Note: Descriptions are shown in the official language in which they were submitted.
CA 02463667 2004-04-28
SHEET METAL REPAIR METHOD, SHEET METAL REPAIR TOOL, AND
SHEET-LIKE N~ER FIXING DEVICE
FIELD OF THE IN~tlENTION
The present invention relates to a sheet metal repair
method and a sheet metal repair tool for repairing a sheet
metal of a damaged car body and the like. Furthermore, the
present invention also relates to a sheet-like member fixing
device for positioning, supporting, and temporarily fixing a
sheet-like member.
BACKGROUND OF THE IrIVf.'~TION
When a sheet metal of a car body and the like is damaged,
a sheet metal repair method for removing a partici.ll..ar portion
of the sheet metal including the damaged part and for~bonding
a repair member to the sheet metal in place of the removed
portion has been often employed so far.
For example, when a car body 1 shown in FIG. 43 is
damaged due t~ a car accident, a particular portion 4 of the
body including a damaged part 2 was removed by cutting it
along a line 3 and then a repair member ~a is bonded to the
body 1 in place of the removed portion 5. Before bonding the
repair member 6 to the body , a reinforcing member 7 is
connected to the portion near the cut part of the body 1, and
then the repair member 6 is bonded onto -the member 7 by spot
welding 8 and 9.
However, in such a sheet metal repair method, the
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CA 02463667 2004-04-28
reinforcing member 7 was indispensable, and therefore a repa?r
process became complicated. In addition, the use of the
repair member 7 increase the number of joint surfaces, which
was a problem in terms of strength and corrosivity.
In a conventional rr~thod for repairing a sheet metal
(sheet-like member) of a car body, a particular portion
including a damaged part of a car body is removed and then a
repair member is connected to the body in place of the removed
portion. For example, as shown in FIG. 44, a repair member
502 is positioned on a sheet metal 501, and the repair member
502 is bonded to the body by spot welding and the like.
However, when the repair member 502 is bonded to the
sheet metal by using such a method, the sheet metal 501 has to
be supported by hand. FT'herefore, it has been desired that
greater safety be secured. In order to position the repair
member 502 by pressing it against the sheet metal 501, the
repair member 502 had to be pushed outward by inserting hand
into the space between the sheet metal 50l and an interior
panel 503. For this reason, bonding of the member 502 to the
sheet metal 501 involved great difficulties. In order to
temporarily join'the repair member 502 to the sheet metal 501
for spot welding, it was indispensable to use fasteners such
as bolts and to insert hand into the space between the sheet
metal 501 and the interior panel 503. Thus, temporarily
joining involved great difficulties.
Accordingly, inventors of the present invention carried
out intensive studies with an objective Uf providing a sheet
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metal repair method and a sheet metal repair tool having a
sufficiently high bonding strength and resistance to
corrosion without using any reinforcing member.
The inventors also carried out intensive studies with an
objective of providing a sheet-like member fixing device
capable of placing or temporarily fixing a sheet-like member
such as a repair member in a particular position while
holding it with ease and safety.
The inventors also carried out intensive studies with an
objective of providing a sheet-like member fixing device
capable of pushing a sheet-like member outward with ease and
safety.
SUMMARY OF THE INVENTION
As the results of intensive studies to overcome the
above difficulties, the inventors of the present invention
have eventually attained the present invention.
Main point of a sheet metal repair method accordz.ng to
the present invention, in which a particular portion
including a damaged part of a sheet metal is removed and a
repair member is bonded to the sheet metal in place of the
removed portion is: to bend a portion near the end part of
the repair meanber which is larger in area than a gap formed
by removing the particular portion or a portion near the end
part of the sheet metal to which the repair member is bonded
in accordance with the shape of the gap so as to form at
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least a first bent part; and to bond the repair member to the
sheet metal in place of the removed portion.
Such a sheet metal repair method makes it possible to
repair the sheet metal without using any reinforcing member
by bending either a portion near the end part of the repair
member or a portion near the end part of 'the sheet metal to
which the repair member is bonded, or by bending both of them
so that the repair member is shaped to fit with the gap.
Another main point of the sheet metal repair method
according to the present invention is to foam a second bent
part by bending a portion nearer to the e:nd part of the
repair member or a portion nearer to the end part of the
sheet metal in the direction opposite to the first bent part
so as to bond the portion near the end of. the repair member
to the sheet metal.
In this sheet metal repair method, a repair member or a
sheet metal is bent stepwise to form a first bent part and a
second bent part which is bent in the direction opposite to
the first bent part. While the end part of the repair
member or of the sheet metal is fitted to the first and
second bent parts of the sheet metal or of the repair member,
the portion nearer to the end than the second bent part of
the repair merrtber or of the sheet metal is bonded to the
sheet metal or the repair memberr and thus the repair member
is bonded flush with the sheet metal. The phrase °the end
part of the regain member or the sheet metal is fitted to the
first and second bent parts of the sheet metal or of the
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repair member" used herein means that the end part of the
sheet metal which is not bent is fitted to the bent parts of
the repair member, or that the and part of the repair member
which is not bent is fitted to the bent parts of the sheet
metal. The phrase "the portion near the end part of the
repair member is bonded to the sheet metal" used herein means
that the portion near the end part of the repair member which
is bent is bonded to the end part of the sheet metal which is
not bent, or that the portion near the end part of the sheet
metal which is bent is bonded to the end part of the repair
member which is not bent.
Still another main point of the sheet metal repair
method according to the present invention is to form the
first and the second bent parts at one time with a sheet
metal repair tool comprising a punch and a die which are
shaped to fit with the first and the second bent parts.
In this sheet metal repair method, the first and the
second bent parts are manually or automatically formed at one
time by sandwiching the repair member between the punch and
the die of the sheet metal repair tool.
A further main point of the sheet metal repair method
according to the gresent invention is to bond a part of or a
whole of joint surfaces of the repair member and the sheet
metal by an adhesive agents an adhesive agent and rivet, or a
combination of an adhesive agent, rivet, and spot welding.
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CA 02463667 2004-04-28
In this sheet metal repay-r method, the repair member is
bonded to the sheet metal by welding, an adhesive agent, or a
combination of welding and an adhesive agent.
A still further main point of the sheet metal repair
method according to the present invention is to bend the
portion near the end part of the repair member and/or the
portion near the end part of the sheet metal to remove
distortion on the portion near the end part before the repair
member and the sheet metal are bonded together.
Another main point of the sheet metal repair method
according to the present invention is to bend the portion
near the end part of the repair member and/or the portion
near the end part of the sheet metal so that the first bent
part is curved.
A main point of a sheet metal repair tool according to
the present invention, which is used in the sheet metal
repair method, for removing a particular portion including a~
damaged part of a sheet metal and for bonding a repair member
to the sheet metal in place of the removed portion is to
comprise a punch and a die for forming at least a first bent
part~by bending the portion near the end part of the repair
member and/or the portion near the end pert of the sheet
metal so that the repair member is bonded to the sheet metal
in accordance with a shape of a gap formed by removing the
particular portion.
Such sheet metal repair tool is used in the sheet metal
repair method of the present invention, and makes it possible
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CA 02463667 2004-04-28
to repair the sheet metal by sandwiching the portion near the
end of the repair member or of the sheet metal between the
punch and the die to form bent parts arid by bonding the
repair member to the sheet metal in accordance with a shape
of the gap without using any reinforcing member.
Another main point of the sheet metal repair tool
according to the present invention is to form a second bent
part by bending a portion nearer to the end than the first
bent part in the direction opposite to the first bent part
simultaneously with the formation of the first bent part.
Such sheet metal repair tool makes it possible to bond
the repair member to the sheet metal in such a manner that
the repair member is flush with the sheet metal, by forming
the first bent part and the second bent part which is bent in
the direction opposite to the first bent part and then by
bonding the portion nearer to the. end than the second bent
part of the repair member or of the sheet metal to the sheet
metal or the repair member.
