MXPA99000997A - Troquel apparatus for the formation of a nucleo plug and method to manufacture a nucleum plug - Google Patents

Abstract

The present invention relates to an apparatus for forming a core matrix for the formation of a core plug of a core blank having a recessed region consisting of: the recessed region of the core blank comprising at least one grooved surface formed therein: a second die member having an upper surface, a blanket acceptance region and a substantially perpendicular opening extending through at least a portion of the second skin member; matrix, the opening includes an introduction region parallel to the blank acceptance region, a transition region, and an end region, wherein the size of the opening in the insertion region is smaller than the size of the blank. core blank and larger than the size of the opening in the end region, the transition region comprises a substantially continuous surface that provides a gradual transition, substantially smoothly from the region of introduction to the end region, to, in turn, facilitate the smooth formation of the core blank in the core plug, without substantially affecting the grooved surfaces of the piece coarse core, and means for propelling the core blank from the upper surface of the second matrix member through the end region of the opening, to, in turn, make a core plug.

Description

TROQUEL APPARATUS FOR THE FORMATION OF NCLEO PLUG AND METHOD TO MANUFACTURE A NUCLEO PLUG. DESCRIPTION OF THE INVENTION: The present invention is directed generally to core plugs and more particularly to a core die forming apparatus for the formation of core plugs and associated method for manufacturing a core plug. Core plugs include, but are not limited to, cup plugs, core hole plugs, freeze plugs and welsh plugs (metal plug for d cylinders), which are known in the art. These are typically used to seal openings, for example, automobile engines, transmissions, choke body parts, water pumps, cylinder heads, and other housings. Generally, the core plug is slightly larger than the opening to be sealed, but also slightly softer. As such when the plug is forced into the opening, it can reach a tight fit which ensures an adequate fit of the plug surfaces to the opening, and in turn a leak proof seal. With many applications, such as automotive engines, an adhesive is used with the outer surface of the core plugs, in addition an exact coupling of the core plug to the opening is promoted, in turn to obtain a better seal and reduce the risk of failure. Current manufacturing techniques apply a wet adhesive to either the opening or the soft outer surface of the core plug. Subsequently, the core plug is forced into the opening. Although such a method can achieve a solid bond between the core plug and the opening, the process is inefficient, first a station must apply a wet adhesive to and be either the core plug or the opening. Then a separate station forces the plug into the opening. As such, in the case of a car engine tester, the assembly line must be stopped at two stations. While the production of the factory must stop each time the assembly line stops, two separate assembly stations significantly affect production, and eliminating one station would be a major improvement. In the U.S. No. 4, 750, 457 granted to Bonutti presents an improvement, machined core plugs are presented, to include grooves around its smooth outer circumferential surface. These slots are pre-filled with a dry adhesive to the touch. This type of adhesive is activated, usually by the absence of air. In the case of automotive engine assembly, those pre-filled core plugs are forced into a single station in the opening of the machine. Once inserted into the opening, the adhesive is activated, and dried to form a solid leak-proof seal. Although this method seems to reduce the motor assembly time by eliminating a station, there are other disadvantages associated with that process. Specifically, the cost of machining the grooves in the outer circumference of the core plug can be prohibitively expensive. In fact, the machining of the core plug is an intensive and time-consuming task. Additionally to make a large volume of plugs, a multitude of expensive milling equipment is necessary. Therefore, any savings achieved by the elimination of a station is more than exceeded by the increased costs associated with the machining of the core plug. Despite the availability of this method, automakers have continued to use the wet adhesive and the two stations as a method, since this seems to be less expensive, than the machining of the core plug. The invention comprises a method for manufacturing a core plug from a core blank, the raw form includes an outer ring, the top surface and a bottom surface. The method comprises the step of placing the blank in a stamping apparatus. A recess shape is then stamped on the outer ring of the lower surface of the blank. The bottom or bottom surface of the blank is then placed in a region of a die forming apparatus that accepts the blank, this is driven through an opening that extends through the die forming apparatus. A