Manufacturing method and apparatus for hinge mail and / or hinge mail.

Abstract

This invention provides a technology that enables a reduction in molding load and an improvement in transportability in the manufacture of hinge mail and / or hinge mail having integrally formed shaft cylinder portion, arm portion and mounting portion. [Solution] In the process of manufacturing hinge mail and / or hinge mail from a plate-shaped material, the thickened portion that will become the shaft cylinder is formed in multiple stages without restraining the ends of the material in the longitudinal direction.

Description

Technical Field

[0001] The present invention relates to a method and an apparatus for manufacturing hinge mail and / or hidden mail.

Background Art

[0002] In this technical field, as a method for manufacturing hinge mail and / or hidden mail, a method is known in which a material that is a plate-like member is pressed in the plate thickness direction to integrally form a thickening portion corresponding to a head portion that becomes a shaft cylinder portion through which a shaft is inserted, an arm portion (also referred to as a "neck portion"), and a thin wall portion that becomes an attachment portion.

[0003] Specifically, for example, in the manufacturing method of a leaf-shaped hinge disclosed in Patent Document 1 (Japanese Patent Publication No. 57-27782), surface pressing forging is repeatedly performed from above and below by a punch on the central portion of a flat plate material sandwiched between upper and lower dies that are symmetrical left and right. After forming shaft cylinder portions (bulging portions) of two leaf-shaped hinges on both left and right sides of the central portion, the central portion that has become a thin plate is punched out to separate the two hinge processing materials.

[0004] Further, the manufacturing method of a hinge member disclosed in Patent Document 2 (Japanese Unexamined Patent Application Publication No. 2018-99723) involves handling a plate surface portion of a plate-like metal material while bending it, thinning one end portion thereof, and forming a thickening portion at a predetermined location of the other end portion in a first step, punching out the plate-like metal material to form an intermediate member having at least the other end portion and one end portion including the thickening portion in a second step, arranging the thickening portion of the intermediate member in a cavity that is pre-formed in a mold and forms a predetermined shape when the intermediate member is compressed, flowing the material from the plate surface portion toward the thickening portion side to fill the cavity while allowing the remaining material to escape to the plate surface portion side, and forming a bulging portion of a predetermined shape at the other end portion in a third step.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

[0006] In the manufacturing method for leaf-type hinges disclosed in Patent Document 1, the thickness of the outer part (leaf) of the thickened portion is the same as the thickness of the flat material used for processing, so the material flows in the longitudinal direction, making it difficult to sufficiently thicken the bulging portion. If a closed die is used to suppress such material flow, it becomes closed forging, raising concerns about increased forming load and / or shortened die life.

[0007] On the other hand, in the manufacturing method for hinge members disclosed in Patent Document 2, the bulge can be formed with high precision by performing a third step of forming a bulge after a first step of forming a thickened portion. However, there is room for improvement in terms of the complexity of the process and the high manufacturing cost, such as the need for a conveying device (poor conveyability) because the processing direction in the first step and the processing direction in the third step are opposite. Furthermore, the third step ultimately becomes closed forging, and as mentioned above, there are concerns about problems such as increased forming load and / or shortened mold life.

[0008] In other words, in this technical field, there is a need for a technology that enables a reduction in molding load and an improvement in transportability in the manufacture of hinge mail and / or hinge mail having integrally formed shaft cylinder portion, arm portion and mounting portion. [Means for solving the problem]

[0009] Therefore, as a result of diligent research, the inventors have found that the above problem can be solved by forming the thickened portion that will become the shaft portion in multiple stages, without restricting the ends of the material in the longitudinal direction, in the process of manufacturing a hinge mail and / or hinge mail having integrally formed shaft portion, arm portion and mounting portion from a plate-shaped material.

[0010] Specifically, the method for manufacturing hinge mail and / or hinge mail according to the present invention (hereinafter sometimes referred to as "the present invention method") is a method for manufacturing hinge mail and / or hinge mail having an integrally formed shaft portion, arm portion and mounting portion. The present invention method includes at least the following thickening steps, straightening steps and separation steps.

[0011] In the material thickening process, the material is compressed in the thickness direction by a pair of first molds while the dimensions in the width direction of the plate-shaped material are constrained by a first restraining means, but the dimensions in the longitudinal direction of the material are not constrained. Each of the pair of first molds has one first protrusion and two second protrusions provided on both sides of the first protrusion in the longitudinal direction of the material at a predetermined distance from the first protrusion. As a result, a first intermediate material is formed having one first thinning portion formed at a position corresponding to one first protrusion, two second thinning portions formed at positions corresponding to two second protrusions, and two first thickening portions formed between the one first thinning portion and the two second thinning portions.

[0012] In the straightening process, the widthwise dimension of the first intermediate material is restrained by a second restraining means, and the distance between the two second thinning portions in the longitudinal direction of the first intermediate material is restrained by a third restraining means so as not to widen, while at least a portion of the first thinning portion is pressed in the thickness direction of the first intermediate material by a pair of first punches. As a result, a second intermediate material is formed having one third thinning portion formed at a position corresponding to one first thinning portion, two fourth thinning portions formed at positions corresponding to two second thinning portions, and two second thickening portions formed between the one third thinning portion and the two fourth thinning portions.

[0013] In the separation process, two third intermediate materials, each having a second thickened portion at one end, are formed by removing at least a portion of the third thinned portion of the second intermediate material.

[0014] As stated at the beginning of this specification, the present invention relates not only to a method for manufacturing hinge mail and / or Hime mail, but also to a manufacturing apparatus for hinge mail and / or Hime mail. The manufacturing apparatus for hinge mail and / or Hime mail according to the present invention (hereinafter sometimes referred to as the "apparatus of the present invention") is a manufacturing apparatus for hinge mail and / or Hime mail having integrally formed shaft cylinder portion, arm portion and mounting portion.

[0015] The present invention apparatus comprises a first restraining means, which is a means for restraining the dimensions of a plate-shaped material in the width direction, and a pair of first molds, each having one first protrusion and two second protrusions provided on both sides of the first protrusion in the longitudinal direction of the material at a predetermined distance from the first protrusion. The present invention apparatus is configured to perform a material thickening process in which the material is compressed in the thickness direction by the first molds, while the dimensions of the material in the width direction are restrained by the first restraining means, but the dimensions of the material in the longitudinal direction are not restrained. By performing the material thickening process, a first intermediate material is formed having one first thinning portion formed at a position corresponding to one first protrusion, two second thinning portions formed at positions corresponding to two second protrusions, and two first thickening portions formed between the one first thinning portion and the two second thinning portions, respectively.

[0016] Furthermore, the apparatus of the present invention includes a second restraining means for restraining the dimensions of the first intermediate material in the width direction, a third restraining means for restraining the distance between two second thinning portions in the longitudinal direction of the first intermediate material from widening, and a pair of first punches configured to be separable and approachable in the thickness direction of the first intermediate material. The apparatus of the present invention is configured to perform a straightening process in which at least a portion of the first thinning portions is clamped by the pair of first punches in the thickness direction of the first intermediate material, while the dimensions of the first intermediate material in the width direction are restrained by the second restraining means and the distance between two second thinning portions in the longitudinal direction of the first intermediate material is restrained by the third restraining means from widening. By performing the straightening process, a second intermediate material is formed having one third thinning portion formed at a position corresponding to one first thinning portion, two fourth thinning portions formed at positions corresponding to two second thinning portions, and two second thickening portions formed between the one third thinning portion and the two fourth thinning portions, respectively.

[0017] In addition, the apparatus of the present invention includes a first cutting means, which is a means for cutting off at least a portion of the third thinning portion of the second intermediate material. The apparatus of the present invention is configured to perform a separation step in which at least a portion of the third thinning portion of the second intermediate material is cut off by the first cutting means. By performing the separation step, two third intermediate materials, each having a second thickening portion at one end, are formed. [Effects of the Invention]

[0018] As described above, in the method and apparatus of the present invention, in the process of manufacturing a hinge mail and / or hinge mail having integrally formed shaft cylinder portion, arm portion and mounting portion from a plate-shaped material, the thickened portion that will become the shaft cylinder portion is formed in multiple stages without restraining the ends in the longitudinal direction of the material. As a result, the method and apparatus of the present invention can reduce the molding load in the manufacture of the hinge mail and / or hinge mail. Furthermore, as will be described in more detail later, the method and apparatus of the present invention can improve the transportability in the manufacture of the hinge mail and / or hinge mail.

[0019] Other objects, other features, and attendant advantages of the present invention will be readily understood from the description of each embodiment of the present invention described while referring to the following drawings.

