Process to manufacture a coated bumper
AssigneePintura, Estampado Y Montaje, S.A. DE
InventorsSergio Ortiz-Garcia, Jose Enriquez-Gomez, Ricardo Morales-Coronilla
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Abstract
This invention relates to a process for the manufacture a coated bumper, which steps are practical and simple, but at the same time, highly efficient for manufacturing coated bumpers, that permits the use of same equipment as those used to manufacture conventional fences. Likewise, this invention relates to a bumper highly efficient for use in any type of vehicle, since it has and exceeds all the aesthetical and mechanical and corrosion resistance characteristics of bumpers found in the state of the art.
Claims27
- A process for the manufacture of a coated bumper, which comprises the following steps:
- (a) stamping of a first metal plate to obtain a base or internal element of the coated bumper, which remains hidden when such bumper is assembled in the vehicle;
- (b) apply an anticorrosion material film in at least on one of the internal element faces;
- (c) clean the internal element to remove any type of grease and impurity on their faces;
- make element undergo a degreasing process to remove dust and any type of grease remaining after application of anticorrosion film;
- (d) place and adhesive material on the other face of internal element that serves as a coupling agent and selected among spraying (aspersing), the use of a paint-brush, extrusion, immersion, among others;
- (e) separately stamp a second metal plate to obtain the coating or external element resting in the visible part of the coated bumper when it is assembled in the vehicle;
- (f) clean the external element to remove any type of grease and impurities remaining on their faces, making it undergo a mechanical cleaning process with solvent and/or detergent solution;
- next, rinse off and dry;
- (g) place on the face to be coupled to the external element, the adhesive material selected among spraying (aspersing), use of a paint-brush, extrusion, immersion, among others;
- (h) assemble the internal element and the external element to shape the coated bumper;
- for such purpose, the face to be coupled of the external element is coupled on the face to be coupled of the internal element by exerting pressure using a press harness keeping the coupling of both pats with a separation between each other requiring such adhesive for optimal adherence and resistance, which is between 0.02 to 1.2 mm;
- (i) pre-cure the adhesive material, where the coated bumper obtained at the previous step is subjected to a setting process to achieve maximum adherence and resistance, the duration and temperature of which, depend on the type of adhesive material used to perform assembly;
- (j) reinforce the coupling of the external element with the internal element through any coupling method selected among locking, clamping, using nuts and bolts, welding points or combinations thereof, among others (k) polish the visible face of the external element to give, or else, recover the “mirror degree” reflective finishing or any other degree damaged during the stamping and, assembling process;
- polishing can be performed by brushing or any other known mechanical polishing process;
- (l) visually inspect the coated bumper to detect any appearance or dimension defect since the surface of the visible face must be free of cracks, dents, skin, die marks, etc.;
- and (m) pack the coated bumper in such a way it is set to be delivered to the assembly facility to assemble it in the vehicle, or else, deliver it to spare part dealers or license holders of assembly facilities trademarks.
- The process for the manufacture of a coated bumper according to claim 1, wherein the external element having the same shape as the internal element, but with dimensions slightly greater than such internal element.
- The process for the manufacture of a coated bumper according to claim 1, wherein the anticorrosion material is a water-based painting o solvent base;
- it is applied through any of the methods selected among electro-depositing, aspersing (spraying), immersion, use of a paint-brush or through any other known application method.
- The process for the manufacture of a coated bumper according to claim 3, wherein the anticorrosion film is applied on at least one of the faces of internal element or base.
- The process for the manufacture of a coated bumper according to claim 3, wherein the anticorrosion film is applied on the face exposed to open air once the bumper is assembled in the vehicle.
- The process for the manufacture of a coated bumper according to claim 1, wherein the adhesive material is applied through a extrusion dosing device that following the shape of the part in an automation application, where such face to be couples is the face opposite to the face in contact with open air.
- The process for the manufacture of a coated bumper according to claim 1, wherein the adhesive material is selected among acrylic, cyano-acrylate, epoxic, urethanic adhesives, or any other adhesive capable to securely couple metal materials.
- The process for the manufacture of a coated bumper according to claim 1, wherein the process used to reinforce the assembly coupling is the locking process.
- The process for the manufacture of a coated bumper according to claim 1, wherein the first metal plate is made of carbon steel material selected among Series SAE 10XX steels.
