US20120047983A1 - Manufacturing method for diffuser - Google Patents
Manufacturing method for diffuser Download PDFInfo
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- US20120047983A1 US20120047983A1 US13/206,011 US201113206011A US2012047983A1 US 20120047983 A1 US20120047983 A1 US 20120047983A1 US 201113206011 A US201113206011 A US 201113206011A US 2012047983 A1 US2012047983 A1 US 2012047983A1
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- section
- axial direction
- flange
- molded component
- bottomed cylindrical
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
- B21J1/02—Preliminary treatment of metal stock without particular shaping, e.g. salvaging segregated zones, forging or pressing in the rough
- B21J1/025—Preliminary treatment of metal stock without particular shaping, e.g. salvaging segregated zones, forging or pressing in the rough affecting grain orientation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K21/00—Making hollow articles not covered by a single preceding sub-group
- B21K21/08—Shaping hollow articles with different cross-section in longitudinal direction, e.g. nozzles, spark-plugs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
- B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
- B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
- B60R21/26—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags characterised by the inflation fluid source or means to control inflation fluid flow
- B60R21/261—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags characterised by the inflation fluid source or means to control inflation fluid flow with means other than bag structure to diffuse or guide inflation fluid
Definitions
- the present invention relates to a manufacturing method for a diffuser of an inflator for an airbag used to expand an airbag of a vehicle.
- a diffuser such as shown in the cross sectional diagram of FIG. 8 has been used as a diffuser of an inflator for this type of air bag. Fiber flow is an important factor, and so in the cross section hatching has been omitted.
- this diffuser 6 A has a flange 61 with a central hole section 61 a and an outer engagement section 61 b , and a bottomed cylindrical section 63 having a communicating hole 63 a that leads to one end, in an axial direction, of the flange 61 and communicates with the hole section 61 a , with a peripheral groove 63 b formed on an outer peripheral section of the bottomed cylindrical section 63 , and a plurality of exhaust ports 64 b that communicate with an airbag extending radially to the bottom section of the communication hole 63 a .
- An outer end surface of the flange 61 is then attached to an opening section of a high pressure gas container 10 by welding, while an airbag 11 is engaged in the outer peripheral portion of the bottomed cylindrical section 63 , and attached by mechanical fastening by means of the peripheral groove 63 b.
- a first molded component 3 A comprising as shown in FIG. 9 a flange 31 having a central hole section 31 a and a bottomed cylindrical section 33 that leads to one end, in the axial direction, of the flange 31 and has a communication hole 33 a communicating with the central hole section 31 a , is formed by gradually forging this cylindrical solid material in the axial direction using a former or press, and then a second intermediate molded component 4 A is formed by forming a peripheral groove 43 b by a cutting operation on the outer periphery of the bottomed cylindrical section 33 of the first molded component 3 A, as shown in FIG.
- the cause of this gas leakage is a phenomenon where very small amounts of high pressure gas escape with an extremely low probability along fiber flow and non-ferrous inclusions within the steel formed with strengthening processing by cold forging of the material (steel).
- leakage of a very small amount of high pressure gas from sections of the peripheral groove 63 b where the fiber flow has bee cut occurs at a very small proportion, e.g., one of ten-thousands of diffuser due to the above described phenomenon.
- After manufacture of the diffuser total inspection of the diffuser to be used is carried out to see whether or not gas leaks have occurred in sections where the fiber flow of the peripheral groove 63 b has been cut, and only those in which gas leaks have not occurred are used.
- the present invention therefore provides a manufacturing method for a diffuser that can be produced with high yield and at low cost, while doing away with locations where fiber flow is cut and that has no gas leakage.