portion of the outer ring is deformed upward and inward to give a core plug. The region with the recess stamped on the core is not affected by the deformation step. In a preferred embodiment, the method further comprises the step of removing the core plug from the die forming apparatus. In addition in another preferred embodiment, the method may comprise the step of applying an adhesive to at least a portion of the recessed region. In a preferred embodiment of the invention, the recessed region embossed in the raw form comprises a uniform concentric groove with an outer perimeter of the raw form. Additionally, the recess region may comprise a dotted or zigzag template. The invention may further comprise a core plug formed by the methods identified above wherein the core plug includes a base region, an outer ring and a recessed region. The outer ring extends upwardly from the base region, around the outer perimeter of the base region and includes an outer surface. The recess region extends around the outer surface of the outer ring. In a preferred embodiment, the core plug includes an adhesive applied to a portion of the recessed region. The invention further comprises a core die forming apparatus for the formation of a core plug from a raw form, wherein the raw form includes a recessed region. The forming apparatus comprises a second member by die. The second die member comprises a top surface, a region accepting the raw form and a substantially perpendicular opening extending through the second die member. The opening includes a region of introduction close to the accepting region of rough form, a region d transition and a final region. The size of the opening in the introduction region is less than the size of the gross form and greater than the size of the opening in the end region. The transition region comprises a continuous convex surface that provides a smooth and gradual transition from the region of introduction to the final region. This surface, on the other hand, facilitates the smooth formation of the blank to the core plug, and the recess regions of the core plug are not affected by the core die forming step. Additionally, the die forming apparatus includes propelling means that urges the blank from the top surface of the second die member through the end region of the aperture to make the core plug. In a preferred embodiment, the transition region comprises an acute angle uniform with respect to an axis perpendicular to the upper surface of the second die member. The junction between the introduction region and the transition region is rounded, as is the junction between the transition region and the final region. In another preferred embodiment, the opening is basically circular in cross section. In addition, the second die member may include a bottom surface where the opening extends from the top surface to the bottom surface of the second die member. In a preferred embodiment, the propelling means may comprise a coupling configured punch for forcing the blank through the opening of the second member by punching. In a preferred embodiment, the die forming apparatus includes means for removing the core plug from the core die after plug formation. In that preferred embodiment, the removal means may comprise a directed levering member positioned to operate close to the propelling means. The guided lever member is slideable with the drive means, and, in turn, with the core plug. In a preferred embodiment, the second die member may comprise a high carbon tool steel. DESCRIPTION OF THE DRAWINGS Figure 1 is a top plan view of a shape or blank of the core; Figure 2 is a partial cross-sectional view of the blank in line 2-2 of Fig. 1; Figure 3 is a side elevational view of a core plug; Figure 4 is a side elevational view of an alternative embodiment of the core plug; Figure 5 is a side elevational view of an alternative embodiment of the core plug; Figure 6 is a front plan view of the embossing apparatus; Figure 7 is a cross-sectional view of a stamping die or die used in association with the stamping apparatus; Figure 8 is a cross-sectional view of a second member by die or die; Figure 9 is a top view of the second member by die; Figure 1 is a front plan view of the core die forming apparatus before the punch makes contact with the blank; Figure II is a front plan view of the core die forming apparatus when the blank passes through the opening of the second apparatus by die; Figure 12 is a front plan view of the core die forming apparatus when the removal means contacts the already formed core plug; and Figure 13 is a front plan view of the core die forming apparatus when the core plug is released from the core die forming apparatus. Although this invention is susceptible of a materialization in many different forms, it is shown in the drawings and a specific embodiment is described in detail, with the understanding that the present presentation is to be considered as an example of the principles of the invention and not it is intended to limit the invention to the illustrated modality. The blank lü from which the core plug 12 is formed