Patent Publication Number: US-2006016235-A1

Title: Contact surface for a crimping roller in a roll forming tool

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      The present application is a Continuation of U.S. Ser. No. 10/386,038 filed Mar. 11, 2003. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
      Not applicable.  
     REFERENCE TO A “SEQUENCE LISTING” 
      Not applicable.  
     BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates to roll forming tools for crimping an edge trim or seal onto a flange of a motor vehicle, and more particularly, to a contact surface for a crimping roller in the roll forming tool, wherein the contact surface provides the necessary friction between the roll forming tool and the edge trim or seal, while minimizing surface damage to the edge trim or seal during installation (crimping) operations.  
      2. Description of the Related Art  
      The fitting of flange mounted automotive weatherstrips encounters a number of traditional problems resulting from manufacturing tolerances in both the weatherstrip and the vehicle.  
      Traditional flange mounted weatherstrips include a U-shaped profile having an embedded metallic reinforcing member, wherein the U-shaped profile is presented to the flange with the legs of the U-shaped profile in a parallel orientation. An inside surface of the U-shaped profile typically included retaining fingers that project into the channel. The U-shaped profile is operably engaged with a flange by urging the U-shaped profile against the flange to seat the closed end of the U-shaped profile against the terminal end of the flange, and the retaining fingers contact the flange and resist removal.  
      Typically, the flange of the vehicle to which the weatherstrip is fitted usually has a predetermined thickness, or number of sheet metal layers. However, the flange often has more or less layers of sheet metal, and thus varies from the predetermined thickness. If the weatherstrip is formed to accommodate the predetermined thickness, the weatherstrip may be too wide for a flange of fewer metal layers, yet too narrow for a flange of more metal layers. As a result, the weatherstrip may not grip satisfactorily where the flange is of fewer layers and conversely, if the flange is of excess layers, the weatherstrip may be extremely difficult to install.  
      These problems have been recently addressed by modifying the traditional flange-gripping portion of the weatherstrip. Specifically, the traditional U-shaped cross section of the gripping portion on the weatherstrip is formed in a splayed configuration. That is, the legs of the profile are not presented to the flange in a parallel orientation, but rather a spread configuration. The spread, or splayed, configuration allows the flange gripping portion of the weatherstrip to be initially presented to the flange with a reduced insertion force.  
      To operatively engage the splayed flange gripping portion, a roll forming tool is employed to deform the internal reinforcement member, such as the metal carrier, so as to engage and be retained upon the flange of the vehicle.  
      The roll forming tool incorporates a pair of crimping rollers rotatable in opposite directions about spaced axes, which may be parallel to one another or alternatively can be adjustable relative to one another. At least one of the rollers is rotated by any of a variety of motors, including pneumatic or electric, in conjunction with corresponding gearing between a drive shaft and the roller.  
      In use, the roll-forming tool is applied to the splayed flange gripping portion, and when the rollers are rotating, the rollers drive themselves onto the flange-gripping portion of the seal and by virtue of the parallel or generally parallel relationship of the rolling surfaces between the rollers will cause the flange gripping portion to be crimped into a clamping engagement on the flange. The crimping of the splayed U-shaped flange-gripping portion deforms the internal carrier and thus retains the weatherstrip relative to the flange.  
      However, it has been found that while the splayed flange-gripping construction offers significant advantages and in the accommodation of varying flange thickness, there is a significant tendency of the rollers to embed into the surface of the seal (upon excessive flange thickness) or spin relative to the seal without corresponding movement along the length of the seal, thereby marring the surface of the strip. Such marring, if on the edge trim portion can reduce the esthetic appeal, and if upon the sealing portion, can damage the seal to reduce its effective sealing capacity.  
      Therefore, the need exists for a contact surface of a crimping roller, or structure, that can reduce damage to the seal being installed. The need also exists for a contact surface to assist in accommodating a variety of flange thickness encountered by the roll forming tool.  