- The process for the manufacture of a coated, bumper according to claim 1, wherein the second metal plate is made of stainless steel with an elongation of at least 40%, which is selected among Series 300, stainless steels.
- The process for the manufacture of a coated bumper according to claim 1, wherein the manufacturing process comprises the following steps:
- place the adhesive material on one of the faces of a first metal plate and a second metal plate;
- (b) couple the first metal plate to the second metal plate by exerting pressure one of them to attain a good coupling with each other, and thus shaping a bi-metal substratum;
- (c) pre-cure the adhesive material;
- for that purpose, the bi-metal substratum obtained in the previous step is subjected to a setting process to attain maximum adherence and resistance, where the time and temperature depend on the type of adhesive material used for assembly;
- (d) stamp the bi-metal substratum to obtain a coated bumper;
- (e) clean the coated bumper to remove any type of grease or impurities on their faces;
- for this purpose, the coated bumper is subjected to a mechanical cleaning process with solvent and/or a detergent solution;
- rinse off and then dry;
- (f) polish the visible face of the coated bumper to give, or else, recover the “mirror degree” reflective finishing or any other degree damaged during the stamping process;
- polishing may be performed by brushing or by any other known mechanical polishing process;
- (g) visually inspect the coated bumper to detect any appearance or dimension defect, since the visible part of the coated bumper must be free of cracks, dents, skin, die marks, etc.;
- (h) pack the coated bumper in such a way it is set to be delivered to the assembly facility to be assemble in the vehicle, or else, deliver it to the spare part dealers or to the license holders of assembly facilities trademarks.
- The process for the manufacture of a bumper coated according to claim 11, wherein the adhesive material is selected among acrylic, cyano-acrylate, epoxic, urethanic adhesives, or any other adhesive capable to securely couple metal materials.
- The process for the manufacture of a coated bumper according to claim 11, wherein the first metal plate is made of a carbon steel material selected among Series SAE 10XX steels.
- The process for the manufacture of a coated bumper according to claim 11, wherein the second metal plate is made of a stainless steel material with an elongation of at least 40%, which is selected among Series 300 stainless steels.
- A bi-metal substratum to manufacture a coated bumper comprised of a first metal plate and a second metal plate securely coupled by an adhesive material.
- The bi-metal substratum to manufacture a coated bumper according to claim 15, wherein the adhesive material is selected among, acrylic, cyano-acrylate, epoxic, urethanic adhesives or any other adhesive capable to securely couple metal materials.
- A coated bumper comprising the association of an internal element or base located at the internal and hidden part of the bumper when it is assembled in the vehicle, and an external element or coating located on the internal element of bumper, shaping the visible part of such bumper, said internal and external elements area securely coupled by an adhesive material.
- The coated bumper according to claim 17, wherein the internal element is of any shape so that it fully covers the front of vehicle for which it was designed.
- The coated bumper according to claim 18, wherein the internal element includes in one of its faces at least one anticorrosion material film.
- The coated bumper according to claim 19, wherein the anticorrosion material film is applied on the face exposed to open air when bumper is assembled to the vehicle.
- The coated bumper according with claim 17, wherein the internal element is manufactured from a carbon steel metal plate selected from Series SAE 10XX steels.
- The coated bumper according to claim 17, wherein the external element is of a complimentary shape and dimensions slightly greater than the shape and dimensions of internal element.
- The coated bumper according to claim 22, wherein the material emerging as a flap that folds inwards and over the profile of the internal element so that the coupling is reinforced and thus avoiding the external element separates from internal element when coated bumper is assembled in the vehicle and it is already servicing.
- The coated bumper according to claim 17, wherein the external element is manufactured from a stainless steel metal substratum with an elongation of at least 40%, so that it loses none of its reflection properties or uniformity of its surface when the material undergoes a stamping process;
- therefore, such stainless steel is selected among Series 300 stainless steels.
- The bumper coated according to claim 17, wherein the adhesive material is selected among acrylic, cyano-acrylate, epoxic, urethanic adhesives or any other adhesive capable to securely couple metal materials.
- The coated bumper according to claim 17, wherein the coupling between internal and external elements is reinforced through any coupling method selected between clamping, passers or non passers, nut and bolts, welding, etc.
- The coated bumper according to claim 17, wherein the external element is of a different shape than that of the internal element, but perfectly coupling with respect to each other.