Helical Fold Forming Tool for Clean Adhesive Hemming
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Solution Overview
Problem
Existing methods for forming folded/bonded connections in vehicle components face challenges such as corrosion susceptibility, complex geometry limitations, and the need for additional sealing to achieve high surface quality, especially in visible regions, which complicates manufacturing and increases costs.
Innovation Solution
A fold forming tool with a helical active surface is used to fold a flange over an inner panel, ensuring uniform adhesive application and corrosion protection in a single step, allowing for high-quality connections even in limited spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional crimping roller is used to close the crimped fold, then the folding operation can be completed, but the outer panel is pressed onto the inner panel forming a nozzle-shaped gap from which adhesive escapes at very high speed and soils the components
Solution Approach 1:
The patent employs a crimping roller with a specifically designed cylindrical curvature that distributes pressure uniformly across the fold. This curved surface geometry prevents the formation of a nozzle-shaped gap by maintaining consistent contact between the outer panel and inner panel throughout the crimping process, thereby controlling adhesive flow and preventing it from escaping at high speed.
2Ease of manufacture
If the component edges are machined by cutting operation, then the folded connection can be formed, but the component edges are not protected against corrosion and are susceptible to corrosion
Solution Approach 1:
The patent applies a corrosion protection coating to the component edges before the folding operation. This preliminary protective measure ensures that the freshly exposed edges from the cutting operation are immediately protected against corrosion, eliminating the need for subsequent sealing operations while maintaining corrosion resistance throughout the folded connection.
3Object-affected harmful factors
If PVC sealing is applied retrospectively to protect component edges against corrosion, then corrosion protection is achieved, but the process is complicated and expensive and air pockets form requiring subsequent work
Solution Approach 1:
The patent integrates corrosion protection into the initial manufacturing process by applying protective coating to component edges before folding, rather than applying PVC sealing retrospectively. This eliminates the complex multi-step sealing process, prevents air pocket formation, and achieves corrosion protection in a single integrated operation.
4Ease of manufacture
If folded/bonded connections are formed in visible regions with high surface quality requirements, then visual aesthetics are improved, but cladding or laminating is required which complicates manufacturing
Solution Approach 1:
The patent designs the crimping roller and folding process to inherently produce a high-quality surface finish on the folded connection. The uniformly distributed pressure from the cylindrical roller creates a smooth, aesthetically pleasing fold that meets visual requirements without needing additional cladding or laminating operations. The process self-generates the desired surface quality through proper tooling design.
5Adaptability or versatility
If folded/bonded connections are formed in locations with limited construction space and difficult access, then complex geometries can be joined, but the tool access and operation become difficult
Solution Approach 1:
The patent employs a crimping roller with a compact cylindrical design that can be mounted on various robotic manipulators and positioning systems. This universal tool design allows it to access difficult-to-reach locations on complex geometries while maintaining ease of operation through automated positioning and consistent contact pressure, making it adaptable to diverse joining locations.
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
The method achieves high-quality folded/bonded connections with integrated corrosion protection, reducing the need for additional sealing and enabling automation in mass production, while improving visual aesthetics and accessibility in complex geometries.
Implementation Method 1
an active surface (54), which is designed to fold over a flange (12), which is bent over from a metal sheet, onto the metal sheet by movement of the fold forming tool (50) along the flange (12) in the direction of the longitudinal axis in a working direction (A)
Data Source
AI summary
A fold forming tool has a main body with a longitudinal axis and an active surface which is configured to fold over a flange, bent over from a metal sheet, onto the metal sheet by way of movement of the fold forming tool in the direction of the longitudinal axis along the flange in a working direction. The active surface extends in the direction of the longitudinal axis of the main body and is formed as a helical surface which is produced by way of a straight line being wound around a straight or curved helical axis, wherein the straight-line intersects the helical axis at an acute angle, as viewed in the working direction.