     BRIEF SUMMARY OF THE INVENTION  
      The present invention provides a contact surface for a crimping roller in the roll forming tool. The contact surface can be permanently or releasably connected to a drum of the respective crimping roller. Preferably, the contact surface is formed of a polymeric material, and can provide a smooth or contoured surface for contacting the flange cap.  
      In one configuration, each crimping roller includes metal drum to which the polymeric contact sleeve is connected. The contact sleeve can be molded to the drum, or molded through radial apertures in the drum.  
      In a further configuration, the drum can be connected to a corresponding drive shaft by a compressible interconnection. The compressible interconnection is selected to provide for movement of the drum between a concentric position and an eccentric position relative to the corresponding drive shaft. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       FIG. 1  is side elevational view showing a roll forming tool operably installing a splayed edge trim.  
       FIG. 2  is a cross sectional view taken along lines  2 - 2  of  FIG. 1 .  
       FIG. 3  is a cross sectional view taken along lines  3 - 3  of  FIG. 1 .  
       FIG. 4  is a perspective view of a typical roll forming tool, showing the crimping rollers.  
       FIG. 5  is a cross sectional view of a roll forming tool with one roller having a moveable axis of rotation.  
       FIG. 6  is a cross sectional view of the roll forming tool of  FIG. 5 , with the moveable axis of rotation in a crimping position.  
       FIG. 7  is a partial cross sectional view showing the crimping rollers engaging a combined edge trim and weatherseal.  
       FIG. 8  is a bottom plan view showing fixed crimping rollers for guiding and crimping the flange engaging portion.  
       FIG. 9  is a side elevational view showing an outer surface of a drum.  
       FIG. 10  is a cross sectional view taken along lines  10 - 10  of  FIG. 9 .  
       FIG. 11  is a side elevational view showing a sleeve configuration of the contact surface on the drum.  
       FIG. 12  is a cross sectional view taken along lines  12 - 12  of  FIG. 11 .  
       FIG. 13  is a side elevational view showing a cap configuration of the contact surface on the drum.  
       FIG. 14  is a cross sectional view taken along lines  14 - 14  of  FIG. 13 .  
       FIG. 15  is a side elevational view showing a cap for the drum.  
       FIG. 16  is a cross sectional view taken along lines  16 - 16  of  FIG. 15 .  
       FIG. 17  is a cross sectional view of a drum connected to a drive shaft by a compliant resilient core in a concentric relation with the drum, such as in a non contacting position relative to the flange cap.  
       FIG. 18  is a cross sectional view of the drum connected to a drive shaft by a compliant resilient core of  FIG. 17 , in an offset relation, such as in a flange cap contacting position, wherein the amount of offset is exaggerated.  
       FIG. 19  is a cross sectional view of a drum connected to a drive shaft by a compliant resilient core in a spoke configuration in a concentric relation, such as the drum being in a non contacting position relative to the flange cap.  
       FIG. 20  is a cross sectional view of the drum connected to a drive shaft by a compliant resilient core in a spoke configuration of  FIG. 19  in an offset relation, such as in a flange cap contacting position, wherein the amount of offset is exaggerated.  
       FIG. 21  is a side elevational view showing a crimping roller with an intermittent contact surface.  
       FIG. 22  is a cross sectional view taken along lines  22 - 22  of  FIG. 21 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      Referring to  FIGS. 1 and 2 , a roll forming tool  30  is shown operably engaging a splayed flange cap  10  on a vehicle flange  8 .  
      Typically, an edge trim or seal includes the generally U-shaped flange cap  10 . The flange cap  10  typically includes a reinforcing member  12  at least partially surrounded by a polymeric body  14  to define the U shape profile.  
      The polymeric material  14  of the flange cap  10  can be any of a variety of materials such as thermoplastics, elastomers or combinations thereof.  