has, as shown in FIGS. 1 and 2, the upper surface 42, the lower surface 44 (Pig 2), the outer ring 46, the outer perimeter 48 and the diameter 40. Preferably the piece or raw form is eustantially circular, wherein the upper surface 42 and the lower surface 44 are substantially flat, resulting in a uniformly thick piece. Of course other shapes and configurations are usable. Additionally, the piece in the rough - it can be made of steel, aluminum, brass and / or other metal that can be cold worked. The core plug 12 is shown in Fig. 3 co or further comprising a base region 52, the upper side 54 and the recessed regions 50. The base region 52 is formed from the inner region of the core blank. . The upper side 54 is formed from the outer ring 46 (Fig. 1) of the blank 10 that has been turned up and inwardly around the upper surface 42 by the novel fabrication method described below. The upper or upward side 54 includes the inner surface (not shown) and the outer surface 78. The inner surface corresponds to the upper surface 42 of the outer ring 46 of the blank 10, and the outer surface 78 corresponds to the surface lower 44 of the outer ring 46 of the blank 10. As shown in Fig 3, the recessed regions may comprise a plurality of circumferential grooves around the outer surface 78 of the upper side 54. As will be explained, the regions in recess 50 shown in Figures I-3, comprise a pattern made on the lower surface 44 of the blank 10 prior to forming. It should be noted that although a plurality of grooves may be placed on the circumference, stamping more than one or two grooves does not improve the operation of the core plug, but may weaken the overall structure. In addition, as shown in Figures 4 and 5, regions in recess may also comprise, dotted 60 or zig -zag 62. Of course the usable templates have no limit, and thus many other templates may be contemplated. To transform the blank 10 into the core plug 1, the rough piece must go through the stamping on two devices. As shown in Figures 6 and 7, the first stamping apparatus comprises the die 66 and the punch 68. The die 66, as shown in Figure 6, comprises the acceptance or receiving region 70 and the projecting region 72. The punch 68 comprises a conventional stamping machine for carrying out the stamping operations indicated. The second stamping operation is performed by the core die forming apparatus 16. The apparatus 16 is shown in Figures 10-13 as comprising a second die member 18 and the propelling means 20. as shown in Figures 8 and 9, the second die member 18 includes the top surface 24, the part receiving region 26 and the opening 28. The blank receiving region 26 is configured to receive a blank of a certain thickness and diameter. The region 26 may also be able to receive a certain margin of pieces of different sized bruco. For high production, the second die member may comprise a CICO Carbide with a TI-8 coating. for low volume production the second die member preferably comprises a high carbon steel tool with a TI-8 coating. However, depending on the particular application, a multitude of other metallic materials are suitable for the second die member. The opening 28 of the second die member 18, as shown in Figures 8 and 9, comprises the introduction region 32, the transition region 34 and the end region 36. As with the part 10, the aperture 28 may have any geometric shape However, the second die member 18, and in turn, the opening 28 will be described with respect to the production of a circular core buffer, to obtain a circular core tampon, the opening 28 will also be circular. As shown in Figures 8 and 9, the introduction region 32 collides with the receiving region of the part 26 at one end and the introduction region 32 collides with the transition region 34 at another end. The introduction region 32 comprises a circular cross-sectional shape having a diameter smaller than the diameter 40 of the blank 10. The transition region 34 comprises a continuously convex surface of a diameter that narrows extending to the final region 36. Although other configurations are considered, the transition region has an angle of approximately 22 ° with respect to the axis 76 (Fig 8), which is perpendicular to the upper surface 24 of the second die. At the junction between the transition region 34 and the introduction region 32, the transition region is rounded. Similarly, the joint between the transition region 34 and the end region 36 is similarly rounded. The final region has a diameter substantially identical to the desired outer diameter of the core plug 12. Depending on the particular size of the core plug, while the transition region retains an angle of 22 °, the rounded ends of the transition region can understand several dimensions that have been determined by experimentation. For example, for a large diameter blank of 5,250 inches. { 13.25 cm) the rounded ends comprise arched fillets of 0.078125 inches . { 0.20 cm). For blanks with an average diameter of approximately 3.975 inches (lcm), the rounded ends comprise arched fillets of 0.125 inches. { ü.325 was). For small diameter pieces of approximately 