配置するように形成されている。この中間材Ｓ_５’を分離する工程での切断線ＳＬ_５は、中間材Ｓ_５’を分離して得られる一本の長尺材Ｓ_５の各取付挟持部５２が、その両側面において別の一本の長尺材Ｓ_５の各取付挟持部５２と互いに隣接した状態に対応した線である。よって、切断線ＳＬ_５に沿って中間材Ｓ_５’の取付板部形成予定部５２’を長手方向に沿って切断することにより二分すると、不要部が生じずに一対の前記長尺材Ｓ_５が同時に形成される。なお、図１８において、５２ａ’は、前記開口部５２ａを形成するための中空部であって、５５は、前記高分子材料の接合部である。
【００５１】
次に、第６実施形態の長尺材Ｓ_６は、第５実施形態の長尺材Ｓ_５と同様に、本体部６１の形成方向と反対側に開口する開口部６２ａを有する取付挟持部６２が、長手方向に沿って自身の幅間隔をおきながら、本体部６１の裏面から側方に突出して形成された長尺材であって、取付挟持部６２の開口部６２ａに、被取付体の縁部を挟んで取り付けて使用される。一対の長尺材Ｓ_６を得るための中間材Ｓ_６’は、前記本体部６１と同一形状の第１及び第２の各本体部形成予定部６１ａ’，６１ｂ’が、前記取付挟持部６２の突出長と同一幅の取付挟持部形成予定部６２’を介して一体に形成された形状であって、横断面視において、取付挟持部形成予定部６２’の幅方向の中心を通る折返し対称線Ｃ_６に対して折返し対称に配置するように形成されている。中間材Ｓ_６’を分離する工程における切断線ＳＬ_６は、第５実施形態と同様に、一本の長尺材Ｓ_６の各取付挟持部６２が、その両側面において別の一本の長尺材Ｓ_６の各取付挟持部６２と互いに隣接した状態に対応した線であって、中間材Ｓ_６’を幅方向に二分すると、不要部が生じずに一対の長尺材Ｓ_６が同時に形成される。なお、図２０において、６２ａ’は、前記開口部６２ａを形成するための中空部である。
【００５２】
上記した各中間材Ｓ_４’（Ｓ_５’，Ｓ_６’）は、互いに離れて配置された一対の同一形状の第１及び第２の各本体部形成予定部４１ａ’ （５１ａ’，６１ａ’），４１ｂ’ （５１ｂ’，６１ｂ’ ）が、横断面視において、取付板部形成予定部４２’ （各取付挟持部形成予定部５２’，６２’）の幅方向の中心を通る折返し対称線Ｃ_４，（Ｃ_５，Ｃ_６）に対して、折返し対称（線対称）に配置するように形成されている。一般に、このような中間材の取付板部形成予定部を長手方向に沿って切断して二分することによって、相互に左右反転させた時に被取付体への取付部となるべき部分が長手方向に沿って重なり合う左右対称の各一本の長尺材を容易に形成することができる（第４ないし第６の各実施形態の場合は、左右対称であると同時に同一の形状となる）。よって、各中間材Ｓ_４’（Ｓ_５’，Ｓ_６’）を分離する工程において、その取付板部形成予定部を長手方向に沿って切断することにより二分されて得られる一対の各長尺材Ｓ_４，（Ｓ_５，Ｓ_６）を、例えば双方が対向するのと反対方向に平行移動させ、左右に対応して仕分けした後に独自の後加工を行い、形状の異なる右側及び左側の各長尺材として個別に取り扱う作業が容易に行える。
【００５３】
次に、第７及び第８の各実施形態の長尺材Ｓ_７，Ｓ_８及びそれらの中間材Ｓ_７’，Ｓ_８’と、その製造方法について説明する。図２２及び図２４は、第７及び第８の各実施形態における各切断線ＳＬ_７，ＳＬ_８を図示した各中間材Ｓ_７’，Ｓ_８’の斜視図であって、図２３及び図２５は、前記各中間材Ｓ_７’，Ｓ_８’から得られる第７及び第８の各実施形態の一対の長尺材Ｓ_７，Ｓ_８の各斜視図である。各長尺材Ｓ_７，Ｓ_８は、少なくともその一部分が金属材料で形成されている点で、他の実施形態と異なっている。
【００５４】
まず、第７実施形態の長尺材Ｓ_７は、長尺な帯板状の本体部７１の裏面に、長手方向に沿って側方に突出する薄板形状の取付板部７２が、自身の幅間隔をおいて形成された長尺材であって、被取付体への取付部となるべき取付板部７２は、被取付体への取付状態において上側に配置する本体部７１の上端部と連続し、ほぼ直角をなして一体に形成されている。各取付板部７２の全てと本体部７１の取付状態において上下方向に沿った大部分とは、スチールストリップ材料をロール成形して形成されていて同一の板厚を有しており、本体部７１のこのストリップ部７１ｓは、上端及び下端に配置する各部分が丸みを有するように裏面側に折り曲げて形成されている。ストリップ部７１ｓの各折曲部分は、高分子可塑材料より形成された上側及び下側の各モールド部７１ｍ_１，７１ｍ_２に、表側から半円弧状に長手方向に沿って覆われていて、ストリップ部７１ｓと上側及び下側の各モールド部７１ｍ_１，７１ｍ_２がそれぞれ一体化している。二本の長尺材Ｓ_７を得るための中間材Ｓ_７’は、前記本体部７１と同一形状の第１及び第２の各本体部形成予定部７１ａ’，７１ｂ’が、前記取付板部７２に対応する取付板部形成予定部７２’を介して一体に形成された形状であって、各本体部形成予定部７１ａ’，７１ｂ’は、横断面視において、取付板部形成予定部７２’の幅方向の中心を通る反転対称線Ｃ_７を中心にして反転対称に配置するように形成されている。
【００５５】
前記中間材を形成するには、まず、中間材Ｓ_７’の前記取付板部形成予定部７２’、及び一対の各本体部形成予定部７１ａ’，７１ｂ’の各ストリップ部形成予定部７１ｓ’に対応する形状の第１中間成形品（図示せず）を、スチールストリップ材料でロール成形する。ロール成形は、前記共押出成形と同様にゆっくりと行えるので、第一中間成形品の形状のバランス及び正確性を維持できる。次に、前記第１中間成形品が供給される押出成形型において、第１中間成形品の前記各ストリップ部形成予定部７１ｓ’の丸みを有する上下の各端部の表面に、上側及び下側の各モールド部形成予定部７１ｍ_１’，７１ｍ_２’を形成する溶融樹脂を押し出して一体化し、第２中間成形品を成形する。押出成形もゆっくりと行えるので、第１中間成形品に対する一対の各モールド部７１ｍ_１，７１ｍ_２の形状の変動を小さくでき、その結果正確な形状の中間材Ｓ_７’が形成され易くなっていて、しかも中間材Ｓ_７’を形成するための各装置の設置面積は縮小可能となる。中間材Ｓ_７’の分離工程における切断線ＳＬ_７は、片側の長尺材Ｓ_７の各取付板部７２が、その両側面において他方側の長尺材Ｓ_７の各取付板部７２と互いに隣接した状態に対応した線であって、中間材Ｓ_７’の取付板部形成予定部７２’を長手方向に沿って切断して二分すると、各取付板部７２の間に不要部が生じずに、同一の二本の長尺材Ｓ_７が同時に形成される。
【００５６】
次に、第８実施形態の長尺材Ｓ_８は、長尺な板形状の本体部８１の裏面であって、その高さ方向の中央より僅かに上方に、長手方向に沿ってほぼ直角に側方に突出する取付板部８２が、自身の幅間隔をおいて形成された長尺材である。長尺材Ｓ_８は、全体に亘ってほぼ同一の板厚を有するアルミニウム材料で形成されている。一対の長尺材Ｓ_８を得るための中間材Ｓ_８’は、前記本体部８１と同一形状の第１及び第２の各本体部形成予定部８１ａ’，８１ｂ’が、前記取付板部８２に対応する取付板部形成予定部８２’を介して一体に形成されおり、各本体部形成予定部８１ａ’，８１ｂ’は、横断面視において、取付板部形成予定部８２’の幅方向の中心を通る折返し対称線Ｃ_８に対して折返し対称に配置する略Ｈ字形状をなしている。この中間材を形成するには、アルミニウム合金のビレットを熱間（又は温間）押出成形することによって容易に所定の横断面形状を有する中間材を形成することができる。
【００５７】
上述した各実施形態の各中間材を形成する工程においては、中間材が、長尺材の整数倍の長さを有する場合について例示したが、前記整数が「１」であって、切断機等にて一本の長尺材の全長に対応する長さに中間成形品を切断して中間材を形成し、一つの中間材から実質的に同一の二本の又は対称の各一本の長尺材のみを同時に得る方法でも構わない。中間材を分離する工程においては、長尺材の整数倍の長さを有する中間材を長手方向に沿って切断して二分すると共に、長手方向に沿って一本の長尺材の全長に対応する長さに幅方向に切断する方法について例示したが、この中間材を取付板部形成予定部において、まず長手方向に沿って切断して二分した後に、二分された長尺材予定部を長手方向に沿って前記整数と同一数に幅方向に切断する方法でも構わない。なお、中間材を形成する工程は必ずしも必要ではなく、状況に応じて予め形成済みの中間材を準備した後に、分離する方法でも構わない。また、取付板部は、同一間隔でなく異なった間隔で設けられていても適用可能である。
【００５８】
【発明の効果】
本発明によれば、中間材は、前記取付部形成予定部において、二本の長尺材のそれぞれの各取付部が、長手方向で交互に形成されるように切断されるので、従来の製造方法による一本のスポイラの隣合う取付板部の間に生じる不要部の発生量と比較すると、二本の長尺材の同一位置に配置される取付部の分だけ、不要部を減少させて長尺材を製造できる。
【図面の簡単な説明】
【図１】本発明の方法により製造されたスポイラＳ_１と、これが取付けられるフロントバンパＢの左側半分を示す部分斜視図である。
【図２】スポイラＳ_１の平面図である。
【図３】スポイラ取付溝１で水平に切断した時のバンパＢとスポイラＳ_１との関係を示す部分平面図である。
【図４】バンパＢにスポイラＳ_１が取付けられた状態における図２のＸ_１−Ｘ_１線拡大断面図である。
【図５】同様の状態の図２のＸ_２−Ｘ_２線拡大断面図である。
【図６】スポイラＳ_１となる前の中間材Ｓ_１’の斜視図である。
【図７】中間材Ｓ_１’の横断面図である。
【図８】中間材Ｓ_１’の切断線ＳＬを示す平面図である。
【図９】中間材Ｓ_１’を切断分離させて同一の二本のスポイラＳ_１が形成される状態を示す平面図である。
【図１０】形成された同一の二本のスポイラＳ_１の斜視図である。
【図１１】中間材Ｓ_１’を形成する工程を示す図である。
【図１２】第２実施形態のバンパスポイラを構成する右側及び左側の各スポイラＳ_２１，Ｓ_２２を示す平面図である。
【図１３】中間材Ｓ_２’を切断分離させて一対のスポイラＳ_２１，Ｓ_２２が形成される状態を示す平面図である。
【図１４】第３実施形態における二本のスポイラＳ_３を製造するための中間材Ｓ_３’の斜視図である。
【図１５】中間材Ｓ_３’を切断分離させて同一の二本のスポイラＳ_３が形成される状態を示す平面図である。
【図１６】第４実施形態における各切断線ＳＬ_４を図示した中間材Ｓ_４’の斜視図である。
【図１７】中間材Ｓ_４’から得られる第４実施形態の一対の長尺材Ｓ_４の斜視図である。
【図１８】第５実施形態における各切断線ＳＬ_５を図示した中間材Ｓ_５’の斜視図である。
【図１９】中間材Ｓ_５’から得られる第５実施形態の一対の長尺材Ｓ_５の斜視図である。
【図２０】第６実施形態における各切断線ＳＬ_６を図示した中間材Ｓ_６’の斜視図である。
【図２１】中間材Ｓ_６’から得られる第６実施形態の一対の長尺材Ｓ_６の斜視図である。
【図２２】第７実施形態における各切断線ＳＬ_７を図示した中間材Ｓ_７’の斜視図である。
【図２３】中間材Ｓ_７’から得られる第７実施形態の一対の長尺材Ｓ_７の斜視図である。
【図２４】第８実施形態における各切断線ＳＬ_８を図示した中間材Ｓ_８’の斜視図である。
【図２５】中間材Ｓ_８’から得られる第８実施形態の一対の長尺材Ｓ_８の斜視図である。
【符号の説明】
Ｂ：バンパ（被取付体）