Brief Description of the Drawings

[0020] [Figure 1] It is a flowchart showing an example of the flow of each step included in the method for manufacturing a hinge mail and / or a hidden mail (first method) according to the first embodiment of the present invention. [Figure 2] It is a schematic diagram illustrating the composition of the material, the first mold, and the first intermediate material formed by performing the bulking process used in the bulking process included in the first method. [Figure 3] It is a schematic diagram illustrating the process of sandwiching the material in the thickness direction by a pair of first molds while restraining the dimension in the width direction of the plate-like material and not restraining the dimension in the longitudinal direction of the material in the bulking process included in the first method. [Figure 4] It is a schematic diagram illustrating the composition of the first intermediate material, the first punch, and the mold used in the correction process included in the first method, and the second intermediate material formed by performing the correction process. [Figure 5] It is a schematic diagram illustrating the process of sandwiching at least a part of the first thinning portion in the thickness direction of the first intermediate material by a pair of first punches while restraining the dimension in the width direction of the first intermediate material and restraining so that the interval between the two second thinning portions in the longitudinal direction of the first intermediate material does not expand in the correction process included in the first method. [Figure 6] It is a schematic diagram showing a state where the third thinning portion of the second intermediate material is cut off in the separation process included in the first method, and two third intermediate materials having a second bulking portion at one end are formed. [Figure 7] It is a schematic diagram illustrating the first region of the first intermediate material abutted by the third restraining means in the correction process included in the method for manufacturing a hinge mail and / or a hidden mail (second method) according to the first embodiment of the invention. [Figure 8] It is a schematic diagram showing an example of the configuration of a mail having a bent shape of an arm portion interposed between a shaft cylinder portion and a mounting portion. [Figure 9] A flowchart showing an example of the flow of each step included in the method for manufacturing hinge mail and / or hidden hinge according to the third embodiment of the present invention (third method). [Figure 10] A schematic diagram illustrating a process of pressing and bending two plate portions with a second punch while sandwiching a first portion of a second intermediate material in the thickness direction of the second intermediate material by a pair of second dies in the bending step included in the third method. [Figure 11] A flowchart showing one example of the flow of each step included in the method for manufacturing hinge mail and / or hidden hinge according to the fourth embodiment of the present invention (fourth method). [Figure 12] A flowchart showing another example of the flow of each step included in the fourth method. [Figure 13] An enlarged view of the portion surrounded by the thick dashed line in (b) of FIG. 10.<000010​​​​​​​​​​​​​​​​​​​

[0023] Figure 1 is a flowchart illustrating an example of the flow of each step included in the first method. As illustrated in Figure 1, the first method includes at least the following steps: a thickening step, a straightening step, and a separation step. In this specification, "longitudinal direction" refers to the longer dimension in a plane perpendicular to the thickness direction of the plate-shaped material and the first and second intermediate materials formed from said material, and "width direction" refers to the direction perpendicular to the longitudinal direction in the above plane.

[0024] In the thickening process performed in step S10, the material is compressed in the thickness direction by a pair of first molds while the dimensions in the width direction of the plate-shaped material are constrained by the first restraining means, but the dimensions in the longitudinal direction of the material are not constrained.

[0025] The material constituting the plate-shaped material is not particularly limited, as long as it is a material that can be forged to form a hinge mail and / or hinge mail of the desired shape and can withstand the environment in which it is used as a hinge mail and / or hinge mail. Typically, such materials are metals such as lead, tin, aluminum, copper, zirconium, titanium, molybdenum, vanadium, niobium, and iron (including steel), as well as alloys containing one or more of these metals.

[0026] Figure 2 is a schematic diagram illustrating the configuration of the material used in the thickening process included in the first method, the first mold, and the first intermediate material formed by the execution of the thickening process. In Figure 2, the left-right direction is the "longitudinal direction," the up-down direction is the "thickness direction," and the depth direction is the "width direction."

[0027] Figure 2(a) is a schematic diagram illustrating the structure of a plate-shaped material when viewed from below. The material 100 illustrated in Figure 2(a) has a rectangular parallelepiped shape, i.e., a flat plate shape, with its dimensions increasing in the order of length, width, and thickness.

[0028] Each of the pair of first molds has one first protrusion and two second protrusions provided on both sides of the first protrusion in the longitudinal direction of the material, spaced apart from the first protrusion.

[0029] Figure 2(b) is a schematic side view illustrating the configuration of a pair of first molds. In Figure 2(b), the left-right direction is the "longitudinal direction," the up-down direction is the "thickness direction," and the depth direction is the "width direction." Each of the pair of first molds 210 illustrated in Figure 2(b) has one first protrusion 211 located in the center of the longitudinal direction of the material 100, and two second protrusions 212 located on both sides of the first protrusion 211 in the longitudinal direction of the material 100, spaced at a predetermined distance from the first protrusion 211.

[0030] In the material thickening process, as described above, the dimensions of the material 100 in the width direction (depth direction) are constrained by the first restraining means. Therefore, the molding apparatus that performs the material thickening process further includes a first restraining means (not shown) that restrains the dimensions of the material 100 in the width direction (for example, a mold or a pad).

[0031] Furthermore, the pair of first molds 210 illustrated in Figure 2(b) have molded surfaces that are generally symmetrical in the thickness direction (up and down direction in the drawing), but depending on the shape of the hinge mail and / or hinge mail to be manufactured by the first method, they may have molded surfaces that are asymmetrical in the thickness direction.

[0032] Figure 3 is a schematic diagram illustrating the process in which a plate-shaped material is compressed in the thickness direction by a pair of first molds while its dimensions in the width direction are restrained by a first restraining means (not shown) and its dimensions in the longitudinal direction are not restrained. In Figure 3, the left-right direction is the "longitudinal direction," the up-down direction is the "thickness direction," and the depth direction is the "width direction." Figure 3(a) illustrates the state at the point when the material is set between the pair of first molds and the thickening process is about to begin, and Figure 3(b) illustrates the state at the point when a first intermediate material having the desired shape is formed by the compression of the material by the pair of first molds and the thickening process is completed.

[0033] In the material thickening process illustrated in Figure 3, the dimensions of the material 100 in the longitudinal direction (left-right direction) are not constrained, and the material 100 is sandwiched between a pair of first molds 210 and pressed in the thickness direction (up-down direction) by a drive mechanism (not shown).

[0034] In the example shown in Figure 3, one of the pair of first molds 210 (the lower first mold 210) is fixed, and the other (upper) first mold 210 is driven to move closer to the lower first mold 210 (see the black-filled arrow in Figure 3(a)) to clamp the material 100. However, in the thickening process, contrary to the example shown in Figure 3(a), the upper first mold 210 of the pair of first molds 210 may be fixed, and the lower first mold 210 may be driven to move closer to the upper first mold 210. Furthermore, both of the pair of first molds 210 may be driven to move closer to each other.

[0035] Furthermore, each of the pair of first molds 210 illustrated in Figure 2(b) is composed of three parts: one part provided with one first protrusion 211, and two parts provided with two second protrusions 212. However, both or either of the pair of first molds may be composed of one part provided with one first protrusion and two second protrusions.

[0036] Furthermore, if the first mold 210 is composed of three parts, such as the pair of first molds 210 illustrated in Figure 2(b), which consist of one part with one first protrusion 211 and two parts with two second protrusions 212, the two parts with two second protrusions 212 may be used as a third restraining means to restrain the gap between the two second thinning parts in the longitudinal direction of the first intermediate material from widening during the next straightening process. In this case, the process can be moved from the thickening process to the straightening process simply by replacing the part with one first protrusion 211 with a pair of first punches that clamp at least a part of the first thinning part in the thickness direction of the first intermediate material, thereby increasing the manufacturing efficiency of hinge mail and / or hinge mail by the first method.

[0037] Furthermore, if each of the pair of molds is composed of three parts as illustrated in Figure 3, the amount of pressure applied to the material by the first protrusion during the material thickening process can be adjusted by inserting a shim into the end of the part where the first protrusion 211 is provided that is opposite to the molding surface (the part shown by the thick solid line in Figure 3(a)). This makes it easy to adjust the molding load during the material thickening process, and consequently the molding load of the entire first method, so as not to become excessive.

[0038] Furthermore, the drive mechanism for clamping the material in the thickness direction between a pair of first molds can be appropriately selected from various drive mechanisms known in the relevant technical field, depending on, for example, the properties of the material constituting the material (e.g., mechanical strength and hardness) and the shape of the first intermediate material, which is the component to be formed by the thickening process. Typically, a press machine such as a hydraulic press is used as the drive mechanism.

[0039] By performing the thickening process as described above, a first intermediate material is formed having one first thinning portion formed at a position corresponding to one first protrusion, two second thinning portions formed at positions corresponding to two second protrusions, and two first thickening portions formed between the one first thinning portion and the two second thinning portions.

[0040] Figure 2(c) is a schematic diagram showing an example of the structure of a first intermediate material formed by performing a thickness-increasing process in which a plate-shaped material is sandwiched between a pair of first molds, as illustrated in Figure 3. In Figure 2(c), the left-right direction is the "longitudinal direction," the up-down direction is the "thickness direction," and the depth direction is the "width direction."

