US3699643A

US3699643A - Method for manufacturing a gill faller of a constant thickness faller body type

Info

Publication number: US3699643A
Application number: US122013A
Authority: US
Inventors: Ichizo Isumi
Original assignee: Individual
Current assignee: Individual
Priority date: 1969-01-27
Filing date: 1971-03-08
Publication date: 1972-10-24
Anticipated expiration: 1989-10-24
Also published as: GB1288734A; JPS4711549Y1; DE2002834A1; US3694858A; FR2029503B1; DE2002834B2; FR2029503A1

Abstract

A method for manufacturing a gill faller of a constant thickness faller body type wherein a faller body is formed by an application of blanking to a plain steel plate of constant thickness, ends of the plain faller body are shaped as desired by pressing and combing pins are attached to thusly shaped faller body by plastic molding technique.

Description

United States Patent Field of Search ..19/129 R; 29/527.1; 264/271 Isumi Y Oct. 24, 1972 [54] METHOD FOR MANUFACTURING A [56] References Cited GILL FALLER OF A CONSTANT THICKNESS FALLER BODY TYPE UNITED STATES PATENTS [72] Inventor: Ichim lsumi A6406, 212a Gazav 2,409,565 10/1946 l-loldsworth ..19/129 R Yamada Shimo Suita shi, Osaka, 2,901,778 9/1959 Sauvage ..l9/l29R Ja an 3,125,801 3/1964 Fields ..29/527.l X p 3,532,077 10/1970 Mann ..19/129 R [22] Filed: March 8, 1971 y Primary Examiner-John F. Campbell [211 A 122013 Assistant Examiner--Donald C. Reiley, Ill

Related li fi D t AttorneyRobert E. Burns and Emmanuel J. Lobato [63] Division Of SCI. NO. 4,218,.1311. 20, I A method for manufacturing a gill faller of ,a constant [30] Foreign Application Priority Data thickness faller body type wherein a faller body is formed by an application of blanking to a plain steel Jan. 27 1969 Japan ..44/7345 1 pl f constant thickness, ends of the plain faller body are shaped as desired by pressing and combing I a-$1 ll! /5 1L. 9l1 9 RLHZ64/ZJHL pins are attached to thusly shaped faller body by Int. Cl ..B23p 17/00, B23p 25/00 plastic molding technique 4 Claims, 36 Drawing Figures PATENTEDB 24 1912 SHEET 1 BF 5.

METHOD FOR MANUFACTURING A GILL FALLER OF A CONSTANT THICKNESS FALLER BODY TYPE The present application is a continuation-in-part type divisional application of my copending US. patent application Ser No.4,218 titled GILL FALLER AND A METHOD FOR MANUFACTURING THE SAME and filedon Jan. 20, 1970. i

The present invention relates to an improved method for manufacturing a gill faller of a constant thickness faller body type, more particularly relates to a method for manufacturing agill faller of a constant thickness faller body type with omission of the conventionally indispensable cutting operation for the purpose of shaping ends.

As is well-known, the typical conventional gill faller is provided with an intermediate portion for upholding combing pins and end portions for engagement with gill faller guide and drive mechanisms of the gill box whereon the gill fallers are used. Generally, the intermediate portion is provided with one or more elongated grooves wherein the combing pinbuttsareto be embedded so that the combing pins are disposed to the gill faller in a prescribed alignment or alignments. In some modification, the combing pins are disposed firstly to a pin strip unit or units and the unit or units are fixedly inserted into the grooves of the gill faller intermediate portion. In any of the two cases, the gill faller intermediate portion has to be provided with one or more of such elongated grooves for the combing pins disposition. Further, shaping of the sideways end portions has been in general, carried out through application of the known cutting operation.

The above-described conventional gill faller manufacturing method is inevitably accompanied with several fatal drawbacks such as mentioned below.