Ｃ_１，Ｃ_７：反転対称線（幅方向中心）
Ｃ_３〜Ｃ_５，Ｃ_６，Ｃ_８：折返し対称線（幅方向中心線）
Ｓ_１，Ｓ_３：バンパスポイラ（長尺材）
Ｓ_２１：右側バンパスポイラ（長尺材）
Ｓ_２２：左側バンパスポイラ（長尺材）
Ｓ_４〜Ｓ_８：長尺材
Ｓ_１’〜Ｓ_８’：中間材
ＳＬ，ＳＬ_４〜ＳＬ_８：切断線（切断部）
１：スポイラ取付溝（係合部）
１１：スポイラ本体部（本体部）
４１，５１，６１，７１，８１：本体部
１１ａ’，２１ａ’，３１ａ’，４１ａ’，５１ａ’，６１ａ’，７１ａ’，８１ａ’：
第１本体部形成予定部
１１ｂ’，２１ｂ’，３１ｂ’，４１ｂ’，５１ｂ’，６１ｂ’，７１ｂ’，８１ｂ’：
第２本体部形成予定部
１２，４２，７２，８２：取付板部（取付部）
１２’，４２’，７２’，８２’：取付板部形成予定部（取付部形成予定部）
５２，６２：取付挟持部（取付部）
５２’，６２’ ：取付挟持部形成予定部（取付部形成予定部）
１３：嵌合支持部（係止部）
１３ａ’，１３ｂ’：嵌合支持部形成予定部（突条）
７１ｓ：ストリップ部（帯板状材料）[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a long material having a long body portion and a plurality of mounting portions projecting laterally from the body portion at predetermined intervals along the longitudinal direction. .
[0002]
[Prior art]
As such a long material, a portion protruding laterally from the main body portion can be used as a mounting portion to a body to be mounted, and an example of the long material is a bumper spoiler mounted on a bumper of a vehicle. it can. In order to manufacture such a bumper spoiler, the respective portions to be formed of the main body and the mounting portion are integrally extruded with a high-molecular plastic material into a constant cross-sectional shape, and the extruded product is cut into a predetermined length. Then, an intermediate material is formed, and a post-processing is performed on the intermediate material to obtain a desired spoiler. The intermediate material is partially removed at a plurality of locations where the mounting portion is to be formed, and the remaining mounting portion is to be formed as a mounting portion, and a spoiler having the mounting portions at predetermined intervals in the longitudinal direction is obtained. Can be The spoiler manufactured as described above is used in a state where the mounting portion is mounted by inserting the mounting portion into an insertion hole formed along the width direction of the bumper.
[0003]
However, in the above-mentioned manufacturing method, there is a problem that an unnecessary portion generated when a portion where the mounting portion is to be formed is partially removed at a plurality of locations is necessarily generated as an offcut.
[0004]
SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for producing a long material in which the generation of the unnecessary portion is smaller than in the conventional production method.
[0005]
[Means for Solving the Problems]
In order to solve the above-mentioned problem, the invention according to claim 1 has an elongated main body and a plurality of mounting portions projecting laterally from the main body at predetermined intervals along the longitudinal direction. A method for manufacturing a long material, comprising: a first and a second main body forming scheduled portion having the same or substantially the same cross-sectional shape and arranged symmetrically apart from each other; and the first and the second main bodies A step of preparing an intermediate material having a fixed-width mounting portion to be integrally connected to the portion-forming portion; and the intermediate portion so that the mounting portions of each long material are alternately formed in the longitudinal direction. Cutting along the longitudinal direction of the portion for forming the mounting portion of the material and separating the intermediate material to a predetermined length, thereby forming a plurality of substantially identical or symmetrical long materials. It is characterized by being obtained at the same time.
[0006]
According to the first aspect of the present invention, it is possible to reduce the amount of unnecessary portions (cut pieces) per long piece generated when the long piece is obtained by cutting the intermediate piece. Further, by cutting and separating one intermediate member, a plurality of long members having the same shape or a symmetric shape can be obtained, so that the production efficiency of the long members is improved.
[0007]
Further, the invention according to claim 2 is a method for manufacturing a long material having a long main body portion and a plurality of mounting portions projecting laterally from the main body portion at predetermined intervals along the longitudinal direction. A method, wherein a first and a second main body portion to be formed, which are arranged symmetrically apart from each other and have the same or substantially the same cross-sectional shape, and the first and the second main body portion to be formed are integrally connected. A step of forming an intermediate material having an attachment portion forming portion having a fixed width, and the mounting portion forming portion of the intermediate material, such that the attachment portions of the long materials are alternately formed in the longitudinal direction. Cutting along the longitudinal direction to separate the intermediate material into a predetermined length to obtain substantially the same or symmetrical long material at the same time.