[0041] As illustrated in Figure 2(c), the first intermediate material 110 has one first thinning portion 111 formed at a position corresponding to one first protrusion 211 of the first mold 210, two second thinning portions 112 formed at positions corresponding to two second protrusions 212, and two first thickening portions 113 formed between the one first thinning portion and the two second thinning portions, respectively.

[0042] As is clear from Figure 2, the shapes of both main surfaces of the first intermediate material 110, which has one first thinning section 111, two second thinning sections 112, and two first thickening sections 113, correspond to the shapes of the molding surfaces of a pair of first molds 210 that face each other when the thickening process is completed.

[0043] Next, in the straightening process performed in step S20, the dimensions of the first intermediate material in the width direction are restrained by the second restraining means, and the distance between the two second thinning portions in the longitudinal direction of the first intermediate material is restrained by the third restraining means so as not to widen, while at least a portion of the first thinning portion is pressed in the thickness direction of the first intermediate material by a pair of first punches.

[0044] Figure 4 is a schematic diagram illustrating the configuration of a first intermediate material, a first punch and a die used in the straightening process included in the first method, and a second intermediate material formed by the execution of the straightening process. In Figure 4, the left-right direction is the "longitudinal direction," the up-down direction is the "thickness direction," and the depth direction is the "width direction."

[0045] Figure 4(a) is the same figure as Figure 2(c), and is a schematic diagram showing an example of the configuration of a first intermediate material formed by performing a thickness-increasing process. Figure 4(b) is a schematic diagram showing an example of the configuration of a molding apparatus for forming a second intermediate material from a first intermediate material in a straightening process. Figure 4(b) illustrates the main part of a molding apparatus for performing a straightening process. The main part of the molding apparatus 220 illustrated in Figure 4(b) consists of a pair of first punches 221 that clamp at least a portion of the first thinning portion 111 of the first intermediate material 110 in the thickness direction of the first intermediate material 110, and two pairs of molds 222 as a third restraining means that restrain the distance between the two second thinning portions 112 in the longitudinal direction of the first intermediate material 110 so as not to widen.

[0046] In the straightening process, as described above, the dimensions of the first intermediate material 110 in the width direction are constrained. Therefore, the molding apparatus 220 illustrated in Figure 4(b) further includes a second restraining means (e.g., a mold or pad, etc.) not shown that restrains the dimensions of the first intermediate material 110 in the width direction.

[0047] Furthermore, the pair of first punches 221 and the two pairs of molds 222 as third restraining means that constitute the molding apparatus 220 illustrated in Figure 4(b) have asymmetrical molding surfaces in the thickness direction (up and down direction in the drawing), but depending on the shape of the hinge mail and / or hinge mail to be manufactured by the first method, they may have symmetrical molding surfaces in the thickness direction.

[0048] Figure 5 is a schematic diagram illustrating a process in which, during the straightening process, the dimensions of the first intermediate material in the width direction are restrained by a second restraining means (not shown), and the distance between the two second thinning portions in the longitudinal direction of the first intermediate material is prevented from widening by a third restraining means, while at least a portion of the first thinning portion is clamped in the thickness direction of the first intermediate material by a pair of first punches. In Figure 5, the left-right direction is the "longitudinal direction," the up-down direction is the "thickness direction," and the depth direction is the "width direction."

[0049] Figure 5(a) illustrates the state at the point when the first intermediate material 110 is set in the molding apparatus 220, which includes the main part illustrated in Figure 4(b), and the straightening process is about to begin. In this state, the first intermediate material 110 is restrained by two pairs of molds 222 as a third restraining means so that the distance between the two second thinning portions 112 in the longitudinal direction does not increase. Although not shown, as described above, the dimensions of the first intermediate material 110 in the width direction (depth direction) are also restrained by a mold as a second restraining means, which is not shown. On the other hand, Figure 5(b) illustrates the state at the point when the straightening process is completed, after the first thinning portions 111 are pressed in the thickness direction of the first intermediate material by a pair of first punches 221 while maintaining the above state, thereby forming the second intermediate material 120 having the desired shape.

[0050] In the example shown in Figure 5, one of the pair of first punches 221 (the lower one) is fixed, and the other (upper) first punch 221 is driven to move closer to the lower first punch 221 (see the black arrow in Figure 5(a)) thereby clamping the first thinned portion 111 of the first intermediate material 110. Alternatively, the upper first punch 221 of the pair of first punches 221 may be fixed, and the lower first punch 221 may be driven to move closer to the upper first punch 221. Or, both first punches 221 of the pair may be driven to move closer to each other.

[0051] In the former case, where one of the first punches 221 is fixed and the other first punch 221 is driven to clamp the first thinned portion 111 of the first intermediate material 110, the fixed first punch 221 may be integrally configured with the adjacent third restraining means, the mold 222. On the other hand, in the latter case, where both of the pair of first punches 221 are driven to move closer to each other to clamp the first thinned portion 111 of the first intermediate material 110, both of the pair of first punches 221 must be configured separately from the adjacent third restraining means, the mold 222.

[0052] Furthermore, the drive mechanism for clamping the first thinned portion of the first intermediate material in the thickness direction of the first intermediate material with a pair of first punches can be appropriately selected from various drive mechanisms known in the art, depending on the properties (e.g., mechanical strength and hardness) and shape of the material constituting the first intermediate material, as well as the shape of the second intermediate material, which is the member to be formed by the straightening process. Typically, a press machine such as a hydraulic press is used as the drive mechanism.

[0053] By performing the straightening process as described above, a second intermediate material is formed having one third thinning portion formed at a position corresponding to one first thinning portion, two fourth thinning portions formed at positions corresponding to two second thinning portions, and two second thickening portions formed between the one third thinning portion and the two fourth thinning portions.

[0054] Figure 4(c) is a schematic diagram showing an example of the structure of a second intermediate material formed by performing a straightening process in which a pair of first punches press the first thinned portion of the first intermediate material in the thickness direction of the first intermediate material, as illustrated in Figure 5. In Figure 4(c), the left-right direction is the "longitudinal direction," the up-down direction is the "thickness direction," and the depth direction is the "width direction."

[0055] As illustrated in Figure 4(c), the second intermediate material 120 has one third thinning portion 121 formed at a position corresponding to one first thinning portion 111, two fourth thinning portions 122 formed at positions corresponding to two second thinning portions 112, and two second thickening portions 123 formed between the one third thinning portion 121 and the two fourth thinning portions 122, respectively.

[0056] As described above, during the straightening process, the third restraining means restrains the two second thinning portions 112 in the longitudinal direction of the first intermediate material 110 so as not to widen the gap between them. Therefore, at least the majority of the material of the first thinning portion 111 that is pressed by the pair of first punches 221 is kept between the two second thinning portions 112. As a result, the straightening process ensures that two second thickening portions 123 having shapes corresponding to the molding surfaces of the pair of opposing first punches 221 and the two pairs of molds 222 acting as the third restraining means can be reliably formed.

[0057] Furthermore, the straightening process is a process aimed at reliably forming two second thickened portions 123 having the desired shape as described above. This objective is achieved by constraining the distance between the two second thinned portions 112 in the longitudinal direction of the first intermediate material 110 so that it does not widen, using two pairs of molds 222 as third restraining means, as described above. Therefore, in the straightening process, it is not necessary to restrain the dimensions of the first intermediate material 110 in the longitudinal direction (i.e., the positions of both ends of the first intermediate material 110). However, the first method does not exclude the possibility of restraining the dimensions of the first intermediate material 110 in the longitudinal direction during the straightening process.

[0058] As is clear from Figure 4, the shapes of both main surfaces of the second intermediate material 120, which has one third thinning portion 121, two fourth thinning portions 122, and two second thickening portions 123, correspond to the shapes of the forming surfaces of a pair of first punches 221 and two pairs of molds 222, which serve as third restraining means, facing each other when the straightening process is completed.

[0059] Furthermore, depending on the materials constituting the material 100, the shape of the first intermediate material 110, and / or the shape of the second intermediate material 120, the two pairs of dies 222 may lift up due to the stress acting on them as a result of the clamping of the first thinning portion 111 by the pair of first punches 221. In such cases, additional members may be provided to restrain the position of the two pairs of dies 222 (particularly in the thickness direction of the first intermediate material 110). Specific examples of such members include, for example, a metal plate pad 223 or a gas cylinder (not shown) that restrains the position of the two pairs of dies 222 by the fastening force of a bolt, as illustrated in Figure 5.

[0060] As explained above, in the first method, the second thickened portion of the second intermediate material, which will ultimately become the shaft portion of the hinge mail and / or hinge mail, is formed in two steps: a thickening step and a straightening step. In addition, in the thickening step, which forms the first thickened portion of the first intermediate material that will become the second thickened portion of the second intermediate material, the ends of the material in the longitudinal direction are not restrained. Furthermore, as mentioned above, in the straightening step, which forms the second thickened portion of the second intermediate material from the first thickened portion of the first intermediate material, there is no need to restrain the ends of the first intermediate material in the longitudinal direction.