By the application of the cutting operation, the sideways end portions are provided with portions of different thicknesses and, during the actual use of the gill faller, various stresses caused by external mechanical attacks tend to concentrate upon boundaries between such portions of different thicknesses. Such stress concentration expedites accidental breakage of the gill faller. Further, because the sideways end portions must be shaped by cutting, the end portions are required to have a sufficient thickness for withstanding mechanical attacks exerted thereto during the cut shaping operation. This inevitably leads to undesirable increase in the resultant weight of the gill faller, which increase is not welcomed in the practical use of the gill faller because it possibly causes unsmooth movement of the gill faller on the gilling machine. It should be noted further that a thick gill faller structure requires unnecessarily in-. creased use of the material steel.

In addition to the above disadvantages, necessary formation of the grooves in the intermediate portion requires a very precise work. It is known that it is very difficult to form a groove through or to a hardmember such as a steel plate, which groove has horizontal sizes considerably small in comparison with its vertical sizes. This difficulty is increased especially when precise work is required as in the manufacturing of the gill fallers. In order to mitigate this difficulty, a use of low carbon steel has been proposed, but this is accompanied with other demerits such as lowering in the fatigue strength.

In view of the above-described drawbacks inevitably encountered in the conventional art, the present invention aims to provide a method for manufacturing a gill faller, which is free from troubles caused by the groove(s) provision, with omission of the conventional cutting operation for the sideways end parts shaping purpose.

In the inventional method, a faller body is firstly formed by an application of blanking, in a prescribed pattern, to a plain steel plate of constant thickness. Subsequent tothis blanking, pressing is applied to the sideways end portions so as to provide them with desired shapes. Thusly prepared gill faller body is placed within a molding die together with combing pins to be attached thereto in a prescribed alignment or alignments. After both are prescribedly mounted in the molding die, a suitable plasticmaterial is extruded into the molding die for the purposed combination of the two. Various modifications are available for effectuating theprescribed alignment or alignments of the combing pins in relation to the already prepared gill faller body.

Furtherfeatures and advantages of the inventional method will be made more apparent from the ensuing description, reference being made to the accompanying drawings, wherein;

FIG. 1 is a front view of thegill faller body plain plate used in the inventional art, 4

FIGS. 2A and 2B are plan views of the gill faller body end portions after press shaping, a

FIG. 3 is a perspective part view of the gill faller made according to the inventional method,

FIGS. 4A to 4D are transversal cross-sectional views of the gill fallers made according to the inventional method, wherein a singlefaller body is used,

FIGS. SAto 5H are transversal cross-sectional views of the gill fallers made according to the inventional method, wherein two faller bodies are used,

FIGS. 6Ato 6C are frontand transversal cross-sectional views of the metallic die used in the inventional method,

FIGS. 7A to 7C are front and transversal cross-sectional views of the metallic die used in combination with the one shown in FIGS. 6A to 6C,

FIGS. 8A to 8C are front and transversal cross-sectional views of the consolidated metallic die with comb- FIG. 9B is a transversal cross-sectional view of the gill faller manufactured thereon,

FIG. 10A is a partly transversal cross-sectional view of another molding die usable in the inventional method and FIG. 10B is a transversal cross-sectional view of the gill faller manufactured thereon,

FIG. 11 is a front view of the provisional ribbon used in the inventional method,

FIG. 12 is a perspective view of a metal casing used in combination with the ribbon shown in FIG. 11,

FIGS. 13A and 13B are cross-sectional views showing the formation of a pin upholding die on the metal casing shown in FIG. 12,

FIG. 14 is a transversal cross-sectional view of the metal casing used in the inventional method,

FIGS. A and 15B are transverse cross-sectional and partly-sectional front views of the pins upholding die with the combing pins being mounted thereto.