[0008]
According to the second aspect of the present invention, since the cross-sectional shape of the intermediate member is formed symmetrically, the intermediate member can be formed in a well-balanced manner at the time of forming the intermediate member. It is possible to reduce the amount of unnecessary portions (cut pieces) per long material generated when a long material is obtained by cutting from the intermediate material. Further, by cutting and separating one intermediate member, a plurality of long members having the same shape or a symmetric shape can be obtained, so that the production efficiency of the long members is improved.
[0009]
According to a third aspect of the present invention, in the first or second aspect of the present invention, the intermediate member has a length that is an integral multiple of the long member, and the intermediate member is formed in a longitudinal direction at a portion where the mounting portion is to be formed. After cutting along and bisecting, the bisected long material portion is cut to a predetermined length, or after cutting the long material scheduled portion to a predetermined length, the intermediate material is scheduled to be attached portion formation. It is characterized in that it is cut along the longitudinal direction at the portion and bisected.
[0010]
According to the third aspect of the present invention, in addition to the effects of the first or second aspect of the present invention, two long members can be formed from one intermediate member in the set of integers, thereby increasing the production efficiency.
[0011]
According to a fourth aspect of the present invention, in the method of any one of the first to third aspects, in the step of separating the intermediate member, the two main body portion forming portions have the same length, It is characterized in that the terminal positions are shifted from each other along the direction and cut in the width direction.
[0012]
According to the invention of claim 4, in addition to the effect of any one of the inventions of claims 1 to 3, the amount of unnecessary portions (cut pieces) generated when forming a long material from the intermediate material is further reduced. Decrease.
[0013]
According to a fifth aspect of the present invention, in any one of the first to fourth aspects of the invention, the intermediate member is line-symmetric with respect to a center line in a width direction of a portion where the mounting portion is to be formed. It is characterized by.
[0014]
For example, when long members are used as various trim members attached to both sides of a vehicle, a pair of long members having a symmetrical shape with respect to the left and right lines is required. According to the fifth aspect of the present invention, in addition to the effect of any one of the first to fourth aspects of the present invention, in the separation step, the formation of the mounting portion of the intermediate material whose line cross-sectional view is line-symmetric (folding symmetry). When the planned portion is cut along the longitudinal direction and bisected, a pair of long members symmetrical with respect to the left and right lines can be easily formed. Then, in preparation for post-processing and sorting corresponding to the left and right, for example, it is easy to move each long material in parallel in a direction opposite to the direction in which both members face each other, and to handle them individually.
[0015]
According to a sixth aspect of the present invention, in any one of the first to fourth aspects of the present invention, the intermediate member is point-symmetric with respect to the center in the width direction of the portion where the mounting portion is to be formed in a cross-sectional view. And
[0016]
According to the invention of claim 6, in addition to the effect of any of the inventions of claims 1 to 4, in the separation step, the mounting portion forming portion of the intermediate material is point-symmetrical (reversal symmetry) in the cross-sectional view. The work of turning the long material on one side, which is divided into two by cutting along the longitudinal direction, by 180 ° and a half around the axis along the longitudinal direction, and projecting the same two long materials In a state where the directions are aligned, it is easy to handle them collectively. In this case, since there is no need to consider the operation of rotating and moving the long material on one side after the separation in the same plane, the work area of the production line can be reduced and the production efficiency can be maintained.
[0017]
According to a seventh aspect of the present invention, in any one of the first to sixth aspects, the intermediate material is extruded from a high-molecular plastic material such as rubber, resin, or elastomer using an extrusion mold. It is characterized by.
[0018]
According to the invention of claim 7, in addition to the effect of any of the inventions of claims 1 to 6, at least two long members are formed from one intermediate member. At least nearly double production per hour. That is, even if the extrusion molding takes almost twice as long and the molding speed is reduced, it is possible to maintain the same production volume as the conventional method. In this case, a change in the shape of the intermediate material during extrusion molding is reduced, and an intermediate material having an accurate shape is easily obtained. Further, in the extrusion molding of rubber or resin, the length of each device for vulcanization or cooling after extrusion is not increased, so that not only the installation area of each device can be reduced, but also the thermal efficiency is improved.
[0019]
An eighth aspect of the present invention is characterized in that, in any one of the first to sixth aspects of the invention, the intermediate material is extruded from a light metal material using an extrusion mold.
[0020]
According to the eighth aspect of the present invention, in addition to the effects of any one of the first to sixth aspects of the present invention, only the light metal is used as a material for forming the intermediate material instead of the high-molecular plastic material. The invention is different from that of the invention described above, and it is possible to prevent the elongation after the extrusion and the lengthening of the equipment in the linearization step.
[0021]
According to a ninth aspect of the present invention, in any one of the first to sixth aspects, the intermediate member is roll-formed from a strip-shaped material having a predetermined width into a predetermined cross-sectional shape.
[0022]
According to the ninth aspect of the invention, in addition to the effect of any one of the first to sixth aspects, for the same reason as the operation and effect of the seventh aspect, while maintaining a production amount equivalent to that of the conventional method, Roll forming speed can be reduced. Therefore, it is easy to obtain an intermediate material having an accurate shape while maintaining the balance of the shape of the intermediate material at the time of roll forming, and the installation area of each device such as a forming machine can be reduced.
[0023]
In a tenth aspect of the present invention, in any one of the first to sixth aspects, the intermediate material is a core material having a predetermined cross-sectional shape made of a hard material, and a polymer extruded on the core material. It is characterized by being composed of both plastic materials.
[0024]
According to the tenth aspect, in addition to the effects of any one of the first to sixth aspects, for the same reason as in the seventh and ninth aspects, the variation and balance of the shape of the intermediate member is reduced or maintained. As a result, an intermediate material having an accurate shape can be easily obtained, and the installation area of each device such as a molding machine can be reduced.
[0025]
According to an eleventh aspect of the present invention, in the invention of any one of the first to tenth aspects, the step of separating the portion where the mounting portion is to be formed is performed by a cutting method using a press die or a concentrated energy means. Features.
[0026]
According to the eleventh aspect of the present invention, in addition to the effect of any one of the first to tenth aspects, in the method of cutting with a press die, the intermediate material can be efficiently separated in a short time. In addition, a cutting method using a concentrated energy means such as fusing by a laser beam or cutting by a water jet can increase the degree of freedom of a cutting shape of a portion where a mounting portion is to be formed, and is suitable for small-lot production of many types.
[0027]
According to a twelfth aspect of the present invention, in any one of the first to eleventh aspects, the elongated member is a member to be attached to a member to be attached, and the portion where the intermediate member is to be formed has a longitudinal portion. A ridge that is formed integrally with the ridge that is continuous along the direction, and the ridge of the long material is locked to the engagement portion of the attached body after the portion where the mounting portion is to be formed is separated. It is characterized by becoming.
[0028]
According to the twelfth aspect of the invention, in addition to the effect of any one of the first to eleventh aspects, by separating the mounting portion forming scheduled portion, a separate locking portion forming step is not required, A locking portion is formed.
[0029]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described in more detail with reference to a plurality of embodiments. First, a bumper spoiler (hereinafter may be simply abbreviated as “spoiler”) S of the first embodiment manufactured by the method of the present invention. ₁ And spoiler S for front bumper B ₁ Will be described briefly, and thereafter, the spoiler S according to the present invention will be described. ₁ A method of manufacturing the device will be described. FIG. 1 shows a spoiler S manufactured by the method of the present invention. ₁ FIG. 2 is a partial perspective view showing a left half of a front bumper B to which the spoiler is attached. ₁ FIG. 3 is a plan view of a bumper B and a spoiler S. ₁ 4 and 5 are partial plan views showing the relationship between the spoiler S and the bumper B. ₁ X in FIG. 2 in a state where ₁ -X ₁ Line and X ₂ -X ₂ It is a line expanded sectional view.
[0030]
As shown in FIGS. 1 and 2, the spoiler S ₁ Has a length corresponding to the bumper B of the vehicle to which it is attached, and has a left-right center line C in the width direction of the front of the vehicle. ₁₁ (See FIGS. 1 and 2) A substantially plate-shaped spoiler main body 11 which is symmetrical with respect to the left and right and is arranged substantially vertically in a state mounted on the bumper B; The spoiler has a plurality of substantially plate-like mounting plate portions 12, 12 which are substantially plate-shaped and protrude from the upper end portion of the spoiler body portion 11 toward the rear surface side (rearward of the vehicle). The plurality of mounting plate portions 12 are provided integrally at predetermined intervals along the longitudinal direction of the spoiler main body portion 11. On the back side of the spoiler main body 11, a fitting support portion 13 fitted in the spoiler mounting groove 1 of the bumper B is provided over the entire length in the longitudinal direction. It is formed integrally on the back side of the support portion 13. The fitting support portion 13 is thicker than each of the mounting plate portions 12 and is formed in a trapezoidal cross section (tapered shape) such that the thickness away from the spoiler body portion 11 is reduced. Spoiler S caused by temperature change ₁ A tape-shaped core member 14 (see FIGS. 4 and 5) for preventing expansion and contraction in the longitudinal direction is embedded over the entire length. The core 14 is preferably made of a material that is higher in rigidity than the materials of the spoiler main body 11 and the mounting plate 12 and has a small elasticity, for example, a steel strip (metal strip).
