US3432909A - Joining of metal sheets so that when said joined sheets are viewed from one side,the illusion is created that they form one continuous metal sheet - Google Patents

Description

March 18.- 1969 Filed Oct. 5, 1966 R. S. HOPKINS JOINING 0F METAL SHEETS so THAT WHEN SAID JOINED SHEETS ARE VIEWED FROM ONE SIDE, THE ILLUSION IS CREATED THAT THEY FORM ONE CONTINUOUS METAL SHEET Sheet of 4 &

RICHARD S. HOPKINS INVENTOR.

ATTORNEY 3,432,909 JOINING OF METAL SHEETS SO THAT WHEN SAID JOINED SHEETS ARE VIEWED FROM ONE SIDE March 18, 1969 R. s. HOPKINS 1 THE ILLUSION IS CREATED THAT THEY FORM ONE CONTINUOUS SHEET Sheet 3 of4 Filed Oct. 5, 1966 FIG. 4

S. HOPKINS INVENTOR.

D R A H E R ATTORNEY March 18, 19169 R. s. HOPKINS 3,432,909

JOINING OF METAL SHEETS SO THAT WHEN SAID JOINED SHEETS ARE VIEWED FROM ONE SIDE, THE ILLUSION IS CREATED THAT THEY, FORM ONE CONTINUOUS METAL SHEET Sheet Filed Oct. 5, 1966 ATTORNEY March 18, 1969 R. s. HOPKINS 3,432,909

JOINING OF METAL SHEETS SO THAT WHEN SAID JOINED SHEETS ARE VIEWED FROM ONE SIDE, THE ILLUSION IS CREATED THAT THEY FORM ONE CONTINUOUS METAL SHEET Filed Oct. 5, 1966 Sheet of 4 FIG. 10

RICHARD S. HOP KINS INVENTOR.

ATTORNEY United States Patent 4 Claims ABSTRACT OF THE DISCLOSURE A V-shaped metal strip with perforation along the apex is joined to a first metal body along one arm of the V and to a second metal body along the other arm. The space between two bodies is filled with a filler material which is then smoothed to give the appearance of continuous metal body.

The present invention relates to joining of metals and more particularly to automobile body and fender repair work.

One of the problems in body and fender work is the removal of torn metal, from a car section, replacing the torn metal with new metal plates and finishing the section so that the mending is invisible. It is well known that cars with torn parts or visible joints on plates will not sell so that this type of vehicle has no resale value and furthermore, is a hindrance to professional people such as actors, doctors, etc. Although, many attempts have been made to provide an arrangement to replace torn portions of automobile sections, none, as far as I am aware has ever been successful when carried out into practice commercially.

Thus, an object of the present invention is to provide an arrangement for joining metals.

Another object of the present invention is to provide an arrangement for joining metals so as to end up with a nice flush finish which gives the illusion that the joined pieces are in reality a single piece.

Still another object of the present invention is to provide an arrangement for the repair of automobile sections which have torn metal.

Yet another object of the present invention is to provide a method of treating metal pieces to be joined so as to end up with a flush finish, particularly in joining metal to automobiles in body and fender work.

Generally speaking, the present invention contemplates joining two sheets of metal having corresponding straight edges, wherein one side, i.e., the outer sides of the two joined sheets must present a continuous smooth painted surface when joined. In other words from the outside, they look like one piece. The sheets to be joined are first inwardly bent to form inner marginal sections along a line parallel to the straight edge, a short distance there from. A V-shaped strip length having a plurality of small elongated apertures between two meeting walls is then placed behind one of these inner marginal sections on one of the sheets and one of the walls of the strip length is fastened to the marginal section. A tool is then passed through the elongated aperture and used to grip the marginal section of the other sheet and this other marginal section is then fastened to the other wall of the strip length, forming a V-shaped groove. This groove is then filled with a hardenable plastic which is generally shaped to occupy the groove contours and extended past the marginal section to the fiat surface of the sheets. After the plastic hardens it is sanded down to present 3,432,909 Patented Mar. 18, 1969 ice a flush surface with the sheets and finally painted and baked to finish the job.

