JP7728072B2 - Roof molding manufacturing method and roof molding cutting device - Google Patents

Description

The present invention relates to a roof molding manufacturing method and roof molding cutting device that are suitable for roof moldings that have flange portions that protrude from the widthwise side edges of the head toward the back surface.

An automobile roof is made up of a center roof panel located in the center of the vehicle's width and side roof panels located on either side of it, joined together by spot welding or other methods. To hide the joint between the two roof panels, a roof groove is formed along the joint, and a roof molding is attached to this roof groove to improve the design.

A roof molding typically includes a head portion that covers the roof groove, legs located on the reverse side of the widthwise center of the head portion, and a lip portion that protrudes widthwise outward from the lower end of the legs. It is manufactured by cutting a continuous extrusion molded body into specified dimensions using a cutting device. The roof groove is shallow at both ends in the vehicle's fore-and-aft direction to prevent damage during press molding of the roof panel. Accordingly, the legs and lip portions at both longitudinal ends of the roof molding are trimmed to match the depth of the roof groove.

Patent Document 1 below, for example, discloses a method and device for cutting roof moldings that include such legs and lips. The cutting method described in Patent Document 1 comprises a leg positioning step in which the legs of the roof molding are positioned between a first cutting blade and a second cutting blade whose cutting edges face each other; a cutting blade opposing advancement step in which the first and second cutting blades are advanced toward the legs from either side of the legs, so that their cutting edges bite into the legs to sandwich the legs; and a cutting blade same-direction sliding step in which the head is fixed in position and, with the first and second cutting blades biting into the legs, the cutting blades are moved toward one of the cutting blades.

The cutting device described in Patent Document 1 also has a first cutting blade and a second cutting blade mounted on a base with their cutting edges facing each other and movable back and forth in a substantially horizontal direction; a cutting blade-side mold with molding receivers above the first and second cutting blades that support the undersides of the heads on both sides of the legs and allow the legs to suspend between the cutting edges; and an operating-side mold that has a first cam formed with a first contact surface that contacts the first rear pressed surface of the first cutting blade and a second cam formed with a second contact surface that contacts the second rear pressed surface of the second cutting blade, and is movable together with the first and second cams in a direction perpendicular to the direction of movement of the first and second cutting blades.

Japanese Patent Application Laid-Open No. 2001-300887

In addition to the typical roof molding shape with a head, leg, and lip, some roof moldings have flanges that protrude from the widthwise side edges of the head toward the backside. In this case, the cutting method and cutting device of Patent Document 1 cannot be applied to roof moldings with such flanges. In Patent Document 1, first and second cutting blades are advanced horizontally from the widthwise outer side of the leg to clamp the leg. However, during this process, the flanges located on the widthwise outer side of the leg come into contact with the first and second cutting blades. Therefore, forcibly advancing the first and second cutting blades can damage the flanges or result in unnecessary cutting. Furthermore, positioning the first and second cutting blades in a position where they do not come into contact with the flanges limits the placement of the first and second cutting blades, making it impossible to cut the leg into the desired shape.

The present invention aims to solve the above-mentioned problems by providing a roof molding manufacturing method that allows for cutting the legs of roof moldings that have flanges that protrude from the widthwise side edges of the head toward the back surface without the leg cutting blade coming into contact with the flanges, and a roof molding cutting device for this purpose.