      A typical reinforcing member  12  has sufficient rigidity to be crimped onto the flange and operably retain the flange cap  10 . The reinforcing member has a U shaped profile corresponding to the flange cap  10 . The reinforcing member  12  can be a plastic, metal, composite or alloy. Satisfactory reinforcing members  12  include a metal core, a knitted wire, a lanced metal or a stamped metal.  
      The flange cap  10  is originally presented to a flange  8  in an open condition shown in  FIGS. 2, 5  and  8 . The open condition allows an operator to easily position the flange cap  10  around the entire periphery of the vehicle opening and onto the flange  8  prior to fully securing the flange cap to the flange by means of the crimping tool  30 . The open condition of the flange cap  10  is created by the leg portions of the generally U-shaped flange cap being initially formed at an angle greater than 90°.  
      To operably retain the flange cap  10  relative to the vehicle flange  8 , the reinforcing member  12  of the flange cap is deformed to dispose the legs into a parallel or flange clinching position.  
      In various constructions, a sealing portion, a trim portion such as a lip or a finger may project from the flange cap  10 . As seen in  FIGS. 2 ,  3 ,  5 ,  6  and  7 , the flange cap  10  can also include an inner flange engaging surface having retaining fingers or ribs  16 .  
      Referring to  FIG. 4 , the roll forming tool  30  generally includes a motor  32  and at least two crimping rollers  40  incorporated into an operator compatible housing  34 .  
      The motor  32  can be any of a variety of mechanisms including electrical, hydraulic, and pneumatic. Typically, the motor  32  is disposed in the housing  34  for manipulation by the operator. It is understood the operator can be a human operator or a robotic actuator. The motive force for the motor  32  can be provided by a supply line, as dictated by the specific type of motor employed.  
      The housing  34  can have any of a variety of configurations, including handle grips, handle orientations relative the crimping rollers and relative motion of the crimping rollers  40 .  
      Further, the roll forming tool  30  includes gearing  36  for operably connecting the motor  32  to the crimping rollers  40 . The gearing  36  can be any type of gearing used in the art and at least transmits the motive power from the motor  32  to the crimping rollers  40 . The gearing  36  often includes or provides a drive shaft  38  for coupling to the crimping rollers  40 .  
      Referring to  FIGS. 7 and 8 , it is also contemplated the roll forming tool  30  can include a guide roller  35 , or rollers, which can be cylindrical, concave, or convex for providing guidance of the crimping rollers  40  relative to a terminal end of the flanges  8 . The guide roller(s)  35  are typically free rotating and thus are rotated by contact with the flange cap  10 . Depending upon the configuration of the flange cap  10  and the flange  8 , the roll forming tool  30  can employ one or more guide rollers  35 , wherein the guide rollers may be disposed at any of a variety of inclinations with respect to the crimping rollers  40 .  
      The crimping rollers  40  are used to apply a compressive force on at least one leg portion or both leg portions of the flange cap  10 , when the rollers are activated and in a closed or crimping position.  
      Although  FIGS. 7 and 8  show the crimping rollers as spaced and parallel rollers, wherein the guide roller  35  extends in a transverse direction, it is understood the crimping rollers and guide rollers can have any of a variety of configurations. The roll forming tool  30  can be configured to employ only a single crimping roller or only guide roller, as well as any combination of crimping and guide rollers. Thus, the roll forming tool  30  can include one, two, three or more rollers, with any combination of crimping and guide rollers. As seen in  FIGS. 9-11  and  13 - 15 , the rollers can have any of a variety of dimensions along the axis of rotation. That is, some rollers can have a length greater than a roller diameter, while other rollers can have a length less than a roller diameter.  
      Generally, each crimping roller  40  is disposed about a corresponding drive shaft  38  for rotation therewith. Typically, the drive shaft  38  is formed of a metal and selected to substantially preclude bending or bowing during anticipated operational forces, created during rotation about a respective drive axis.  