- An invention of a first aspect of this application is a manufacturing method for a diffuser including a flange with a central hole section and an outer engagement section, and a bottomed cylindrical section having a communicating hole that leads to one end, in an axial direction, of the flange and communicates with the hole section, with a peripheral groove formed on an outer peripheral section of the bottomed cylindrical section, and a plurality of expulsion ports that communicate with an airbag extending radially to the bottom section of the communication hole, comprising:
- An invention of a second aspect of this application is a manufacturing method for a diffuser including a flange with a central hole section and an outer engagement section, and a bottomed cylindrical section having a communicating hole that leads to one end, in an axial direction, of the flange and communicates with the hole section, with a peripheral groove formed on an outer peripheral section of the bottomed cylindrical section, and a plurality of expulsion ports that communicate with an airbag extending radially to the bottom section of the communication hole, comprising:
- an intermediate component formed by gradually forging a cylindrical solid material that has fiber flow extending in an axial direction using a multistage former or press, the intermediate component including a flange and a cylindrical section that extends axially outward from a central section at one end, in the axial direction, of the flange, via a step section and having a smaller diameter than the step section, and having fiber flow flowing in substantially the axial direction without being cut;
- a first process of forming a first molded component by press forming the intermediate component from the axial direction using a press unit the first molded component including a flange having a central hole section, and a bottomed cylindrical section of smaller diameter than the outer diameter of a step section, the first molded component having a communication hole that extends axially outwards from a central section of one end of the flange in the axial direction and communicates with the hole section, with fiber flow flowing in a substantially axial direction without being cut;
- the manufacturing method for a diffuser of the first aspect of this application it is possible to gradually forge shape a solid cylindrical material that has fiber flow extending in an axial direction from the axial direction thereof, and so it is possible to achieve high yield and low cost, and moreover in the second process, since the second molded component has the peripheral groove formed on an outer periphery of the bottomed cylindrical section without cutting the fiber flow by split forging a peripheral groove using the split dies on an outer periphery of the bottomed cylinder, fiber flow is not cut accompanying peripheral groove formation, and it is possible to prevent gas leaking from locations where the peripheral groove is formed when attaching a high pressure gas container to an outer surface of the flange In this way, after manufacture of a diffuser it is not necessary to test whether or not gas leaks occur at the peripheral groove section, meaning it is possible to omit the time taken for testing, and also, since it is also possible to guarantee the gas leak free with the manufacturing process it is safe to use, and it is possible to reduce cost.
- an intermediate component including a flange and a cylindrical section of a smaller diameter than a step section that extends axially outward from one end central section in the axial direction, of the flange, via the step section, and having fiber flow flowing in substantially the axial direction without being cut, is formed by gradually forging a cylindrical solid material that has fiber flow extending in an axial direction, from the axial direction, using a multistage former or press, next, in the first process, a first molded component is formed by press forming the intermediate component from the axial direction using a press unit, the first molded component including a flange having a central hole section, and a bottomed cylindrical section of smaller diameter than the outer diameter of a step section having a communication hole that extends axially outwards from a central section of one end of the flange in the axial direction and communicates with the hole section, and having fiber flow axially flowing without
- the intermediate component is forge shaped inexpensively using a former, the first molded component is formed to high precision using a press unit, and the second molded component can be manufactured to high precision by carrying out a split mold upset process using the split dies, and it is possible to proactively reduce costs.
- FIG. 1 is a cross sectional drawing of a blank for a diffuser manufacturing method of the present invention
- FIG. 2 is a cross sectional drawing of an intermediate molded component in which a blank is formed by cold forging
- FIG. 3 is a cross sectional drawing of a molded component with a hole section formed in the process after that shown in FIG. 2 ;
- FIG. 4 is a cross sectional drawing showing a molded component that has had a peripheral groove upset molded with a split mold in the process after FIG. 3 ;
- FIG. 5 is a cross sectional drawing of a molded component that has been subjected to cutting process in the process after that shown in FIG. 4 ;
- FIG. 6 is a cross sectional drawing of a final molded component that has had expulsion holes cut in the process after that shown in FIG. 5 ;
- FIG. 7 is an outline explanatory drawing showing a usage state of the diffuser
- FIG. 8 is a drawing for describing a diffuser manufacturing method of related art
- FIG. 9 is a cross sectional drawing of a molded component before forming a peripheral groove in the diffuser manufacturing method of the related art.
- FIG. 10 is a cross sectional drawing of a molded component that has had a peripheral groove formed by cutting in the diffuser manufacturing method of the related art.
- FIG. 1 to FIG. 7 respectively show formation explanatory drawings for one embodiment using the diffuser manufacturing method of the present invention, and a molded component at each step is shown in a front elevation or a cross sectional view. Fiber flow is an important factor the embodiment, and so in the case of cross sectional views hatching has been omitted.
- FIG. 1 shows a cylindrical solid material 1 having fiber flow extending in an axial direction.
- This solid material 1 may be a blank formed by previously cutting a wire to specified dimensions, or may be a material formed by cutting sequentially supplied wire using a cutting machine at the time of forging using a former.
