Patent Application
20230264437
The subject disclosure relates to the art of manufacturing and, more particularly, to a multi-component reinforced part forming device.
Many vehicle parts are created through stamping, vacuum forming, molding and the like. Creating a stamping die or mold to form parts is a time consuming and very costly process. A stamping die can cost upwards of a million dollars or more. Typically, a stamping die is formed by subtraction. For example, a block of metal is milled, machined, and drilled to form a desired shape. Once the desired shape in formed, a polishing process is initiated. The subtraction process is time consuming and very wasteful.
Other part forming devices, injection molds, vacuum forming molds and the like are equally costly, time consuming to produce and result in a significant amount of wasted material. The need to reduce tooling investment in manufacturing automobiles is a long standing problem. In particular, there is a need to reduce tooling investment for limited vehicle runs in order to maintain vehicle cost at an obtainable level while, at the same time, generating profit for a manufacturer. Accordingly, the industry would welcome a low cost, readily manufacturable, part forming device for vehicle fabrication.
A multi-component reinforced part forming device in accordance with a non-limiting example includes a forming member having a first side including a wear surface defining a part-shaped cavity, an opposing second side including a protrusion corresponding to the part-shaped cavity, and a peripheral edge. A frame extends about the peripheral edge. The frame includes a first edge arranged adjacent the wear surface and a second edge spaced from the opposing second side. The frame and the opposing second side define a void. A plurality of reinforcing members is arranged in the void. A first number portion of the plurality of reinforcing members supports the opposing second side and a second number of the plurality of reinforcing members supports the protrusion. An amount of reinforcing backing material is disposed in the void.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the plurality of reinforcing members form a three-dimensional (3D) lattice.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the forming member includes a first portion defining the part-shaped cavity and a second portion defining a substantially planar surface having the first side and the second side.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the second portion includes a part feature that extends into the part-shaped cavity.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include a raised element mounted in the part-shaped cavity.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the part-shaped cavity includes an opening, the raised element being mounted in the part-shaped cavity in the opening.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the forming member is formed from sheet metal.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the first portion is mechanically connected to the second portion.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the first portion is chemically connected to the second portion.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the amount of reinforcing backing material comprises a volumetrically stable material.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the volumetrically stable material comprises epoxy resin.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the volumetrically stable material comprises cementitious grout.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the volumetrically stable material comprises a Kirksite casting alloy.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein the plurality of reinforcing members is bonded to the forming member.
A method of forming a multi-component reinforced part forming device in accordance with a non-limiting example includes creating a forming member having a wear surface including a part-shaped cavity and an opposing surface including a protrusion corresponding to the part-shaped cavity, connecting a plurality of reinforcing members to form a reinforcing lattice, joining the reinforcing lattice to the opposing surface and the protrusion, creating a frame about the forming member and the reinforcing lattice, and supporting the forming member and reinforcing lattice with a reinforcing backing material.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein creating the forming member includes bending a piece of sheet metal to form the part-shaped cavity.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein creating the forming member includes forming a member having a substantially planar surface including a part feature that extends into the part-shaped cavity.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include wherein creating the forming member includes joining the member having the substantially planar surface to the piece of sheet metal.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include polishing the member including the substantially planar surface and the piece of sheet metal to smooth joints and eliminate imperfections.
In addition to one or more of the features described above or below, or as an alternative, further embodiments could include creating a design in the wear surface of the part-shaped cavity.
The above features and advantages, and other features and advantages of the disclosure are readily apparent from the following detailed description when taken in connection with the accompanying drawings.
Other features, advantages and details appear, by way of example only, in the following detailed description, the detailed description referring to the drawings in which:
The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
A multi-component reinforced part forming device is indicated generally at 10 in
In a non-limiting example depicted in
In a non-limiting example depicted in
Second portion 48 is a unitized member formed from a single piece of material such as sheet metal. When first portion 28 is joined to second portion 48, part feature 60 nests with gap 45 and forms two additional wear surfaces 61 and 62. First portion 28 also creates a protrusion 68 that extends outward from second side 56 as shown in
In a non-limiting example, first portion 28 is joined to second portion 48 as shown in
After completing forming member 14, the plurality of reinforcing members 18 are connected to form a three-dimensional (3D) lattice 85 and joined to second side 56 and protrusion 68 as shown in
At this point, it should be appreciated that the multi-component reinforced part forming device such as shown in
Multi-component reinforced part forming device 10 may be created through a variety of processes such as in
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
While the above disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from its scope. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiments disclosed, but will include all embodiments falling within the scope thereof