Further main points of the sheet metal repair tool
according to the present invention are; place the punch and
the die on the point of action of a lever element having the
point of application of force, the fulcrum, and the point of
action; and to form at least the first bent part by bringing
the punch and the die closer by the application of griping
force or pushing force to the point of action.
Such sheet metal :repair tool makes it possible to bend
the portion near the end part of the repair member or of the
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° sheet metal by the application of griping force or pushing
force to the punch and the die, using the action of the lever
element.
A still further main point of the sheet metal repair
tool of the present invention is that the punch and the die
each have a first bending edge arid a second bending edge, and
that the first bending edges of the punch and the die form
the first bent part and the second bending edges form the
second bent part.
Such sheet metal repair tool makes it possible to ensure
the formation of the first bent part and the second bent part
by using the first bending edges to form the first bent part
and by using the second bending edges to form the second part.
In addition, this tool also makes it possible to form the
first bent part and the second bent part at predetermined
angles by using the first bending edges and the second
bending edges.
Another main point of the sheet metal repair tool
according to the present invention is that the distance
between the first bending edge and the second bending edge of
the punch and the distance between the first bending edge and
the second bending edge of the die are substantially same as
the thickness of the repair member or the sheet metal.
In such sheet metal repair tool, the distance between
the first bending edge and the second bending edge of the
punch and the distance between the first bending edge and the
second bending edge of the die are substantially same as the
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CA 02463667 2004-04-28
thickness of the repair member or the sheet metal, so that
the difference in level between the first bent part and the
second bent part becomes substantially same as the thickness
of the repair member or the sheet metal. Therefore, this
tool makes it possible to ensure that the repair member is
bonded to the sheet metal so that it becomes flush with the
sheet metal.
Still another main point of the sheet metal repair tool
according to the present invention is that either the punch
or the die or both of them has/have a tapered portion in a
position where the first bent part is to be formed, so that
the first bent part is bent curvedly by the tempered portion.
Main points of a sheet-like member fixing device
according to the present invention are: to comprise a rod-
like male thread having a hook on its one end portion and a
female thread into which the male thread is screwed; to
tighten the female thread after passing the male thread
through a hole of a sheet-like member; and to support the
sheet-like member by sandwiching it between the hook and the
female thread. The term "sheet-like member" used herein
includes not only a sheet~r~tal but also sheet-like resin,
lumber, glass and the like..
Such sheet-like member fixing device is fixed to the
sheet-like member, or the sheet-like member is fa..xed to the
fixing device while the sheet-like member is supported by
being sandwiched between the female thread and the hook,
using holes formed in the sheet-like member. The hole can be
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formed in advance or it can be fo~ned when the sheet-like
member fixing device is used:
Another main point of the sheet-like member fixing
device according to the present invention. is to pass the male
thread through the hole from its hook's side.
In the sheet-like member fixing device of such a
structure that the male thread is passed through the hole
from its hook's side, the hook is first inserted into the
hole of a sheet-like member; and then the male thread is
passed through the hole as a matter of course because the
hook is part of the male thread.
Still another main point of the sheet-like member fixing
device according to the present invention is that the hook is
substantially square to the male thread.
In the sheet-like member fixing device of such a
structure that the hook is substantially square to the male
thread, the sheet-like member can be supported by sandwiching
it between the hook and the female thread while the hook is
in close contact with the back surface of the sheet-like
member.
A further main point of the sheet-like member fixing
device according to the present invention is that the male
thread is fixed in the direction substantially perpendicular
to the hook while the hook is brought in close contact with
the surface of the sheet-like member.
Such sheet-like member fixing device can be easily
supported by fixing the male thread in the direction
CA 02463667 2004-04-28
substantially perpendicular to the sheet-like member while
the sheet-like member is supported by being sandwiched
between the hook and the female. In other words, when the
sheet-like member fixing device is fixed to the sheet-like
member, the sheet-like member fixing device is fixed in the
direction substantially perpendicular to the sheet-like
member.
Still another main point of the sheet-like member fixing
device according to the present invention is that the hook
points to one direction.
Since the hook does not branch off in various directions
from the male thread. but it points to one direction, the hook
can be inserted into the hole while the sheet-like member
fixing device is tilted against the sheet-hlce member. By
moving the device to the direction where the hook points, the
hook can be easily locked in the sheet-like member.
Furthernnore , the sheet -like member f fixing device can be
easily inserted into the hole of the sheet-like member
without getting stuck in the hole when thf~ hook is inserted
into the hole.
A further main point of the sheet-like member fixing
device according to the present invention.is that the edge of
the hook fixed in the direction substantially perpendicular
to the male thread is beveled.
In the sheet-like member fixing device, the edge of the
hook is beveled to form a tapered tip. Therefore, the sheet-
like member fixing device can be easily inserted into the
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CA 02463667 2004-04-28
hole of the sheet-like member even when the hole is small.
In addition, when the sheet-like member is made of soft
material, the hole is not necessarily formed in advance. In
this case, the sheet-like member fixing device can be passed
through the sheet-like member while piercing the member with
the hook.
A still further main point of the sheet-like member
fixing device according to the present invention is that a
handle is provided to the other end of the male thread.
In such sheet-like r~terial fixing device, a handle is
provided to the other end of the device so that the sheet-
like member can be supported by holding the device with hand
or tool.
Another main point of the sheet-like member fixing
device according to the present invention is that the handle
is shaped like a ring.
Such sheet-like member fixing device can be easily
supported by holding the ring-like handle. Furthermore,
force can be easily applied to the sheet-like member by
pulling out of the sheet-like member fixing device by putting
a finger into the rang-like handle.
Still another main point of the sheet-like member fixing
device according to the present invention. is that the female
thread can be screwed down by hand.
The female thread of such sheet-like member fixing
device has wings that rn~kes it easier to apply force, and
therefore the female thread can be screwed down by hand.
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BRIEF DESCRIPTION OF THE DRAWINGS
FIGs. 1(a) and (b) are views to help explain a sheet
metal repair method of the present invention. FIG. 1(a) is a
side view showing a car body to be repaired, and FIG. 1(b) is
a sectional plan view showing a part repaired by bonding a
repair member.
FIG. 2 is a side view showing a sheet metal repair tool
of the present invention which is used in the sheet metal
repair method of the present invention.
FIG. 3 is a front view showing the sheet metal repair
tool shown in FIG. 2.
FIGs. 4 (a) to (c) are views showing embodiments of the
punch and the die of the sheet metal repair tool shown in FIG.
2. FIG. 4(a), 4(b), and 4(c) are a side viewu a front view,
and a plan view of the die, respectively.
FIG. 5 is a side view showing another embodiment of the
sheet metal repair tool of the present invention.
FIGs. 6 (a) and 6(b) are a back view and a plan view of
the sheet metal repair tool shown in FIG..S, respectively.
FIG. 7 is a perspective view showing a repair member,
whose one portion near the end part is bent by the sheet
metal repair tool shown in FIG. 5.
FIGs. 8 (a) and 8(b) are views showing further
embodiments of the punch and the die of the sheet metal
repair tool shown in FIG. 5. FIG. 8(a) is a side view and
FIG. 8(b) is a plan view.
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' FIGs. 9(a) and 9(b) are views-showing still further
embodiments of the punch and the die of the sheet metal
repair tool shown in FIG. 5. FIG. 9(a) is a side view, and
FIG. 9(b) is a plan view.
FIG. 10 is a perspective view.showin!~ another embodiment
of the punch and the die of the sheet metal repair tool of
the present invention.
FIG. 11 is a. perspective view showing still another
embodiment of the punch and the die of the sheet metal repair
tool of the present invention.
FIG. 12 is a view to help explain another embodiment of
the sheet metal repair method of the present invention, and
it is a sectional'view of the joint between the sheet metal
and the repair member.
FIG. 23 is a view to help explain still another
embodiment of the sheet metal repair method of the present
invention, and it is a sectional view of the connection
between the sheet metal. and the repair mert~ber .
