Manufacturing process of kettle body and kettle body structure

Abstract

The invention relates to the field of metal processing, and provides a manufacturing process of a kettle body and a kettle body structure.The manufacturing process of the kettle body comprises the following steps that a plate for manufacturing the kettle body is obtained through cutting; rolling the plate, and welding the lapped edge to obtain a cylindrical part; performing curved surface stretching and bulging appearance molding on the whole cylindrical part to obtain a rough blank kettle body; one side of a top opening of the rough blank kettle body is stretched outwards in the radial direction through a mold, and a spout is formed; and performing edge folding and punching on the part, without the spout, of the top opening of the rough blank kettle body to obtain the kettle body. By the adoption of the manufacturing process of the integrated kettle body and spout structure, the complexity of independent forming and assembly procedures of a spout of a traditional assembly type structure is avoided, complex integrated modeling such as an ox horn shape can be stably achieved, the time cost of labor is reduced, the manufacturing process steps are reduced, the production cost is reduced, and the production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of metal processing, specifically to a manufacturing process and structure of a kettle body. Background Technology

[0002] As a common small household appliance, the structural design and molding process of the stainless steel body of an electric kettle directly affect the product's production cost, quality, and aesthetic appearance. Currently, most mainstream stainless steel kettles on the market are manufactured using an assembly structure of "kettle body and spout," which means that the spout and body are joined together by welding, riveting, or threaded connections to obtain the desired kettle body structure.

[0003] In the application with application number 00117462.2, entitled "Manufacturing Method of Metal-Cased Kettle," the spout is manufactured by directly stretching the spout at the mouth of the kettle. This method, especially for the annular spout, easily leads to thinning of the spout and even tearing. Although a mold is used for forming and stretching, the aforementioned problems still easily occur in the actual process of spout forming, resulting in a low yield or poor quality.

[0004] In the process of developing this invention, the inventors discovered the following problems with the existing technology: 1. High processing costs: An additional separate forming process for the spout and an assembly process for the body and spout are required, necessitating investment in more equipment, labor, and time. Furthermore, positioning deviations during assembly can easily lead to production defects or require rework. 2. Poor structural stability: Sealing issues and structural stress problems exist at assembly points, leading to leaks and loosening after long-term use, affecting product lifespan. 3. Significant design limitations: The modular structure is constrained by splicing processes, making it difficult to achieve integrated design for complex body structures and failing to meet consumers' high-end demands for product aesthetics. Summary of the Invention

[0005] The purpose of this invention is to provide a manufacturing process for the kettle body, which aims to improve the existing electric kettle body manufacturing process, where the quality of the spout is often substandard.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a manufacturing process for a kettle body, comprising the following steps: Cut the board material to make the teapot body, cut a "W"-shaped spout groove in the middle of the top edge of the board material, and reserve the baseline for making the top opening of the teapot body. The sheet metal is rolled into a circle, and the overlapping edges are welded to obtain a cylindrical part; After the bottom of the cylindrical part is flared and widened, the entire cylindrical part is stretched and expanded to obtain the rough pot body. The spout groove of the rough teapot body is radially stretched outward using a mold to form the spout. After folding and punching the top rim of the rough-formed teapot along the baseline, the spout is positioned higher than the top rim of the body, thus obtaining the teapot body.

[0007] Preferably, after cutting the sheet material, the entire sheet material is immersed in or coated with water-based stretching oil, and the edges that need to be overlapped are bent to form an overlap structure.

[0008] Preferably, a process positioning part is made at the opening of the sheet metal to cooperate with the molding die.

[0009] Preferably, the welded area is rolled to make the arc and thickness of the welded area the same as other parts of the pot body.

[0010] Preferably, before integrally molding the cylindrical part, the cylindrical part is immersed in or coated with water-based stretching oil, and then the bottom of the cylindrical part is flared outward to obtain the bottom process fold.

[0011] Preferably, the sheet material is a fan-shaped sheet material, and the spout groove is located in the middle of the arc-shaped side of the short side of the fan.

[0012] Preferably, the spout is formed into a bull's horn shape by top pressure stretching, and when the spout is top pressure stretched, the spout part is ensured to have water-based stretching oil.