[0031]
A plurality of mounting plate insertion holes 3 are formed at predetermined intervals in the longitudinal direction of the mounting groove bottom wall 2 constituting the spoiler mounting groove 1 of the bumper B. ₁ The respective mounting plate portions 12 are inserted into the respective mounting plate portion insertion holes 3 to be in a state of being superimposed on the upper surface of the bumper bottom wall plate portion 4. Spoiler S ₁ The shape of the mounting plate portion 12 is such that the base portion neck portion 12a has a constant width, and gradually widens from the neck portion 12a toward the distal end (free end). It is formed in a shape that is gradually narrowed from the maximum width portion toward the tip. At both ends in the width direction of the mounting plate 12, deformation assisting grooves 12 b are provided in the front-rear direction to assist the deformation when the mounting plate 12 is inserted into the mounting plate insertion hole 3 of the bumper B and to prevent the mounting plate 12 from coming out. Is formed along. Further, a spoiler S with respect to the bumper B is provided at the tip of the mounting plate portion 12. ₁ With spoiler S ₁ When the mounting plate portion 12 of the bumper B is inserted through the mounting plate portion insertion hole 3 of the bumper B, a fixing tool insertion hole 12c that matches the fixing tool insertion hole 5 of the bottom wall plate portion 4 of the bumper B is formed. The spoiler S ₁ The width of the maximum width part, the tip part (free end part), and the width of the neck part 12a of ₁₁ , W ₁₂ , W _Thirteen And the inner width of the mounting plate insertion hole 3 of the bumper B is W ₁₄ Then, between these, (W ₁₄ > W ₁₂ , W ₁₄ <W ₁₁ , W ₁₄ ≤W _Thirteen ) Is set to satisfy the relationship. The thickness of the mounting groove bottom wall 2 of the bumper B and the thickness of the neck 12a of the mounting plate 12 are respectively t ₁ , T ₂ Then (t ₁ ≒ t ₂ ) Is set to satisfy the relationship. In addition, the gap between adjacent mounting plate portions along the longitudinal direction requires a gap that can be formed by the mounting plate portion of the other spoiler, and this gap is the maximum width portion W ₁₁ Is set not to fall below.
[0032]
The spoiler main body 11 is formed of a material that is softer and more elastically deformable than the mounting plate 12 and the fitting support 13, for example, a soft TPE resin (preferably JIS K 7215 durometer hardness HDA 70 ° or less) and mounted. The plate portion 12 and the fitting support portion 13 are harder and more rigid than the spoiler main body portion 11, and are made of an elastically deformable rubber or a synthetic resin material such as a PP resin or a hard TPE resin (preferably JIS K 7215 durometer hardness HDD50). ° or more), and the joint portion 15 (see FIG. 4) of the two portions is integrally combined by welding at the time of co-extrusion molding of both portions. The material of the above-mentioned TPE (thermoplastic elastomer) is not particularly limited, and for example, a vinyl-based TPE, an olefin-based TPE (hereinafter, simply referred to as “TPO”), a styrene-based TPE, and the like can be applied. It is preferable to use TPO from the viewpoint of weight reduction and environmental protection. That is, Spoiler S ₁ When the main body 11, the mounting plate 12, and the fitting support 13 are molded by TPO, the spoiler S ₁ When the waste is no longer needed and disposed of, it can be incinerated and has the advantage that no toxic gas is generated. Further, as a material other than the TPE, a soft rubber is used for the spoiler main body 11, and a rubber material harder than the main body 11 is used for the mounting plate 12 and the fitting support 13, and EPDM is also preferable. one of.
[0033]
Spoiler S against bumper B ₁ The installation is performed as follows. First, each of the mounting plate portions 12 integrally provided on the back surface side of the spoiler main body portion 11 is inserted into each of the mounting plate portion insertion holes 3 provided at the back of the spoiler mounting groove 1 of the bumper B, and S ₁ Is fitted in the spoiler mounting groove 1 of the bumper B. Spoiler S ₁ During the insertion, each of the mounting plate portions 12 is elastically deformed so as to have a reduced width by the action of the deformation assisting groove 12b, and is restored to its original shape after being inserted. Spoiler S inserted through insertion hole 3 ₁ The mounting plate portion 12 does not come off. Thereby, the spoiler S with respect to the bumper B ₁ Is temporarily fixed. In the bent portion of the corner portion of the bumper B, the spoiler S follows this bend. ₁ Of the spoiler S by bending the mounting plate portion 12 into the mounting plate portion insertion hole 3 of the bumper B while bending the spoiler S. ₁ Is temporarily fixed to the bumper B over its entire length in a slightly curved state following the plane shape of the bumper B.
[0034]
Finally, as shown in FIG. 4, the spoiler S is attached to the bottom wall plate portion 4 of the bumper B by using a fixing tool 6 such as a clip. ₁ Are fixed. That is, the spoilers S overlapping each other ₁ The fixing tool 6 is inserted into the fixing tool insertion holes 12c and 5 of the bumper bottom wall plate part 4, and the head is crimped. The spoiler S ₁ In the mounting state (1), the resilient lip 16 integrally formed from the upper end of the spoiler main body 11 toward the oblique front side elastically contacts the lower surface of the mounting groove upper side wall 7 of the bumper B to perform a sealing action.
[0035]
Next, the spoiler S according to the present invention ₁ A method of manufacturing the device will be described. FIG. 6 shows the spoiler S ₁ Intermediate material S before becoming ₁ 7 is a perspective view of FIG. ₁ 8 is a cross-sectional view of FIG. ₁ 9 is a plan view showing a cutting line SL of FIG. ₁ 'To separate two identical spoilers S ₁ FIG. 10 is a plan view showing a state in which the same spoiler S is formed. ₁ It is a perspective view of. Intermediate material S ₁ As shown in FIG. 6 and FIG. 7, the first and second main body forming scheduled portions 11a ′ and 11b ′ of the same shape arranged so as to be separated from each other and to be inversion symmetry (point symmetry). , A long shape integrally connected via a mounting plate portion forming portion 12 ′, and formed by co-extrusion molding described later. The width W of the mounting plate portion forming scheduled portion 12 ' ₁ Is Spoiler S ₁ Length L of each mounting plate 12 constituting ₂₁ The protruding length L of the two fitting support portions 13 ₂₂ Dimension [L ₂₁ + (2 × L ₂₂ )] (See FIG. 3). Here, the planned body portion forming portions 11a ′ and 11b ′ are formed by an inversion symmetrical line C passing through the center in the width direction of the mounting plate portion forming planned portion 12 ′. ₁ Are arranged symmetrically with respect to the center. Therefore, in FIG. 7, the main body forming portions 11 a ′ and 11 b ′ are indicated by the inverted symmetry line C. ₁ When they are inverted about each other, they are in a mutually overlapping relationship. 6 and 7, reference numerals 13a 'and 13b' denote fitting support portion forming portions formed on the mounting plate portion forming portion 12 ', and 16a' and 16b 'denote elastic lip forming portions. And the respective inversion symmetry lines C ₁ Are arranged symmetrically with respect to the center.
[0036]
Then, as shown in FIG. ₁ ′ Is punched out by a press blank mold (not shown) to cut and separate two identical spoilers S. ₁ , S ₁ To form That is, Spoiler S ₁ Total length (L ₁ ) Corresponds to the length of the bumper B to which it is attached, one of which is used independently, and the inverted symmetry line C at the center in the longitudinal direction. ₁ Have the same shape. Therefore, the intermediate material S ₁ 'And cut two identical spoilers S ₁ In order to increase the material yield when forming the main body, the main body forming portions 11a 'and 11b' which are reversed are arranged at a predetermined length (L) along the longitudinal direction. ₁₁ ) It is cut only by shifting. Also, the intermediate material S ₁ 'Means that two identical spoilers S formed by cutting this ₁ The mounting plate portions 12 arranged at the same position are in contact with each other and are adjacent to each other, and are cut in a state in which the generation of unnecessary portions (cut materials) therebetween is smaller than in the related art.