- fiber flow is flowing in the axial direction, as shown in FIG. 1 .
- the solid material 1 is gradually forge shaped from the axial direction thereof using a die and a punch, at each forging station of a multistage former, to form a solid intermediate component 2 that comprises a flange 21 having a circular outer periphery, a cylindrical section 23 extending axially outward via a step section 22 from a central section at one end in the axial direction of the flange 21 , and a small diameter projecting section 24 .
- fiber flow of the intermediate molded component 2 is flowing substantially in the axial direction, without being cut, as shown in FIG. 2 .
- the solid intermediate molded component 2 that was forge shaped by the former is subjected to press forming from an axial direction of the intermediate molded component 2 using an upper mold and a lower mold at a first press station of a vertical press unit (not shown), to form a high precision first molded component 3 comprising a flange 31 having a central hole section 31 a , a bottomed cylindrical section 33 that extends axially outward via a step section 32 from a center section at one end, in the axial direction, of the flange 31 and has a communication hole 33 a leading to the hole 31 a of the flange 31 , and a small diameter projecting section 34 .
- fiber flow of the first molded component 3 is flowing substantially in the axial direction, without being cut, as shown in FIG. 3 .
- the first molded component 3 is subjected to forging processing so as to expand only tip end of the bottomed cylindrical section 33 in a second press station, using the upper mold and the lower mold provided with the split dies of a vertical press unit, from an axial direction of the first molded component 3 , with a boundary portion of the step section 32 and the bottomed cylindrical section 33 being restrained by the split dies.
- a high precision second molded component 4 comprising the flange 41 having the central hole section 41 a as shown in FIG.
- the bottomed cylindrical section 43 (also including the step section 32 ) extending axially outwards from the central hole section of one end in the axial direction of the flange 41 at the same diameter as the outer diameter of the step section 32 , and being provided with the peripheral groove 41 b at the middle of the axial length of the outer periphery of the bottomed cylinder section 33 , and having a communication hole 43 a leading to the central hole section 41 a of the flange 41 , and the small diameter projecting section 44 , is formed.
- fiber flow of the second molded component 4 is flowing substantially in the axial direction, without being cut, as shown in FIG. 4 .
- the second molded component is shaped by cutting out an engagement section 51 b for attachment of a blocking plate etc. of a gas canister around a central hole section 51 b of an outer surface of the flange 41 using a first cutting station of a cutting unit (not shown), and a third molded component 5 is formed by cutting out a small diameter communication hole 54 a extending into the small diameter projecting section 54 from the bottom section of the communicating hole 53 a of the bottomed cylindrical section 53 .
- blackened sections are cutting locations, and reference numeral 7 indicates a holding section for when cutting the second molded component 4 .
- a diffuser 6 is formed as a finished product by cutting a plurality of expulsion holes 64 b . . . 64 b extending in a radial direction close to the bottom section of the small diameter communication hole 54 a of the small diameter projecting section 54 of the third molded component 5 .
- blackened sections are cutting locations, and reference numerals 8 and 9 indicate holding sections for when cutting the second molded component 4 .
- the diffuser 6 that has been formed in this way then has an outer end surface of the flange 61 attached to an opening section of a high pressure gas container 10 by welding, as shown in FIG. 7 , while an airbag 11 is engaged in the outer peripheral portion of the bottomed cylindrical section 63 , and attached by mechanical fastening by means of the peripheral groove 63 a.
- the diffuser 6 manufactured as descried above there are no places where fiber flow of the portion of the peripheral groove 63 b is cut, and it is possible to prevent gas leaking from portions of the peripheral groove 63 a , when attaching a high pressure gas container 10 to an outer surface of the flange. In this way, after manufacture of a diffuser 6 it is not necessary to test whether or not gas leaks occur at parts of the peripheral groove 64 b , meaning that it is possible to omit the time and effort for testing, and it is possible to reduce cost.
- the intermediate second molded component is inexpensively mass produced by forging using a multi-stage former, then the first and second molded components 3 , 4 are press molded to high precision using a vertical press unit, and after that the third molded component 5 and final molded component 6 are cut using a cutting unit, which means that it is possible to finally manufacture with high precision by combining these steps, and it is also possible to proactively achieve cost reduction.
- the multi-stage former, the vertical press unit and the cutting unit may be combined, but it is also possible, for example, to continuously carry out using only a press unit by carrying out using press forming of the intermediate molded component 2 .