To achieve this, the present invention employs the following means.
(1) A method for manufacturing a roof molding to be attached to a roof groove provided on a roof of a vehicle, comprising:
The roof molding includes a head portion covering the roof groove, a leg portion provided on the back surface of the widthwise center portion of the head portion, a flange portion protruding from the widthwise side edge of the head portion toward the back surface side, and a lip portion protruding outward in the width direction from the lower end portion of the leg portion, and is manufactured by cutting an extrusion-molded continuous molding into pieces of predetermined dimensions using a cutting device,
the cutting device includes a first cutting tool and a second cutting tool each having a leg cutting blade and a lip cutting blade;
the first cutting tool and the second cutting tool are each movable in a horizontal direction and a vertical direction;
the leg cutting blades are arranged horizontally facing each other and are formed to be able to reside within a space surrounded by the head, the leg, the flange, and the lip;
The lip portion cutting blade is disposed facing downward,
a continuous molded body supplying step of supplying the continuous molded body in a longitudinal direction to the cutting device so that the leg portions are disposed between the leg cutting blades and the flange portions are disposed outside the leg cutting blades;
a leg cutting step of horizontally advancing the first cutting tool and the second cutting tool relative to each other at a predetermined location on the continuous molded body to cut the leg with the leg cutting blade;
a lip portion cutting step in which, while the leg portion cutting step is in the same state, the first cutting tool and the second cutting tool are each moved downward to cut the lip portion with the lip portion cutting blade.
(2) The cutting device has a third cutting tool equipped with a head cutting blade above the first and second cutting tools,
The method for manufacturing a roof molding as described in (1) also includes a head cutting step in which, after the continuous molding supply step, the third cutting tool is moved downward and at least the head and flange portions are cut off with the head cutting blade.
(3) The method for manufacturing a roof molding according to (1) or (2), wherein the cutting device is arranged so as to be continuous with the extrusion molding line that extrudes the continuous molding.
(4) A method for manufacturing a roof molding as described in (1) or (2), in which, after the lip portion cutting process, the leg portion cutting blades of the first cutting tool and the second cutting tool are separated from each other before returning to the continuous molding supply process.
(5) A roof molding cutting device that is attached to a roof groove provided on a vehicle roof,
The roof molding includes a head portion covering the roof groove, a leg portion provided on the back surface of the widthwise center portion of the head portion, a flange portion protruding from the widthwise side edge of the head portion toward the back surface side, and a lip portion protruding outward in the width direction from the lower end portion of the leg portion, and is manufactured by cutting an extrusion-molded continuous molding into pieces of predetermined dimensions by the cutting device,
the cutting device includes a first cutting tool and a second cutting tool each having a leg cutting blade and a lip cutting blade;
The first cutting tool and the second cutting tool are each movable in a horizontal direction and a vertical direction,
the leg cutting blades are arranged horizontally facing each other and are formed to be able to reside within a space surrounded by the head portion, the leg portion, the flange portion, and the lip portion;
The lip portion cutting blade is disposed facing downward,
A roof molding cutting device capable of receiving the continuous formed body in the longitudinal direction so that the legs are arranged between the leg cutting blades and the flange portions are arranged outside the leg cutting blades.
(6) In a state where the continuous molded body is received so that the leg portion is disposed between the leg portion cutting blades and the flange portion is disposed outside the leg portion cutting blades,
the first cutting tool and the second cutting tool are moved forward in a horizontal direction relative to each other at a predetermined location on the continuous molded body, and the leg portions are cut off with the leg portion cutting blades;
The roof molding cutting device described in (5) above, wherein the first cutting tool and the second cutting tool are moved downward while being advanced, and the lip portion is cut by the lip portion cutting blade.
(7) A roof molding cutting device as described in (5) or (6), which has a third cutting tool above the first cutting tool and the second cutting tool, and which has a head cutting blade for cutting at least the head portion and the flange portion.

According to methods (1), (5), and (6), for a roof molding having a flange portion protruding from the widthwise side edge of the head portion toward the rear surface, the leg cutting blade is formed so that it can reside within the space surrounded by the head portion, leg portion, flange portion, and lip portion. The continuous molding is then fed longitudinally to the cutting device so that the leg portion is positioned between the leg cutting blades and the flange portion is positioned outside the leg cutting blades. The first and second cutting tools are then advanced relative to each other to cut the leg portion with the leg cutting blade. In this way, the leg cutting blade is cut while still inside the flange portion, so it does not come into contact with the flange portion when the first and second cutting tools are advanced. Furthermore, in the lip cutting process, the lip cutting blade is simply moved downward while remaining in the leg cutting process state, so the lip cutting blade does not come into contact with the flange portion even during the lip cutting process. Therefore, the flange portion is not damaged or cut unnecessarily during the leg cutting process and lip cutting process, and the cutting position and shape of the leg cutting blade are not restricted by the presence of the flange portion.

According to measures (2) and (7), the head and flange portions are cut using a third cutting tool equipped with a head cutting blade, allowing the continuous molding to be cut into a roof molding of a predetermined length.

By using the method (3), the extrusion molding line and the continuous molding cutting line are on the same line, eliminating the need to transport the extruded continuous molding to the cutting device, thereby improving productivity.