[0013] Preferably, the part of the top opening of the rough-formed teapot that does not have a spout is beveled and then bent horizontally. The excess material is removed by punching and the edges are turned inward to obtain the top opening of the required size; After obtaining the required top opening size, the process fold is cut off.

[0014] Preferably, the surface of the rough-formed teapot body is polished.

[0015] The present invention also provides a kettle body structure, which is manufactured using the kettle body manufacturing process described above.

[0016] By adopting the above technical solution, the present invention has the following advantages compared with the prior art: 1. This invention adopts an integrated manufacturing process for the body and spout, avoiding the complexity of separate spout molding and assembly processes in traditional assembled structures. It can stably achieve complex integrated shapes such as horn shapes, reduce labor time costs, reduce manufacturing process steps, lower production costs, and improve production efficiency and quality.

[0017] 2. This invention uses laser cutting to replace traditional mechanical edge cutting, reducing blade maintenance costs and lowering production costs. Simultaneously, the automatic evaporation function of the water-based drawing oil eliminates the need for pre-polishing cleaning, further reducing manufacturing steps and lowering processing costs.

[0018] 3. The weld joints of this invention are treated with fillerless laser welding and roll forming, and their performance is close to that of the base material, ensuring structural strength; each process is optimized through process positioning and mold design to ensure product size consistency and improve product yield.

[0019] 4. Each step of the manufacturing process of the kettle body of the present invention is a simple forming or processing action. The connection between each process is smooth, which makes it easy to realize automated continuous production, significantly improves production efficiency and product consistency, reduces reliance on operator skills, further compresses labor costs, provides a reliable technical path for the large-scale manufacturing of high-quality electric kettles, and improves production quality. Attached Figure Description

[0020] Figure 1 This is a flowchart illustrating the manufacturing process of the kettle body described in this invention. Figure 2 This is a flowchart illustrating the detailed steps of the manufacturing process of the kettle body described in this invention.

[0021] Figure 3 This is a schematic diagram of the structural process of forming the teapot body according to the manufacturing process of the teapot body described in this invention.

[0022] Explanation of reference numerals in the attached figures: 1. Fan-shaped sheet material; 2. Cylindrical part; 3. Roll forming; 4. Process folding; 5. Shape shaping; 6. Stretch deformation to create the spout; 7. Beveling the top opening; 8. Flattening the top opening horizontally; 9. Punching the top opening; 10. Process folding and trimming; 11. Teapot body. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0024] Additionally, it should be noted that the terms "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" are all based on the orientation or positional relationship shown in the accompanying drawings. They are merely for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element of the present invention must have a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0025] When an element is referred to as being "fixed to," "set on," or "contained on" another element, it can be directly on or indirectly on that other element. When an element is referred to as being "connected to," it can be directly connected to or indirectly connected to that other element.

[0026] Unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0027] Example 1 Please refer to Figure 1 , Figure 2 and Figure 3 As shown, this embodiment provides a manufacturing process for a kettle body, including the following steps: S101. Cut and obtain the board material for making the pot body 11. Cut out a "W"-shaped spout groove in the middle of the top edge of the board material and reserve the baseline for making the top opening of the pot body.

[0028] Specifically, SUS304 stainless steel cold-rolled sheet DQ material (DQ stands for drawing quality, stamping grade) can be selected. The material parameters meet the following requirements: thickness 0.6mm, surface condition 2B (here, 2B is a term for the surface condition of stainless steel sheet, which is the surface condition of stainless steel sheet after cold rolling process); chemical composition meets national standard requirements; physical performance indicators are hardness 165-180HV, tensile strength ≥600N / mm², yield strength ≥250N / mm², elongation ≥50%. This material has good ductility and welding fusion performance, and can be adapted to multiple subsequent forming processes.

[0029] Laser cutting can be used to obtain sheet metal with the required contour, ensuring a smooth, burr-free cut to guarantee the precision of subsequent bending and welding processes. This avoids the cutting stress that can occur after traditional cutting tools, which can lead to deformation due to residual stress during the forming process.

[0030] S1011, The board material is a fan-shaped board 1, and the spout groove is set in the middle of the arc edge of the short side of the fan.