In the inventional method for manufacturing a gill faller, a purposed pattern of a gill faller body plain plate such as shown in FIG. 1 is formed in the first plate through application of a blanking operation to a plain steel plate of a constant thickness. This gill faller body plain plate 1 consists of an intermediate portion 2 and a pair of end portions 3 integral sideways of the intermediate portion 2. It will be understood that the intermediate portion is purposed for later dispositions of the combing pins whereas the end portions 3 are purposed for engagement with the known gill fallers guide and drive mechanisms.

Next,-the end portions 3 are subjected to suitable press shaping so as to provide them with necessary shapes adapted for engagement with the known gill fallers guide and drive mechanisms of the gilling machines. Some typical shapes are illustrated in FIGS. 2A and 2B. In the example shown in FIG. 2A, the end portion 3 is composed of a portion 4 integral sideways of the intermediate portion 2 and adapted for engagement with faller guides and ends of faller rails, a terminal portion 6 adapted for engagement with gill screws and a connecting portion 7 intervening between the portion 4 and the terminal portion 6. In the case of the gill faller having these type end portions 3, only one side of the portion 4, that is, downside of the portion in the drawing, is cooperative with the faller guides during the shifting cycle movement. Another typical example is shown in FIG. 2B, wherein the end portion 3 is also composed of a portion 4, a terminal portion 6 and a connecting portion 7. In the case of this structure, both sides of the portion 4 is cooperative with the faller guides. In the case of this example, both comer parts 8 and 9 engage with the faller guides of the machine.

It should be greatly appreciated that no cutting operation is employed in the shaping process of the end portions 3. As is apparent from the foregoing discussion, because the cutting operation is not a need in the art of the present invention, the end portions are not required to have a sufficient thickness suitable for such shaping by the cutting operation naturally resulting in the thinner construction thereof. Reduction in the thickness naturally results in reduction in the gill fallers weight and a lightweight gill faller can be acquired accordingly. Elimination of the cutting operation is one of the most important merits of the manufacturing method of the present invention. Thusly, troubles arising from heavy weight construction can be solved by the employment of the method of the present invention. In addition to this weight problem, elimination of the cutting operation has one more significant meaning. Elimination of the cutting operation makes it unnecessary to use low carbon steel as the gill .faller material and this enables the gill faller of the present invention to be released from the problems relating to impact strength and fatigue strength.

After the gill faller body is thus prepared, combing pins must be disposed to it in a prescribed alignment or, when required, alignments.

In general, in the disposition of the pins 11 to the faller body, combing pins are held by a jig in a prescribed arrangement. Next, thusly held combing pins are placed within a molding die together with the gill faller body with their foot ends being in a predesigned positional relationship to the side surface of the gill faller body. By filling the molten plastic substance into the molding die, the pins are firmly combined with the faller body after solidification of the plastic substance. In another embodiment of the method, a pair of gill faller bodies are amalgamated together in a side by side superposed relationship leaving a gap at least at a portion corresponding to the intermediate portions. Next, a plurality of combing pins are combined with one or more plastic strip units in a prescribed arrangement. Thusly obtained pins holding plastic strip units are inserted into the gap and fixed therein by any of the known manners. Also in the pins disposition, formation of cavernous portions through or to the faller body is eliminated. As already explained, elimination of such operation releases the gill faller from any stress concentration problem, thick construction and the use of low carbon steel. Especially, elimination of precision work needed in such operation greatly contributes to the reduction of the gill fallers manufacturing cost.

Stable fixing of the pins in relation to the faller body can be easily controlled as desired through suitable selection of the used plastic substance in rotation to the molding condition.

One example of the gill faller thusly manufactured is shown in FIG. 3, wherein the combing pins 11 are firmly upheld by the intermediate portion 2 of the gill faller body with their butts (not seen in the illustration) being embedded within a plastic layer 13 at least partly covering the intermediate portion 2.

Several types of combinations of the combing pins 1 1 with the gill faller body intermediate portion 2 via the plastic layer 13 are illustrated in FIGS. 4A to 4D. As is seen in the illustrations, butts 12 of the combing pins 11 are embedded firmly in the plastic layer 13,

The number of the gill faller bodies for a single gill faller can be modified as desired and some of the examples are shown in FIGS. 5A to 5H.