By means of (4), even if scrap material (unwanted parts cut from the legs and lip) cut by the leg cutting blade and the lip cutting blade becomes caught and remains between the opposing leg cutting blades, the leg cutting blades can be moved away from each other before returning to the next cycle process, ensuring that the scrap material falls downward.

FIG. FIG. FIG. 2 is a cross-sectional view taken along line AA in FIG. 1. FIG. FIG. 2 is a perspective view of a first cutting tool and a second cutting tool. FIG. 10 is a front view of the continuous compact supplying step. FIG. 10 is a side view of a continuous molded body supplying step. 9A and 9B are cross-sectional views corresponding to the line BB in FIG. 8 showing the leg cutting step and the head cutting step. FIG. 10 is a side view of the lip portion cutting step. 11 is a cross-sectional view taken along line CC in FIG. 10. FIG. 10 is a perspective view showing a state in which a roof molding and scrap material are produced from a continuous formed body.

The present invention will be specifically described below by way of representative examples.
(roof molding)
As shown in Figure 1, a roof molding 10 to which the present invention is applicable is attached to the roof of a vehicle such as an automobile 1. The roof panel of the automobile 1 is composed of a center roof panel 2 located in the center of the vehicle width direction and side roof panels 3 disposed on both sides of the center roof panel 2 in the vehicle width direction. The center roof panel 2 and the side roof panels 3 are joined by spot welding or the like. As a result, linear joints extending in the fore-and-aft direction of the vehicle are present at both side edges of the roof panel, which does not look good as is. Therefore, a roof groove 4 is provided along the joint between the center roof panel 2 and the side roof panel 3, and the roof molding 10 is attached to the roof groove 4 to conceal the joint.

Figures 2 and 3 show the roof molding 10 of this embodiment. The roof molding 10 of this embodiment includes a head 11, a leg portion 12 provided on the back surface of the widthwise center of the head 11, a flange portion 13 protruding from the widthwise side edge of the head 11 toward the back surface, and a lip portion 14 protruding outward in the widthwise direction from the lower end of the leg portion 12.

The roof molding 10 is made of a thermoplastic resin such as olefin elastomer (TPO) or polyvinyl chloride resin (PVC resin), or a rubber such as ethylene-propylene-diene rubber (EPDM). It is a long, elongated component with a substantially uniform shape in the longitudinal direction, manufactured by cutting a continuous extrusion molding 100 (see Figures 8 and 12, etc.) into specified dimensions. Its length matches the length of the roof groove 4. At both longitudinal ends of the roof molding 10, portions of the legs 12 and lip 14 are removed to correspond to the depth of the roof groove 4 (which is shallower than other portions). The roof molding 10 is attached and fixed to the roof groove 4 via attachment members (not shown).

The head 11 is approximately flat (slightly curved) and has a width sufficient to cover the upper opening of the roof groove 4. The leg 12 extends downward from the back surface of the head 11, with a reinforcing metal core 15 embedded within. The flange 13 also extends downward from the back surface of the head 11, but is shorter than the leg 12 (approximately half the length of the leg 12 in this embodiment). As shown in FIG. 4 , the flange 13 abuts the upper surfaces of the center roof panel 2 and the side roof panel 3, preventing rainwater and other moisture from entering the roof molding 10 and the groove 4. In this embodiment, the center roof panel 2 is designed lower than the side roof panels 3, allowing moisture to flow rearward along the flange 13 on the inside side of the vehicle width and preventing rainwater and other moisture from dripping onto the side windows on the outside side of the vehicle width. The lip 14 elastically contacts the side wall of the roof groove 4 when the roof molding 10 is installed in the roof groove 4.

(cutting device)
5 and 6 show a cutting device 20 for cutting the continuous molding 100 to a predetermined length to obtain the roof molding 10. The cutting device 20 includes a first cutting tool 25L and a second cutting tool 25R, each equipped with a leg cutting blade 21 and a lip cutting blade 22, and a third cutting tool 26 equipped with a head cutting blade 23. The first cutting tool 25L and the second cutting tool 25R are connected to a cylinder device (not shown) and are movable horizontally and vertically. The first cutting tool 25L and the second cutting tool 25R are always raised and lowered simultaneously at the same height and are arranged side by side across the width of the continuous molding 100 (roof molding 10), sandwiching the supply line for the continuous molding 100 (described later). The first cutting tool 25L and the second cutting tool 25R are metal blocks, and the leg cutting blade 21 and the lip cutting blade 22 are formed by wire cutting and machining so that the upper edges of the opposing surfaces of the first cutting tool 25L and the second cutting tool 25R extend inward in the width direction by a predetermined amount.