[0031] A pneumatic punch press can be used to cut the outline of the sheet metal in one piece, resulting in a fan-shaped sheet with a spout groove. A "W"-shaped spout groove is then punched into the short, curved edge of the fan to facilitate subsequent top-pressure stretching and formation of the spout structure.

[0032] Specifically, the spout groove design disrupts the annular structure of the top opening, allowing for better deformation of the groove at the spout during stretching or pressing during spout manufacturing. In other words, the "W"-shaped design of the spout groove creates a recessed groove at the connection between the spout and the body, while simultaneously providing the spout with the deformation required for outward stretching. This counteracts the stretching deformation, preventing tension issues between the spout and the body, ensuring a well-formed spout and reducing the likelihood of tearing.

[0033] To complement the spout groove design, two symmetrical arc-shaped edges are incorporated between the spout groove and the side of the sheet metal, creating a straight-line overlap. After the spout groove is pressed and stretched to form the spout, a height difference is created between it and the top opening. By flanging, folding, and punching the top opening, the spout structure is formed, ensuring the top surface of the spout is flush with the body of the teapot and preventing spillage.

[0034] S1012. After cutting the sheet material, immerse the entire sheet material in or coat it with water-based stretching oil, and bend the edges that need to be overlapped to create an overlap structure.

[0035] The water-based stretching oil disclosed in this embodiment can effectively reduce surface damage caused by material flow friction with the mold. After standing for 10 hours, the water-based stretching oil can automatically evaporate with the water, so there is no need to clean it before polishing, thus avoiding affecting the surface condition of the product and the performance of the polishing material during the polishing process.

[0036] The edge of the fan-shaped part is folded over by a crimping machine to create an overlapping structure, allowing for lap joint connection after rolling, facilitating shaping and subsequent welding. The overlapping size can be adjusted to a reasonable value through practical experiments. This is achieved by adjusting the size of the folded edge and subsequently measuring the size of the cylindrical part 2, and then making continuous adjustments to compensate for the microscopic uncertainties in material flow during the stamping process, thus ensuring the dimensional accuracy of subsequent manufacturing.

[0037] S102. Roll the sheet metal into a circle and weld the overlapping edges to obtain a cylindrical part 2.

[0038] Automated rolling equipment is used to roll fan-shaped sheet metal into cylindrical shapes, with a straight joint at the cylindrical joint. Then, a laser welding machine's welding beam is used to perform fillerless single-sided welding along the joint path, achieving double-sided melting and ensuring sufficient weld fusion. Fillerless welding avoids increasing the thickness at the joint, facilitating subsequent processing; it also ensures a consistent structural thickness at the welded area, improving the aesthetic appearance.

[0039] S1021. Perform roll forming on the welded area 3 to make the arc and thickness of the welded area the same as other parts of the pot body. That is, perform roll forming on the welded area to make it flush with the plate surface and / or the same thickness 3.

[0040] After being picked up by a robotic arm, the welded cylindrical material is transferred to a specialized rolling mill. High-hardness rolling rollers apply equal pressure to the weld seam until the welded area is flush with the butt joint of the thin plate and has a consistent thickness, resulting in a uniform product surface. Furthermore, the physical properties of the weld seam, after testing, reach 91.67%–97% of the base material. With proper processing, it can achieve the same physical properties as the base material, with chemical properties essentially identical and good corrosion resistance, meeting the requirements of subsequent processing steps. Additionally, the radial diameter or circumference of any part of the finished cylindrical material (i.e., the rough pot body) is less than or equal to the corresponding dimension of the formed product.

[0041] Specifically, after the rolling process 3, the radial rotation position deviation is ≤0.1mm, ensuring that the overall deformation of the cylindrical part 2 is controlled within the tolerance range, thus guaranteeing the assembly accuracy and structural stability of subsequent processes.

[0042] S1022. A process positioning part is made at the opening of the sheet metal to cooperate with the molding die.

[0043] A process positioning part is designed in advance at the edge of the cylindrical material opening of the sheet metal so that the subsequent process can use the process positioning part to position and cooperate with the mold before feeding the material, ensuring the consistency of the radial rotation position of the irregular curved surface product in each mold and improving the quality and efficiency of production.