      The crimping roller  40  can be a substantially straight cylindrical shape. Alternatively, the crimping roller  40  can be a tubular structure. The crimping roller  40  can have a contoured longitudinal profile to match the contour of the flange  8  or the flange cap  10 . Such contouring generally allows the crimping forces to be applied in a controlled manner to optimize deformation of the reinforcing member  12  within the flange cap  10 . Such profiled crimping rollers  40  can be selected to assist in positively locating the crimping roller relative to a particular part of the flange cap  10  to improve accuracy and control of the roll forming tool  30 . Thus, the crimping rollers  40  may have a distal end diameter greater than proximal end diameter.  
      It is also contemplated the crimping rollers  40  may be formed in more than one rolling part which are rotatable relative to each other but about the common axis of rotation (drive axis). For example, one part of a crimping roller  40  may be free running while an adjacent part may be driven so as to reduce frictional forces, which occur during deformation of the flange cap.  
      The crimping rollers  40  can be sized in accordance with the intended operating parameters of the roller. Typical crimping roller  40  diameters can range from slightly less than one inch, such as on the order of 0.8 inches to slightly over one inch, such as on the order of 1.2 inches.  
      Each crimping roller  40  includes a rigid drum  42  and a contact surface  50 . The contact surface  50  can be at least partially defined by a contact sleeve  60 .  
      The rigid drum  42  connected to the drive shaft  38  for rotation with the drive shaft about a drive axis. The drum  42  can be any of a variety of rigid materials, wherein metal, such as tool steel, has been found satisfactory. The drum  42  is constructed to preclude deformation of the drum during operation of the crimping roller  40 . That is, under the intended operating conditions, the drum  42  does not deform, or flex by an amount that is materially significant when compared to the remaining components of the crimping roller  40 . Thus, the drum  42  is non compliant. Although the drum  42  can have a variety of sizes, the drum having a radial thickness of approximately 0.1 to 0.2 inches is believed to be satisfactory. The diameter of the drum  42  can range from slightly less than an inch, such as on the order of 0.8 inches to slightly over an inch, such as on the order of 1.2 inches.  
      The drum  42  can be connected to the drive shaft  38  by a fixed or a compressible interconnection. In the fixed interconnection, the drum  42  maintains a fixed position relative to the drive shaft  38 , even under loading. In contrast, referring to  FIGS. 17-20 , the compressible interconnection allows an offset or eccentricity of the drum  42  and the drive shaft  38  under loading.  
      For the fixed interconnection, the drum  42  can be connected to the drive shaft  38  by any of a variety of conventional mechanisms including friction fits, key ways, blind or threaded engagement, for rotation therewith. In either configuration of the connection, the shaft can have any of a variety of diameters, as required by intended operating parameters. A typical shaft diameter is approximately 0.4 inches, however, the specific diameter is at least partially determined by intended operating parameters.  
      As seen in  FIGS. 17-20 , for the elastic, resilient interconnection, a resilient inner core  44  connects the drive shaft  38  to an inner surface  41  of the drum  42 . The inner core  44  can have any of a variety of configurations including flexible spokes, varying density resilient material, or cellular or foam construction. Foamed or expanded polymeric materials and compositions, including, but not limited to thermoplastic and thermoset materials as well as combinations thereof. Although the inner core  44  can have any of a variety of dimensions, depending upon the intended operating parameters, a radial thickness of approximately 0.1 to 0.3 inches is believed to be satisfactory, with a radial thickness of approximately 0.15 inches being preferred.  
      Thus, in the resilient elastic (offsetting) interconnection configuration, the drum  42  (and hence contact surface  50 ) can be disposed at varying distances from the drive shaft  38 , depending upon the radial loading of the crimping roller  40 . Therefore, while the distance between the drive shafts  38  of the two spaced crimping rollers  40  can be at a fixed distance, the distance between the contact surface of the crimping rollers  40  may vary in response to loading. At least a portion of the loading can result from variation in flange thicknesses and layers. Thus, the resilient, elastic interconnection allows the contact surface of the crimping rollers  40  to vary, without requiring movement of the corresponding drive shafts  38 .  