2,975 (7.5cm) the rounded ends comprise arched fillets of 0.125 inches (0.325cm) in the vicinity of the introduction region and 0.250 inches (or .625cm) in the vicinity of the final region. Of course, other radii can be used, which gradually form the plug and core, facilitating and promoting the integrity of the outer surface of the core plug, but allowing a large volume of production. As shown in Figure 8, in one embodiment, where the opening 28 extends through the entire base member, the opening further includes a finishing region 80 comprising an angled surface away from the final region of approximately 30 °. with respect to shaft 76. Finishing region 80 facilitates uniform passage of the core plug through the opening. The propulsion means 20 shown in Figures 10-13 comprising the punch 38 and the recirculation means 88. The punch 38 comprises a conventional punch on a press, and the punch is configured to fit the aperture 28 of the second member with adjustment. die 18. Removal means 88 comprises guided leverage members 84, 84 'positioned below the opening 28 of the second die member 18. each of the guided leverage members 84, 84' include angled members 86, 86 ', respectively. When operating, to manufacture the core plug 12 from the core blank 10, as shown in FIG. 6, the piece 10 is placed first on the first die 66 of the embossing apparatus 2. The punch 68 of the embossing apparatus 22 presses the lower surface 44 of the blank 10 against the protruding region 72, thereby forming the recessed region 50 in the lower surface of the blank. Next, piece 10 is placed in the core die forming apparatus 16. Specifically as shown by Fig. 10, the blank is placed in the receiving region 26 with the lower surface 44 facing downward and resting against the receiving region of the blank. As shown in Figure 11, the propelling means 20 are then activated and contact the upper surface of the part. While the driving means continues to move downward, the piece is forced through the opening 28 of the apparatus 16. Thus, as shown in Figure 11, while the diameter of the piece is greater than the diameter of the piece. opening 28, the outer ring 46 is forced upward and inward as the part continues through the opening 28, forming the upward side 54. Due to the particular configuration of the opening 28, and in particular, to the decrease The diameter of the opening in the opening 28 from the region of introduction through the transition region and into the final region, the piece is formed gradually. Actually, the gradual formation does not basically affect the regions in recess that were introduced by the recess 72 of the embossing apparatus 22. Using conventional embossing techniques, and conventional core embossing dies, the shock waves would tend to propagate and destroy the slots placed on the outer surface of the piece as it progresses through the opening 28. However, the special geometric configuration of the die, identified above, and the gradual formation of the plug from the blank prevents line formation. of shock, or shock waves.

Thus, the formed core plug retains the regions in recess even after forming. Once the shape or blank (core plug) comes out of the opening, the piece. { core plug), as shown in Figures 12 and 13, can pass beyond the guided leverage members 84, 84 '. However, as seen in FIG. 13, since the driving means is returned through the opening 28, the leverage members 86, 86 'collide with the propulsion means and stop the core plug 12, disconnecting the plug of the plug. core of the propellant medium. Once fully formed, adhesive 14 is applied (Fig. 1) to the core plug 12, and in particular, to the recessed region 50. The adhesive comprises a dry adhesive to the touch. Such adhesives are aerobic (activated in the absence of air) or include microencapsulated adhesive that is activated by abrasion. Any adhesive that can be activated during the assembly step of pushing the core plug into the opening can be used. The first stamping process and the pushing process can be done on the assembly line. While both steps require approximately the same amount of time, the two presses can be placed in line and in succession in an assembly line. Additionally a single press can be configured to stamp and punch several plugs at the same time, using dies or dies configured with multiple openings and multiple corresponding protruding regions. Additionally, while the adhesive can be quickly applied to the formed core plugs, a high production volume that is cheap to manufacture the core plugs can be achieved. To apply the adhesive to the core plug, for example a core opening in a machine block or automobile engine, the core plug (having the dry adhesive) is simply pushed into the core opening. Once pushed, the adhesive is activated and hardened to form an airtight seal between the core opening and the core plug. The foregoing description and the drawings simply explain and illustrate the invention and the invention is not limited except by the claims, and the technicians will find many modifications and variations without departing from the scope of the present invention.

