JP3859314B2 - Mold for shell molding of brake booster - Google Patents

Mold for shell molding of brake booster Download PDF

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Publication number
JP3859314B2
JP3859314B2 JP21673297A JP21673297A JP3859314B2 JP 3859314 B2 JP3859314 B2 JP 3859314B2 JP 21673297 A JP21673297 A JP 21673297A JP 21673297 A JP21673297 A JP 21673297A JP 3859314 B2 JP3859314 B2 JP 3859314B2
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JP
Japan
Prior art keywords
shell
die
peripheral wall
punch
brake booster
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
JP21673297A
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Japanese (ja)
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JPH1157876A (en
Inventor
利雄 湯原
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bosch Corp
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Bosch Corp
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Filing date
Publication date
Application filed by Bosch Corp filed Critical Bosch Corp
Priority to JP21673297A priority Critical patent/JP3859314B2/en
Publication of JPH1157876A publication Critical patent/JPH1157876A/en
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Publication of JP3859314B2 publication Critical patent/JP3859314B2/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Description

【0001】
【発明の属する技術分野】
本発明は、バス、トラック等に備えられるブレーキ倍力装置のシェルを深絞り加工する際に用いる成形用金型に関するものである。
【0002】
【従来の技術】
一般に、バス、トラック等に備えられるのブレーキ倍力装置のシェルは、図7に示すように、一端が開口した円筒状のシェル本体1の開口部に取付フランジ2が形成された構造となっている。
【0003】
そして、このような形状をしたシェルを製造するには図9に示すように、絞り板3を金型4のポンチ6上に設置し(図9(A))た後、ダイス5を押し下げ(図9(B))、そのダイス肩5aによって絞り板3を絞り加工して成形するようになっている(図9(C))。その後、図8に示すように、強度が要求されるシェル本体1の天井部1aに補強部材7を取り付けて、加工後のシェル本体1の強度を増すようになっている。
【0004】
【発明が解決しようとする課題】
ところで、絞り加工後のシェル本体1にこのような補強部材7を後から取り付ける方法では、製造工程が増えてしまう上に、シェル本体1の重量が増大してしまうといった不都合がある。
【0005】
そのため、強度が要求される天井部1aの肉厚t1 はそのままで、周壁部1bの肉厚t2 のみを天井部1aの肉厚t1 の40〜70%程度まで薄肉化する絞り加工を行うことで、充分な強度を保持しつつ製造工程の簡略化とシェル本体1の軽量化を達成することができる。
【0006】
しかしながら、従来の金型による絞り加工では周壁部1bの肉厚t2 を天井部1aの肉厚t1 の40〜70%程度まで薄肉化することは極めて困難なため、良好な成形品を得ることができなかった。すなわち、絞り加工によってシェル本体1の周壁部1bのみを薄肉化するには、ダイス5とポンチ6とのクリアランスを所望の肉厚程度に狭くすることによって行うことになるが、単にダイス5とポンチ6とのクリアランスを狭くしただけでは、ダイス5による絞り加工時にシェル本体1の周壁部1bがその応力によって簡単に破断してしまうこととなっていた。
【0007】
そこで、本発明はこのような課題を有効に解決するために試行錯誤した結果、案出されたものであり、その目的はブレーキ倍力装置のシェルの周壁部の薄肉化を容易・確実に達成することができる新規なブレーキ倍力装置のシェル成形用金型を提供するものである。
【0008】
【課題を解決するための手段】
上記課題を解決するために本発明は、冷間圧延鋼板を深絞り加工して、天井部と、その天井部から下向きに広がるテーパ部と、そのテーパ部から下方に延びる筒状の周壁部と、その周壁部の下端に外側に延びるよう形成された取付フランジとを有し、上記周壁部の板厚t2上記天井部板厚t1 の40〜70%となるブレーキ倍力装置のシェルを成形するための金型において、ポンチと、そのポンチと嵌合すべく昇降する筒状のダイスとを備え、それらポンチとダイスとのクリアランスを上記冷間圧延鋼板のスプリングバック分に応じて上記シェルの周壁部の板厚t2 よりも5〜15%程度狭く設定すると共に、上記ダイス肩の丸み半径Rを0.5t2 〜2.0t2 に設定し、上記ポンチの先端部に、上記テーパ部を成形するための面取部を設けたものである。
【0009】
すなわち、本発明はポンチとダイスとのクリアランスを上記冷間圧延鋼板のスプリングバック分に応じて設定し、ダイス肩の丸み半径Rを上記の範囲に設定したものであり、これによって、絞り加工時の破断を招くことなく軽量化と強度を兼ね備えたブレーキ倍力装置のシェルを容易且つ確実に得ることができる。
【0010】
【発明の実施の形態】
次に、本発明を実施する好適一形態を添付図面を参照しながら説明する。
【0011】
図1は本発明に係るブレーキ倍力装置のシェル成形用金型の実施の一形態を示す縦断面図、図3はこの成形用金型で得られるブレーキ倍力装置のシェル8の実施の一形態を示す縦断面図である。
【0012】
図示するように、この金型は円筒状をしたポンチ6と、このポンチ6を嵌合すべく昇降する筒状のダイス5とから構成されており、上述したように、このポンチ6上に冷間圧延鋼板(SPC−A〜E)等の絞り板3を載置した後、ダイス5を降下させることで図3に示すようなブレーキ倍力装置のシェル8を深絞り加工できるようになっている。
【0013】
また、このシェル8は、図3及び図4に示すように、その天井部1aの板厚t1 に対してその周壁部1bの板厚t2 が40〜70%程度の薄さに加工されており、必要な強度を保持しつつ軽量化を達成できるようになっている。
【0014】
そして、このようなシェル8を深絞り加工するために、本発明は金型に以下に示すような構造をしている。
【0015】
先ず、図2及び図4に示すように、このダイス5とポンチ6のクリアランスcはシェル8の周壁部1bの板厚t2 よりも約5〜15%程度狭く設定されている。例えば、このシェル8の天井部1aの板厚t1 が4.0mm、周壁部1bの板厚t2 が2.0mmの場合にはダイス5とポンチ6とのクリアランスcは1.7〜1.9mmの幅となっている。すなわち、低炭素鋼である冷間圧延鋼板(SPC−A〜E,JIS−No3141)等の絞り板3は、深絞り加工後にスプリングバックと称される戻りが約5〜15%程度発生することから、このクリアランスcを周壁部1bの板厚t2 と同じ2.0mmとすると加工後のスプリングバックによって周壁部1bの板厚t2 が所望の値より大きくなってしまうためである。