As for the above-mentioned plastic molding type disposition of the combing pins to the gill faller body, various methods are employable, some typical embodiments being explained in detail in the ensuing description.

In the first embodiment, a pair of metallic dies 21a and 21b, such as shown in FIGS. 6A to 6C and 7A to 7C, respectively, are used. As shown in FIG. 6A, the metallic die 21a is provided, on its one surface to be associated with the metallic die 21b, multiple vertical (in the drawing) grooves 23a of a semi-circular transversal cross section. The grooves 23a are formed parallel to each other and, distances between the neighboring grooves are selected according to the particulars required for the resultant gill faller. In communication with the bottom ends of the grooves 23a, a horizontal (in the drawing) groove 24a is formed as shown in FIGS. 6A and 6B. Near both sideway ends of the metallic die 21a, a pair of stepped center holes 26a are 26a, a pair of recesses 27a are formed in the metallic die 21a body as shown in FIG. 6C.

On the other hand, the other metallic die 21b is also provided with vertical grooves 23b in an arrangement to conform to the vertical grooves 23a of the metallic die 21a when both dies 21a and 211) are consolidated together as later described. With dimension corresponding to that of the horizontal groove 24a of the metallic die 21a, horizontal projection 24b is formed (see FIGS. 7A and 7B). Near both sideways ends, a threaded centerhole 26b and a pair of projections 27b are formed as shown in FIG. 7C. Dimensions of the above-described parts are selected with regard to the center holes 26a and recesses 27a of the metallic die 21a.

Next, both metallic dies 21a and 21b are consolidated together as shown in FIGS. 8A to 8C, wherein the combing pins 11 are inserted into circular holes 28, which are formed by the

semi-circular grooves

23a and 23b, with their butts being exposed outside of the consolidated metallic die 21. In this consolidated condition, the

projection

24b and 27b of the metallic die 21b are accepted within the horizontal groove 24a and the recesses 27a of the metallic die 210, respectively. In order to fixedly consolidate the two dies 21a and 21b, a pair of set screws 29 are threaded into the threaded center holes 26b through the stepped center hole 26a as shown in FIG. 8C.

Next, the consolidated metallic die 21 upholdingthe combing needles 11 is placed within a separable type molding die 31 with the gill faller body 1 as shown in FIG. 9A. As is seen from the drawing illustration, the molding die 31 is internally provided with, in addition to a cavity for accommodating the consolidated metallic die '21, an internal cavity 32 embracing the faller body 1 and the combing pin butts and a conduit 33 for communicating the internal cavity 32 with a plastic material inlet 34. After the placing of the two

members

1 and 21, suitable plasticmaterial is'introducedinto the internal cavity 32 via the inlet 34 and the conduit 33. After adequate solidification, a gill faller having a transversal cross section such as shown in FIG. 9B, which is the same with that shown in FIG. 4A, is obtained. By adjusting the relative .positionof the faller body 1 and the combing pin butts within the internal cavity 32 various types of gill fallers such as shown in FIGS. 4B to 4D and A to 5H can be obtained. For example, when the arrangement is so designed as shown in FIG. A, a gill faller such as shown in FIG. 10B, which is the same with that shown in FIG. 5E, can be obtained.

Another embodiment of the plasticmolding in the inventional method will be describedhereinafter. In the case of this embodiment, a pin die upholding which in some sense corresponds to the consolidated metallic die 21 used in the foregoing embodiment, is prepared in the first place as follows.