[0037]
Therefore, the intermediate material S ₁ 'Is cut along a cutting line SL shown in FIG. 8, and the mounting plate portion forming scheduled portion 12' is cut along the longitudinal direction and bisected, as shown in FIG. Two types of unnecessary parts D ₁ , D ₂ (Except for the deformation auxiliary groove 12b and the fixing tool insertion hole 12c) in the state where the ₁ Are simultaneously formed. The spoiler S ₁ The deformation auxiliary groove 12b and the fixing tool insertion hole 12c formed in each mounting plate portion 12 ₁ Is formed at the same time as the cutting or in a later step. Also, two spoilers S immediately after cutting ₁ Has two spoilers S by inverting one of them at that position. ₁ Of the spoiler S after cutting is the same. ₁ Is easy to handle. The spoiler S ₁ The auxiliary deformation groove 12b formed in the mounting plate portion 12 is not shown except in FIG.
[0038]
Next, Spoiler S ₁ Intermediate material S ₁ 'Will be described. FIG. 11 shows the intermediate material S ₁ Is a view showing a process of manufacturing the intermediate material S. ₁ Is co-extruded in an extrusion mold 22. The extrusion mold 22 is provided with first and second resin supply paths 22a and 22b for supplying soft and hard TPE molten resins to the inside while applying a predetermined extrusion pressure. Each of the soft and hard TPE molten resins is an intermediate material S ₁ ′, The first and second main body portion forming portions 11a ′ and 11b ′ and the resilient lip forming portions 16a ′ and 16b ′, and the mounting plate portion forming portion 12 ′ and the fitting support portion forming portion 13a. ', 13b'.
[0039]
In order to form the intermediate material, first, the two steel strips 21a forming the core material 14 are unwound from the core material uncoiler 21 and supplied in the downstream direction P. (Not shown) to continuously supply the inside. The steel strip 21 a is covered with a hard TPE molten resin inside the extrusion mold 22, and the mounting plate is formed while forming portions corresponding to the fitting support forming portions 13 a ′ and 13 b ′. It is extruded in the downstream direction P together with the molten resin in a portion corresponding to the portion 12 ′. Further, the hard TPE molten resin merges with the soft TPE molten resin that is extruded together to form a portion corresponding to the joining portion 15, and a fitting support projecting in a tapered shape at the mounting plate portion forming scheduled portion 12 '. The molten resin in a state where the portion-to-be-formed portions 13a ', 13b' and the pair of first and second body-portion-to-be-formed portions 11a ', 11b' are joined together is extruded. Thus, the intermediate material S ₁ Extruded product S co-extruded with each resin material of TPE having the same cross-sectional shape and different hardness ₁ '' Is extruded downstream from the opening, which is the outlet of the extrusion mold 22.
[0040]
Next, the extruded product S ₁ '' Is further taken downstream from the extrusion mold 22 and supplied to a cooling device 23 to be cooled. Extruded product S cooled and kept near normal temperature ₁ '' Is further taken by a take-off device 24 on the downstream side of the cooling device 23, and a predetermined length (≧ spoiler S ₁ Total length L ₁ Of the intermediate material S ₁ 'Is formed.
[0041]
As described above, a plurality of long members (spoilers) are formed from one intermediate member formed according to the present invention, so that the output per unit time is doubled when the extrusion speed is the same. In the case where the conventional predetermined production amount per unit time is maintained, the co-extrusion molding speed can be reduced. Therefore, in the above-mentioned co-extrusion molding step, the intermediate material S inside the extrusion mold 22 is formed. ₁ The shape corresponding to each part of 'can be held more accurately, so that the shape of the extruded product ₁ '' Is obtained. Moreover, the intermediate material S ₁ Is a reversal symmetric shape in which its own center of gravity coincides with the reversal center, so that it can be extruded from the extrusion mold 22 in a well-balanced manner and taken downstream, and the intermediate material S that more accurately reflects the design shape ₁ 'Is obtained. Further, since the co-extrusion molding can be performed relatively slowly, the installation area can be reduced without increasing the length of the cooling device 23.
[0042]
Next, the formed intermediate material S ₁ A process of cutting and separating the 'attachment plate portion forming scheduled portion 12' along the longitudinal direction is performed. Intermediate material S ₁ Is cut along the cutting line SL at the mounting plate portion forming portion 12 'as described above, and is divided into two portions, and the two main body portion forming portions 11a' and 11b 'have the same length. To one spoiler S ₁ Total length L ₁ , And set the terminal positions to each other along the longitudinal direction by a predetermined length (L ₁₁ ) And cut in the width direction (see FIG. 9), and the same two spoilers S facing each other in the width direction. ₁ But one intermediate material S ₁ ', The integer set is obtained along the longitudinal direction. Since the fitting support portion forming portions 13a 'and 13b' projecting in a tapered shape are continuously and integrally formed in the mounting plate portion forming portion 12 'along the longitudinal direction, as described above. At the same time as the intermediate material is cut, each spoiler S ₁ Is formed with the fitting support portion 13 which is fitted and locked in the spoiler mounting groove 1 of the bumper B. Intermediate material S ₁ Is cut out by punching with a press blank mold, so that this separating operation can be performed efficiently in a short time, and at the same time, a pair of integer pairs having a fitting support portion 13 to be a locking portion to the bumper B. Book spoiler S ₁ As a result, the production efficiency is increased.
[0043]
Intermediate material S ₁ ′ Indicates two spoilers S in the mounting plate portion forming scheduled portion 12 ′. ₁ Are cut so that the respective mounting plate portions 12 are adjacent to each other in contact with each other and are alternately formed in the longitudinal direction, and thus are generated between the adjacent mounting plate portions of one spoiler according to the conventional manufacturing method. Compared to the amount of unnecessary parts, two spoilers S ₁ The unnecessary portion is reduced by the amount of the mounting plate portion 12 arranged at the same position. Further, the intermediate material S ₁ Are two spoilers S facing each other in the width direction in the respective main body portion forming scheduled portions 11a and 11b '. ₁ The terminal of each of the main bodies 11 has a predetermined length (L ₁₁ ), So that unnecessary portions generated between the next two spoilers adjacent in the longitudinal direction are reduced. In the present embodiment, the predetermined length (L ₁₁ ) Is two spoilers S ₁ The mounting plate portions 12 arranged at both ends are alternately adjacent to each other and are determined in accordance with the size shifted in the longitudinal direction.
[0044]
One side spoiler S immediately after cutting ₁ Is turned upside down at that position, and the other side spoiler S ₁ And the mounting plate portion 12 in the same projecting direction, and at the same time ₁ Collected with. In this case, the one side of the elongated spoiler S ₁ Need not be rotated in the same plane, so that the collecting operation can be easily performed. Spoiler S collected ₁ Are collected with similar spoilers formed from other intermediate materials, one spoiler S each. ₁ Is used by being attached to a bumper B in a vehicle assembling process.
[0045]
Next, the bumper spoiler of the second embodiment and its intermediate material S ₂ 'And the manufacturing method thereof will be described. In addition, in each part of the other embodiments of the first embodiment described below, the same parts as those described above are denoted by the same reference numerals, and are different from those of the first embodiment. It is mainly explained and illustrated. The terms “right” and “left” in the second embodiment are used as directions along the width direction of the vehicle and correspond to directions when the occupant faces the traveling direction. FIG. 12 shows right and left spoilers S constituting the bumper spoiler of the second embodiment. ₂₁ , S ₂₂ FIG. Each spoiler S ₂₁ , S ₂₂ Are used as a pair as a spoiler (long material), and have a total length of about half of a length corresponding to the bumper B of the vehicle to be mounted, respectively, and are respectively a right half and a left half of the bumper B. Installed in half. Right and left spoilers S ₂₁ , S ₂₂ Each of the spoiler main bodies 11 is formed with the five mounting plate parts 12 at the same intervals. Each of the mounting plate portions 12 disposed at both ends of the spoiler main body 11 along the longitudinal direction is formed so that dimensions calculated from each end face of the spoiler main body 11 are different. As shown, each of the right and left spoilers S ₂₁ , S ₂₂ End faces 17a on one side (disposed on the right side in the mounted state) and on the other side (disposed on the left side in the mounted state) of each spoiler body 11 ₁ , 17b ₂ Are formed at the same position, and the other end surface 17a on the other side and one side ₂ , 17b ₁ The formation positions of the respective mounting plate portions 12 starting from are the same. Therefore, both spoilers S ₂₁ , S ₂₂ Although the overall shape is different from each other, when inverted with respect to a folded symmetrical line (not shown), the formation position along the longitudinal direction of the mounting plate portion 12 with respect to the spoiler main body portion 11 is slightly shifted. It is a pair of long materials. Both spoilers S ₂₁ , S ₂₂ Is the right spoiler S ₂₁ The other end face 17a ₂ And left spoiler S ₂₂ The end face 17b on one side ₁ And the right and left center lines C of the bumper B. ₂₁ (See FIG. 1). A vehicle number plate or the like is attached to the center of the bumper B, and the actual spoilers S ₂₁ , S ₂₂ Is shorter than half the length of the corresponding bumper B, but for convenience of explanation, about half (L ₁ / 2).