【0016】
次に、図5に示すように、ダイス5の内周縁に位置するダイス肩5aの丸み半径Rは周壁部1bの板厚t2 に対して0.5t2 〜2.0t2 の範囲に設定されている。例えば、周壁部1bの板厚t2 が2.0mmの場合には、ダイス肩5aの丸み半径Rは1.0〜4.0mmとなっている。すなわち、この範囲を超えると、深絞り加工時に絞り板3に加わるダイス肩5aの応力によって絞り板3が破断してしまい、良好な薄肉化が達成できなくなるからである。尚、このクリアランスc及びダイス肩5aの丸み半径Rについて幅を持たせたのは、使用する絞り板3の材質によって加工時の引張り強さ、耐力、伸び、スプリングバック等の機械的・物理的特性が微妙に異なるからである。
【0017】
そして、このような構造をした金型を用い、従来と同様に冷間圧延鋼板からなる絞り板3を深絞り加工すると、破断などの不都合を招くことなく容易かつ確実に周壁部1bの薄肉化を行うことができる。
【0018】
このように、本発明の深絞り加工用金型は、ポンチとダイスとのクリアランスを冷間圧延鋼板のスプリングバック分に応じてシェルの周壁部の板厚t2 よりも5〜15%程度狭く設定すると共に、ダイス肩の丸み半径Rを0.5〜2.0t2 に設定したため、周壁部1bの薄肉化を確実に行うことが可能となり、従来の金型では困難であった軽量化と高強度を兼ね備えたブレーキ倍力装置のシェルを容易且つ確実に得ることができる。尚、ダイス肩5aの初期食い込みによる破断を防止するために、さらに図6に示すようにダイス肩5a内側上部5bを数μm〜数十μm程度削るようにしても良い。
【0019】
【発明の効果】
以上要するに本発明によれば、深絞り加工時の破断を招くことなく軽量化と強度を兼ね備えたブレーキ倍力装置のシェルを容易且つ確実に得ることができる。従って、従来のような補強部材が不要となって加工工程が省略されるため、製造コストの低下も達成できるといった優れた効果を発揮することができる。
【図面の簡単な説明】
【図1】本発明に係る加工用金型の実施の一形態を示す縦断面図である。
【図2】図1中S部を示す部分拡大図である。
【図3】本発明の成形用金型で得ることができるブレーキ倍力装置のシェルの一例を示す縦断面図である。
【図4】図3中S部を示す部分拡大図である。
【図5】図2中S部を示す部分拡大図である。
【図6】本発明の他の実施の一形態を示す部分拡大図である。
【図7】従来のブレーキ倍力装置のシェルの一例を示す斜視図である。
【図8】(A)は従来のブレーキ倍力装置のシェルの一例を示す縦断面図である。(B)は図8(A)中S部を示す部分拡大図である。
【図9】従来のブレーキ倍力装置のシェルの絞り加工の一例を示す工程図である。
【符号の説明】
3 絞り板
5 ダイス
5a ダイス肩
6 ポンチ
シェル
1a 天井部
1b 周壁部
[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a molding die used when deep drawing a shell of a brake booster provided in a bus, a truck, or the like .
[0002]
[Prior art]
In general, a shell of a brake booster provided in a bus, a truck or the like has a structure in which a mounting flange 2 is formed at an opening of a cylindrical shell body 1 having one end opened as shown in FIG. Yes.
[0003]
Then, in order to manufacture a shell having such a shape, as shown in FIG. 9, the diaphragm plate 3 is placed on the punch 6 of the mold 4 (FIG. 9A), and then the die 5 is pushed down ( 9 (B)), the drawing plate 3 is drawn and formed by the die shoulder 5a (FIG. 9 (C)). After that, as shown in FIG. 8, the reinforcing member 7 is attached to the ceiling portion 1a of the shell main body 1 where strength is required to increase the strength of the shell main body 1 after processing.
[0004]
[Problems to be solved by the invention]
By the way, the method of attaching such a reinforcing member 7 to the shell body 1 after the drawing process has the disadvantage that the manufacturing process is increased and the weight of the shell body 1 is increased.
[0005]
Therefore, the drawing process is performed to reduce the thickness t 2 of the peripheral wall portion 1b to about 40 to 70% of the thickness t 1 of the ceiling portion 1a while keeping the thickness t 1 of the ceiling portion 1a where strength is required. By doing so, simplification of the manufacturing process and weight reduction of the shell body 1 can be achieved while maintaining sufficient strength.
[0006]
However, it is extremely difficult to reduce the wall thickness t 2 of the peripheral wall portion 1b to about 40 to 70% of the wall thickness t 1 of the ceiling portion 1a by drawing with a conventional mold, so that a good molded product is obtained. I couldn't. That is, thinning only the peripheral wall portion 1b of the shell body 1 by drawing is performed by narrowing the clearance between the die 5 and the punch 6 to a desired thickness. If the clearance with 6 is narrowed, the peripheral wall portion 1b of the shell body 1 is easily broken by the stress when the die 5 is drawn.
[0007]