[0044] S1023. After immersing or coating the cylindrical part 2 with water-based stretching oil, the bottom of the cylindrical part 2 is flared outward to obtain the bottom process fold 4.

[0045] The welded cylindrical material is placed in a flaring mold, and the bottom area of ​​the cylindrical material is radially expanded using hydraulic pressure. The expanded diameter is larger than the diameter of the drawing die opening. For example, the bottom of the cylindrical part 2 is radially expanded by 10mm, so that the diameter at this position is larger than the opening of the drawing die, resulting in a process flange 4 at the bottom of the cylindrical part. This flange serves as a fixing point for subsequent clamping, blocking, or hanging operations, preventing damage to the cylindrical part.

[0046] S103. After the bottom edge of the cylindrical part is turned and flared, the cylindrical part 2 is stretched and expanded to form a curved shape 5, thus obtaining a rough pot body.

[0047] Before stretching and expanding, the parameters of the hydraulic press (pressure, stroke, speed) need to be matched and calibrated in advance in conjunction with the mold design and product characteristics. Then, the punch of the mold is inserted into the interior of the cylindrical part 2 to apply uniform pressure to the inner wall of the cylindrical part 2, and the material is stretched and expanded to gradually form the target curved surface profile. Finally, the area of ​​the cylindrical part 2 except the top is shaped, that is, the shape of the cylindrical part 2 after stretching and expanding is consistent with the curved surface of the product, and the transition of the curved surface is smooth without wrinkles. In this way, a rough pot body with the required curved surface shape and uniform wall thickness is obtained.

[0048] For example, the lower middle part of the rough pot body can be expanded and shaped as a whole, while the side away from the spout can be bent and stretched towards the spout. In this way, when pressing the spout later, the pulling force on the pot body can be reduced, which is conducive to the stretching and shaping of the spout, without affecting the structure of the pot body, without stretching and deforming the spout, and improving the quality of the shaping.

[0049] S104. Using a mold, the spout groove of the rough pot body is stretched radially outward to produce the spout 6.

[0050] The spout disclosed in this embodiment is formed into a bull's horn shape by top pressure stretching, and when the spout is top pressure stretched, it is ensured that the spout part has water-based stretching oil.

[0051] After the initial stretching and bulging, the rough teapot body is placed in the mold. As the hydraulic press descends, the upper mold's inclined block continuously pushes the lower mold's core's grooved forming block radially outward. This radial stretching deformation of the spout of the rough teapot body gradually forms an outward-expanding horn-shaped spout structure, ensuring uniform material flow and preventing excessive thinning or cracking. Simultaneously, the mold's limiting mechanism controls the spout's extension length and angle, ensuring it conforms to the design curvature and assembly standards. The finished spout root has a smooth transition, free of wrinkles and stress concentration, meeting the requirements for subsequent trimming and finishing. In this way, the spout of the rough teapot body is pressed into the desired horn-shaped spout, achieving step-by-step spout forming and simplifying single-process mold operations.

[0052] S105. After folding and punching the top opening of the rough pot body along the baseline, the spout is positioned higher than the top opening of the pot body, thus obtaining pot body 11.

[0053] The scheme disclosed in this embodiment first involves beveling the top opening of the rough pot body where there is no spout 7, and then flattening the top opening horizontally 8. Next, the top opening is punched 9 to remove excess edge material and then turned inward to obtain the top opening of the required size; after obtaining the top opening of the required size, the process edge is folded off 10 to obtain the pot body 11.

[0054] Specifically, a 63T non-standard high-stroke pneumatic punch press can be used. The semi-finished product with the spout formed is placed in a mold. Using the bending line formed by the top and spout as a reference, the non-spouse area of ​​the top is bent at a 45° angle towards the center. Then, following the bent top, the non-spouse area of ​​the top is bent at a 45° angle towards the center, again using the bending line as a reference, until the area is level. Finally, the leveled top is placed in the mold, and the pre-set holes on the top are punched regularly to remove waste material, forming the top opening structure.

[0055] Furthermore, the semi-finished product, after being punched and roughly polished at the top, is placed in a mold, and the top hole is flanged. This avoids forming a sharp edge at the top opening, improving safety during use. At the same time, the mold structure design during the stamping process avoids scratches or indentations on the polished surface.