[0046]
Next, each of the right and left spoilers S ₂₁ , S ₂₂ Will be described simultaneously. Each spoiler S ₂₁ , S ₂₂ Intermediate material S having a total length of an integral number of ₂ 'Shape and intermediate material S ₂ Is formed by the intermediate material S of the first embodiment. ₁ (See FIGS. 6 and 11), and in the second embodiment, the next intermediate material S ₂ Only the cutting line in the step of separating 'differs. FIG. 13 shows the intermediate material S ₂ 'Is cut and separated to form a pair of spoilers S ₂₁ , S ₂₂ FIG. 4 is a plan view showing a state in which is formed. As shown, the intermediate material S ₂ By cutting the 'attachment plate portion forming scheduled portion 12' along the longitudinal direction, the cutting line (not shown) for forming each of the attachment plate portions 12 is the same as in the first embodiment. There is an intermediate material S ₁ The terminal positions of the first and second main body forming portions 11a 'and 11b' of the ' ₁₁ ) Is eliminated, and instead a cutting line parallel to the width direction is obtained.
That is, in the second embodiment, the intermediate material S ₂ Is cut in the longitudinal direction by cutting the mounting plate portion forming scheduled portion 12 ′, and the terminal positions of the first and second main body forming scheduled portions 11 a ′ and 11 b ′ extend in the longitudinal direction. The entire length (L ₁ / 2) is cut in the width direction. When cut and separated, the end faces 17a on one side of each of the pair of spoiler main bodies 11 are formed. ₁ , 17b ₁ And the other end face 17a ₂ , 17b ₂ A pair of spoilers S with the terminal positions of ₂₁ , S ₂₂ Is obtained. Obtained pair of spoilers S ₂₁ , S ₂₂ Is a symmetrical shape, and the left spoiler S after cutting is ₂₂ Is turned upside down at that position and the right spoiler S ₂₁ After collecting both separately, they are attached to the bumper B respectively.
[0047]
Next, in the third embodiment, the spoiler S of the second embodiment is used. ₂₁ And two spoilers S, one of which is used independently. ₃ With the intermediate material S of each of the above-described embodiments. ₁ Intermediate material S with shape different from ' ₃ Here is an example of how to get from FIG. 14 shows two spoilers S ₃ Material S for producing ₃ It is a perspective view of '. As shown, the intermediate material S ₃ ′ Is a folded symmetry in which a pair of first and second main body forming portions 11a ′ and 11b ′ having the same shape and arranged apart from each other pass through the center in the width direction of the mounting plate forming portion 12 ′. They are arranged in reverse symmetry about a plane (not shown), and are formed by co-extrusion similarly to the above-described embodiments. Each of the main body portions 11 a ′ and 11 b ′ is formed by an intermediate material S ₃ In the cross-sectional view of ′, the folded symmetrical line C of the mounting plate forming portion 12 ′ is attached to itself. ₃ When the left and right sides are inverted with respect to the (center line in the width direction), the end faces 17 'of the main body forming portions 11a' and 11b 'are arranged so as to overlap each other. FIG. 15 shows the intermediate material S ₃ 'And two spoilers S of the same shape ₃ FIG. 9 is a plan view showing a state in which a is obtained. As shown, the intermediate material S ₃ The cutting line in the step of separating 'is the same as in the second embodiment, ₃ 'Is cut into two parts by cutting the mounting plate portion forming portion 12' along the longitudinal direction, and the spoiler S ₃ Total length L ₁ Two spoilers S cut in the width direction corresponding to ₃ Is manufactured.
[0048]
Next, the long material S of each of the fourth to sixth embodiments ₄ , S ₅ , S ₆ And their intermediate materials S ₄ ', S ₅ ', S ₆ 'And its manufacturing method. FIGS. 16, 18 and 20 show respective cutting lines SL in the fourth to sixth embodiments, respectively. ₄ , SL ₅ , SL ₆ Of each intermediate material S ₄ ', S ₅ ', S ₆ 17, FIG. 19, and FIG. 21 show the respective intermediate members S. ₄ ', S ₅ ', S ₆ 'And a pair of long members S of the fourth to sixth embodiments obtained from ₄ , S ₅ , S ₆ It is each perspective view of. Each long material S ₄ , S ₅ , S ₆ Are all formed of a polymeric plastic material, and their intermediate materials S ₄ ', S ₅ ', S ₆ 'Is formed by cutting each extruded product (not shown) extruded into a predetermined cross-sectional shape using an extrusion die into a predetermined length. In each of the embodiments described above, the case where the long material is formed of TPE has been described. However, the intermediate material can be similarly formed of other high-molecular plastic materials such as thermoplastic resin and rubber instead of TPE.
[0049]
First, the long material S of the fourth embodiment ₄ Is an elongated plate formed along the longitudinal direction with mounting plates 42 projecting sideways at an obtuse angle at the base end of a strip-shaped main body 41 having a hollow portion. A rubber molded product that is attached between the edge of the engine hood of the vehicle and the opening edge of the vehicle body to prevent water and dust from entering the engine room and prevent engine noise from leaking. It is. The main body portion 41 is formed of soft sponge rubber so as to have a hollow elastic contact portion 41c, and is a portion used by elastically contacting the hollow elastic contact portion 41c with an edge portion of a hood of a vehicle disposed to face an engine hood. It is. The mounting plate portion 42 is formed of hard rubber so that a base portion of the mounting plate portion 42 is continuous along the longitudinal direction, is superimposed on an edge of the engine hood, and is attached by inserting a fixing tool or the like. Part. A pair of long materials S ₄ Material S for obtaining ₄ The symbol “′” is a shape in which first and second main body portion forming portions 41 a ′ and 41 b ′ having the same shape as the main body portion 41 are integrally formed via a mounting plate portion forming scheduled portion 42 ′. The mounting plate portion forming portions 42 ′ have a width corresponding to the protruding length of the pair of mounting plate portions 42 that are opposed to each other while being alternately adjacent to each other, and each of the main body portion forming portions 41 a ′ and 41 b ′ is , A folded symmetric line C passing through the center in the width direction of the mounting plate portion forming scheduled portion 42 ′ in a cross sectional view. ₄ Is formed so as to be folded symmetrically with respect to. This intermediate material S ₄ 'In the process of separating' ₄ Is the intermediate material S ₄ 'And a pair of long materials S obtained by separating ₄ Are the lines corresponding to the state in which the mounting plate portions 42 arranged at the same position are adjacent to each other. Cutting line SL ₄ Along the intermediate material S ₄ By cutting along the longitudinal direction of the 'attachment plate portion forming portion 42' of the ' ₄ Unnecessary part D inevitably in the part surrounded by ₄ Occurs and a pair of long members S ₄ Are simultaneously formed. In addition, long material S ₄ Is made of a rubber material, the intermediate material S ₄ In the co-extrusion process, a vulcanizing device is installed instead of the cooling device. Since the co-extrusion can be performed relatively slowly, the length of the vulcanizing device does not increase. 16 and 17, reference numeral 41d denotes an extension extending from a hollow elastic contact portion 41c elastically contacting the edge of the hood in the main body portion 41, and 41c 'and 41d' denote the hollow elastic contact portion 41c and its extension. The portion to be formed of the portion 41d, 42c is a fixture insertion hole for attachment to an engine hood, and 45 is a joint between the two rubber materials.
[0050]
Next, the long material S of the fifth embodiment ₅ Is a long material in which mounting holding portions 52 protruding laterally are formed on the back surface of the rounded substantially prismatic main body portion 51 along the longitudinal direction at an interval of its own width. The mounting sandwiching portion 52 is a two-plate-shaped protruding portion in which the bases of a pair of low isosceles triangles are opposed to each other in a cross-sectional view, and opens on the opposite side to the forming direction of the main body 51. The long material S having an opening 52a is provided by sandwiching edges, which are attached bodies on both right and left sides of the vehicle, with the opening 52a. ₅ Used to attach. Most of the main body 51 disposed on the front surface in the mounted state, and a part of the main body 51 and the mounting holding portion 52 disposed on the back surface are formed of different polymer plastic materials. A pair of long materials S ₅ Material S for obtaining ₅ The first and second main body portion forming portions 51a 'and 51b' having the same shape as the main body portion 51 have a mounting / clamping portion forming portion 52 'having the same width as the protruding length of the mounting / clamping portion 52. And a folded symmetrical line C passing through the center in the width direction of the mounting / clamping portion forming planned portion 52 'in a cross-sectional view. ₅ Is formed so as to be folded symmetrically with respect to. This intermediate material S ₅ 'In the process of separating' ₅ Is the intermediate material S ₅ Single long material S obtained by separating ' ₅ Each of the mounting and holding portions 52 has another long material S on both side surfaces thereof. ₅ Are lines corresponding to the state of being adjacent to each of the mounting and holding portions 52 of FIG. Therefore, the cutting line SL ₅ Along the intermediate material S ₅ By cutting the mounting plate portion forming portion 52 ′ of the 'longitudinal portion 52' along the longitudinal direction, unnecessary portions do not occur and a pair of the long members S ₅ Are simultaneously formed. In FIG. 18, reference numeral 52a 'denotes a hollow portion for forming the opening 52a, and reference numeral 55 denotes a joining portion of the polymer material.