Therefore, the present invention has been devised as a result of trial and error in order to effectively solve such problems, and its purpose is to easily and reliably achieve the thinning of the peripheral wall portion of the shell of the brake booster. The present invention provides a mold for forming a shell of a novel brake booster that can be used.
[0008]
[Means for Solving the Problems]
In order to solve the above problems, the present invention provides a deep drawing of a cold-rolled steel sheet, a ceiling portion, a tapered portion extending downward from the ceiling portion, and a cylindrical peripheral wall portion extending downward from the tapered portion. , and a mounting flange formed so as to extend outwardly at the lower end of the peripheral wall portion, the thickness t 2 of the peripheral wall portion 40 to 70 percent Do Lube rake booster of the ceiling plate thickness t 1 A die for forming a shell of a steel sheet is provided with a punch and a cylindrical die that moves up and down to fit the punch, and the clearance between the punch and the die is in accordance with the amount of spring back of the cold-rolled steel sheet. and sets also approximately 5-15% narrower than the thickness t 2 of the peripheral wall portion of the shell Te, the rounding radius R of the die shoulder is set to 0.5t 2 ~2.0t 2, the tip portion of the punch Chamfered part for forming the tapered part Those were.
[0009]
That is, according to the present invention, the clearance between the punch and the die is set in accordance with the amount of spring back of the cold rolled steel sheet, and the round radius R of the die shoulder is set in the above range. Therefore, the shell of the brake booster having both weight reduction and strength can be easily and reliably obtained without causing breakage.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Next, a preferred embodiment for carrying out the present invention will be described with reference to the accompanying drawings.
[0011]
FIG. 1 is a longitudinal sectional view showing an embodiment of a shell molding die of a brake booster according to the present invention, and FIG. 3 shows an embodiment of a shell 8 of a brake booster obtained with this molding die. It is a longitudinal cross-sectional view which shows a form.
[0012]
As shown in the figure, this mold is composed of a cylindrical punch 6 and a cylindrical die 5 that moves up and down to fit the punch 6. As described above, the mold is cooled on the punch 6. After placing the drawing plate 3 such as a cold rolled steel plate (SPC-A to E), the die 8 is lowered, and the shell 8 of the brake booster as shown in FIG. 3 can be deep drawn. Yes.
[0013]
Further, the shell 8, as shown in FIGS. 3 and 4, the plate thickness t 2 of the peripheral wall portion 1b is processed into thin as 40% to 70% relative to the thickness t 1 of the ceiling portion 1a Thus, weight reduction can be achieved while maintaining the required strength.
[0014]
In order to deep-draw such a shell 8 , the present invention has a structure as shown below in the mold.
[0015]
First, as shown in FIGS. 2 and 4, the clearance c between the die 5 and the punch 6 is set to be about 5 to 15% narrower than the plate thickness t 2 of the peripheral wall portion 1 b of the shell 8 . For example, when the plate thickness t 1 of the ceiling portion 1a of the shell 8 is 4.0 mm and the plate thickness t 2 of the peripheral wall portion 1b is 2.0 mm, the clearance c between the die 5 and the punch 6 is 1.7 to 1. The width is 9 mm. That is, the drawing plate 3 such as a cold rolled steel plate (SPC-A to E, JIS-No 3141), which is a low carbon steel, generates about 5 to 15% of return called a springback after deep drawing. from is because the plate thickness t 2 of the peripheral wall portion 1b by the spring back after processing to the clearance c between the same 2.0mm plate thickness t 2 of the peripheral wall portion 1b becomes larger than a desired value.