Claims (3)

1. CLAIMS 1. A method for manufacturing a core plug from a core blank having an outer ring, an upper surface and a lower surface, the method comprising the steps of: placing the blank in a stamping apparatus stamping a region in recess in the outer ring of the lower surface of the blank; placing the bottom surface of the blank in a receiving region of the part of a core die forming apparatus; propelling the blank through an opening extending through the core die forming apparatus; and deforming a portion of the ring inwardly and upwardly to obtain a core plug, wherein the recessed region impressed in the core plug is essentially infected by the deformation step.
2. 2. The method according to claim 1, which further comprises the step of: removing the core plug of the core die forming apparatus.
3. 3. The method according to claim 1, further comprising the step of: applying an adhesive to at least a portion of the recess region. 4. - The method according to claim 1, wherein the recessed region stamped on the blank comprises a uniform concentric groove with an outer perimeter of the core blank. 5. - The method according to claim 1, wherein the recessed region stamped on the blank comprises a stippling. 6. - The method according to claim 1, wherein the recessed region stamped on the blank comprises a zig-zag template. 7. - A core plug formed by the method of claim 1, comprising: a base region an outer ring extending upwardly from the base region and around the outer perimeter of the base region, the outer ring includes a surface Exterior; and a recessed region around the outer surface of the outer ring.2 8. A core plug formed by the method of claim 3, comprising: a base region; an outer ring extending upwardly from the base region and around the outer perimeter of the base region, the outer ring includes an outer surface; and a region in recess around the outer surface of the outer ring. an adhesive applicable to a portion of the recessed region. . - a core plug formed by a method comprising the steps of: placing a core blank in a stamping apparatus, the blank including an outer ring, an upper surface and a lower surface; stamping a region in recess in the outer ring of the bottom surface of the blank; placing the bottom surface of the blank in a receiving region thereof of a core die forming apparatus; propelling the blank through an opening extending through the core die forming apparatus; deforming a portion of the outer ring inwardly and upwardly to obtain a core plug, wherein the recessed region impressed in the core plug is not substantially effected by the deformation step. 10. - A core die forming apparatus for the formation of a core plug from a core blank having a recessed region, apparatus comprising: a second die member having a top surface, a receiving region? and the blank and a substantially perpendicular opening extending through at least one portion of the second die member; the opening includes an introduction region close to the receiving region of the blank, a transition region and a final region, wherein the size of the opening in the insertion region is smaller than the size of the blank. and greater than the size of the opening in the final region; The transition region comprises a continuous convex surface that provides a gradual, smooth transition from the region of introduction to the final region, to, in turn, facilitate the smooth formation of the blank in a core plug, without substantially affecting it. the grooved surfaces of the blank; and means for propelling the blank from the upper surface of the second die member through the end region of the opening, in turn, to obtain a core plug. 11. The apparatus according to claim 10, wherein: the transition region forms a uniform acute angle with respect to an axis perpendicular to the upper surface of the second die member; the junction between the introduction region and the transition region is rounded; and the meeting between the transitional region and the final region is rounded up. 12. - The core die forming apparatus according to claim 10, wherein the opening is substantially circular in cross section. 13. - The core die forming apparatus according to claim 1, wherein the second die member includes a lower surface, the opening extends through the upper surface to the lower surface of the second die member. 1 . - The core die forming apparatus according to claim 10, further comprises means for removing the plug and the core ends from the core after the formation. 15. - The core die forming apparatus according to claim 14, wherein the removal means comprises a guided levering member functionally positioned near the propeller means, the guided levering member slidingly engages the core plug on the driving means and disconnects it from it. 16. - The die forming apparatus according to claim 14 wherein the propulsion means comprises a punch member configured to be forced to force the blank through the opening of the second member? E? ?or. 17. - The core die forming apparatus according to claim 10, wherein the second member of the aforementioned member purchases a carbide material having a TI-8 coating. 18. The core die forming apparatus according to claim 10 wherein the second die member comprises high carbon tool steel.