[0051]
Next, the long material S of the sixth embodiment ₆ Is the long material S of the fifth embodiment. ₅ Similarly to the above, the mounting sandwiching portion 62 having the opening 62a opened on the opposite side to the forming direction of the main body 61 projects laterally from the back surface of the main body 61 while keeping its own width interval along the longitudinal direction. It is a long material formed by being used by being attached to the opening 62a of the attachment holding portion 62 with the edge of the attached body sandwiched. A pair of long materials S ₆ Material S for obtaining ₆ The first and second main body portion forming portions 61 a ′ and 61 b ′ having the same shape as the main body portion 61 have a mounting / clamping portion forming scheduled portion 62 ′ having the same width as the protruding length of the mounting / clamping portion 62. And a folded symmetrical line C passing through the center in the width direction of the mounting / clamping portion forming portion 62 ′ in a cross-sectional view. ₆ Is formed so as to be folded symmetrically with respect to. Intermediate material S ₆ Line SL in the process of separating ' ₆ Is a single long material S as in the fifth embodiment. ₆ Each of the holding members 62 has another long material S on both side surfaces thereof. ₆ And the intermediate material S ₆ 'Is divided into two in the width direction, and unnecessary portions do not occur. ₆ Are simultaneously formed. In FIG. 20, 62a 'is a hollow portion for forming the opening 62a.
[0052]
Each intermediate material S mentioned above ₄ '(S ₅ ', S ₆ ') Is a cross section of a pair of first and second main body forming portions 41a' (51a ', 61a') and 41b '(51b', 61b ') having the same shape and arranged apart from each other. In sight, the folded symmetrical line C passing through the center in the width direction of the mounting plate portion forming portion 42 ′ (each mounting pinching portion forming portion 52 ′, 62 ′). ₄ , (C ₅ , C ₆ ) Are formed so as to be folded symmetrically (linearly symmetric). In general, by cutting along the longitudinal direction the mounting plate portion forming portion of such an intermediate material and bisecting the portion, the portion to be the mounting portion to the mounted body when the left and right sides are turned over each other in the longitudinal direction. It is possible to easily form a single symmetrical long material that is symmetrical along each other (in the case of each of the fourth to sixth embodiments, it is symmetrical and has the same shape). Therefore, each intermediate material S ₄ '(S ₅ ', S ₆ '), In the step of separating, a pair of long materials S obtained by cutting the mounting plate portion forming portion along the longitudinal direction into two parts. ₄ , (S ₅ , S ₆ ), For example, is translated in the opposite direction to the direction in which they are opposed to each other. Can be done.
[0053]
Next, the long material S of each of the seventh and eighth embodiments ₇ , S ₈ And their intermediate materials S ₇ ', S ₈ 'And its manufacturing method. FIGS. 22 and 24 show each cutting line SL in the seventh and eighth embodiments. ₇ , SL ₈ Of each intermediate material S ₇ ', S ₈ 23 and FIG. 25 show the respective intermediate members S. ₇ ', S ₈ 'And a pair of long members S of the seventh and eighth embodiments obtained from ₇ , S ₈ It is each perspective view of. Each long material S ₇ , S ₈ Is different from the other embodiments in that at least a part thereof is formed of a metal material.
[0054]
First, the long material S of the seventh embodiment ₇ Is a long material in which a thin plate-shaped mounting plate portion 72 protruding laterally along the longitudinal direction is formed on the back surface of a long strip-shaped main body portion 71 at an interval of its own width. Thus, the mounting plate portion 72 to be a mounting portion to the mounted body is continuous with the upper end portion of the main body portion 71 disposed on the upper side in a state of being mounted to the mounted body, and is formed integrally at a substantially right angle. I have. All of the mounting plate portions 72 and most of the mounting plate portions 72 along the vertical direction in the mounted state are formed by roll-forming a steel strip material and have the same plate thickness. The strip portion 71s is formed by bending the rear portion so that each portion disposed at the upper end and the lower end has a roundness. Each bent portion of the strip portion 71s is formed of an upper mold portion 71m and a lower mold portion 71m formed of a polymer plastic material. ₁ , 71m ₂ The strip portion 71s and the upper and lower mold portions 71m are covered along the longitudinal direction in a semi-arc shape from the front side. ₁ , 71m ₂ Are integrated. Two long materials S ₇ Material S for obtaining ₇ The first and second main body portion forming portions 71a 'and 71b' having the same shape as the main body portion 71 are integrated via a mounting plate portion forming planned portion 72 'corresponding to the mounting plate portion 72. The main body portion forming portions 71 a ′ and 71 b ′ each have an inverted symmetry line C passing through the center in the width direction of the mounting plate portion forming portion 72 ′ in a cross-sectional view. ₇ Are formed so as to be arranged in an inverted symmetry with respect to the center.
[0055]
To form the intermediate material, first, the intermediate material S ₇ The first intermediate molded product (not shown) having a shape corresponding to the 'attachment plate portion forming portion 72' and the strip portion forming portions 71s' of the pair of main body portion forming portions 71a 'and 71b'. Is roll formed from a steel strip material. Since the roll forming can be performed slowly as in the case of the co-extrusion, the balance and accuracy of the shape of the first intermediate molded product can be maintained. Next, in the extrusion mold to which the first intermediate molded product is supplied, the upper and lower sides of the upper and lower ends of the first intermediate molded product having rounded upper and lower ends of the respective strip portion forming scheduled portions 71 s ′ are provided. 71m of each mold part to be formed ₁ ', 71m ₂ The molten resin forming 'is extruded and integrated to form a second intermediate molded product. Since extrusion molding can be performed slowly, a pair of each mold part 71m for the first intermediate molded product is provided. ₁ , 71m ₂ Of the shape of the intermediate material S can be reduced. ₇ 'Is easily formed, and the intermediate material S ₇ The installation area of each device for forming the 'can be reduced. Intermediate material S ₇ Line SL in the separation process of ' ₇ Is a long material S on one side ₇ Each of the mounting plate portions 72 has a long material S on the other side on both side surfaces thereof. ₇ And a line corresponding to a state adjacent to each of the mounting plate portions 72, ₇ When the 'attachment plate portion forming portion 72' is cut and bisected along the longitudinal direction, unnecessary portions do not occur between the attachment plate portions 72, and the same two long members S are formed. ₇ Are simultaneously formed.
[0056]
Next, the long material S of the eighth embodiment ₈ Is a back surface of the long plate-shaped main body portion 81, and a mounting plate portion 82 slightly protruding from the center in the height direction and protruding laterally at substantially a right angle along the longitudinal direction is provided on its own. It is a long material formed with a width interval. Long material S ₈ Is formed of an aluminum material having substantially the same thickness throughout. A pair of long materials S ₈ Material S for obtaining ₈ The first and second main body portion forming portions 81a 'and 81b' having the same shape as the main body portion 81 are integrated via a mounting plate portion forming portion 82 'corresponding to the mounting plate portion 82. Each of the main body portion forming portions 81a 'and 81b' has a folding symmetry line C passing through the center in the width direction of the mounting plate portion forming portion 82 'in a cross-sectional view. ₈ Has a substantially H-shape arranged to be folded symmetrically with respect to. In order to form this intermediate material, an intermediate material having a predetermined cross-sectional shape can be easily formed by hot (or warm) extrusion forming a billet of an aluminum alloy.
[0057]
In the step of forming each intermediate material in each of the above-described embodiments, the case where the intermediate material has an integral multiple of the length of the long material has been described as an example, but the integer is “1” and the cutting machine or the like is used. The intermediate product is cut to a length corresponding to the entire length of one long material at, and an intermediate material is formed. From one intermediate material, two substantially identical or two symmetrical lengths are formed. A method of obtaining only the shank at the same time may be used. In the step of separating the intermediate material, the intermediate material having an integral multiple of the length of the long material is cut along the longitudinal direction and bisected, and corresponds to the entire length of one long material along the longitudinal direction. Although the method of cutting in the width direction to the length to be performed has been exemplified, in the portion where the intermediate material is to be formed, first, the intermediate material is cut along the longitudinal direction and bisected, and the bisected long material portion is longitudinally cut. A method of cutting in the width direction to the same number as the integer along the direction may be used. The step of forming the intermediate material is not always necessary, and a method of preparing an intermediate material that has been formed in advance according to the situation and then separating the intermediate material may be used. Further, the present invention is applicable even if the mounting plate portions are provided not at the same interval but at different intervals.