[0061] Due to the above technical features, the first method can reduce the molding load in the manufacture of hinge mail and / or hinge mail. As a result, secondary effects such as extending the mold life can also be achieved. In the above description, the process up to forming the second intermediate material was described in which the process is divided into two steps: a thickening step and a straightening step. However, depending on the materials constituting the material and / or the shape of the second intermediate material, for example, the thickening step may be further divided into multiple steps and executed gradually.

[0062] Next, in the separation step performed in step S30, two third intermediate materials, each having a second thickened portion at one end, are formed by cutting off at least a portion of the third thinned portion of the second intermediate material.

[0063] Figure 6 is a schematic diagram showing how, in the separation step included in the first method, the third thinning portion of the second intermediate material is removed and two third intermediate materials, each having a second thickening portion at one end, are formed. In Figure 6, the left-right direction is the "longitudinal direction," the up-down direction is the "thickness direction," and the depth direction is the "width direction."

[0064] Figure 6(a) is identical to Figure 4(c) and is a schematic diagram showing an example of the structure of the second intermediate material formed by performing a straightening process. Figure 6(b) is a schematic diagram showing an example of the structure of the two third intermediate materials separated from the second intermediate material by performing a separation process. As illustrated in Figure 6, by performing a separation process, two third intermediate materials 130, each having a second thickening portion 123 at one end, can be obtained from one second intermediate material 120.

[0065] The means for removing at least a portion of the third thinning portion of the second intermediate material in the separation process is not particularly limited, as long as it is possible to achieve the shape required for the shaft portion of the hinge mail and / or hinge mail manufactured by the first method, or the head portion which is to become the shaft portion (i.e., the second thickening portion of the third intermediate material), at one end of the two third intermediate materials formed by the execution of the separation process, including the second thickening portion. Specific examples of such means include, for example, punching and / or cutting using a press.

[0066] As described above, according to the first method, two third intermediate materials can be formed from one material, so ultimately two hinge mail and / or hinge mail can be manufactured from one material. Therefore, compared to forming one third intermediate material from one material, the amount of scrap generated when punching out individual materials from a large sheet of raw material can be reduced, thereby improving yield and production efficiency.

[0067] Furthermore, in order to manufacture the hinge mail and / or hinge mail from the third intermediate material, it is necessary to drill a hole in the second thickened portion at one end of the third intermediate material for inserting the hinge shaft. That is, after performing the first method, the drilling process for manufacturing the hinge mail and / or hinge mail can be performed by drilling a hole in the second thickened portion of the third intermediate material for inserting the shaft to form a shaft cylinder portion.

[0068] However, the hole drilled in the shaft portion does not necessarily have to be a through hole. As long as it can withstand use as a hinge, it may be a recess (i.e., a non-through hole) into which a protrusion formed on the other component that also constitutes the hinge can rotatably engage. In this case, a protrusion that rotatably engages with the recess is provided on the other component that also constitutes the hinge at a position opposite to the recess.

[0069] As explained above, in the thickness-increasing step included in the first method, the first intermediate material is formed by pressing the material in the thickness direction with a pair of first molds. In the straightening step included in the first method, the second intermediate material is formed by pressing the first intermediate material in the thickness direction with a pair of first punches. Therefore, by aligning the driving direction (processing direction) of the pair of first molds in the thickness-increasing step with the driving direction (processing direction) of the pair of first punches in the straightening step, it is possible to move from the thickness-increasing step to the straightening step without changing the orientation (direction) of the first intermediate material.

[0070] Furthermore, if punching with a press is used as a means of removing at least a portion of the third thinned portion of the second intermediate material in the separation process, then by aligning the driving direction (processing direction) of the pair of first punches in the straightening process with the direction (processing direction) of punching in the separation process, the process can be moved from the straightening process to the separation process without changing the orientation (direction) of the second intermediate material.

[0071] In other words, according to the first method, without changing the orientation (direction) of the workpiece, the processing direction can be aligned in all processes from the thickening process and the straightening process, or from the thickening process to the separation process, thereby improving transportability.

[0072] <effect> As described above, in the first method, in the process of manufacturing a hinge mail and / or hinge mail having integrally formed shaft cylinder portion, arm portion and mounting portion from a plate-shaped material, the thickened portion that will become the shaft cylinder portion is formed in multiple stages without restraining the ends in the longitudinal direction of the material. As a result, the molding load in the manufacture of the hinge mail and / or hinge mail can be reduced according to the first method.

[0073] Furthermore, in the first method, the processing direction relative to the workpiece can be aligned in all processes, from the thickening process and the straightening process, or from the thickening process to the separation process. Therefore, according to the first method, the processing direction can be aligned in all processes, from the thickening process and the straightening process, or from the thickening process to the separation process, without changing the orientation (direction) of the workpiece, thereby improving transportability.

[0074] In other words, according to the first method, it is possible to reduce the molding load and improve transportability in the manufacture of hinge mail and / or hinge mail having integrally formed shaft cylinder portion, arm portion and mounting portion.

[0075] 《Second Embodiment》 Hereinafter, a method for manufacturing a hinge mail and / or hinge mail according to a second embodiment of the present invention (hereinafter sometimes referred to as the "second method") will be described with reference to the drawings.

[0076] As described above, in the straightening step included in the first method, the dimensions of the first intermediate material in the width direction are restrained by the second restraining means, and the distance between the two second thinning portions in the longitudinal direction of the first intermediate material is restrained by the third restraining means so as not to widen, while at least a part of the first thinning portion is pressed in the thickness direction of the first intermediate material by a pair of first punches. As a result, the straightening step makes it possible to reliably form two second thickening portions 123 having shapes corresponding to the molding surfaces of a pair of opposing first punches 221 and two pairs of molds 222 as third restraining means.

[0077] From the viewpoint of reliably forming the second thickened portion 123, it is preferable to prevent the material to constitute the second thickened portion 123 from plastically flowing through the second thinned portion of the first intermediate material toward the end, and ultimately it is even more preferable to completely restrain the region from the thinnest part of the second thinned portion of the first intermediate material toward the end. However, if this region is completely restrained, the clamping of the first thinned portion by the first punch during the straightening process will become a closed forging, raising concerns about increased forming load and / or shortened die life.

[0078] Therefore, the inventors investigated conditions that could restrain the gap between the two second thinning portions in the longitudinal direction of the first intermediate material so as not to widen while avoiding an excessive increase in the molding load. As a result, the inventors found that the above objective can be achieved by bringing the third restraining means into contact with the region of the first intermediate material from the point where the curved surface changes from a curved surface that is convex inward to a curved surface that is convex outward, in the middle of the curved surface that goes from the point where the thickness of the second thinning portion of the first intermediate material is thinnest to the point where the thickness of the first thickening portion is thickest.

[0079] <composition> Therefore, the second method is a method for manufacturing hinge mail and / or hinge mail, which is the first method described above, wherein in the straightening step, a third restraining means is brought into contact with at least a first region to restrain the distance between the two second thinning portions in the longitudinal direction of the first intermediate material so as not to widen. The first region is a region on the surface of the second thinning portion that corresponds to the portion between the inflection point on the curve from the thinnest point, which is the position where the thickness of the second thinning portion is smallest in a perpendicular projection view onto a plane perpendicular to the width direction of the first intermediate material, to the thickest point, which is the position where the thickness of the adjacent first thickening portion is largest, and the thinnest point.

[0080] Figure 7 is a schematic diagram illustrating a first region of the first intermediate material that is in contact with the third restraining means in the straightening step included in the second method. Figure 7(a) is a schematic perspective view showing an example of the configuration of the first intermediate material formed by performing a thickness-increasing step, similar to Figure 2(c) and Figure 4(a). Figure 7(b) is a schematic perpendicular projection of the portion of the first intermediate material enclosed by the thick dashed line in Figure 7(a) onto a plane perpendicular to the width direction.

[0081] In Figure 7(b), the thinnest point of the second thinning portion 112 of the first intermediate material 110, where the wall thickness is smallest, is represented by the straight line Pn, and the thickest point of the first thickening portion 113, where the wall thickness is largest, is represented by the straight line Pb. Furthermore, the inflection point on the curve between the straight line Pn representing the thinnest point and the straight line Pb representing the thickest point of the adjacent first thickening portion 113 is represented by the straight line Pi. Therefore, the first region described above is the region on the surface of the second thinning portion 112 corresponding to the region R1 between the straight line Pn representing the thinnest point and the straight line Pi representing the inflection point in Figure 7(b).

