Bumper Drilling Jig for Clean Coated Resin Hole Edges
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Solution Overview
Problem
Conventional drilling methods for creating holes in resin members with coatings, such as vehicle bumpers, often result in damage to the coating due to rotational forces and burr formation, requiring additional steps to remove these imperfections, which can impair the appearance and are cumbersome.
Innovation Solution
A drilling jig comprising a male blade and a female blade with a shaft member, where the male blade and shaft member are coupled to minimize rotation and maximize control, allowing for precise cutting and punching of holes without significant damage to the coating, by using a method that sandwiches the workpiece and applies controlled shear forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rotatable tool such as a drill or hole saw is used to bore a hole in the bumper, then the hole can be created efficiently, but the coating on the bumper surface is torn off by the rotational force, severely impairing the appearance
Solution Approach 1:
The patent replaces the conventional rotatable drilling tool with a punching tool that applies linear reciprocating motion instead of rotational motion. The punching tool includes a punch member that moves linearly to punch through the bumper, eliminating the rotational force that causes coating tearing while maintaining efficient hole creation
Solution Approach 2:
The patent changes the motion parameter from rotational to linear reciprocating. The punching tool applies upward and downward forces in a linear motion pattern, controlled by a slider mechanism that guides the punch member along a vertical path, thereby preventing the coating damage associated with rotational drilling
2Productivity
If a rotatable tool is used to drill a hole, then the hole can be bored quickly, but burrs are formed on the opening edge of the hole, requiring additional steps to remove them
Solution Approach 1:
The patent substitutes the rotatable drilling mechanism with a linear punching mechanism. The punch member moves in a straight line to create the hole, which eliminates burr formation on the opening edge while maintaining high drilling speed, thus removing the need for additional deburring operations
Solution Approach 2:
The punching tool creates a clean hole edge through its linear punching action itself, without requiring subsequent deburring operations. The upward and downward forces applied by the punch member cleanly sever the material, making the hole ready for immediate use without additional processing steps
3Manufacturing precision
If a file or the like is used to remove burrs from the hole opening edge, then the burrs can be eliminated, but the coating is scraped off by such file or the like
Solution Approach 1:
The patent replaces the file-based deburring method with a punching method that creates burr-free holes directly. The linear reciprocating motion of the punch member cleanly cuts through the bumper material without generating burrs, eliminating the need for file-based removal that would damage the coating
Solution Approach 2:
The punching tool performs the hole creation and edge finishing in a single operation. By applying controlled upward and downward forces, the punch member creates a clean edge during the punching process itself, preventing burr formation before it occurs and eliminating the need for subsequent coating-damaging deburring operations
4Ease of manufacture
If shear processing is used to bore a stepped hole, then the hole can be created, but there occurs deformation of shape in addition to the formation of a hole, causing coating to peel off
Solution Approach 1:
The patent replaces shear processing with a direct punching mechanism. The punch member applies linear compressive forces to push through the bumper material, creating a clean hole without the lateral shearing forces that cause deformation and coating peeling associated with conventional shear processing methods
5Ease of manufacture
If a punch is used to punch out the bumper, then the hole can be created, but the surface of the bumper produces a burr protruding upward, and such burr is then pressed downward to be collapsed, subjecting the edge to load that may cause coating cutting-off or peeling-off
Solution Approach 1:
The patent uses a controlled punching mechanism with linear reciprocating motion instead of conventional punching that creates protruding burrs. The slider-guided punch member applies controlled forces that cleanly sever the material without creating burrs that would require collapsing, thereby preventing coating damage from the burr collapse process
Solution Approach 2:
The patent changes the punching mechanism to apply controlled upward and downward forces through a slider mechanism. This controlled linear motion creates a clean hole edge without the uncontrolled material deformation and burr formation that occurs with conventional punching, eliminating the need for burr collapse operations that damage the coating
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively drills holes in resin members with coatings while minimizing damage to the coating, ensuring a clean edge and maintaining the appearance of the workpiece, as the boundary between the material and coating is made less noticeable, reducing the need for additional post-processing steps.
Implementation Method 1
a blade portion (20) and a planar blade surface (18) are formed on the male blade (2). The drilling jig (1) sandwiches the resin member (51) having the coating (54) applied thereto, between the male blade (2) and the female blade (3), and the male blade (2) is rotated by a given angle about the shaft (4) so as to cut the coating (54) by the blade portion (20)
Data Source
AI summary
A drilling jig for drilling a punching hole with a boundary between a basis material and a coating of a workpiece less noticeable, and a drilling method using this drilling jig. It includes a male blade, a female blade, and a hexagon bolt; the male blade and the hexagon bolt are capable of being coupled to each other; a screw hole, through which the hexagon bolt is inserted, and a blade portion are formed in the male blade; the blade portion has a planar blade surface; a shaft insertion hole, through which the hexagon bolt is inserted, and a blade portion housing hole capable of housing the blade portion are formed in the female blade, whereby the boundary between the basis material and the coating of a bumper can be positioned on the inside of the punching hole, preventing the appearance of the punching hole from being impaired.