[0016]
Next, as shown in FIG. 5, set in the range of 0.5t 2 ~2.0t 2 against the plate thickness t 2 of the rounding radius R peripheral wall 1b of the die shoulder 5a located on the inner periphery of the die 5 Has been. For example, if the plate thickness t 2 of the peripheral wall portion 1b of 2.0mm, the rounding radius R of the die shoulder 5a has a 1.0 to 4.0 mm. That is, if this range is exceeded, the drawing plate 3 is broken by the stress of the die shoulder 5a applied to the drawing plate 3 during the deep drawing process, making it impossible to achieve a good thickness reduction. The clearance c and the rounding radius R of the die shoulder 5a have a width depending on the material of the diaphragm plate 3 to be used, such as mechanical strength, physical strength such as tensile strength, yield strength, elongation, and springback during processing. This is because the characteristics are slightly different.
[0017]
Then, if the die 3 having such a structure is used and the drawing plate 3 made of a cold-rolled steel plate is deep-drawn as in the conventional case, the peripheral wall portion 1b can be thinned easily and reliably without causing inconvenience such as breakage. It can be performed.
[0018]
Thus, deep drawing die of the present invention is about 5-15% than the thickness t 2 of the peripheral wall of the shell in accordance with the clearance between the punch and the die to the springback of the cold-rolled steel sheet narrow In addition to setting, the round radius R of the die shoulder is set to 0.5 to 2.0 t 2 , so that it is possible to reliably reduce the thickness of the peripheral wall portion 1b. A brake booster shell having high strength can be obtained easily and reliably. In order to prevent breakage of the die shoulder 5a due to initial biting, the die shoulder 5a inner upper portion 5b may be further shaved by several μm to several tens μm as shown in FIG.
[0019]
【The invention's effect】
In short, according to the present invention, it is possible to easily and surely obtain a shell of a brake booster that has both weight reduction and strength without causing breakage during deep drawing. Therefore, since a conventional reinforcing member is not required and the processing step is omitted, it is possible to achieve an excellent effect that a reduction in manufacturing cost can be achieved.
[Brief description of the drawings]
FIG. 1 is a longitudinal sectional view showing an embodiment of a processing mold according to the present invention.
FIG. 2 is a partially enlarged view showing an S portion in FIG.
FIG. 3 is a longitudinal sectional view showing an example of a shell of a brake booster that can be obtained with the molding die of the present invention.
4 is a partially enlarged view showing a portion S in FIG. 3. FIG.
5 is a partially enlarged view showing an S portion in FIG. 2. FIG.
FIG. 6 is a partially enlarged view showing another embodiment of the present invention.
FIG. 7 is a perspective view showing an example of a shell of a conventional brake booster .
FIG. 8A is a longitudinal sectional view showing an example of a shell of a conventional brake booster . (B) is the elements on larger scale which show the S section in FIG. 8 (A).
FIG. 9 is a process diagram showing an example of drawing of a shell of a conventional brake booster .
[Explanation of symbols]
3 Diaphragm plate 5 Dice
5a Dice shoulder 6 Punch 8 shell
1a Ceiling
1b Perimeter wall