A plurality of combing pins 11 are fixed at their butts to an elongated member 41 by, for example, soldering with prescribed intervening distances so as to form a provisional ribbon 42, as shown in FIG. 11. Separately from this, a metal casing 43 having an internal cavity 44 such as shown in FIG. 12 is prepared. Surrounding the upper opening of the internal cavity 44, a cover plate 46 is fixed to the metal casing 43 by set screws 47. Next, the above-prepared provisional ribbon 42 is mounted on the metal casing 43 with the points of the resinous powder as shown in FIGS. 13A and 13B. After i the filled substance is solidified, the provisional ribbon 42 is removed therefrom and a pin upholding die 49 having holes 51 receptive of the combing pins 1 l is obtained, which die is illustrated in FIG. 14. Next, the

combing pins 11 are inserted into the holes 51 with their butts being exposed outside as shown in FIGS. 15A and 15B. Thusly prepared pin upholding die 49 and the gill faller body or bodies 1 are placed within the molding die 31 such as used in the preceding embodiment and after extrusion of the plastic material, a gill faller is acquired in a mannersimillarto that used in the preceding embodiment.

Although in the case of the foregoing embodiment, only a singleset of consolidated metallic dies 21 and its related parts or pin upholding die 49 and its related parts are placed within the molding die 31, multiple sets of them can be placed within the molding die 31 for the plastic molding purpose.

What is claimed is:

1. An improved method for manufacturing a gill faller of a constant thickness faller body type comprising,in combination, forming a plain faller body plate of a prescribed pattern by an application of blanking to a plain steel plate of a constant thickness, subjecting sideway end portions of said plain faller body plate to a press shaping so as to form a gill faller body of a desired shape, placing thusly obtained gill faller body within a molding die together with combing pins to be attached thereto in a prescribed alignment or alignments and ex truding a suitable plastic material into said molding die for combination of said gill fallerbody with said combing pins.

2. An improved method as' claimed in claim 1, wherein two sets of gill faller bodies are placed within said molding die in a side by side disposition leaving at least a partial gap between the two and said combing pins are aligned with their butts inserted within said gap.

3. An improved method as claimed in claim 1, wherein after preparation of said gill faller body, a plurality of combing pins are upheld by a consolidated metallic die with their butts being exposed outside and said consolidated metallic die upholding said combing pins is placed within a molding die together with said gill faller body.

4. An improved method as claimed in claim 1, wherein after preparation of said gill faller body, a plurality of combing pins are soldered at their butts to an elongated member so as to form a provisional ribbon, said provisional ribbon is mounted on a metal casing with points of said combing pins directed towards a bottom of an internal cavity of said metal casing, said metal casing is filled with a metallic powder solution containing resinous powder, said ribbon is removed from said metal casing after solidification of said metallic powder solution, combing pins are inserted into holes formed in said solidified metallic powder solution v r 7 in the preceding operation, thusly formed pin upholding die is placed within said molding die together with said gill faller.

Claims

1. An improved method for manufacturing a gill faller of a constant thickness faller body type comprising, in combination, forming a plain faller body plate of a prescribed pattern by an application of blanking to a plain steel plate of a constant thickness, subjecting sideway end portions of said plain faller body plate to a press shaping so as to form a gill faller body of a desired shape, placing thusly obtained gill faller body within a molding die together with combing pins to be attached thereto in a prescribed alignment or alignments and extruding a suitable plastic material into said molding die for combination of said gill faller body with said combing pins.

2. An improved method as claimed in claim 1, wherein two sets of gill faller bodies are placed within Said molding die in a side by side disposition leaving at least a partial gap between the two and said combing pins are aligned with their butts inserted within said gap.

4. An improved method as claimed in claim 1, wherein after preparation of said gill faller body, a plurality of combing pins are soldered at their butts to an elongated member so as to form a provisional ribbon, said provisional ribbon is mounted on a metal casing with points of said combing pins directed towards a bottom of an internal cavity of said metal casing, said metal casing is filled with a metallic powder solution containing resinous powder, said ribbon is removed from said metal casing after solidification of said metallic powder solution, combing pins are inserted into holes formed in said solidified metallic powder solution in the preceding operation, thusly formed pin upholding die is placed within said molding die together with said gill faller.