FIGs. 14 (a) and (b) are views showing further
embodiments of the sheet metal repair tool of the present
invention. FIG. 14(a) is a back view, and FIG. 14(b) is a
plan view.
FIG. 15 is a side view showing a still further
embod~.ment of the sheet metal repair toot of the present
invention.
FIG. 16 is a side view of the opposite side of the sheet
metal repair tool of the present invention.
24
CA 02463667 2004-04-28
FIGs. 17(a) to 17(c) are views showing a punch and die
of the sheet metal repair tool shown in FIG. 15. FIGS. 17(a)
and 17(b) are a front view and a plan view of the punch, and
FIG. 17(c) is a plan view of the die.
FIG.-18 is a view showing another embodiment of the
punch and the die of the sheet metal repair tool shown in FIG.
15.
FIG. 19 is a view showing still another embodiment of
the punch and the die of the sheet metal repair tool shown in
FIG. 15.
FIGs. 20(a) to 20(c) are views showing further
embodiments of the punch and the die of the sheet metal
repair tool shown in FIG. 15. FIGs. 20(a) and 20(b) are a
front view and a plan view of the punch, and 20(c) is a plan
view of the die.
FIGs. 21 are views showing still further embodiments of
the punch and the die provided for the sheet metal repair
tool shown in FIG. 15. FIGs. 21(a) and 21(b) are a front
view and a plan view of the punch, and 2I(c) is a plan view
of the die.
FIG. 22 is a side view showing another embodiment of the
sheet metal repair tool of the present invention.
FIGs. 23(a) to 23(c) are views showing the punch and the
die of the sheet metal repair tool shown in FIG. 15. FIGs.
23(a) and 23(b) are a front view and a plan view of the punch,
and 23(c) is a plan view of the die.
CA 02463667 2004-04-28
FIGs. 24(a} to 24(c} are views showing a repair member
which is bent with the sheet metal repair tool shown in FIGs.
23(a) to 23(c). FIG. 24(a) and FIG. 2~(b) are a perspective
view and a sectional view showing a repair member on which
folds are formed, and FIG. 24(c) is a sectional view showing
a repair ember on which no folds are formed.
FIGs. 25(a) and 25(b} are views showing further
embodiments of the sheet metal repair tool of the present.
invention. FIG. 25(a) is a plan view of the punch and the
die, and FIG. 25(b) is a general side view of the tool.
FIGS. 26(a) to 26(c) are views showing still further
embodiments of the sheet metal repair tool of the present
invention. FIG. 26(a), 26(b), and 26(c) are a side view, a
front view, and a bottom view, respectively.
FIG. 27 is a side view showing a reciprocating drive of
the sheet metal repair tool shown in FIGS. 26{a) to 26(c).
FIG.28 is a side view showing another embodiment of the
reciprocating drive of the sheet metal repair tool shown in
FIGs. 26(a) to 26(c).
FIGs. 29(a) to 29(c} are views showing further
embodiments of the sheet metal repair tool of the present
invention. FIG. 29(a), 29(b), and 29(c) are a side view, a
front view, and a bottom view, respectively.
FIGs. 30(a) to 30(c) are views showing still further
embodiments of the sheet metal repair tool of the present
invention. FIGs. 30(a), 30(b), and 30(c) are a side view, a
front view, and a bottom view, respectively.
1 f>
CA 02463667 2004-04-28
FIGs. 31(a) and 31{b) are views showing further
embodiments of the sheet metal repair tool of the present
invention. FIG. 31(a) is a side view and. FIG. 31(b) is a
general front view of the tool.
FIGs. 32(a) to 32(c) are views of the sheet metal repair
tool shown in FIGs. 31(a) and 31(b) of the present invention,
which is being used. FIG. 32(a) is a front sectional view
showing a joint between the repair member and the sheet metal
which is bent with the tool shown in FIGS. 31(a) and 31(b).
FIG. 32(b) is'a front sectional view showing a joint between
the repair member and the sheet metal which is not bent with
the tool shown in FIGs. 31(a) and 31(b). FIG. 32(c) is a
plan view showing a coated surface of the sheet metal which
is not bent with the tool shown in FIGs.. 32(a) and 31(b).
FIGs. 33(a) and 33(b) are views showing still further
embodiments of the sheet metal repair tool of the present
invention. FIG. 33(a) is a side view, arrd FIG. 33(b) is a
general front view of the tool.
FIG. 34 is a front view showing a sheet-like member
fixing device of the present invention.
FIG. 35 is an enlarged front sectional view showing a
major part of the sheet-like member fixing device shown in
FIG. 1, which is being used.
FIG. 36 is a an enlarged front sectional view showing a
major part of the sheet-like member fixing device shown in
FIG. l, which is being used.
17
CA 02463667 2004-04-28
FIG. 37 a front sectional view showi~ag a major part of
the sheet-like member fixing device shown in FIG. 2, which is
being used.
FIG. 38 is an enlarged front sectional view showing a
major part of another er~nbod~.ment. of the sheet-like member
fixing device of the present invention, which is being used.
FIG. 39 is an enlarged front sectional view showing the
major part of the sheet-like member fixing device shown in
FIG. 5, which i.s being used.
FIGS. 40 are views for showing further embodiments of
the sheet-like member fixing device of the present invention,
which is being used. FIG. 40(a) is an enlarged front
sectional view, and FIG. 40(b) is a bottom view of a major
part of the sheet-like member.
FIG. 41 is a front sectional view showing still another
embodiment of the sheet-like member fixing device of the
present invention, which is being used.
FIG. 42 is a front view showing a further embodiment of
the sheet-like member fixing device of the present invention.
FIGS. 43 are views to help explain a conventional sheet
metal repair method. FIG. 43(a) is a s.i_de view of a car
body, and FIG. 43(b) is a perspective view showing a part
repaired by bonding a repair member.
FIG. 44 is a front sectional view to help explain the
direction of repairing a conventional sheet-like member.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
18
CA 02463667 2004-04-28
Embodiments the sheet metal repair method, the sheet
metal repair tool, and the sheet-like member fixing device
according to the present invention will hereinafter be
described in detail with reference to the accompanying
drawings.
In FIGS. 1 to 3, the numeral 10 indicates a car body -
which is to be repaired by the sheet metal repair method of
the present invention, and the numeral 12 indicates the sheet
metal repair tool of the present invention.
The sheet metal repair tool 12 is used in the sheet
metal repair method for removing a particular portion 18
including a damaged part 16 of a sheet metal 14 of a car body
and bonding a repair member 22 to stop up a gag 20 of the
sheet metal. This tool 12 comprises a punch 28 and a die 30
for forming a first bent part 24 by bending a portion near
the end part of the repair member 22 and for forming a second
bent part 26 by bending a portion nearer to the end part in
the direction opposite to the first bent part 24, so as to
bond the repair member 22 in accordance with the shape of the
gap 20 as shown in FIGs. 2 and 3.
The punch 28 and the die 30 are attached to the end of
pliers 32. The pliers 32 includes a handle 34, to the end
portion of which the die 30 is attached; a pivotable handle 38
which pivots about a pivot pin 36; a pin 40; and a lever
element 42 which pivots about a pivot pin 41(fulcrum). The
punch 28 is fixed to a portion 44 near the end of the lever
eleanent 42, that is, the point of action of the element 42.
29
_CA 02463667 2004-04-28
When the handle 34 and 'the pivotable handle 38 are brought
close together by the application of griping force or pushing
force, the first bent part 24 and the second bent part 26 are
formed on the repair member 22 between the punch 28 and the
die 30. A spring 43 is attached to the handle 34 and the
pivotable handle 38 and exerts a force tc> cause them to move
apart.
In the pliers 32, the pivotable 36 is considered as a
fulcrum of the pivotable handle 38, a point of contact between
the pin 40 and the handle 38 is considered as a point of
action of the handle 38, the pivot pin 41 is considered as a
fulcrum of the lever element 42, and the punch 28 is
considered as a point of action of the lever element 42.