[0082] <effect> As described above, in the straightening step included in the second method, the third restraining means is brought into contact with at least the first region to restrain the distance between the two second thinning portions in the longitudinal direction of the first intermediate material so as not to widen. The first region is a region on the surface of the second thinning portion that corresponds to the portion between the inflection point on the curve from the thinnest point, which is the position where the thickness of the second thinning portion is smallest in a perpendicular projection view onto a plane perpendicular to the width direction of the first intermediate material, to the thickest point, which is the position where the thickness of the adjacent first thickening portion is largest, and the thinnest point.

[0083] As a result of the above, the straightening step included in the second method allows for the reliable formation of two second thickened portions having shapes corresponding to the forming surfaces of a pair of opposing first punches and two pairs of molds acting as third restraining means, while constraining the two second thinned portions in the longitudinal direction of the first intermediate material so as not to widen the gap between them.

[0084] 《Third Embodiment》 The following describes a method for manufacturing a hinge mail and / or hinge mail according to a third embodiment of the present invention (hereinafter sometimes referred to as the "third method") with reference to the drawings.

[0085] In the descriptions of the first and second methods described above, Figures 2 to 7 illustrate a case in which two third intermediate materials, each having a second thickening portion at one end, are formed by cutting off at least a portion of the third thinning portion of a second intermediate material, in which one third thinning portion, two fourth thinning portions, and two second thickening portions are arranged in a generally straight line.

[0086] However, as is well known to those skilled in the art, depending on the application of the hinge, a bent shape may be required for the arm interposed between the shaft portion and the mounting portion in the mail and / or hinge. Figure 8 is a schematic diagram showing an example of a mail configuration having a bent shape for the arm interposed between the shaft portion and the mounting portion. In the mail 140 illustrated in Figure 8, the arm 143 interposed between the shaft portion 141 and the mounting portion 142 has a bent shape.

[0087] In order to manufacture a mail and / or Hime mail having a bent arm portion as described above using the method for manufacturing a hinge mail and / or Hime mail according to the present invention (method of the present invention), it is necessary to perform a step of bending the portion of the second intermediate material that will later become the arm portion in a desired direction and angle before the separation step.

[0088] <composition> Therefore, the third method is a method for manufacturing hinge mail and / or hinge mail, which is the first or second method described above and further includes a bending step between the straightening step and the separation step. The bending step is a step of pressing and bending two plate portions with a second punch while a first portion of the second intermediate material is held in the thickness direction of the second intermediate material by a pair of second molds. The first portion is at least the portion between two fourth thinning portions in the longitudinal direction of the second intermediate material. The plate portions are the portions between both ends and the first portion in the longitudinal direction of the second intermediate material.

[0089] Figure 9 is a flowchart showing an example of the flow of each step included in the third method. The flowchart illustrated in Figure 9 is the same as the flowchart illustrated in Figure 1, which was referenced in the description of the first method, except that step S25, which performs the bending process described above, is added between step S20, which performs the straightening process, and step S30, which performs the separation process.

[0090] Technically, it is possible to perform the bending process before the straightening process. However, from the viewpoint of reducing the man-hours and / or time required to change the configuration of the molding apparatus in each process, it is preferable to perform the bending process between the straightening process and the separation process.

[0091] Figure 10 is a schematic diagram illustrating the process in which, in the folding process included in the third method, the first portion of the second intermediate material is held in the thickness direction of the second intermediate material by a pair of second molds while the two plate portions are pressed and folded by a second punch. In Figure 10, the left-right direction is the "longitudinal direction," the up-down direction is the "thickness direction," and the depth direction is the "width direction."

[0092] Figure 10(a) illustrates the state at the point when the second intermediate material 120 is set in a molding apparatus 230 configured to perform a bending process and the bending process is about to begin. In this state, at least the first portion of the second intermediate material 120, which is the portion between the two fourth thinning portions (122) in the longitudinal direction of the second intermediate material 120, is held in the thickness direction of the second intermediate material 120 by a pair of second molds 231. In the example shown in Figure 10, the lower second mold 231 in the drawing is composed of three parts. However, both or either of the pair of first molds may be composed of a combination of multiple parts in this manner, or they may be composed integrally by a single part.

[0093] On the other hand, Figure 10(b) illustrates the state at the point when the second intermediate material 120b is formed by bending the second intermediate material 120, which has a generally straight shape, by performing a bending process in which the two plate portions between the two ends in the longitudinal direction of the second intermediate material 120 and the first portion are pressed in the thickness direction of the second intermediate material 120 by the second punch 232 while maintaining the above state.

[0094] Furthermore, the direction and angle at which the second punch bends the plate portion of the second intermediate material during the bending process can be appropriately set by adjusting the configuration of the molding apparatus that performs the bending process, such as the shape of the pair of second molds and the second punch, and the direction in which the second punch presses the plate portion.

[0095] Furthermore, by aligning the direction in which the second punch presses the plate portion of the second intermediate material (processing direction) in the bending process with the processing direction in other processes, it becomes possible to perform all processes from the thickening process to the bending process or from the thickening process to the separation process without changing the orientation (direction) of the workpiece, thereby improving the transportability in the third method.

[0096] <effect> As described above, in the third method, between the straightening process and the separation process, a bending process is performed in which the first portion of the second intermediate material is held in the thickness direction of the second intermediate material by a pair of second molds, while the two plate portions are pressed and bent by a second punch. Therefore, according to the third method, mail and / or Hime mail used in applications where a bent shape of the arm portion interposed between the shaft portion and the mounting portion is required can be efficiently manufactured.

[0097] 《Fourth Embodiment》 The following describes a method for manufacturing a hinge mail and / or hinge mail according to the fourth embodiment of the present invention (hereinafter sometimes referred to as the "fourth method") with reference to the drawings.

[0098] As described above, in the third method, between the straightening process and the separation process, a bending process is performed in which the first portion of the second intermediate material is held in the thickness direction of the second intermediate material by a pair of second molds, while the two plate portions are pressed and bent by a second punch. The thickness of the plate portion between the bent portion and both ends of the second intermediate material is the same as the thickness of the material, since it has not been thickened or thinned in the thickening and straightening processes described above. Furthermore, this plate portion is the part that will become the mounting portion of the hinge mail and / or hinge mail to be obtained in the end. Therefore, if a material having a thickness equal to the thickness of the mounting portion of the hinge mail and / or hinge mail to be obtained in the end is used, the plate portion can be used as a mounting portion without changing its thickness.

[0099] However, depending on the size and / or shape of the shaft portion of the hinge mail and / or hinge mail to be ultimately obtained, if the thickening and straightening processes are performed using a material with a thickness equal to the thickness of the mounting portion, it may be difficult to form a second thickened portion with the required size and / or shape. In such cases, it is desirable to use a material with a thickness greater than the thickness of the mounting portion to increase the thickness of the first thickened portion accompanying the thinning (crushing) of the first and second thinned portions in the thickening process, or to increase the thickness from the first thickened portion to the second thickened portion accompanying the thinning (crushing) from the first thinned portion to the third thinned portion in the straightening process.

[0100] However, as described above, if a material with a thickness greater than the thickness of the mounting portion of the hinge mail and / or hinge mail to be ultimately obtained is used, it is necessary to reduce the thickness of the plate portion to match the thickness of the mounting portion. Furthermore, even if it is not necessary to change the thickness of the plate portion as described above, it may be necessary to perform some kind of secondary processing on the plate portion, for example, to improve the flatness and / or surface roughness of the plate portion.

[0101] <composition> Therefore, the fourth method is a method for manufacturing hinge mail and / or hinge mail, which is the third method described above and further includes a scraping step in parallel with the bending step or between the bending step and the separation step, in which scraping is performed on the outer surface of the bent plate portion.

[0102] Figure 11 is a flowchart illustrating one example of the flow of each step included in the fourth method. The flowchart illustrated in Figure 11 is similar to the flowchart illustrated in Figure 9, which was referenced in the description of the third method, except that it includes step S25i, which performs the above-described scrubbing process in parallel with the folding process, instead of step S25, which performs only the folding process.

[0103] On the other hand, Figure 12 is a flowchart showing another example of the flow of each step included in the fourth method. The flowchart illustrated in Figure 12 is similar to the flowchart illustrated in Figure 9, which was referenced in the description of the third method, except that step S27, which performs the aforementioned rubbing process, is added between step S25, which performs only the folding process, and step S30, which performs the separation process.

[0104] First, we will explain the case in which the bending process is performed in parallel with the folding process, as illustrated in Figure 11. Here, we will refer again to Figure 10, which was referenced in the explanation of the third method. As is clear from the comparison between the thickness of the plate portion of the second intermediate material 120 shown in Figure 10(a) and the thickness of the plate portion of the second intermediate material 120b shown in Figure 10(b), Figure 10 already contains the technical features of the fourth method.