The invention as well as other objects and advantages thereof will become more apparent from the following description taken in conjunction with the accompanying drawing in which:

FIG. 1 represents the rear portion of an automobile in perspective with a torn rear right side plate;

FIG. 2a is a perspective view of one tool which may be used on a straight edge cut in the rear right side plate of the automobile of FIG. 1;

FIG. 2b relates to a front perspective view of the tool of FIG. 2a;

FIG.2c shows a section view of the tool shown in FIG. 212, along lines 2c2c thereof;

FIG. 3a illustrates in perspective, a portion of a strip length used in joining two sheets of metal;

FIG. 3b presents an end view of the strip length illustrated in FIG. 3a;

FIG. 4 depicts in perspective the use of the tool described in FIGS. 2a to 20 on a sheet of metal;

FIG. 5 shows in perspective the use of the strip length of FIGS. 3a and 3b in the joining operation;

FIG. 6 provides a partly schematic explanation of an alternate means of fastening the strip length to a sheet of metal;

FIG. 7 is a perspective view of a second tool which may be used in the operations herein described;

FIG. 8 then explains by a perspective view the use of the tool of FIG. 7 in joining a second sheet of metal to the strip length;

FIG. 9a is a perspective view of the now joined sheets of metal workpiece at an early stage of the finishing operation;

FIG. 9b provides a perspective view of the now joined sheets of metal workpiece at an intermediate stage of the finishing operation;

FIG. 96 shows the now joined sheets of metal workpiece at the final stage of the finishing operation; and,

FIG. 10 is a side view corresponding generally to the perspective View of FIG. 9a presenting a cross-sectional explanation of the work to be performed in FIGS. 9b and on the workpiece.

The automobile 12 shown in FIG. 1 has been in some sort of accident which has torn a portion of the right rear side plate sheet 14. In order to repair this plate 14, the torn edge 16 and part of the plate 18 is out along a straight line 20 so as to form a straight edge 22 (see FIG. 5), and another plate sheet 24 must be joined to plate sheet 14. When the work is finished the new plate must form an intimate continuous section with the rest of the automobile so that even on close inspection it is impossible to tell that the rear plate consists of two sections and not one section. First, the rear plate in the vicinity of the cut edge 22 is carefully sanded down. A marginal section 26 is defined parallel to edge 22 and, the defined marginal section 26 is then bent inwards towards the automobile by means of a power tool 28.

Power tool 28 includes a solid three walled box-like housing 30. The end piece 32 of this housing has a rectangular wall section 34 and an inwardly inclined wall section 36. A hammer 38 is fitted for reciprocating action between the three walls. This hammer is in general rectangular shape except for an outwardly inclined plate 40 designed to mate with the inwardly inclined wall section 36. Therefore, when the side plate 14 placed between the end piece 32 and hammer 38 is struck by the hammer, the sheet will be bent inwardly by the blows of the hammer. Passing out of the housing from the hammer through an opening in the housing is a piston rod 42 which can be attached to a power source, i.e., a pneumatic power source which can work the hammer.

Using power tool 28 the two marginal sections along the metal sheets to be joined are inwardly bent. It is now necessary to join the two metal sheets and to accomplish this, a section of strip length 44 is used.

Strip length 44 has a V-shaped cross-section and consists of two walls 46 and 48 meeting at an apex 50. Strip length 44 may be made of either metal or strong plastic. A key feature of strip length 44 are the keyhole shaped apertures 52. A plurality of these apertures are disposed along the length of the apex 50.

To join two sheets of metal using strip length 44, the strip length is first fastened to the marginal section 26 of one of the metal sheets by conventional means, e.g., rivets 54. Thus, rivet holes 56 first are made in the metal sheet marginal section and in the strip length, or the strip length 44 may have ready for-med rivet holes already in the strip walls. The riveting of the strip wall to the marginal section is accomplished by means known in the art.

With regard to joining the marginal section to the strip wall, spot Welding may also be employed according to technique described by Arthur L. Phillips Welding Handbook American Welding Society (1962 edition) or by Rupert Le Grand The New American Machinist Handbook--McGraw-Hill Book Co., Inc. 1955, Section 22.