Therefore, when the pivotable handle 38 pivots about the pivot
pin 36 and a force is applied to the pin 40, the lever element
42 pivots about the pivot pin 41 and a force is applied to the
repair member 22. Thus, double leverage action can be
achieved in the pivot pin 38 and the lever element 42. F'or
example, where the distance between the point of application
of force of the pivotable-handle 38 and the pivot pin 36 is 90
mm, the distance between the pivot pin 38 and the pin 40 is 12
mm, the distance between the pin 40 and the pivot pin 41 is 75
mn, and the distance between the pivot pin 41 and the point of
action of the punch 28 is 42 mm, the force applied to the
repair member 22 by the punch 28 is 13.4 times the force
applied to the pivotable handle 38.
(90/12) * (75/42) - 13.4
CA 02463667 2004-04-28
The punch 28 is detachably or attachably secured to the
portion near the end portion 44 of the lever element 42 by a
screw 46, and the die 30 is detachably or attachably fixed to
the end portion of the handle 34 by a screw of 48. The punch
28 has a first bending edge 50 and a second bending edge 52,
and the die 30 has a first bending edge 54 and a second
bending edge 56. The first bending edges 50 and 54 form a
first bent part 24 and the second bending edges 52 and 56 fornn
a second bent part 26. In this case, the first bending edges
50 and 54 and the second bending edges 52 and 56 are arranged
parallel with the direction of the axis o:f the pivot pin 36 in
a line. The distance between the first bending edge 50 and the
second bending edge 52 and the distance between the first
bending edge 54 and the second bending edge 5E; are
substantially same as the thickness of the repair member 22.
Next, a sheet metal repairing method v,iill be described
below by taking a method for repairing a sheet metal 14 of a
car body 10 with such sheet metal repair tool 12 as an example.
When a part of a sheet metal 14 of a c;ar body 10 is
damaged in an accident, a particular portion 18 including a
damaged part 16 is cut along a cutting line 58 in a fusion
process and the like, and thus removed from the car body 10.
By removing the portion 18, a gap 20 is formed in the sheet
metal:
Then a repair member 22 which is a bit: larger in area than
the gap 20 is prepared. As shown in FIGs. 2 and 3, an end
portion of the repair member 22 is insertE~d between the punch
21
CA 02463667 2004-04-28
28 and the die 30 of the sheet metal repair tool 12, and the
handle 34 and the pivotable handle 38 are. griped by hand.
When gripping force is thus applied to th.e handle 34 arid the
pivotable handle 38, the pivotable handle 38 pivots about the
pivot pin 36 and therefore a pin 40 of the lever element 42 is
pushed upwards. When the pin 40 is pushed upwards, the lever
element 42 pivots about the pivot pin 41, the punch 28 is
brought closer to the die 30. When the punch 28 is brought
closer to the die 30, the repair member 2.2 is pressed by the
punch 28 and the die 30. Thus, the first: bent part 24 is
fozmed by the first bending edge 50 of tree punch 28 and the
first bencu.ng edge 54 of the die 30, and the second bent part
26 is formed by the second bending edge 52 of the punch 28 and
the second bending edge 56 of the die 30.
After the first and the second bent parts 24 and 26 are
foamed on the repair member 22, the portion near the second
bent part 26 and the portion 57 near the end of the repair
member 22 is attached to the cut 58 of the sheet metal 14, as
shown in FIG. 1(b). At this time, a difference 160 in level
formed by bending the repair meanber 22 is fitted to the end
portion of the sheet metal 14. Since the distance between the
first bending edge 50 and the second bending edge 52 and the
distance between first bending edge 54 and the second bending
edge 56 are substantially same as the thickness of the repair
member 22, the repair member 22 is bonded flush with the sheet
metal 14 of the outer surface of the car body 10. The repair
member 22 is bonded to the sheet metal 14: by an adhesive agent
22
CA 02463667 2004-04-28
60, and it may also be welded if necessary. After being thus
bonded to the sheet metal 14, repair member 22 is coated by a
primer and then given a finish so as to hide the bonded part
from view. Thus, all the repair processes are completed.
In such sheet metal repair method, the first bent part 24
and the second bent part 26 are fornned by bending a portion
near the end of the repair member 22, so that the repair
member 22 of a substantially same shape a.s the gap 20 can be
bonded to the sheet metal. For this reason, unlike a
conventional repair method, there is no need to use a
reinforcing member in the present invention, and therefore the
repairing process can be simplified, and the number of
repairing steps and the cost can be reduced. In addition,
compared to the case where a reinforcing member is used, the
number of bonded parts are reduced in the present invention,
so that bonding strength and resistance to corrosion can be
improved.
Furthermore, in the sheet metal repair tool 12, since the
distance between the first bending edge 50 and the second
bending edge 52 and the distance between the first bending
edge 54 and the second bending edge 56 are substantially same
as the thickness of the sheet metal 14, t:he difference 260 in
level between the first bent part 24 and 'the second bent part
26 is the same as the thickness of the sheet metal 14. For
this reason, when the repair member 22 is bonded to the sheet
metal 14, the repair member 22 becomes flush with the sheet
metal I4, so that painting can be easily conducted after
23
CA 02463667 2004-04-28
bonding and outward appearance can be enhanced.
One embodiment of the present invention has thus been
described, however, the present invention can also be
materialized in the other embodiments.
For example, the punch and the die of the sheet metal
repair tool 12 of the present invention may be a punch 62 and
a die 64 shown in FIG. 4. A first bending edge 66 and a
second bending edge 68 of the punch 62 arid a first bending
edge 70 and a second bending edge 72 of the die 64 are curved
in the direction substantially perpendicular to the direction
to which the repair member 22 is pushed. Such punch 62 and
die 64 can be useful when the part obtained by cutting a
predetermined portion of the sheet metal is curved.
Alternatively, the sheet metal repair tool of the present
invention may be a sheet metal repair tool 74 shown in FIGs. 5
and 6. A pair of pliers 74 of this sheet metal repair tool 74
is composed of a handle 78, a pivotable handle 80, and a lever
element 82, and a force is applied to the repair member 22 in
substantially the same direction as the gripping force is
applied. A punch 84 has a first bending edge 86 and a second
bending edge 88, both of which are right-angled bending edges,
as shown in FIG. 6(a). A die 90 has a first bending edge 92
and a second bending. edge 94, both of which are right-angled
bending edges shaped to fit with the punch 84, as shown in FIG.
6(b). Where the cut part obtained by cutting a particular
portion of the sheet metal is of a shape bent into an angle of
90 degrees, a repair member 96 having a portion 162 bent into
24
CA 02463667 2004-04-28
an angle of 90 degrees is bent with the sheet metal repair
tool 74 to form a first bent part 98 and a second bent part
100, so that it can be bonded to the cut part of a shape bent
into an angle of 90 degrees.
Alternatively, the punch and the die of the sheet metal
repair tool 74 may be a punch 102 and a die 104 as shown in
FIG. 8. The punch 102 has a first bending edge 106 and a
second bending edge 108, both of which are bent into a
particular angle, and the die 104 has a first bending edge 110
and a second bending edge 112, both of which are bent into a
particular angle. The edge of the die 104 is angled
oppositely to the edge of the punch 102. In other words,
jutting parts of the punch 102 and the di.e 104 face each other.
When the jutting part of the punch 102 is brought close to the
jutting part of the die 104, only a particular portion of a
repair member can be bent. Thus, the particular portion of a
repair member can be easily and reliably bent by concentrating
a force onto the particular portion.
Alternatively, the punch and the die of the sheet metal
repair tool 74 may be a punch 114 and a die 116 as shown in
FIG. 9.~ The punch 114 has a first bending edge 118 and a
second bending edge 120 which are curved, and the die 116 has
a first bending edge 122 and a second bending edge 124 which
are straight. When the jutting part of the punch 114 having a
curved edge is brought close to the first and the second
bending edges of the die 116 having a straight edge, a certain
range of a repair member can be bent. Fuurthennore, the
CA 02463667 2004-04-28
repair member can be easily and reliably bent by concentrating
a force onto the center portion of the curved edge..