[0105] In other words, in the molding apparatus 230 illustrated in Figure 10, the distance between the outer surface of the lower second mold 231 and the inner surface of the second punch 232 in the longitudinal direction of the second intermediate material 120 is smaller than the thickness of the plate portion of the second intermediate material 120. Therefore, when the first portion of the second intermediate material 120 is held in the thickness direction of the second intermediate material 120 by a pair of second molds 231 during the bending process, and the two plate portions are pressed and bent by the second punch 232, a scraping process by the second punch 232 is also performed on the outer surface of the plate portion of the second intermediate material 120 in parallel.

[0106] However, if there is a large difference between the thickness of the plate portion of the second intermediate material 120 and the target thickness, attempting to reach the target thickness in a single scraping process may result in excessive processing load, potentially leading to problems such as fracture of the second intermediate material 120 and / or damage to the second mold 231 and / or the second punch 232. In such cases, it is preferable to perform the scraping process in multiple steps.

[0107] Figure 13 is an enlarged view of the area enclosed by the thick dashed line in Figure 10(b). As illustrated in Figure 13, the distance between the inner surface of the second punch 232 (the surface facing the outer surface of the plate portion of the second intermediate material 120b) and the outer surface of the second die 231 (the surface facing the inner surface of the plate portion of the second intermediate material 120b) is smaller than the thickness of the plate portion of the second intermediate material 120. The inner surface of the second punch 232 and the tip surface (lower end surface) of the second punch 232 are surfaces that smoothly connect the two, and constitute the first-stage land L1 to which the plate portion of the second intermediate material 120 that has been folded in the bending process is first subjected to scraping.

[0108] Furthermore, on the base end side (upper side in the drawing) of the inner surface of the second punch 232, a region is formed where the distance from the outer surface of the second die 231 is even smaller. At the tip end (lower side in the drawing) of this region, a step is formed where the distance from the outer surface of the second die 231 gradually decreases as it progresses from the tip end to the base end. This step constitutes a second land L2 that applies a second scraping process to the outer surface of the plate portion of the second intermediate material 120b, which has been scraped by the land L1 described above.

[0109] As described above, by providing multiple lands on the inner surface of the second punch 232, the scraping process can be performed in multiple stages. This reduces the problems mentioned above caused by excessive processing loads, while allowing for a large overall scraping volume to be applied to the plate portion of the second intermediate material 120.

[0110] Furthermore, when the scraping process is performed in multiple stages as described above, the amount of deformation (scraping) in the workpiece (the plate portion of the second intermediate material) in each scraping stage is smaller compared to when the desired scraping amount is achieved in a single scraping stage. Therefore, the amount of springback after scraping can be reduced, and the dimensional accuracy and / or flatness and / or surface roughness of the plate portion of the second intermediate material can be improved.

[0111] Next, we will describe the case in which a scraping process is performed between the bending process and the separation process (i.e., separately from the bending process), as illustrated in Figure 12. In this case, the bending process is performed using a second punch that does not have lands, as illustrated in Figures 10 and 13. Then, before the separation process, scraping can be performed by sliding a third punch, which is a separate punch from the second punch and has an inner surface at a position where the distance between it and the outer surface of the second die is smaller than the thickness of the plate portion of the second intermediate material, along the outer surface of the plate portion of the second intermediate material.

[0112] Even when a slapping process is performed between the bending and separating processes, if there is a large difference between the thickness of the second intermediate material sheet and the target thickness, attempting to reach the target thickness in a single slapping process may result in excessive processing load, potentially leading to the problems described above. In such cases, it is preferable to perform the slapping process in multiple steps.

[0113] As described above, even when the scraping process is performed separately from the bending process in multiple stages, the scraping process can be performed in multiple stages by providing multiple lands on the surface of the third punch that slides along the outer surface of the plate portion of the second intermediate material, as exemplified by the second punch 232 shown in Figure 13, which was referenced in the explanation of when the scraping process is performed in parallel with the bending process. Alternatively, multiple third punches having inner surfaces with different distances from the outer surface of the second die can be prepared, and the scraping process can be performed in multiple stages by switching the third punches so that the distance gradually decreases.

[0114] Furthermore, in both the scrubbing process performed in parallel with the bending process and the scrubbing process performed between the bending process and the separation process, if the scrubbing process is performed without constraining the widthwise dimensions of the second intermediate material, depending on the materials constituting the material and / or the conditions in the scrubbing process (e.g., scrubbing amount and scrubbing speed), the widthwise dimensions of the plate portion of the second intermediate material may expand as the scrubbing process is performed. If such dimensional changes are unacceptable for the intended use of the hinge mail and / or hinge mail obtained in the end, it is preferable to perform the scrubbing process while constraining the widthwise dimensions of the plate portion of the second intermediate material.

[0115] <effect> As described above, in the fourth method, a scraping process is performed on the outer surface of the bent plate portion in parallel with the bending process or between the bending process and the separation process. Therefore, according to the fourth method, even if the thickness of the material required to form a second thickened portion having the required size and / or shape is greater than the thickness of the mounting portion of the hinge mail and / or hinge mail to be ultimately obtained, the thickness of the plate portion of the second intermediate material can be appropriately adjusted by scraping to ensure that the hinge mail and / or hinge mail having the desired shape can be reliably manufactured.

[0116] Incidentally, as stated at the beginning of this specification, the present invention relates not only to a method for manufacturing hinge mail and / or hinge mail, but also to an apparatus for manufacturing hinge mail and / or hinge mail.

[0117] 《Fifth Embodiment》 Hereinafter, with reference to the drawings, a manufacturing apparatus for hinge mail and / or hinge mail according to the fifth embodiment of the present invention (hereinafter sometimes referred to as the "fifth apparatus") will be described.

[0118] <composition> The fifth apparatus is a manufacturing apparatus for hinge mail and / or hinge mail having an integrally formed shaft cylinder portion, arm portion and mounting portion.

[0119] The fifth apparatus is configured to perform the first method described above. The flow of each step included in the first method has already been described in detail in the description of the first method and in Figure 1, which was referenced in that description, so a detailed explanation is omitted here.

[0120] The fifth apparatus comprises a first restraining means, which is a means for restraining the dimensions of a plate-shaped material in the width direction, and a pair of first molds, each having one first protrusion and two second protrusions provided on both sides of the first protrusion in the longitudinal direction of the material at a predetermined distance from the first protrusion. The fifth apparatus is configured to perform a material thickening process in which the material is compressed in the thickness direction by the first molds, while the dimensions of the material in the width direction are restrained by the first restraining means, but the dimensions of the material in the longitudinal direction are not restrained. By performing the material thickening process, a first intermediate material is formed having one first thinning portion formed at a position corresponding to one first protrusion, two second thinning portions formed at positions corresponding to two second protrusions, and two first thickening portions formed between the one first thinning portion and the two second thinning portions, respectively.

[0121] The configuration of the first restraining means and the pair of first molds provided in the fifth device, as well as the details of the thickening process performed by the fifth device and the configuration of the first intermediate material formed by the thickening process, have already been described in detail in the above-mentioned explanation of the first method and in Figures 2 and 3 which were referenced in that explanation, so a further explanation is omitted here.

[0122] Furthermore, the fifth apparatus includes a second restraining means for restraining the dimensions of the first intermediate material in the width direction, a third restraining means for restraining the distance between the two second thinning portions in the longitudinal direction of the first intermediate material from widening, and a pair of first punches configured to be separable and approachable in the thickness direction of the first intermediate material. The fifth apparatus is configured to perform a straightening process in which at least a portion of the first thinning portions is clamped by the pair of first punches in the thickness direction of the first intermediate material, while the dimensions of the first intermediate material in the width direction are restrained by the second restraining means and the distance between the two second thinning portions in the longitudinal direction of the first intermediate material is restrained by the third restraining means from widening. By performing the straightening process, a second intermediate material is formed having one third thinning portion formed at a position corresponding to one first thinning portion, two fourth thinning portions formed at positions corresponding to two second thinning portions, and two second thickening portions formed between the one third thinning portion and the two fourth thinning portions, respectively.

[0123] The configuration of the second restraining means, third restraining means, and first punch provided in the fifth device, as well as the details of the straightening process performed by the fifth device and the configuration of the second intermediate material formed by the execution of the straightening process, have already been described in detail in the above-mentioned explanation of the first method and in Figures 4 and 5 referenced in that explanation, so a further explanation is omitted here.

[0124] In addition, the fifth apparatus includes a first cutting means, which is a means for cutting off at least a portion of the third thinning portion of the second intermediate material. The fifth apparatus is configured to perform a separation step in which at least a portion of the third thinning portion of the second intermediate material is cut off by the first cutting means. By performing the separation step, two third intermediate materials, each having a second thickening portion at one end, are formed.

[0125] The details of the first excision means provided by the fifth apparatus, the separation process performed by the fifth apparatus, and the composition of the third intermediate material formed by the execution of the separation process have already been described in detail in the above-mentioned explanation of the first method and in Figure 6 which was referenced in that explanation, so a further explanation is omitted here.