Abstract
A manufacturing method for a diffuser comprises a first process of forming a first molded component, by gradually forging a cylindrical solid material having fiber flow extending in an axial direction from an axial direction thereof, the first molded component including a flange section having a central hole section, and a bottomed cylindrical section having a communication hole leading to one end, in the axial direction, of the flange, and communicating with the hole section, and having fiber flow that is flowing substantially in the axial direction without being cut, and a second process of forming a second molded component, by split molding a peripheral groove using split dies at the outer periphery of the bottomed cylindrical section of the first molded component, including a flange having a central hole section, and a bottomed cylindrical section having a communication hole leading to one end, in the axial direction, of the flange, and communicating with the hole section, and having the peripheral groove formed without cutting fiber flow. The embodiment provides a manufacturing method for a diffuser that can be produced with high yield and at low cost, while doing away with locations where fiber flow is cut and that has no gas leakage.
Description
- This application claims priority to Japanese Patent Application No. 2010-206091, filed on Aug. 27, 2010, the entire content of which is incorporated herein by reference.
- The present invention relates to a manufacturing method for a diffuser of an inflator for an airbag used to expand an airbag of a vehicle.
- Conventionally, a diffuser such as shown in the cross sectional diagram of
FIG. 8 has been used as a diffuser of an inflator for this type of air bag. Fiber flow is an important factor, and so in the cross section hatching has been omitted. - As shown in
FIG. 8 , thisdiffuser 6A has aflange 61 with acentral hole section 61 a and anouter engagement section 61 b, and a bottomedcylindrical section 63 having a communicatinghole 63 a that leads to one end, in an axial direction, of theflange 61 and communicates with thehole section 61 a, with a peripheral groove 63 b formed on an outer peripheral section of the bottomedcylindrical section 63, and a plurality ofexhaust ports 64 b that communicate with an airbag extending radially to the bottom section of thecommunication hole 63 a. An outer end surface of theflange 61 is then attached to an opening section of a highpressure gas container 10 by welding, while anairbag 11 is engaged in the outer peripheral portion of the bottomedcylindrical section 63, and attached by mechanical fastening by means of the peripheral groove 63 b. - As a method for manufacturing the above described diffuser, first, in order to increase yield and reduce cost, using cylindrical solid material (wire rod cut to a specified length) extending in the axial direction of fiber flow, a first molded
component 3A comprising as shown inFIG. 9 aflange 31 having acentral hole section 31 a and a bottomedcylindrical section 33 that leads to one end, in the axial direction, of theflange 31 and has acommunication hole 33 a communicating with thecentral hole section 31 a, is formed by gradually forging this cylindrical solid material in the axial direction using a former or press, and then a second intermediate moldedcomponent 4A is formed by forming aperipheral groove 43 b by a cutting operation on the outer periphery of the bottomedcylindrical section 33 of the first moldedcomponent 3A, as shown inFIG. 10 . After that, as shown inFIG. 8 , a cutting operation of an outerend engagement section 61 b for engaging with an outer end surface of aflange 41 of the second moldedcomponent 4A, and a cutting operation of a small diameter communication hole 64 a that communicates with a bottom section of thecommunication hole 43 a of the bottomedcylindrical section 43 and a plurality ofexpulsion holes 64 b that communicate with the small diameter communication hole 64 a, are carried out. - However, according to the above described manufacturing method for a diffuser, while it is possible on the one hand to improve yield and reduce cost, when forming the
outer groove 43 b on the outer periphery of the bottomedcylindrical section 33 of the first molded component 3, formation of theperipheral groove 43 b is carried out using a cutting operation, which means that fiber flow extending in the axial direction is cut midway, as shown inFIG. 10 . As a result, as shown inFIG. 8 , when having attached thediffuser 6A to the high-pressure gas container 10 by welding, there is a problem that high-pressure gas leaks out from the peripheral groove section 63 b where fiber flow is cut at a very small proportion of one in several ten-thousands components. - The cause of this gas leakage is a phenomenon where very small amounts of high pressure gas escape with an extremely low probability along fiber flow and non-ferrous inclusions within the steel formed with strengthening processing by cold forging of the material (steel). As a result, leakage of a very small amount of high pressure gas from sections of the peripheral groove 63 b where the fiber flow has bee cut occurs at a very small proportion, e.g., one of ten-thousands of diffuser due to the above described phenomenon. With respect to this problem, after manufacture of the diffuser total inspection of the diffuser to be used is carried out to see whether or not gas leaks have occurred in sections where the fiber flow of the peripheral groove 63 b has been cut, and only those in which gas leaks have not occurred are used. As a result, inspection is time consuming and this in turn pushes up costs. The occurrence of fiber flow arises naturally with cold forging, and non-ferrous inclusions in the material have been considerably improved at the time of steel making at a steel producer, but the actual situation is that they have not been completely eliminated.