The sheet metal repair tool of the present invention is
not limited to the one whose punch and die are manually
brought close to each other. For example, as shown in FIG.
10, the sheet metal repair tool may be a sheet metal repair
tool 164 whose punch 126 is brought close. to a die 128 by
moving pistons 230 by a hydraulic or an a.ir cylinder. The
punch 126 has a first bending edge 132 anal a second bending
edge 134 which are straight, and the die 128 has a first
bending edge 136 and a second bending edge 138 which are
straight. By using such punch 126 and die 128, a portion
near the end of a repair member can be easily and reliably
bent by a cylinder. In addition, the punch 126 and the die
128 is wide, so that a. wide range of the repair member can be
bent at a time.
Alternatively, the sheet metal repair tool may be a sheet
metal repair tool 166 whose punch 140 is 'brought close to a
die 142 by moving pistons 144 by a hydraulic or an air
cylinder. The punch 140 has a first bending edge 146 and a
second bending edge 148 which are curved, and the die 142 has
a first bending edge 150 and a second bending edge 152 which
are curved. The punch _L40 and the die 142 are used for
repairing a curved car body and the like.
The sheet metal repair method of the present invention is
not limited to the method for bending only one end of a repair
member as shown in FIG. l, but it may be a method for bending
26
CA 02463667 2004-04-28
both ends or a periphery of a repair member. For example, as
shown in FIG. 12, where a gap 156 formed 'by removing a
particular portion from a sheet metal 154 is of a round shape,
the periphery of the repair member 158 may be bent with the
sheet metal repair tool of the present invention and then the
repair member 158 may be bonded to the metal sheet in such a
manner that the repair member 158 stops u;p the gap 156.
Alternatively, in the sheet metal repair method of the
present invention, both a portion near the end of a repair
meanber and a portion near the end of a sheet metal may be bent.
For example, as shown in FIG. 13, not only a portion 172 near
the end of a repair member 170 but also a portion 176 near the
end of a sheet metal 174 may be bent into a normal angle so as
to bond the portion 172 to the portion 176.
The sheet metal repair tool of the present invention may
be a sheet metal repair tool 184 as shown in FIGs. 14(a) and
14(b}. A pair of pliers 186 of this sheet metal repair tool
184 is composed of a handle 188, a pivotalble handle 190, and a
lever element 192, and a force is applied to the repair member
22 in substantially the same direction as the gripping force
is applied. As shown in FIG. 14(b), the hunch 194 has a first
bending edge 196 and a second bending edge (not shown), each
of which has a sharply-angled edge. As shown in FIG. 14(b},
the die 200 has a first bending edge 202 and a second bending
edge 204, each of which has a sharply-angled edge which is
angled oppositely to the edge of the punch 194. Such sheet
metal repair tool I84 makes it possible to bend a repair
27
CA 02463667 2004-04-28
member of a shape bent into an acute angle when the part
obtained by cutting a predetermined portion of the sheet metal
is of a shape bent into an acute angle. Alternatively, where
a part obtained by cutting~a~partl.cular portion of the sheet
metal is of a shape bent into a normal angle, it can be bent
by sandwiching the tip of that portion between the punch 194
and the die 196. FIG. 14(b) is drawn on a scale of one to two.
In FIG. 14(b), widths of the punch 194 anal the die 196 may be
1 mm, 2 non, 3 mm 4 mm, 5 rrgn, 6 mm, 7 mm, 8 mm or the like and
are not particularly limited. The angles of the tips of the
punch 194 and the die 196 may be 10~ , 15~ , 20~ , 25~ , 30~ ,
35~ , 40~ , 45~ , 50~ , 55~ , 60~ or the l.i.lke, and are not
particularly l~.mited.
The sheet metal repair tool of the present invention may
be a sheet metal repair tool 210 as shown in FIGs. 15 and 16.
In this repair tool 210, a punch 212 and a die 214 are
attached to the ends of pliers 216. The pliers 216 includes a
handle 218, to the end portion of which the die 214 is
attached; a pivotable handle 222 which pivots about a pivot
pin 220; and a lever element 228 which pivots about a pivot
pin (fulcrum) 226 by be=ing pulled up by a link 224 when the
pivotable handle 222 pivots about the pin 220. In addition,
the punch 212 is fixed to an end portion (point of action) of
a the lever element 228. As shown in FIGS. 17(a) to 17(c), a
first bending edge 232 and a second bending edge 234 of the
punch 212 and a first bending edge 236 and a second bending
edge 238 of the die 214 are curved parallel to each other. In
28
CA 02463667 2004-04-28
addition, this tool has a latch 240 for holding the handle 222
closed. Proper positioning can be achieved by pushing the
repair member 22 until it goes to the end 241 of a recess.
In the sheet metal repair tool 210, the punch 212 and the
die 214 have cavities 242 and 244, respecaively, as shown in
FIG. 18. The cavities 242 and 244 may prevent the contact
with,the repair member 22 when the tool 210 is moved while the
repair member is being sandwiched between the punch and the
die.
As shown in FIG. 19d the sheet metal .repair tool 210 may
have a stopper 246 on a position where the punch 212 and the
die 214 face each other. The stopper 24~ rnay secure a certain
space between the punch 212 and the die 214~ which avoids the
deformation or damage of the repair member 22.
The sheet metal repair tool 220 may comprise a punch 250
and a die 252 as shown in FIGs. 20(a) to (c). The punch 250
has a first beading edge 254 and a second bending edge 256
which are curved, and the punch itself juts downward. The
punch 250 and the die 252 are so configured that a pushing
force is concentrated to the center portion of the punch 250
when the repair member 22 is pinched between the punch 250 and
the die 252. The punch 250 and the die 252 may have cavities
242 and 244, respectively. In addition, the tool 210 may
comprise a stopper 246.
The sheet metal repair tool 220 may comprise a punch 254
and a die 256 as shown in FIGS. 21(a) to 21(c). The punch 254
and the die 256 are shaped like the punch 250 and the die 252,
29
CA 02463667 2004-04-28
but they are wider than the punch 250 and the die 252. The
punch 254 and the die 256 may have cavities 242 and 244,
respectively. In addition, the tool 210 may comprise a stopper
246.
The sheet metal repair tool of the present invention may
be a sheet metal repair tool 258 as shown. in FTG. 22. In the
sheet metal repair tool 258, the punch 260 comprises a
downwardly-jutting triangular pyramid 262, while the die 262
comprises a recess 266 into which the triangular pyramid 262
fits, as shown in FIG. 23. The die 262 also comprises a
jutting part 268 for positioning the repair metal 22. In such
sheet metal repair tool 258, cavities 270 and 272 are formed
by attaching the punch 260 and the die 264 to the pliers. The
punch 260 and the die 262 may also have cavities 242 and 244,
respectively. In addition, the punch 260 and the die 264 may
comprise a stopper 246.
Such sheet metal repair tool 258 can be used to form folds
259 on the repair member 22 as shown in FIG. 24(a). Therefore,
distortions produced in the bending process as shown in FIG.
24(b) are corrected as shown in FIG. 24(c) to make the tip
portion of the repair member 22 parallel to the portion which
is not bent. Such a step of forming folds is conducted after
sanding the surfaces of the repair member 22 and the sheet
metal 14 so as to promote their adhesion; bending the repair
member with the sheet metal repair tool 12 shown in FIG. 2 and
the like, and then forming a first bent part 24 and a second
bent part 26.
- CA 02463667 2004-04-28
The sheet metal repair tool of the present invention may
be a sheet metal repair tool 274 as shown in FIG. 25. In
this repair tool 274, a punch 276 and a die 278 are integral
with pliers 280. The pliers 280 includes a handle 284, to
the end portion of which the die 278 is attached; a pivotable
handle 222 which pivots about a pivot pin 220; and a lever
element 288 which pivots about a pivot p3_n (fulcrum) 286 by
being pulled up by a link 224 when the p~_votalble handle 222
pivots about the pin 220. The punch 276 and the die 278 are
so configured that the repair member 22 c;an be pinched
between jutting parts 292 and 294. The punch 276,and the die
278 may have cavities 242 and 244, respectively. In addition,
the punch 276 and the die 278 may compri:~e a stopper 246.