[0126] <effect> As will be apparent from the description of the first method, in the first method performed by the fifth apparatus, in the process of manufacturing a hinge mail and / or hinge mail having integrally formed shaft portion, arm portion and mounting portion from a plate-shaped material, the thickened portion that will become the shaft portion is formed in multiple stages without restraining the ends in the longitudinal direction of the material. As a result, the fifth apparatus makes it possible to reduce the molding load in the manufacture of the hinge mail and / or hinge mail.

[0127] Furthermore, in the first method performed by the fifth device, the processing direction relative to the workpiece can be aligned in all processes, from the thickening process and the straightening process, or from the thickening process to the separation process. Therefore, with the fifth device, the processing direction can be aligned in all processes, from the thickening process and the straightening process, or from the thickening process to the separation process, without changing the orientation (direction) of the workpiece, thereby improving transportability.

[0128] In other words, the fifth apparatus makes it possible to reduce the molding load and improve transportability in the manufacture of hinge mail and / or hinge mail.

[0129] 《Sixth Embodiment》 Hereinafter, a manufacturing apparatus for hinge mail and / or hinge mail according to the sixth embodiment of the present invention (hereinafter sometimes referred to as the "sixth apparatus") will be described with reference to the drawings. The sixth apparatus is configured to carry out the second method described above.

[0130] <composition> That is, the sixth apparatus is the fifth apparatus described above, which is a manufacturing apparatus for hinge mail and / or hinge mail, which restrains the gap between two second thinning portions in the longitudinal direction of the first intermediate material so as not to widen by bringing a third restraining means into contact with at least a first region during the straightening process. The first region is an area on the surface of the second thinning portion that corresponds to the portion between the inflection point on the curve from the thinnest point, which is the position where the thickness of the second thinning portion is smallest in a perpendicular projection view onto a plane perpendicular to the width direction of the first intermediate material, to the thickest point, which is the position where the thickness of the adjacent first thickening portion is largest, and the thinnest point.

[0131] Details regarding the first region to which the third restraining means is brought into contact during the orthodontic process performed by the sixth device have already been described in detail in the explanation of the second method and in Figure 7 referenced in that explanation, so further explanation is omitted here.

[0132] <effect> As will be apparent from the description of the second method, in the straightening step included in the second method performed by the sixth apparatus, the third restraining means is brought into contact with at least the first region to restrain the distance between the two second thinning portions in the longitudinal direction of the first intermediate material so as not to widen. The first region is a region on the surface of the second thinning portion that corresponds to the portion between the inflection point on the curve from the thinnest point, which is the position where the thickness of the second thinning portion is smallest in a perpendicular projection view onto a plane perpendicular to the width direction of the first intermediate material, to the thickest point, which is the position where the thickness of the adjacent first thickening portion is largest, and the thinnest point.

[0133] As a result of the above, the sixth apparatus can reliably form two second thickened portions having shapes corresponding to the forming surfaces of a pair of opposing first punches and two pairs of molds acting as third restraining means, while avoiding an excessive increase in the forming load and restraining the two second thinned portions in the longitudinal direction of the first intermediate material so as to prevent the gap between them from widening.

[0134] 《Seventh Embodiment》 Hereinafter, with reference to the drawings, a manufacturing apparatus for hinge mail and / or hinge mail according to the seventh embodiment of the present invention (hereinafter sometimes referred to as the "seventh apparatus") will be described.

[0135] As described above, in the manufacturing method of hinge mail and / or hinge mail according to the present invention, including the first and second methods (methods of the present invention), the thickening process is performed without restricting the dimensions in the longitudinal direction of the material in order to reduce the molding load, and the second intermediate material is formed by dividing the process into a thickening process and a straightening process. However, if the molding space in which the first thickened portion is formed is excessively filled with the material of the material during the thickening process, the molding load in the thickening process becomes excessive, and the advantages of forming the second intermediate material by dividing the process into a thickening process and a straightening process are reduced. From this viewpoint, it is preferable that the molding space in which the first thickened portion is formed is not excessively filled with the material of the material during the thickening process.

[0136] As a result of diligent research, the inventors have found that the above objective can be achieved more reliably by configuring a pair of first molds that clamp the material in the thickening process such that the distance between the opposing first protrusions of the pair of first molds and the distance between the opposing second protrusions of the pair of first molds match a predetermined relationship.

[0137] <composition> Therefore, the seventh apparatus is the fifth or sixth apparatus described above, which is a manufacturing apparatus for hinge mail and / or hinge mail, wherein in the thickening process, when a pair of first molds face each other with a material in between, the first distance, which is the distance between a pair of first protrusions facing each other, is greater than the second distance, which is the distance between two pairs of second protrusions facing each other.

[0138] Figure 14 is a schematic diagram showing an example of the configuration of a pair of first molds provided in the seventh apparatus. In the pair of first molds 210f illustrated in Figure 14, the first distance D1, which is the distance between a pair of opposing first protrusions 211, is greater than the second distance D2, which is the distance between two pairs of opposing second protrusions 212 (D1 > D2). As a result, in the seventh apparatus, the molding space in which the first thickened portion is formed is not excessively filled with material during the thickening process.

[0139] <effect> As described above, in the first mold of the seventh device, the first distance, which is the distance between a pair of opposing first protrusions, is greater than the second distance D2, which is the distance between two pairs of opposing second protrusions. As a result, in the seventh device, the molding space in which the first thickened portion is formed is not excessively filled with material. Consequently, the molding load in the thickening process is not excessive, and the effect of forming the second intermediate material in two separate processes, the thickening process and the straightening process, can be reliably achieved.

[0140] 《Eighth Embodiment》 Hereinafter, with reference to the drawings, a manufacturing apparatus for hinge mail and / or hinge mail according to the eighth embodiment of the present invention (hereinafter sometimes referred to as the "eighth apparatus") will be described. The eighth apparatus is configured to carry out the third method described above.

[0141] <composition> That is, the eighth apparatus is the fifth or sixth apparatus described above, and is a manufacturing apparatus for hinge mail and / or hinge mail, comprising a pair of second molds and a second punch. The pair of second molds clamp a first portion, which is at least the portion between two fourth thinning portions in the longitudinal direction of the second intermediate material, in the thickness direction of the second intermediate material. The second punch presses and bends two plate portions, which are the portions between both ends and the first portion in the longitudinal direction of the second intermediate material.

[0142] Furthermore, the eighth apparatus is configured to perform a bending process between the straightening process and the separation process. The bending process involves pressing and bending two plate portions, which are the two portions between the first portion and both ends in the longitudinal direction of the second intermediate material, with a second punch while at least the first portion is held in the thickness direction of the second intermediate material by a pair of second dies. The first portion is the portion between the two fourth thinning portions in the longitudinal direction of the second intermediate material.

[0143] The configuration of the pair of second molds and second punches provided in the eighth apparatus, the details of the bending process performed by the eighth apparatus, and the configuration of the second intermediate material formed by bending the plate portion as a result of the bending process have already been described in detail in the above-mentioned explanation of the third method and in Figures 9 and 10 referenced in that explanation, so a further explanation is omitted here.

[0144] <effect> As will be clear from the description of the third method, in the third method performed by the eighth apparatus, a bending process is performed between the straightening process and the separation process, in which the first portion of the second intermediate material is held in the thickness direction of the second intermediate material by a pair of second molds, while the two plate portions are pressed and bent by a second punch. Therefore, the eighth apparatus makes it possible to efficiently manufacture mail and / or Hime mail used in applications where a bent shape of the arm portion interposed between the shaft portion and the mounting portion is required.

[0145] 《Ninth Embodiment》 Hereinafter, with reference to the drawings, a manufacturing apparatus for hinge mail and / or hinge mail according to the eighth embodiment of the present invention (hereinafter sometimes referred to as the "ninth apparatus") will be described. The eighth apparatus is configured to carry out the third method described above.

[0146] <composition> In other words, the ninth apparatus is the eighth apparatus described above, and is configured to perform a scraping process on the outer surface of the plate portion bent by the execution of the bending process, either in parallel with the bending process using a land formed on the second punch, or between the bending process and the separation process using a land formed on the third punch, which is a separate punch from the second punch. This apparatus is a manufacturing apparatus for hinge mail and / or hinge mail.

[0147] The configuration of the second or third punch in the ninth device and the details of the scraping process performed by the ninth device have already been described in detail in the above-mentioned explanation of the fourth method and in Figures 10 to 13 referenced in that explanation, so a further explanation is omitted here.