It is now necessary to join the repair sheet or second plate sheet 24 to the strip length 44. To accomplish this, use is made of a second tool, namely hand angle vise 58. Angle vise 58 includes a handle 60 and a shaft 62 extending from the handle 60. A portion of the outer length of shaft is threaded 64 and the shaft ends in a locking key 66 which can be a fiat rectangle. Locking key 66 will penetrate keyhole apertures 52 in strip length 44 and when turned 90 will hold the shaft to the strip length. Disposed on the outer length of shaft 62 is a free moving wedge-shaped vice piece 68 which is engaged by a wing nut 70 thre'adedly mounted on the inner end of the shaft threads. In order to fasten the repair plate sheet, i.e., sheet 24 to the strip length 44, locking key 66 is first passed through the keyhole aperture 52. The repair plate sheet 24 is then placed over the strip length 44. The handle 58 of the angle vise is turned so that the locking key 66 locks the outer end of the angle vise in place. The wing nut 70 is turned forcing the apex of the triangular vise piece 68 towards the apex of strip length 44 so as to firmly hold the repair plate sheet 24. With the repair plate sheet 24 firmly held in place, as shown in FIG. 8, the marginal section of the repair plate sheet 24 is fastened to the strip length either by rivets or by welding as in the case of the first sheet.

The two plate sheets 14 and 44 are now firmly held together and the marginal sections which form a V- shaped groove. This groove is now filled with a hardenable plastic filler material 72 commercially available which will adhere firmly to the groove. Some of the plastic filler material is spread out on both sides of the groove. This will provide an appearance somewhat like that shown in FIGS. 9a and 10. The plastic filler material is then ground down or sanded down with a grinder or sander until a flat even surface is obtained. The joined workpiece is then subjected to a first coating treatment, i.e., a first coat of paint 74 as shown in FIG. 9b. After this, the final finishing operation can be performed using enameling and baking techniques known in the art. The finished joined workpiece then looks like one sheet of metal 76 from the outside.

In carrying the invention into practice, a Spot welding arrangement commercially sold by Blair Equipment Co. of Flushing, Mich., known as the Blair Triangle Spot Welder, and described in that companys catalogue of 1963, has been found particularly useful. As a plastic filler material, successful use has been made of such products as Black Magic, Silver Magic, Snowite which are sold by Swiss Laboratory, Inc. of Cleveland, Ohio. A lead or other filler may also be used.

Although the present invention has been described in conjunction with preferred embodiments, it is to be understood that modifications and variations may be resorted to Without departing from the spirit and scope of the invention as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the invention and appended claims.

I claim: 1. A method of joining two sheets of metal having corresponding straight edges so that when joined, one side of the two joined sheets presents a continuous, smooth surface appearance giving the illusion that the two joined sheets are one continuous sheet, comprising the steps of: inwardly bending a portion of each sheet along a line parallel to said straight edge thereof so as to define a marginal section;

placing a V-shaped strip length having a plurality of elongated apertures along the apex thereof behind one of said defined marginal sections;

fastening said strip length to said marginal section;

passing a holding tool through said elongated aperture;

placing the second marginal section over said strip length;

gripping said second marginal section with said tool from behind and firmly holding said marginal section to said strip length;

fastening said second marginal section to said strip thereby creating a workpiece of two joined sheets with a groove in between;

filling said workpiece groove with a filler material;

grind polishing said filled groove filler material so as to obtain a smooth surface; and,

paint finishing said joined workpiece so as to present a continuous outer surface.

2. A method of joining metals as claimed in claim 1 wherein filler material is also placed on some of the area surrounding said groove and the filled groove as well as the surrounding area is treated by grind polishing.

3. The method of claim 2 wherein said marginal sections are fastened to said strip length by welding.

4. The method of claim 2 wherein said marginal sections are fastened to said strip length by riveting.

References Cited UNITED STATES PATENTS 2,463,561 3/1949 Riley.

2,946,118 7/ 1960 Steck 29401 2,953,847 9/1960 Reed 29--401 3,066,719 12/ 1962 Seznick 2940l 3,091,983 6/1963 Kliss 29-401 JOHN F. CAMPBELL, Primary Examiner.

PAUL M. COHEN, Assistant Examiner.

US. Cl. X-R.

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