In the sheet metal repair tool of the present invention,
the closing and opening of the punch and the die may be
carried out by an air cylinder or a hydraulic cylinder. In
this case, a piston of the air cylinder or the hydraulic
cylinder may be attached to the punch or the die for opening
and closing of the punch and the die. Alternatively, the
opening and closing of the punch and the die may be carried
out by rotating a pivotable handle by the air cylinder or the
hydraulic cylinder.
For example, the sheet metal repair tool of the present
invention may be a sheet metal repair tool 300 as shown in
FIGS. 26(a) to 26(c). In the sheet metal repair tool 300, a
punch 304 is brought away from or close to a die 306 by an
air-pressure reciprocating drive 302 shown in-FIG. 27. The
31
CA 02463667 2004-04-28
tool 300 bends a sheet metal automatically as in the case of
the sheet metal repair tool 210 shown in FIG. 19. The punch
304 is fixed to a piston 308 of the reci~>rocating drive 302,
and the die 306 is slidably fit into the piston 308. The
reciprocating drive 302 used herein is commercially available.
In this drive, air is inhaled from an air supply unit 310, and
the piston 308 is pulled ug by pressing down a lever 312.
Specifically, the punch 304 is brought close to the die 306 by
pressing down the lever 312. As a substitute for the
reciprocating drive 302, a reciprocating drive 318 shown in
FIG. 28, in which a piston 316 is pulled up by pressing down a
lever 3I4, can be used. Alternatively, :in such a
reciprocating drive, a die can be brought close to a punch by
pressing down a lever and pulling up a piston. It is
considered that such a construction in which piston is pulled
up by pressing down a lever makes a reciprocating drive more
compact and increases pressing force. Alternatively, the
sheet metal repair tool 300 may comprise a cover which cover
the punch 304 and the die 306 and in which the punch 304 is
slidable so that the punch 304 moves reliably to a position
parallel to itself.
Alternatively, the sheet metal repair tool can be a.sheet
metal repair tool 320 as shown in FTGs. 29(a) to 29(c). In
this repair tool 320, a punch 322 is brought away from and
close to a die 324 by 'the reciprocating drive 302, and a sheet
metal can be automatically bent as in th.e case of the sheet
metal repair tool 276 shown in FIG. 25. In such sheet metal
32
CA 02463667 2004-04-28
repair tool 320, when the repair member 22 is pinched between
a punch 322 and a die 324, the punch 32 is brought close to
the die 324 from its back toward the front. For this reason,
a recess 326 is provided to the back of the punch.322 so as to
reliably bend the repair member 22.
.Alternatively, the sheet metal repair tool can be a sheet
metal repair tool 328 as shown in FIGs. 30(a) to 30(c). In
this repair tool 328, a punch 330 is brought away from and
close to a die 332 by the reciprocating drive 302,. and folds
can be automatically formed on a repair member as in the case
of the sheet metal repair tool 258 shown in FIG. 22.
Alternatively, the sheet metal repays tool can be a sheet
metal repair tool 334 as shown in FIGs. 31(a) and 3~.(b). In
this repair tool 334, a punch 336 is brought close to a die
338 by the reciprocating drive 302 and a sheet metal is
automatically bent as in the case of the sheet metal repair
tool 300 shown in FIGs. 26{a) to 26(c). However, unlike the
tool 304 shown in FIGs. 26(a) to 26(c), the punch 336 does not
have right-angled first and second bending edges, but it has a
tapered portion 339 on a position where 'the repair member is
bent. The side edge of the tapered portion 339 on the tip
portion of the punch 304 is radiused, which ~_s shown as a
radiused part 340 in FIG. 32(a). The inventors of the present
invention actually made an experiment to bend the repair
member 22, setting a radius of the radiused edge 340 to 25mm.
As shown in FIG. 32(a), a tapered part 342 was also formed on
a bent portion of the repair member 22, and both edge portions
33
CA 02463667 2004-04-28
of the tapered part 342 were radiused, which are shown as -
radiused parts 344 and 345 in this figure. Then, the repair
member 22 was bent over as shown in FIG. 32(a) and bonded to
the sheet metal 14 by an adhesive agent 346. .After that,
putty 348 was applied onto the bonded part, and a coating 350
is applied onto the surfaces of the repair meanber 22 and the
sheet metal 14. The seam between the repair member and the
sheet metal can not be seen at all from the side of the
surface where coating 350 is applied.
On the other hand, when the repair member 22 was bent to
form bent parts 352 and 354 as shown in FIG. 32(b), the seam
354 was observed on a portion near the bent part 352 on the
side of the surface where coating 350 is applied as shown in
FIG. 32(c). Particularly, the seam was clearly observed when
it was exposed to the scorching sun. It is conventionally
considered that the seam 354 was observed on the portion 356
near the tip of the sheet metal 14 when it was seen from the
side of the surface where coating 350 is applied. However,
the inventors of the present invention found that the seam 354
was appeared on the portion near the bent part 352 because
heat is accumulated in the bent part 352., Based on such
finding, the inventors of the present invention found the
effectiveness of the tapered part 342 fo~_med on the bent part
of the repair member 22 and succeeded in erasing the seam 354
so as not to be seen from the side of the surface where the
coating 350 is applied.
The sheet metal repair tool can be a sheet metal repair
34
CA 02463667 2004-04-28
tool 358 as shown in FIGs. 33(a) and 33(b). In this tool 358,
a punch 360 is brought close to a die 362 by the reciprocating
drive 302, and bent parts are automatically formed on a sheet
metal as in the case of the sheet metal repair tool 320 shown
in FIG. The punch 360 has a tapered portion 364 on a position
where the repair member 22 is bent.The side edge of the
tapered portion 364 on the tip portion of the punch 360 is
radiused, which is shown as a radiused part 366. The die 362
has a recess 368 for preventing the contact with the repair
member 22 and for bending the repair member 22 reliably by
inserting the repair member until it goes to the end. It is
clear from an experiment made in the present invention that
the recess 368 is more preferably formed in the die 362 on the
upper side than in the punch 360 on the bottom side when a
bending process is actually conducted.
In FIGs. 34 to 36, the numeral 510 indicates a sheet-
like member fixing device of the present invention. In this
sheet-like meamber fixing device 510, a hook 514 is provided
to an end of the rod-like male thread 512, and the male
thread 522 is screwed into a female thread 516. Specifically,
the male thread 512 passes through holes 520 of sheet metals
(sheet-like member) 518 and 519, and the female thread 516 is
tightened to support the sheet metals 518 and 519 by
sandwiching them between the hook 514 and the female thread
516. A washer 520 is put between the hook 514 and the female
thread 516.
CA 02463667 2004-04-28
The hook 514 is square to the male thread, and is
allowed to Bass through holes 522 and 523 from its tip so
that the male thread 512 can pass through the holes 522 and
523. While the male thread 514 touches the surface of the
sheet metal 518, the male thread 512 is secured to the sheet
metals 518 and 519 in such a manner that the male thread 512
is square to the sheet metals 518 and 519. The edge 524 on
the tip of the hook 514 is beveled and tapered.
The female thread 516 has wings 526 that make it easier
to apply force by hand. The female thread 516 is tightened
by hand so as to support the sheet metals 518 and 519 by
sandwiching them between the hook 514 and the female thread
516.
The male thread 512 has a ring-like handle 528 on its
other end. The sheet-like meanber fixing device can be fixed
to or pulled out of the sheet metals by putting a finger into
the handle 528_
The sheet-like member fixing device 510 is formed by:
performing thread cutting on one end of a straight rod-like
member; screwing it into the female thread; attaching a washer
520 thereto; and then bending the one end of the member at the
right angle to form the hook 514 while the other end of the
member is bent into a ring-like shape to foam the handle 528.