- The present invention therefore provides a manufacturing method for a diffuser that can be produced with high yield and at low cost, while doing away with locations where fiber flow is cut and that has no gas leakage.
- An invention of a first aspect of this application is a manufacturing method for a diffuser including a flange with a central hole section and an outer engagement section, and a bottomed cylindrical section having a communicating hole that leads to one end, in an axial direction, of the flange and communicates with the hole section, with a peripheral groove formed on an outer peripheral section of the bottomed cylindrical section, and a plurality of expulsion ports that communicate with an airbag extending radially to the bottom section of the communication hole, comprising:
- a first process of forming a first molded component using a cylindrical solid material having fiber flow extending in an axial direction in order to prevent material loss, and by gradually forging a cylindrical solid material from an axial direction thereof, the first molded component including a flange section having a central hole section, and a bottomed cylindrical section having a communication hole leading to one end, in the axial direction, of the flange, and communicating with the hole section, and having fiber flow that is not cut and flowing substantially in the axial direction; and
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- a second process of forming a second molded component by split molding a peripheral groove using split dies at the outer periphery of the bottomed cylindrical section of the first molded component, the second molded component including a flange having a central hole section and a bottomed cylindrical section having a communication hole leading to one end, in the axial direction, of the flange, and communicating with the hole section, and having the peripheral groove formed without cutting fiber flow.
- An invention of a second aspect of this application is a manufacturing method for a diffuser including a flange with a central hole section and an outer engagement section, and a bottomed cylindrical section having a communicating hole that leads to one end, in an axial direction, of the flange and communicates with the hole section, with a peripheral groove formed on an outer peripheral section of the bottomed cylindrical section, and a plurality of expulsion ports that communicate with an airbag extending radially to the bottom section of the communication hole, comprising:
- a advance process of forming an intermediate component, formed by gradually forging a cylindrical solid material that has fiber flow extending in an axial direction using a multistage former or press, the intermediate component including a flange and a cylindrical section that extends axially outward from a central section at one end, in the axial direction, of the flange, via a step section and having a smaller diameter than the step section, and having fiber flow flowing in substantially the axial direction without being cut;
- a first process of forming a first molded component by press forming the intermediate component from the axial direction using a press unit, the first molded component including a flange having a central hole section, and a bottomed cylindrical section of smaller diameter than the outer diameter of a step section, the first molded component having a communication hole that extends axially outwards from a central section of one end of the flange in the axial direction and communicates with the hole section, with fiber flow flowing in a substantially axial direction without being cut; and
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- a second process of forming a second molded component by a split mold upset process so as to extend only tip end of the bottomed cylindrical section in a state where a boundary division of the step section and the bottomed cylindrical component of the first molded component is restrained by split dies, the second molded component including a flange having a central hole section, and a bottomed cylindrical section extending axially outward at the same diameter as the outer diameter of the step section from the center section of one end, in the axial direction, of the flange, and having a peripheral groove at the middle in the axial length of the bottomed cylindrical section, the peripheral groove being formed without cutting the fiber flow.
- According to the manufacturing method for a diffuser of the first aspect of this application, it is possible to gradually forge shape a solid cylindrical material that has fiber flow extending in an axial direction from the axial direction thereof, and so it is possible to achieve high yield and low cost, and moreover in the second process, since the second molded component has the peripheral groove formed on an outer periphery of the bottomed cylindrical section without cutting the fiber flow by split forging a peripheral groove using the split dies on an outer periphery of the bottomed cylinder, fiber flow is not cut accompanying peripheral groove formation, and it is possible to prevent gas leaking from locations where the peripheral groove is formed when attaching a high pressure gas container to an outer surface of the flange In this way, after manufacture of a diffuser it is not necessary to test whether or not gas leaks occur at the peripheral groove section, meaning it is possible to omit the time taken for testing, and also, since it is also possible to guarantee the gas leak free with the manufacturing process it is safe to use, and it is possible to reduce cost.