[0058]
【The invention's effect】
According to the present invention, the intermediate member is cut so that the respective attachment portions of the two long members are alternately formed in the longitudinal direction at the attachment portion formation scheduled portion. Compared to the amount of unnecessary parts generated between the adjacent mounting plate parts of one spoiler by the method, the unnecessary parts are reduced by the mounting parts arranged at the same position of the two long materials. Long materials can be manufactured.
[Brief description of the drawings]
FIG. 1 shows a spoiler S manufactured by the method of the present invention. ₁ FIG. 4 is a partial perspective view showing a left half of a front bumper B to which this is attached.
FIG. 2 Spoiler S ₁ FIG.
FIG. 3 shows a bumper B and a spoiler S when cut horizontally by the spoiler mounting groove 1. ₁ FIG. 4 is a partial plan view showing the relationship between
FIG. 4 Spoiler S on bumper B ₁ X in FIG. 2 in a state where ₁ -X ₁ It is a line expanded sectional view.
FIG. 5 is a view similar to FIG. ₂ -X ₂ It is a line expanded sectional view.
FIG. 6: Spoiler S ₁ Intermediate material S before becoming ₁ It is a perspective view of '.
FIG. 7: Intermediate material S ₁ FIG.
FIG. 8: Intermediate material S ₁ It is a top view which shows the cutting line SL of '.
FIG. 9: Intermediate material S ₁ 'To separate the same two spoilers S ₁ FIG. 4 is a plan view showing a state in which is formed.
FIG. 10 shows two identical spoilers S formed. ₁ It is a perspective view of.
FIG. 11: Intermediate material S ₁ 'Is a view showing a step of forming'.
FIG. 12 shows right and left spoilers S constituting the bumper spoiler of the second embodiment. ₂₁ , S ₂₂ FIG.
FIG. 13: Intermediate material S ₂ 'Is cut and separated to form a pair of spoilers S ₂₁ , S ₂₂ FIG. 4 is a plan view showing a state in which is formed.
FIG. 14 shows two spoilers S according to the third embodiment. ₃ Material S for producing ₃ It is a perspective view of '.
FIG. 15: Intermediate material S ₃ 'To separate the same two spoilers S ₃ FIG. 4 is a plan view showing a state in which is formed.
FIG. 16 shows each cutting line SL in the fourth embodiment. ₄ Intermediate material S ₄ It is a perspective view of '.
FIG. 17: Intermediate material S ₄ ', A pair of long members S of the fourth embodiment obtained from ₄ It is a perspective view of.
FIG. 18 shows each cutting line SL in the fifth embodiment. ₅ Intermediate material S ₅ It is a perspective view of '.
FIG. 19: Intermediate material S ₅ ', A pair of long members S of the fifth embodiment obtained from ₅ It is a perspective view of.
FIG. 20 shows each cutting line SL in the sixth embodiment. ₆ Intermediate material S ₆ It is a perspective view of '.
FIG. 21: Intermediate material S ₆ 'From the pair of long members S of the sixth embodiment ₆ It is a perspective view of.
FIG. 22 shows each cutting line SL in the seventh embodiment. ₇ Intermediate material S ₇ It is a perspective view of '.
FIG. 23: Intermediate material S ₇ 'A pair of long members S of the seventh embodiment obtained from ₇ It is a perspective view of.
FIG. 24 shows each cutting line SL in the eighth embodiment. ₈ Intermediate material S ₈ It is a perspective view of '.
FIG. 25: Intermediate material S ₈ ', A pair of long members S of the eighth embodiment obtained from ₈ It is a perspective view of.
[Explanation of symbols]
B: Bumper (attached body)
C ₁ , C ₇ : Inversion symmetry line (center in width direction)
C ₃ ~ C ₅ , C ₆ , C ₈ : Folded symmetry line (center line in the width direction)
S ₁ , S ₃ : Bumper spoiler (long material)
S ₂₁ ： Right bumper spoiler (long material)
S ₂₂ ： Left bumper spoiler (long material)
S ₄ ~ S ₈ ： Long material
S ₁ '~ S ₈ ': Intermediate material
SL, SL ₄ ~ SL ₈ : Cutting line (cut section)
1: Spoiler mounting groove (engagement part)
11: Spoiler main body (main body)
41, 51, 61, 71, 81: main body
11a ', 21a', 31a ', 41a', 51a ', 61a', 71a ', 81a':
Planned portion for forming first main body
11b ', 21b', 31b ', 41b', 51b ', 61b', 71b ', 81b':
Planned portion for forming the second main body
12, 42, 72, 82: mounting plate portion (mounting portion)
12 ', 42', 72 ', 82': scheduled mounting plate portion formation (planned mounting portion formation)
52, 62: mounting holding section (mounting section)
52 ′, 62 ′: a portion where a mounting portion is to be formed (a portion where a mounting portion is to be formed)
13: Fitting support part (locking part)
13a ', 13b': Planned portion for forming the fitting support portion (protrusion)
71s: Strip part (strip-like material)

Claims

A method for manufacturing an elongated material having an elongated main body portion and a plurality of attachment portions projecting sideways from the main body portion at predetermined intervals along a longitudinal direction thereof,
A first and a second main body portion to be formed, which are symmetrically disposed apart from each other and have the same or substantially the same cross-sectional shape, and a fixed width attachment for integrally connecting the first and the second main body portion to be formed. Preparing an intermediate material having a portion to be formed, and
As the attachment portions of each long material are formed alternately in the longitudinal direction, the process of cutting and separating the attachment portion formation scheduled portion of the intermediate material along the longitudinal direction, and
A method for manufacturing a long material, wherein the intermediate material is cut into a predetermined length to obtain a plurality of substantially the same or symmetric long materials at the same time.

A method for manufacturing an elongated material having an elongated main body portion and a plurality of attachment portions projecting sideways from the main body portion at predetermined intervals along a longitudinal direction thereof,
A first and a second main body portion to be formed, which are symmetrically disposed apart from each other and have the same or substantially the same cross-sectional shape, and a fixed width attachment for integrally connecting the first and the second main body portion to be formed. Forming an intermediate material having a portion to be formed, and
As the attachment portions of each long material are formed alternately in the longitudinal direction, the process of cutting and separating the attachment portion formation scheduled portion of the intermediate material along the longitudinal direction, and
A method for manufacturing a long material, wherein the intermediate material is cut into a predetermined length to obtain a plurality of substantially the same or symmetric long materials at the same time.

The intermediate material has a length that is an integral multiple of the length of the long material, and after cutting the intermediate material along the longitudinal direction at the portion where the mounting portion is to be formed and bisecting the intermediate material, the bisected long material portion Cutting the intermediate material into a predetermined length, or cutting the long material planned portion into a predetermined length, and then cutting the intermediate material along the longitudinal direction at the mounting portion forming planned portion and bisecting the intermediate material. Item 3. The method for producing a long material according to Item 1 or 2.

In the step of separating the intermediate material, the two main body portion forming portions are cut in the width direction while keeping their lengths the same and displacing the terminal positions from each other along the longitudinal direction. Item 4. The method for producing a long material according to any one of Items 1 to 3.

The method for manufacturing a long material according to any one of claims 1 to 4, wherein the intermediate material is line-symmetric with respect to a center line in a width direction of a portion where a mounting portion is to be formed, in a cross-sectional view thereof. .

The method for manufacturing a long material according to any one of claims 1 to 4, wherein the intermediate material is point-symmetric with respect to the center in the width direction of the portion where the mounting portion is to be formed in a cross-sectional view.

The method for producing a long material according to any one of claims 1 to 6, wherein the intermediate material is extruded from a high-molecular plastic material such as rubber, resin, or elastomer using an extrusion mold. .

The method according to any one of claims 1 to 6, wherein the intermediate material is extruded from a light metal material using an extrusion mold.

The method according to any one of claims 1 to 6, wherein the intermediate member is roll-formed from a strip-shaped material having a predetermined width into a predetermined cross-sectional shape.

7. The intermediate material according to claim 1, wherein the intermediate material is composed of a core material having a predetermined cross-sectional shape made of a hard material and a high-molecular plastic material extruded on the core material. The method for producing a long material according to the above.

The method of manufacturing a long material according to any one of claims 1 to 10, wherein the step of separating the portion where the mounting portion is to be formed is performed by a cutting method using a press die or a concentrated energy means.

The elongate member is a member to be attached to the body to be attached, and a ridge continuous along the longitudinal direction is integrally formed at a portion where the intermediate member is to be formed, and a portion where the intermediate member is to be formed. 12. The long member according to any one of claims 1 to 11, wherein the protrusions of the long member serve as locking portions for locking to the engaging portions of the attached member after the is separated. Production method.