Claims (1)

冷間圧延鋼板を深絞り加工して、天井部と、その天井部から下向きに広がるテーパ部と、そのテーパ部から下方に延びる筒状の周壁部と、その周壁部の下端に外側に延びるよう形成された取付フランジとを有し、上記周壁部の板厚t2上記天井部板厚t1 の40〜70%となるブレーキ倍力装置のシェルを成形するための金型において、
ポンチと、そのポンチと嵌合すべく昇降する筒状のダイスとを備え、
それらポンチとダイスとのクリアランスを上記冷間圧延鋼板のスプリングバック分に応じて上記シェルの周壁部の板厚t2 よりも5〜15%程度狭く設定すると共に、上記ダイス肩の丸み半径Rを0.5〜2.0t2 に設定し、上記ポンチの先端部に、上記テーパ部を成形するための面取部を設けたことを特徴とするブレーキ倍力装置のシェル成形用金型。
Deep- drawn cold-rolled steel sheet so that the ceiling, the taper extending downward from the ceiling, the cylindrical peripheral wall extending downward from the taper, and extending outward to the lower end of the peripheral wall and a formed mounting flange, in a mold for a plate thickness t 2 of the peripheral wall portion forming the shell 40 to 70 percent Do Lube rake booster of the ceiling plate thickness t 1,
A punch and a cylindrical die that moves up and down to fit with the punch ,
The clearance between the punch and the die is set to be about 5 to 15% narrower than the thickness t 2 of the peripheral wall portion of the shell according to the amount of spring back of the cold-rolled steel plate, and the round radius R of the die shoulder is set. A shell molding die for a brake booster , which is set to 0.5 to 2.0 t 2 and is provided with a chamfered portion for molding the tapered portion at the tip of the punch .
JP21673297A 1997-08-11 1997-08-11 Mold for shell molding of brake booster Expired - Fee Related JP3859314B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP21673297A JP3859314B2 (en) 1997-08-11 1997-08-11 Mold for shell molding of brake booster

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP21673297A JP3859314B2 (en) 1997-08-11 1997-08-11 Mold for shell molding of brake booster

Publications (2)

Publication Number Publication Date
JPH1157876A JPH1157876A (en) 1999-03-02
JP3859314B2 true JP3859314B2 (en) 2006-12-20

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Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS49115070A (en) * 1973-02-21 1974-11-02
US4412440A (en) * 1981-02-13 1983-11-01 American Can Company Process for making container
JPS6116402U (en) * 1984-07-04 1986-01-30 自動車機器株式会社 booster housing

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