- Also, according to the manufacturing method for a diffuser of the second aspect of this application, first, as the advance process, an intermediate component, including a flange and a cylindrical section of a smaller diameter than a step section that extends axially outward from one end central section in the axial direction, of the flange, via the step section, and having fiber flow flowing in substantially the axial direction without being cut, is formed by gradually forging a cylindrical solid material that has fiber flow extending in an axial direction, from the axial direction, using a multistage former or press, next, in the first process, a first molded component is formed by press forming the intermediate component from the axial direction using a press unit, the first molded component including a flange having a central hole section, and a bottomed cylindrical section of smaller diameter than the outer diameter of a step section having a communication hole that extends axially outwards from a central section of one end of the flange in the axial direction and communicates with the hole section, and having fiber flow axially flowing without being cut, and after that, a second molded component is formed by a split mold upset process so as to expand only tip end of the bottomed cylindrical section in a state where a boundary division of the step section and the bottomed cylindrical component of the first molded component is restrained by the split dies, the second molded component including a flange having a central hole section, and a bottomed cylindrical section having a peripheral groove extending axially outward at the same diameter as the outer diameter of the step section from the center section of one end, in the axial direction, of the flange, and at the middle of the axial length of the outer peripheral of the bottomed cylindrical section, and the peripheral groove is formed without cutting fiber flow, which means that similarly to the above described first aspect, there are no places where fiber flow of the peripheral groove section is cut, and it is possible to completely prevent gas leaking at places where the peripheral groove is formed, when having attached a high pressure gas container to an outer surface of the flange. In this way, after manufacture of a diffuser it is not necessary to test whether or not gas leaks occur at the peripheral groove section, meaning it is possible to omit the time and effort for testing, and surely guarantee the gas leak free with the manufacturing process, and it is possible to reduce cost. Further, the intermediate component is forge shaped inexpensively using a former, the first molded component is formed to high precision using a press unit, and the second molded component can be manufactured to high precision by carrying out a split mold upset process using the split dies, and it is possible to proactively reduce costs.
- The present invention will be further described with reference to the accompanying drawings wherein like reference numerals refer to like parts in the several views, and wherein:
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FIG. 1 is a cross sectional drawing of a blank for a diffuser manufacturing method of the present invention; -
FIG. 2 is a cross sectional drawing of an intermediate molded component in which a blank is formed by cold forging; -
FIG. 3 is a cross sectional drawing of a molded component with a hole section formed in the process after that shown inFIG. 2 ; -
FIG. 4 is a cross sectional drawing showing a molded component that has had a peripheral groove upset molded with a split mold in the process afterFIG. 3 ; -
FIG. 5 is a cross sectional drawing of a molded component that has been subjected to cutting process in the process after that shown inFIG. 4 ; -
FIG. 6 is a cross sectional drawing of a final molded component that has had expulsion holes cut in the process after that shown inFIG. 5 ; -
FIG. 7 is an outline explanatory drawing showing a usage state of the diffuser; -
FIG. 8 is a drawing for describing a diffuser manufacturing method of related art; -
FIG. 9 is a cross sectional drawing of a molded component before forming a peripheral groove in the diffuser manufacturing method of the related art; and -
FIG. 10 is a cross sectional drawing of a molded component that has had a peripheral groove formed by cutting in the diffuser manufacturing method of the related art. - A diffuser manufacturing method of the present invention will be described in the following based on the drawings.