[0056] Finally, using automated laser cutting equipment, the bottom of the rough teapot body, which has completed all stamping processes, is processed by removing the pre-reserved process fold 4 to obtain the final teapot body 11. Laser cutting has the advantages of simple positioning, burr-free cutting edges, and no need for blade wear maintenance, ensuring a smooth bottom cut.

[0057] S106. Polish the surface of the obtained rough pot body.

[0058] Polishing methods can be employed, including mechanical polishing, chemical polishing, electrolytic polishing, or ultrasonic polishing, to enhance the surface smoothness and aesthetics of the kettle body. Specifically, the inner and outer surfaces of the rough-cast kettle body need to be polished to ensure that the surface roughness and texture meet the product's appearance design standards. These standards can be set according to actual product requirements, such as Ra below 0.4μm, or a mirror finish. After polishing, the surface should be free of scratches, pits, or orange peel texture, with a uniform and consistent gloss, meeting the visual and tactile standards of high-end kitchenware.

[0059] Polishing in this step removes burrs generated by the top punching. At the same time, the product structure of the rough pot body is basically formed in this step, and the state of the rough pot body has little interference with the polishing action. Therefore, it will not affect the subsequent processing accuracy and forming stability, and avoids surface damage or deformation caused by subsequent processes.

[0060] Example 2 This embodiment provides a kettle body structure, which is manufactured using the kettle body manufacturing process described in Embodiment 1. This results in a kettle body structure in which the kettle body and spout are manufactured as a single piece, avoiding the complexity of separate spout molding and assembly processes in traditional assembled structures. It can stably achieve complex integrated shapes such as horn shapes, reduce labor time costs, reduce manufacturing process steps, lower production costs, and improve production efficiency.

[0061] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A manufacturing process for a teapot body, characterized in that, Includes the following steps: Cut the board material to make the teapot body, cut a "W"-shaped spout groove in the middle of the top edge of the board material, and reserve the baseline for making the top opening of the teapot body. The sheet metal is rolled into a circle, and the overlapping edges are welded to obtain a cylindrical part; After the bottom of the cylindrical part is flared and widened, the entire cylindrical part is stretched and expanded to obtain the rough pot body. The spout groove of the rough teapot body is radially stretched outward using a mold to form the spout. After folding and punching the top rim of the rough-formed teapot along the baseline, the spout is positioned higher than the top rim of the body, thus obtaining the teapot body.

2. The manufacturing process of the kettle body according to claim 1, characterized in that, After cutting the sheet material, immerse or coat the entire sheet material with water-based stretching oil, and bend the edges that need to be overlapped to create an overlap structure.

3. The manufacturing process of the kettle body according to claim 1, characterized in that: A process positioning part is made at the opening of the sheet metal to cooperate with the molding die.

4. The manufacturing process of the kettle body according to claim 1, characterized in that: The welded areas are rolled to make the curvature and thickness of the welded areas the same as other parts of the pot body.

5. The manufacturing process of the kettle body according to claim 1, characterized in that, Before integrally shaping the cylindrical part, the entire cylindrical part is immersed in or coated with water-based stretching oil, and then the bottom of the cylindrical part is flared outward to obtain the bottom edge.

6. The manufacturing process of the kettle body according to claim 1, characterized in that: The board material is a fan-shaped board, and the spout groove is located in the middle of the arc-shaped side of the short side of the fan.

7. The manufacturing process of the teapot body according to claim 1 or 6, characterized in that: The spout is formed into a bull horn shape by top pressure stretching, and water-based stretching oil is ensured at the spout part during top pressure stretching.

8. The manufacturing process of the kettle body according to claim 5, characterized in that, The part of the rough-formed teapot body that does not have a spout is beveled and then bent horizontally. The excess material is removed by punching and the edges are turned inward to obtain the top opening of the required size; After obtaining the required top opening size, the process fold is cut off.

9. The manufacturing process of the kettle body according to claim 1, characterized in that, The surface of the rough-formed teapot is polished.

10. A kettle body structure, characterized in that, The pot body is manufactured using the manufacturing process described in any one of claims 1 to 9.

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