[0148] <effect> As will be clear from the description of the fourth method, in the fourth method performed by the eighth apparatus, a scraping process is performed on the outer surface of the bent plate portion in parallel with the bending process or between the bending process and the separation process. Therefore, according to the ninth apparatus, even if the thickness of the material that can form a second thickened portion having the required size and / or shape is greater than the thickness of the mounting portion of the hinge mail and / or hinge mail to be ultimately obtained, the thickness of the plate portion of the second intermediate material can be appropriately adjusted by scraping to ensure that the hinge mail and / or hinge mail having the desired shape can be reliably manufactured.

[0149] In order to explain the present invention, several embodiments having specific configurations have been described with reference to the accompanying drawings. However, it should not be interpreted that the scope of the present invention is limited to these exemplary embodiments, and it goes without saying that modifications can be made as appropriate within the scope of the claims and the specification. [Explanation of Symbols]

[0150] 100...Materials 110...First Intermediate Material 111…1st thinning part 112…Second thinning part 113...1st thickened part 120...Second intermediate material 121...Third thinning section 122…4th thinning part 123…Second thickening section 120b...Bent second intermediate material 130...Third Intermediate Material 140... Mail (flexible type) 141...Shaft cylinder part 142... Mounting part 143...Arm (neck) 210,210f…First mold 211...First protrusion 212...Second protrusion 220…Forming equipment (straightening process) 221...First punch 222...Third restraining means (mold) 223... pad 230… Molding equipment (bending process) 231... Second mold 232...Second punch Pn...A straight line indicating the position of the thinnest point. Pb...A straight line indicating the position of the thickest point. Pi...a straight line indicating the position of the inflection point. R1…first area L1...1st tier land L2...2nd level land D1…First distance D2…Second distance

Claims

1. A method for manufacturing a hinge mail and / or hinge mail having an integrally formed shaft portion, arm portion and mounting portion, A thickness-increasing step is performed to form a first intermediate material having one first thinning portion formed at a position corresponding to one of the first protrusions, two second thinning portions formed at positions corresponding to the two of the second protrusions, and two first thickening portions formed between the one first thinning portion and the two of the second thinning portions, respectively, by pressing the material in the thickness direction of the material with a pair of first molds having one first protrusion and two second protrusions provided on both sides of the first protrusion in the longitudinal direction of the material at a predetermined distance from the first protrusion, while restricting the dimensions of the plate-shaped material in the width direction with a first restraining means, but not restricting the dimensions of the material in the longitudinal direction of the material, and thereby forming a first intermediate material having one first thinning portion formed at a position corresponding to one of the first protrusions, two second thinning portions formed at positions corresponding to the two of the second protrusions, and two first thickening portions formed between the one first thinning portion and the two of the second thinning portions, respectively. A straightening step to form a second intermediate material having one third thinning portion formed at a position corresponding to one first thinning portion, two fourth thinning portions formed at positions corresponding to two second thinning portions, and two second thickening portions formed between the one third thinning portion and the two fourth thinning portions, respectively, by constraining the width dimension of the first intermediate material with a second restraining means and constraining the distance between the two second thinning portions in the longitudinal direction of the first intermediate material with a third restraining means so as not to widen, while pressing at least a part of the first thinning portion with a pair of first punches in the thickness direction of the first intermediate material, A separation step of forming two third intermediate materials having the second thickened portion at one end by cutting off at least a portion of the third thinned portion of the second intermediate material, including at least, A method for manufacturing hinge mail and / or hinge mail.

2. A method for manufacturing a hinge mail and / or hinge mail as described in claim 1, In the straightening process, the third restraining means is brought into contact with the first region, which is a region on the surface of the second thinned portion that corresponds to the area between the thinnest point, which is the position with the smallest thickness of the second thinned portion in a perpendicular projection view onto a plane perpendicular to the width direction of the first intermediate material, and the thickest point, which is the position with the largest thickness of the adjacent first thickened portion, thereby restraining the distance between the two second thinned portions in the longitudinal direction of the first intermediate material from widening. A method for manufacturing hinge mail and / or hinge mail.

3. A method for manufacturing hinge mail and / or hinge mail according to claim 1 or claim 2, Between the straightening step and the separation step, the process further includes a bending step in which, while a first portion, which is the portion between the two fourth thinning portions in the longitudinal direction of the second intermediate material, is held in the thickness direction of the second intermediate material by a pair of second molds, two plate portions, which are the two portions between both ends in the longitudinal direction of the second intermediate material and the first portion, are pressed and bent by a second punch. A method for manufacturing hinge mail and / or hinge mail.

4. A method for manufacturing a hinge mail and / or hinge mail as described in claim 3, The process further includes a scraping step in parallel with the bending step or between the bending step and the separation step, in which the outer surface of the bent plate portion is scraped. A method for manufacturing hinge mail and / or hinge mail.

5. A manufacturing apparatus for hinge mail and / or hinge mail having integrally formed shaft portion, arm portion and mounting portion, The invention comprises a first restraining means, which is a means for restraining the dimensions of a plate-shaped material in the width direction, and a pair of first molds, each having one first protrusion and two second protrusions provided on both sides of the first protrusion in the longitudinal direction of the material at a predetermined distance from the first protrusion. The device is configured to perform a thickness-increasing process in which a first intermediate material is formed having one first thinning portion formed at a position corresponding to one first protrusion, two second thinning portions formed at positions corresponding to two second protrusions, and two first thickening portions formed between the one first thinning portion and the two second thinning portions, respectively, by pressing the material in the thickness direction with the first mold while constraining the dimensions of the material in the width direction with the first restraining means, without constraining the dimensions of the material in the longitudinal direction, and thereby forming a first intermediate material having one first thinning portion formed at a position corresponding to one first protrusion, two second thinning portions formed at positions corresponding to two second protrusions, and two first thickening portions formed between the one first thinning portion and the two second thinning portions. The first intermediate material comprises a second restraining means for restraining the dimensions in the width direction, a third restraining means for restraining the distance between the two second thinning portions in the longitudinal direction of the first intermediate material from increasing, and a pair of first punches configured to be separable and approachable in the thickness direction of the first intermediate material. The device is configured to perform a straightening process in which a second intermediate material is formed having one third thinning portion formed at a position corresponding to one first thinning portion, two fourth thinning portions formed at positions corresponding to two second thinning portions, and two second thickening portions formed between the one third thinning portion and the two fourth thinning portions, respectively, by restricting the widthwise dimension of the first intermediate material with the second restraining means and restricting the distance between the two second thinning portions in the longitudinal direction of the first intermediate material with the third restraining means so as not to widen, while clamping at least a part of the first thinning portion with a pair of first punches in the thickness direction of the first intermediate material. The device comprises a first cutting means which is a means for cutting off at least a portion of the third thinning portion of the second intermediate material, The system is configured to perform a separation step in which two third intermediate materials, each having a second thickened portion at one end, are formed by cutting off at least a portion of the third thinned portion of the second intermediate material with the first cutting means. Manufacturing apparatus for hinge mail and / or hinge mail.

6. A manufacturing apparatus for hinge mail and / or hinge mail as described in claim 5, In the straightening process, the third restraining means is configured to contact a first region, which is a region on the surface of the second thinned portion that corresponds to the area between the inflection point on the curve from the thinnest point, which is the position with the smallest thickness of the second thinned portion, to the thickest point, which is the position with the largest thickness of the adjacent first thickened portion, in a perpendicular projection onto a plane perpendicular to the width direction of the first intermediate material, and the thinnest point. Manufacturing apparatus for hinge mail and / or hinge mail.

7. A manufacturing apparatus for hinge mail and / or hinge mail according to claim 5 or claim 6, In the aforementioned thickening process, when a pair of first molds face each other with the material in between, the first distance, which is the distance between the pair of first protrusions facing each other, is greater than the second distance, which is the distance between the two pairs of second protrusions facing each other. Manufacturing apparatus for hinge mail and / or hinge mail.

8. A manufacturing apparatus for hinge mail and / or hinge mail according to claim 5 or claim 6, A pair of second molds that clamp a first portion of the second intermediate material in the thickness direction, which is at least the portion between the two fourth thinning portions in the longitudinal direction of the second intermediate material, A second punch presses and bends two plate portions, which are the portions between the ends of the second intermediate material in the longitudinal direction and the first portion, Equipped with, Between the straightening step and the separation step, a bending step is performed in which at least the first portion, which is the portion between the two fourth thinning portions in the longitudinal direction of the second intermediate material, is held in the thickness direction of the second intermediate material by a pair of second molds, while two plate portions, which are the two portions between both ends and the first portion in the longitudinal direction of the second intermediate material, are pressed and bent by a second punch. Manufacturing apparatus for hinge mail and / or hinge mail.

9. A manufacturing apparatus for hinge mail and / or hinge mail as described in claim 8, The system is configured to perform a scraping process on the outer surface of the plate portion that has been folded by the execution of the bending process, either in parallel with the bending process using a land formed on the second punch, or between the bending process and the separation process using a land formed on a third punch, which is a separate punch from the second punch. Manufacturing apparatus for hinge mail and / or hinge mail.

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