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FIG. 1 toFIG. 7 respectively show formation explanatory drawings for one embodiment using the diffuser manufacturing method of the present invention, and a molded component at each step is shown in a front elevation or a cross sectional view. Fiber flow is an important factor the embodiment, and so in the case of cross sectional views hatching has been omitted. -
FIG. 1 shows a cylindrical solid material 1 having fiber flow extending in an axial direction. This solid material 1 may be a blank formed by previously cutting a wire to specified dimensions, or may be a material formed by cutting sequentially supplied wire using a cutting machine at the time of forging using a former. Here fiber flow is flowing in the axial direction, as shown inFIG. 1 . - As shown in
FIG. 2 , the solid material 1 is gradually forge shaped from the axial direction thereof using a die and a punch, at each forging station of a multistage former, to form a solidintermediate component 2 that comprises aflange 21 having a circular outer periphery, acylindrical section 23 extending axially outward via astep section 22 from a central section at one end in the axial direction of theflange 21, and a smalldiameter projecting section 24. Here, fiber flow of the intermediate moldedcomponent 2 is flowing substantially in the axial direction, without being cut, as shown inFIG. 2 . - Next, as shown in
FIG. 3 , the solid intermediate moldedcomponent 2 that was forge shaped by the former is subjected to press forming from an axial direction of the intermediate moldedcomponent 2 using an upper mold and a lower mold at a first press station of a vertical press unit (not shown), to form a high precision first molded component 3 comprising aflange 31 having acentral hole section 31 a, a bottomedcylindrical section 33 that extends axially outward via astep section 32 from a center section at one end, in the axial direction, of theflange 31 and has acommunication hole 33 a leading to thehole 31 a of theflange 31, and a smalldiameter projecting section 34. Here, fiber flow of the first molded component 3 is flowing substantially in the axial direction, without being cut, as shown inFIG. 3 . - In
FIG. 4 , the first molded component 3 is subjected to forging processing so as to expand only tip end of the bottomedcylindrical section 33 in a second press station, using the upper mold and the lower mold provided with the split dies of a vertical press unit, from an axial direction of the first molded component 3, with a boundary portion of thestep section 32 and the bottomedcylindrical section 33 being restrained by the split dies. In this way, a high precision secondmolded component 4 comprising theflange 41 having the central hole section 41 a as shown inFIG. 4 , the bottomed cylindrical section 43 (also including the step section 32) extending axially outwards from the central hole section of one end in the axial direction of theflange 41 at the same diameter as the outer diameter of thestep section 32, and being provided with the peripheral groove 41 b at the middle of the axial length of the outer periphery of the bottomedcylinder section 33, and having acommunication hole 43 a leading to the central hole section 41 a of theflange 41, and the smalldiameter projecting section 44, is formed. Here, fiber flow of the second moldedcomponent 4 is flowing substantially in the axial direction, without being cut, as shown inFIG. 4 . - After that, as shown in
FIG. 5 , the second molded component is shaped by cutting out an engagement section 51 b for attachment of a blocking plate etc. of a gas canister around a central hole section 51 b of an outer surface of theflange 41 using a first cutting station of a cutting unit (not shown), and a third moldedcomponent 5 is formed by cutting out a smalldiameter communication hole 54 a extending into the smalldiameter projecting section 54 from the bottom section of the communicatinghole 53 a of the bottomedcylindrical section 53. InFIG. 5 , blackened sections are cutting locations, andreference numeral 7 indicates a holding section for when cutting the second moldedcomponent 4. - Further, as shown in
FIG. 6 , adiffuser 6 is formed as a finished product by cutting a plurality ofexpulsion holes 64 b . . . 64 b extending in a radial direction close to the bottom section of the smalldiameter communication hole 54 a of the smalldiameter projecting section 54 of the third moldedcomponent 5. InFIG. 6 , blackened sections are cutting locations, andreference numerals component 4. - The
diffuser 6 that has been formed in this way then has an outer end surface of theflange 61 attached to an opening section of a highpressure gas container 10 by welding, as shown inFIG. 7 , while anairbag 11 is engaged in the outer peripheral portion of the bottomedcylindrical section 63, and attached by mechanical fastening by means of theperipheral groove 63 a. - According to the
diffuser 6 manufactured as descried above, there are no places where fiber flow of the portion of the peripheral groove 63 b is cut, and it is possible to prevent gas leaking from portions of theperipheral groove 63 a, when attaching a highpressure gas container 10 to an outer surface of the flange. In this way, after manufacture of adiffuser 6 it is not necessary to test whether or not gas leaks occur at parts of theperipheral groove 64 b, meaning that it is possible to omit the time and effort for testing, and it is possible to reduce cost. Further, with the above described embodiment, first the intermediate second molded component is inexpensively mass produced by forging using a multi-stage former, then the first and second moldedcomponents 3, 4 are press molded to high precision using a vertical press unit, and after that the third moldedcomponent 5 and final moldedcomponent 6 are cut using a cutting unit, which means that it is possible to finally manufacture with high precision by combining these steps, and it is also possible to proactively achieve cost reduction. - As described above, the multi-stage former, the vertical press unit and the cutting unit may be combined, but it is also possible, for example, to continuously carry out using only a press unit by carrying out using press forming of the intermediate molded
component 2. - Although the present invention has been fully described by way of examples with reference to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art. Therefore, unless such changes and modifications depart from the spirit and the scope of the present invention, they should be construed as being included therein.