When the sheet-like member fixing device 510 supports
the sheet metals 518 and 519, the device is tilted against
the sheet metals 518 and 519 and the hook 514 is threaded
through the holes 522 and 523, as shown i_n FIG. 35. After
36
CA 02463667 2004-04-28
threading the hook 514 through the holes 522 and 523, the
sheet-like member fixing device 510 is held in the position
perpendicular to the sheet metals 518 and 519, and then the
female thread 516 is tightened. After that, the sheet metals
518 and 519 are.supported by being sandwiched between the
hook 514 and the female thread 516 and the washer 520, so
that the female thread 512 is fixed in a direction
substantially perpendicular to the sheet metals 518 and 519.
Thus, the sheet metals 518 and 519 are repaired and
improved. In other words, the sheet metals 518 and 529 are
thus positioned and temporarily fixed. The sheet metals 518
and 519 are then pulled out by holding the handle 528 with
hand.
The sheet-like member fixing device 520 can be fixed with
the sheet metals 518 and 519 sandwiched between the hook and
the female thread, by locking the hook 514 in the sheet metals
518 and 519 and then tightening the female thread 516. For
this reason, the sheet metals 518 and 519 can be positioned
and temporarily fixed with safety without touching them with
hand. Since the sheet-like member fixing device 520 can be
'fixed to the sheet metals 518 and 519 by inserting the male
thread 512 into the holes 522 and 523 from the right side of
the sheet metals 518 and 519 and by tighltening the female
thread 526, there is no need to insert hand from the back side
of the sheet metals with hand to tighten a nut and the like,
which makes it easier to fix the sheet-like member fixing
device 520 to the sheet metals 518 and 519. In addition, by
37
CA 02463667 2004-04-28
o inserting hand into the space behind the sheet metals 518 and
5I9, a service person can work without receiving a wound in
the hand, thus greater safety can be secured.
Since the sheet-like member fixing device 510 of the
present invention has the handle 528, the sheet metals 518 and
519 can be supported by holding the handle 528 with hand while
the sheet metals 528 and 519 are sandwiched between the hook
and the female thread. Moreover, the sheet metals 518 and 519
can be pulled out, positioned and temporarily fixed by holding
the handle 528 with hand with safety without touching them
with hand. Thus a service person can work without receiving a
wound in the hand, and therefore greater safety can be secured.
Next, a sheet metal repair method for removing a
particular portion 18 including a damaged part 16 of a sheet
metal 14 shown in FIG. 1 using the sheet--like member fixing
device 520 will be described below. Firsts a repair member
22 is bent to form a first bent part 24 and a second bent
part 26 using the sheet metal repair tool 12 shown in FIG. 2,
and then the upper surface of the end portion of the repair
member 22 is sanded down to be tapered, which makes it easier
to apply pate thereto. Then, a hole 511 for the sheet-like
member repair device 510 is formed in the sheet metal, and
the sheet-like member fixing device 510 :i.s irxserted into the
hole 511 to position and temporarily fix the repair member 22.
After rivet holes are formed in the repair member 22 and the
sheet metal 14, the sheet-like member fixing device 510 are
removed, and burrs are shaved off. Then, adhesive agent is
38
CA 02463667 2004-04-28
ry applied to the contact surfaces of the repair member 22 and
the sheet metal 14. The repair member 22 is put in a
particular position of the sheet rr~tal 14, and then bonded
thereto. The sheet-like member fixing device 510 is inserted
into the hole 511 and is temporarily fixed. rt'hen, the repair
member 22 and the sheet metal 14 are fixed together by fixing
rivets into the rivet holes, and dried. After that, a pate
is applied to a portion 513, and a coating is applied to the
surfaces of the repair member 22 and the sheet metal 24.
One embodiment of the sheet-like member fixing device of
the present invention has thus been described, however, the
sheet-like member fixing device of the present invention can
also be materialized in other embodiments.
For example, the sizes of the holes 522 and 523 of the
sheet metals 518 and 519 are not particularly limited, but
they can be bigger than the hook 514 as shown in FIGS. 38 and
39. In this case, as shown in FIG. 38, the hook 514 and the
male thread 512 can be passed through the holes 522 and 523
by tilting the male thread 512 to the direction substantially
perpendicular to the surfaces of the sheet metals 518 and 519.
The female thread 516 is tightened by moving it to the
direction substantially parallel to the surface of the sheet
metals 518 and 519 while the male thread is inserted into the
holes 522 and 523. By tightening the female thread, the male
thread can be fixed while the sheet metals 518 and 519 are
sandwiched between the hook 514 and the female thread 516 as
39
CA 02463667 2004-04-28
shown in FIG. 39. Thus the hook 5l4 can be easily passed
through the sheet metals 518 and 519 and fixed thereto.
The sheet-like member fixing device can be a sheet-like
member fixing device 530 shown in FIGs. 40(a) and 40(b).
This device 530 has an oval-shaped hook 532. The hook 532 is
passed through an oval-shaped hole 536 of. a sheet metal
(sheet-like member) 534 as shown in FIG. 40(a) and is tamed
about 90 degrees. Then the female thread 516 is tightened,
and thus the fixing device 530 can be fixed to the sheet
metal 534 as shown in FIG. 40(b).
The sheet-like member fixing device can ~be a sheet-like
member fixing device 540 as shown in FIG. 42. This fixing
device 540 has a rod-like handle 542 which is fixed in the
direction perpendicular to the male thread 5I2. A plurality
of such fixing devices can be fixed to a sheet metal (sheet-
like member) 544 to carry the sheet metal 544 by holding the
handles with hand. Since such fixing device 540 makes it
possible to carry the sheet metal 544 without directly holding
the sheet metal with hand, a service person can work without
receiving a cut on a finger, and thus greater safety can be
secured.
The sheet-like member fixing device can be a sheet-like
member fixing device 550 as shown in FIG. 42. This fixing
device 550 has an elastic hook 552 functioning as a spring,
and makes it possible to press the sheet metal elastically by
the hook 552 while the sheet metal is sandwiched between the
female thread 526 and the hook 552.
CA 02463667 2004-04-28
While the embodiments of the present invention have thus
been described with reference to the accompanying drawings,
it should be understood that the sheet metal repair n~thod,
the sheet metal repair tool, and the sheet-like member fixing
device of the present invention be not limited to the
embodiments shown in the drawings, but the repair method, the
repair tool and the fixing device of the present invention
can be materialized in other embodiments.
For example, the use of the sheet metal repair method
and the sheet metal repair tool of the present invention is
not limited to repairing a car body, but this method and tool
can be used for repairing sheet-metal parts of shipboard,
buildings, and the like. In addition, what is bent by using
the sheet-metal repair method or the repair tool of the
present invention is not limited to a repair member, but a
sheet metal of a car body and the like can be bent. The
shape and the size of a bent part is not particularly limited,
as far as the repair member fits the shape of the gap in the
sheet metal.
The sheet-like member fixing device of the present
invention can be used not only for repair on a sheet metal
but also for repair on or conveyance of a sheet-like member
made of wood, resin, or glass. The sheet-like member fixing
device of the present invention can also be fixed to other
material than a sheet-like member.
Furthermore, the hook is not limited to the one brought
into close contact with the sheet metal, but it can be the
41
CA 02463667 2004-04-28
one whose tip is only brought into close contact with the
sheet metal. Additionally, the female thread is not limited
to the above, but it can be a nut which is tightened by a
fastener. The shape of the handle is not particularly limited
as far as it can be held with hand or tools. The number of
sheet-like members supported by being sandwiched between the
female thread and the hook is not limited to one or two as
described above, but three or more sheet-like members can be
also used. For example, the sheet-like member fixing device
can be used for carrying or storing a plurality of sheet
metals.
The present invention is intended to. embrace various
modifications, alternations and changes made on the basis of
knowledge of those skilled in the art without departing from
the scope of the invention. Furthermore, any of the
specific inventive aspects of the present invention may be
replaced with other technical equivalents for eanbodiment of
the present invention, as long as the effects and advantages
intended by the invention can be insured..