The leg cutting blades 21 are formed facing inward in the width direction so that they face each other horizontally. The projection dimension of the leg cutting blades 21 from the upper edges of the first cutting tool 25L and second cutting tool 25R is sufficient if the lip portion 14 fits below them between the first cutting tool 25L and the second cutting tool 25R when the leg cutting blades 21 are butted against each other. In other words, when the leg cutting blades 21 are butted against each other, a space is formed below them in which the lip portion 14 fits.

The leg cutting blade 21 is used to cut away the unnecessary leg portion 12 from the continuous molding 100 in a predetermined shape. Therefore, it is formed in a special shape. In this embodiment, the leg cutting blade 21 has a flat blade portion 21a from the midstream to downstream portions of the first cutting tool 25L and the second cutting tool 25R, and a bulging blade portion 21b that bulges upward in the upstream portion. The bulging blade portion 21b is formed integrally with the first cutting tool 25L and the second cutting tool 25R by wire cutting and machining a metal plate. The bulging blade portion 21b is sized so that it can reside within the space surrounded by the head portion 11, leg portion 12, flange portion 13, and lip portion 14 of the roof molding 10 when the continuous molding 100 is inserted into the cutting device 20. Reference numeral 24 denotes a slit that receives the head cutting blade 23.

The lip cutting blades 22 are used to cut off a predetermined length of the unnecessary lip portion 12 from the continuous molding 100. The lip cutting blades 22 are formed facing downward on both the upstream and downstream edges of the leg cutting blades 21.

The third cutting tool 26 is positioned above the first cutting tool 25L and the second cutting tool 25R, with the head cutting blade 23 facing downward from the underside of the third cutting tool 26. The third cutting tool 26 is connected to a cylinder device (not shown) and can be raised and lowered vertically. The third cutting tool 26 is positioned in the widthwise center of the cutting device 20, and the widthwise center line of the head cutting blade 23 coincides with the widthwise center line of the supplied continuous molded product 100. In this embodiment, the head cutting blade 23 consists of a single blade arranged side by side in the widthwise direction. Furthermore, with respect to the supply line direction (longitudinal direction) of the continuous molded product 100 as the reference, the head cutting blade 23 is located above the slit 24 formed in the bulging blade portion 21b.

Upstream of the first cutting tool 25L, the second cutting tool 25R, and the third cutting tool 26, there is an upstream base 30 to which the continuous molded product 100 is supplied. This upstream base 30 is installed continuously on the same line as the extrusion molding line for the continuous molded product 100 supplied from an extrusion molding machine (not shown). In other words, the cutting device 20 is installed so as to be continuous on the same line as the extrusion molding line for the continuous molded product 100. Therefore, there is no need to move or transport the continuous molded product 100 from the extrusion molding machine to the cutting device 20.

Downstream of the first cutting tool 25L, second cutting tool 25R, and third cutting tool 26, there is a downstream base 31 through which the cut and manufactured roof molding 10 flows. A groove 32 that matches the shape of the underside of the lip portion 14 is formed in the center of the width direction of the upper surface of the upstream base 30 and downstream base 31. The groove 32 of the upstream base 30 and the groove 32 of the downstream base 31 are also on the same line. The upstream base 30 and downstream base 31 are stationary.

(Manufacturing method)
Next, a method for manufacturing the roof molding 10 will be described. In the initial state of the cutting device 20, the first cutting tool 25L, the second cutting tool 25R, and the third cutting tool 26 are all in their upper limit positions. The first cutting tool 25L and the second cutting tool 25R are also in their retracted positions, and the leg cutting blades 21 are spaced apart.