      In this construction, the compliant or resilient core  44  is disposed about the drive shaft  38  to be intermediate the drive shaft and the inner surface  41  of the drum  42 . The resilient, elastic compliant core  44  is selected to be nominally disposed in a concentric configuration with the rotatable drive shaft  38  and permit eccentric disposition of the drive shaft relative to the drum  42  in a crimping position.  
      The resilient, elastic compliant core  44  can be formed from any of a variety of materials that provide sufficient resiliency for the drum  42  to movement between the concentric position and the eccentric position with respect to the drive shaft  38 . That is, the shaft  38  can be offset from the concentric position with the drum  42  by between approximately 0.03 to 0.1 inches, with a preferred offset of approximately 0.05 inches. Suitable materials for the compliant core  44  include including spring metal, thermoplastics, thermosets, composites and alloys. As at least partially determined by the specific construction and materials, the compliant core  44  can be solid or spoked. Further, the material of the compliant core  44  can be a sponge or cellular formation.  
      The desired offset can be formed by the compliant core  44  having a radial dimension of approximately ⅓ the diameter of the drum  42 . Alternatively stated, the compliant inner core  44 , may yield up to ⅓ the radial dimension of the inner core upon an operating compressive force.  
      It is understood the contact sleeve  60  can be either continuous or intermittent and employed with either the fixed or offsetting crimping rollers  40 . It is further contemplated, the offsetting rollers can be employed without the contact sleeve  60 , wherein the contact surface  50  is at least partially defined by the drum  42 .  
      In a first configuration, the contact surface  50  of the crimping roller  40  is defined by the contact sleeve  60 , which is connected to the drum  42 . The contact sleeve  60  which forms the contact surface  50  of the crimping roller  40  can include a variety of configurations, including (i) a continuous surface and (ii) an intermittent surface. The contact sleeve  60  can be employed with a fixed drum and offset drum.  
      The material of the contact sleeve  60  is selected to provide sufficient friction to avoid slippage between the crimping roller  40  and the flange cap  10 , while reducing marring of the surface of the flange cap upon slippage between the crimping tool  30  and the flange cap. Typical materials for the contact sleeve  60 , include but are not limited to polymers including, but not limited to thermoplastics, thermosets and combinations thereof, wherein a satisfactory material is nylon. Thus, the contact surface  50  is defined by a different material than the drum  42 .  
      Continuous Contact Sleeve  
      In the continuous contact sleeve configuration, the contact sleeve  60  can be connected to the drum  42  by either (i) molding or (ii) a releasable engagement between the contact sleeve and the drum. That is, the contact sleeve  60  can be integrally molded onto or about the drum  42 , or the contact sleeve can be separately formed and subsequently attached to the drum. For example, the contact sleeve  60  could be an extruded component, which is subsequently attached to the drum  42  by adhesives, bonding, glues, ultrasonic welding or any other interconnection compatible with respective materials of the contact sleeve and the drum. The molding of the contact sleeve  60  to the drum  42  can be accomplished by a variety of techniques, including but not limited to dip coating, injection molding or casting.  
      Referring to  FIG. 13 , an outer surface  43  of the drum  42  includes surface features such as recesses, grooves, slots or kerfs  45  for receiving and engaging a corresponding portion of the contact sleeve  60 . The surface features can also include ribs, bumps or ridges, extending along any direction of the outer surface of the drum  42 .  
      The contact sleeve  60  includes an inner surface  61  having corresponding features or structures for cooperatively engaging the surface features of the drum  42  to preclude rotation of the contact sleeve relative to the drum during operation.  
      Although a variety of surface contours and features can be employed, a plurality of grooves can be formed in the drum  42 . The grooves  45  can extend either axially, circumferentially or helically with intermittent gaps. In forming this configuration, the drum  42  is etched, cast or machined to form the grooves, kerf or channels  45 . It is understood the inner surface  61  of the contact sleeve  60  would include a corresponding structure.  