Claims (2)
1. A manufacturing method for a diffuser comprising a flange with a central hole section and an outer engagement section, and a bottomed cylindrical section having a communicating hole that leads to one end, in an axial direction, of the flange and communicates with the hole section, with a peripheral groove formed on an outer peripheral section of the bottomed cylindrical section, and a plurality of expulsion ports that communicate with an airbag extending radially to the bottom section of the communication hole, comprising:
a first process of forming a first molded component, by gradually forging a cylindrical solid material from an axial direction thereof using the cylindrical solid material having fiber flow extending in an axial direction in order to prevent material loss, the first molded component including a flange section having a central hole section, and a bottomed cylindrical section having a communication hole leading to one end, in the axial direction, of the flange, and communicating with the hole section, and having fiber flow that is not cut and flowing substantially in the axial direction; and
a second process of forming a second molded component, by split molding a peripheral groove using split dies at the outer periphery of the bottomed cylindrical section of the first molded component, the second molded component including a flange having a central hole section, and a bottomed cylindrical section having a communication hole leading to one end, in the axial direction, of the flange, and communicating with the hole section, and having the peripheral groove formed without cutting fiber flow.
2. A manufacturing method for a diffuser comprising a flange with a central hole section and an outer engagement hole section, and a bottomed cylindrical section having a communicating hole that leads to one end, in an axial direction, of the flange and communicates with the hole section, with a peripheral groove formed on an outer peripheral section of the bottomed cylindrical section, and a plurality of expulsion ports that communicate with an airbag extending radially to the bottom section of the communication hole, comprising:
an advance process of forming an intermediate molded component, by gradually forging a cylindrical solid material that has fiber flow extending in an axial direction using a multistage former or press, the intermediate molded component including a flange, and a cylindrical section of a smaller diameter than a step section that extends axially outward from a central section at one end, in the axial direction, of the flange, via the step section, and having fiber flow flowing in substantially the axial direction without being cut;
a first process of forming a first molded component by press forming the intermediate component from the axial direction using a press unit, the first molded component comprising a flange having a central hole section, and a bottomed cylindrical section of smaller diameter than the outer diameter of a step section having a communication hole that extends axially outwards from a central section of one end of the flange in the axial direction and communicates with the hole section, with fiber flow flowing in a substantially axial direction without being cut; and
a second process of forming a second molded component by a split mold upset process so as to expand only a tip end of the bottomed cylindrical section in a state where a boundary division of the step section and the bottomed cylindrical section of the first molded component is restrained by split dies, the second molded component including a flange having a central hole section, and a bottomed cylindrical section having a peripheral groove and extending axially outward at the same diameter as the outer diameter of the step section from the center section of one end, in the axial direction, of the flange, at a middle of the axial length of the outer periphery of the bottomed cylindrical section, and having the peripheral groove formed without cutting fiber flow.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2010206091A JP5152288B2 (en) | 2010-08-27 | 2010-08-27 | Manufacturing method of diffuser |
JP2010-206091 | 2010-08-27 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20120047983A1 true US20120047983A1 (en) | 2012-03-01 |
Family
ID=45695342
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/206,011 Abandoned US20120047983A1 (en) | 2010-08-27 | 2011-08-09 | Manufacturing method for diffuser |
Country Status (2)
Country | Link |
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US (1) | US20120047983A1 (en) |
JP (1) | JP5152288B2 (en) |
Cited By (3)
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CN110234425A (en) * | 2016-12-27 | 2019-09-13 | 日本化药株式会社 | The manufacturing method of gas generator, gas generator body and gas generator body |
CN113631299A (en) * | 2019-03-25 | 2021-11-09 | 株式会社大赛璐 | Metal assembly |
CN115032328A (en) * | 2021-03-04 | 2022-09-09 | 郑州宇通客车股份有限公司 | False alarm prevention control system and control method for gas leakage detection in vehicle |
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JP5165804B2 (en) | 2011-03-11 | 2013-03-21 | Thk株式会社 | Wind power generator |
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Also Published As
Publication number | Publication date |
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JP2012045618A (en) | 2012-03-08 |
JP5152288B2 (en) | 2013-02-27 |
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