<Continuous molding supply process>
In this initial state, as shown in Fig. 7, the continuous molded product 100 is continuously supplied in the longitudinal direction from an extruder (not shown) along the groove 32 of the upstream base 30 so that the leg 12 is disposed between the leg cutting blades 21. At this time, the bulging blade portion 21b of the leg cutting blade 21 is present in the space surrounded by the head 11, leg 12, flange 13, and lip 14 of the continuous molded product 100. In other words, the flange 13 is located outward in the width direction from the bulging blade portion 21b of the leg cutting blade 21. Furthermore, in the vertical direction, the flat blade portion 21a of the leg cutting blade 21 is located between the flange 13 and the lip 14. The front view of the continuous molded product 100 shown in Fig. 7 shows the state before cutting, and the longitudinal tip surface is flat.

<Leg cutting process>
When the continuous molded product 100 is supplied to the cutting device 20 and the dimensions of the continuous molded product 100 downstream of the head cutting blade 23 reach a specified dimension as shown in FIG. 8 , the first cutting tool 25L and the second cutting tool 25R advance horizontally, i.e., widthwise inward, toward each other, as shown in FIG. 9 . The leg cutting blades 21 then abut against each other, cutting the leg 12 in a manner that removes unnecessary portions. Because the flange 13 is located widthwise outward of the bulging blade 21b, the leg cutting blade 21 does not come into contact with the flange 13 when cutting the leg 12. The timing for advancing the first cutting tool 25L and the second cutting tool 25R may be a specified time after the continuous molded product 100 is supplied, or it may be determined by installing a proximity sensor in the cutting device 20 that the continuous molded product 100 has passed a specified distance through the cutting device 20.

<Head cutting process>
Furthermore, in the leg cutting process, as the first cutting tool 25L and the second cutting tool 25R are advanced, the third cutting tool 26 is simultaneously lowered, as shown in FIG. 9 . The head cutting blade 26 then enters the slit 24 of the leg cutting blade 21, and cuts off the head 11 and flange 13 of the continuous molding 100. This results in a roof molding 10 of a predetermined size downstream of the head cutting blade 26. The third cutting tool 23 is lowered only to the extent that the head cutting blade 26 can cut off the head 11 and flange 13 of the continuous molding 100. The core material 15, which is harder than the other portions, is cut by butting the two leg cutting blades 21 against each other. Alternatively, the third cutting tool 23 may be lowered until it reaches the core material 15, and the core material 15 is cut by the head cutting blade 26.

The head cutting process may be carried out simultaneously with the leg cutting process, or may be carried out immediately before or after the leg cutting process (simultaneously with the lip cutting process described below), or may be carried out immediately after the lip cutting process. Furthermore, the head cutting process may not be carried out immediately after the leg cutting process, but may be carried out before the leg cutting process or after the lip cutting process.

<Lip cutting process>
Next, as shown in Figures 10 and 11, while the leg cutting blades 21 are abutted against each other in the leg cutting process, the first cutting tool 25L and the second cutting tool 25R are lowered, whereby the lip cutting blade 22 cuts off the lip portion 14, and the unnecessary portions of the leg portion 12 and lip portion 14 are removed in a predetermined shape.

Once the unnecessary leg 12 and lip 14 portions have been cut off in the lip cutting process, the process returns to the initial state shown in Figure 7. By repeating this series of steps, as shown in Figure 12, it is possible to cut off the unnecessary leg 12 and lip 14 portions from the continuous molding 100 and simultaneously continuously produce roof moldings 10 of a predetermined length. Note that if multiple dancer rollers are installed between the extrusion molding line and the cutting device 20 to create a temporary stopping route for the supply to the cutting device 20, the cutting process by the cutting device 20 can be carried out smoothly.

When returning to the initial state from the lip cutting process, the first and second cutting tools 25L and 25R can be raised while the leg cutting blades 21 are still abutted against each other, and then the first and second cutting tools 25L and 25R can be retracted. However, it is preferable to retract the first and second cutting tools 25L and 25R to separate the leg cutting blades 21 from each other before raising the first and second cutting tools 25L and 25R. This latter method ensures that the unnecessary offcuts 101 resulting from the cutting are dropped downward.

In the above embodiment, the continuous molded product 100 is continuously supplied in the longitudinal direction from the extrusion molding machine, but the cutting device does not have to be located on the same line as the extrusion molding line. For example, the continuous molded product 100 may be extruded and cut to a specified length before being supplied to the cutting device 20. In this case, the cutting device 20 does not need to perform the head cutting process.