      In the molded sleeve configuration, the drum  42  having the grooves  45  is disposed in a mold and the material forming the contact sleeve  60  is introduced into the mold to bond to the drum and occupy the grooves. Upon sufficient curing, the drum  42  is removed from the mold. The crimping roller  40  thus has a drum  42  with a molded on contact sleeve  60 , wherein the contact sleeve will rotate with the drum.  
      In the releasable engagement configuration of the contact sleeve  60 , the contact sleeve is formed or cast in a mold to provide the desired dimensions for engaging the drum  42 . The mold includes the features for forming the inner surface  61  of the contact sleeve  60  to engage the corresponding grooves  45  in the drum.  
      The contact sleeve  60  can be formed of polymers including, but not limited to thermoplastics, thermosets and combinations thereof, wherein nylon has been found satisfactory. In one configuration, the contact sleeve  60  has a radial thickness of approximately 0.02 to 0.1 inches, with a preferred radial thickness of approximately 0.05 inches. In one configuration, the features on the inner surface  61  of the contact sleeve  60  are sized on the order of 0.05 inches. However, the specific size of the features on the inner surface is at least partially dictated by the intended operating parameters and materials of construction. The contact sleeve  60  is preferably of sufficient hardness to preclude deformation upon crimping.  
      Intermittent Contact Sleeve  
      In the intermittent configuration of the contact sleeve  60 , an outer surface  63  of the contact sleeve provides spaced contact points  66  between the sleeve and the flange cap  10 . That is, the contact sleeve  60  has a plurality of relatively raised surfaces or portions  66  for contacting and engaging the flange cap  10 . As seen in  FIG. 12 , a plurality of projections  66  are shown. Although the projections are disposed about the periphery of the contact sleeve, the projections in  FIG. 12  are shown on approximately ¼ of the periphery for purposes of illustration.  
      It is understood either the molded or releasable engagement contact sleeves can include a contoured outer or contact surface. That is, the contact sleeve  60  can have a plurality of projections to contact and engage the flange cap  10 . The projections can have any of a variety of configurations, including but not limited to, axial ribs, circumferential ribs, helical ribs, knurled, patterned or randomly disposed projections. Again, the contacting portions of the crimping roller  40  are thereby defined by a first material, such as a polymeric material, wherein the contact sleeve is formed of a different material than the supporting drum. The raised portions  66  can extend from an adjacent portion of the contact sleeve  60  by between approximately 0.02 inches to approximately 0.1 inch, with a preferred projection of approximately 0.05 inches.  
      Intermittent Contact Surface  
      It is also understood the contact surface of the crimping roller  40  can be formed of the polymeric material, without requiring an entire sleeve, as seen in  FIGS. 21 and 22 . That is, the contacting projections can be formed to project from the drum  42 , such that the outer surface of the drum, while having exposed portions, does not contact the flange cap  10  during operation of the roll forming tool  30 . The projections can extend from an adjacent portion of the drum  42  by between approximately 0.02 inch to approximately 0.1 inch, with a preferred projection of approximately 0.05 inches.  
      The contacting projections  66  can have any of a variety of configurations including, but not limited to axial ribs, circumferential ribs, helical ribs, knurled, patterned or randomly disposed projections. It is understood the contacting projections are exaggerated in  FIG. 22  for purposes of illustration. In addition, terminal ends of the projections  66  can have any of a variety of shapes, such as rounded, curved, angular or faceted, as at least partially dictated by the intended operating parameters of the rollers and the materials of the flange cap.  
      In formation, the drum  42  can be formed with a central recess and a plurality of radially extending apertures  47 . The drum  42  is disposed in a mold and the material forming the contacting projections is disposed in the mold to travel through the central recess of the drum and extend radially outward through the radial apertures  47 . The mold includes corresponding structure to define the outer surface of the contacting projections, thereby forming the contacting projections of the contact surface.  
      While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.