1 Automobile 2 Center roof panel 3 Side roof panel 4 Roof groove 10 Roof molding 11 Head 12 Leg 13 Flange 14 Lip 15 Core 20 Cutting device 21 Leg cutting blade 21a Flat blade 21b Bulging blade 22 Lip cutting blade 23 Head cutting blade 24 Slit 25L First cutting tool 25R Second cutting tool 26 Third cutting tool

Claims (7)

A method for manufacturing a roof molding to be attached to a roof groove provided in a roof of a vehicle, comprising:
The roof molding includes a head portion covering the roof groove, a leg portion provided on the back surface of the widthwise center portion of the head portion, a flange portion protruding from the widthwise side edge of the head portion toward the back surface side, and a lip portion protruding outward in the width direction from the lower end portion of the leg portion, and is manufactured by cutting an extrusion-molded continuous molding into pieces of predetermined dimensions using a cutting device,
the cutting device includes a first cutting tool and a second cutting tool each having a leg cutting blade and a lip cutting blade;
the first cutting tool and the second cutting tool are each movable in a horizontal direction and a vertical direction;
the leg cutting blades are arranged horizontally facing each other and are formed to be able to reside within a space surrounded by the head, the leg, the flange, and the lip;
The lip portion cutting blade is disposed facing downward,
a continuous molded body supplying step of supplying the continuous molded body in a longitudinal direction to the cutting device so that the leg portions are disposed between the leg cutting blades and the flange portions are disposed outside the leg cutting blades;
a leg cutting step of horizontally advancing the first cutting tool and the second cutting tool relative to each other at a predetermined location on the continuous molded body to cut the leg with the leg cutting blade;
a lip portion cutting step in which, while the leg portion cutting step is in the same state, the first cutting tool and the second cutting tool are each moved downward to cut the lip portion with the lip portion cutting blade. the cutting device has a third cutting tool provided with a head cutting blade above the first and second cutting tools,
2. The method for manufacturing a roof molding according to claim 1, further comprising a head cutting step of moving the third cutting tool downward after the continuous molding supply step and cutting at least the head and the flange portion with the head cutting blade. The method for manufacturing a roof molding according to claim 1 or 2, wherein the cutting device is arranged so as to be continuous with the extrusion molding line that extrudes the continuous molding. The method for manufacturing a roof molding according to claim 1 or 2, wherein, after the lip cutting step, the leg cutting blades of the first cutting tool and the second cutting tool are separated from each other before returning to the continuous molding supplying step. A roof molding cutting device that is attached to a roof groove provided in a roof of a vehicle,
The roof molding includes a head portion covering the roof groove, a leg portion provided on the back surface of the widthwise center portion of the head portion, a flange portion protruding from the widthwise side edge of the head portion toward the back surface side, and a lip portion protruding outward in the width direction from the lower end portion of the leg portion, and is manufactured by cutting an extrusion-molded continuous molding into pieces of predetermined dimensions by the cutting device,
the cutting device includes a first cutting tool and a second cutting tool each having a leg cutting blade and a lip cutting blade;
The first cutting tool and the second cutting tool are each movable in a horizontal direction and a vertical direction,
the leg cutting blades are arranged horizontally facing each other and are formed to be able to reside within a space surrounded by the head portion, the leg portion, the flange portion, and the lip portion;
The lip portion cutting blade is disposed facing downward,
A roof molding cutting device capable of receiving the continuous formed body in the longitudinal direction so that the legs are arranged between the leg cutting blades and the flange portions are arranged outside the leg cutting blades. In a state where the continuous molded body is received such that the leg portions are disposed between the leg cutting blades and the flange portions are disposed outside the leg cutting blades,
the first cutting tool and the second cutting tool are moved forward in a horizontal direction relative to each other at a predetermined location on the continuous molded body, and the leg portions are cut off with the leg portion cutting blades;
6. The roof molding cutting device according to claim 5, wherein the first cutting tool and the second cutting tool are moved downward while being advanced, and the lip portion is cut by the lip portion cutting blade. 7. The roof molding cutting device according to claim 5, further comprising a third cutting tool above the first and second cutting tools, the third cutting tool having a head cutting blade for cutting at least the head portion and the flange portion.