INDUSTRIAL APPLICABTLITY
The sheet-metal repair method and the sheet metal repair
tool of the present invention make it possible to repair the
sheet metal by bending a portion near the end part of a
repair member or a portion near the end part of a sheet metal
to which the repair member is fixed and then by bonding the
repair member to the sheet metal in accordance with a shape
42
CA 02463667 2004-04-28
m of the gap without using any reinforcing member. Thus, the
present invention makes it easier to repair a sheet metal of
a car body and the like, and repairing steps and costs can be
reduced. Furthermore, compared to the case where a
reinforcing member is used, the number of bonded parts is
reduced in the present invention, so that bonding strength
and resistance to corrosion are improved.
In the sheet metal repair method and tool of the present
invention, a repair member or a sheet metal is bent stepwise
to form a first bent part and a second bent part which is
bent in the direction opposite to the first bent part.
While the end part of the repair member or the end part of
the sheet metal is fitted to the bent parts of the sheet
metal or the repair member, the portion nearer to the end
than the second bent part of the repair member or the sheet
metal is bonded to the sheet metal or the repair member, and
thus the repair member is bonded flush with the sheet metal.
For this reason, a finish can be easily given to the bonded
part, and the appearance is enhanced.
According to the sheet metal repair method of the
present invention characterized in that the first and the
second bent parts are formed at one time with a sheet metal
repair tool comprising a punch and a die which are shaped to
fit with the first and the second bent parts, the first and
the second bent parts are manually or automatically fornned at
one time. For this reason, the first and the second bent
parts can be quickly and easily formed. Furthermore, the
43
CA 02463667 2004-04-28
a.
. first and second bent parts of a particular shape can be
reliably formed by a punch and a die.
According to the sheet metal repair method of the
present invention characterized in that a pari~ of or a whole
of joint surfaces of the bonded part of the repair member and
the sheet metal is bonded by an adhesive agent, an adhesive
agent and rivet, or a combination of an adhesive agent, rivet,
and spot welding. For this reason, the repair member can be
easily and firmly bonded to the sheet metal by welding, an
adhesive agent, or a combination of welding and an adhesive
agent.
According to the sheet metal repair method of the
present invention characterized in that the portion near the
end part of the repair member and/or the portion near the end
part of the sheet metal is/are bent to remove distortion on
the portion near the end part before the repair member and
the sheet metal are bonded together, the repair member can be
easily, accurately, and firmly bonded to the sheet metal by
removing distortion. .
According to the sheet metal repair method of the
present invention characterized in that the portion near the
end part of the repair member and/or the portion near the end
part of the sheet metal is/are bent so that the first bent
part is curved, a seam can be prevented from appearing on the
outer surface of the bonding part between the repair member
and the sheet metal. Such an effect was obtained in the
actual experiment made by the inventors of the present
44
CA 02463667 2004-04-28
invention, and the inventors of the present invention found
that a seam appearing on the surface to be painted was caused
by the first bent part.
According to the sheet metal repair tool of the present
invention characterized in that at least the first bent part
is formed by placing the punch or die on the point of action
of a lever element having the point of application of force,
the fulcrum, and the point of action, and then bringing the
punch and the die closer by the application of griping force
or pushing force to the point of action, the portion near the
end part of the repair member or the portion near the end
part of the sheet metal can be easily bent by the application
of griping force or pushing force to the punch and the die,
using an action of the lever element. Furthermore, the tool
is a hand-held and compact one, so that it can be easy to
handle and carry.
According to the sheet metal repair tool. of the present
invention characterized in that the punch and the die each
have a first bending edge and a second bending edge, desired
shapes of the first bent part and the second bent part can be
reliably formed at predetermined angles 'by using the first
and second bending edges. Therefore, bending accuracy and
workability can be improved.
According to the sheet metal repair tool of the present
invention characterized in.that the distance between the
first bending edge and the second bending edge of the punch
and the distance between the first bending edge and the
CA 02463667 2004-04-28
v
second bending edge of the die are substantially same as the
thickness of the repair member or the sheet metal,. the repair
member is reliably bonded flush with the sheet metal by
making the difference in level between th.e first bent part
and the second bent part substantially equal to the thickness
of the repair member or the sheet metal. Therefore, a finish
can be easily given after the bonding process, and the
outward appearance can be enhanced after repairing process.
According to the sheet metal repair tool of the present
invention characterized in that either the punch or the die
or both of them has/have a tapered portion in a position
where the first bent part is to be formed and the first bent
part is bent curvedly by the tapered portion, a seam can be
prevented from appearing on the outer surface of the bonding
part between the repair member and the sheet metal.
According to the sheet-like member fixing device of the
present invention, the fixing device is fixed to the sheet-
like member, or the sheet-like member is fixed to the fixing
device while the sheet-like member is supported by being
sandwiched between the female thread and the hook, using
holes formed in the sheet-like member. Therefore, a
plurality of sheet-like members can be banded by being
sandwiched between the female thread and the hook, and a
plurality of sheet-like members can be easily positioned and
temporarily fixed.
According to the sheet-like member fixing device of the
present invention characterized in that the male thread is
46
CA 02463667 2004-04-28
n
passed through the hole from its hook°s side, the male thread
can be easily passed through the hole by inserting the hook
into the hole of a sheet-like mez~nber. Therefore, the sheet-
like merrtber fixing device can be fixed to the sheet-like
member, or the sheet-like member can be fixed to the sheet-
like member fixing device by inserting the male thread into
the hole form the front side of the sheet-like member and then
tightening the female thread without inserting hand from the
back side of the sheet metals to tighten a nut and the like.
thus workability can be improved and-greater safety can be
secured.
According to the sheet-like member fixing device of the
present invention characterized in that the hook is
substantially square to the male thread, the sheet-like
member can be supported by being sandwiched between the hook
and the female thread while the hook is in close contact with
the back surface of the sheet-like member. Therefore, the
sheet-like member fixing device can be fixed firmly to the
sheet-like member, or the sheet-like member can be fixed
firmly to the fixing device by increasing a contact surface
of the hook and the sheet-like member to produce a larger
friction.
According to the sheet-like member fixing device of the
present invention characterized in that the male thread is
fixed in the direction substantially perpendicular to the
hook which is brought in close contact with the surface of
the sheet-like member, the sheet-like member fixing device
47
CA 02463667 2004-04-28
.~ can be easily supported because the male ithread and the
sheet-like member are fixed in the direction perpendicular to
each other when the sheet-like member fixing device and the
sheet-like member are fixed together. When the sheet-like
member is pulled out, force can be applied in the direction
substantially perpendicular to the surface of the sheet-like
member by applying a pulling force in the direction to the
make thread. Therefore, the sheet-like member can be pulled
out, positioned, and temporarily fixed with efficiency and
accuracy.
According to the sheet-like member fixing device of the
present invention characterized in that the hook points to
one direction, the hook can be easily inserted into the hole
while the device is tilted against the sheet-like member.
Furthermore, the hook can be easily locked in the sheet-like
member by moving the device to the direction where the hook
points, while the hook and the male thread are being inserted
into the hole. Additionally, the sheet-like member fixing
device can be easily inserted into the hole of the sheet-like
member without getting stuck in the hole when the hook is
inserted into the hole. Therefore, the sheet-like member
fixing device can be fixed to the sheet-like member with
efficiency. In addition, since the hook only points to one
direction, the sheet-like member faxing device become compact,
which leads to the easy production and cost reduction.
According to the sheet-like member fixing device of the
present invention characterized in that the edge of the hook
48
CA 02463667 2004-04-28
fixed in the direction substantially perpendicular-to the
male thread is beveled, the tip portion of the hook is
tapered, so that the hook can be easily inserted into the
hole even when the hole is small. Furthermore, great safety
can be achieved by beveling the edge of the hook. In
addition, when the sheet-like member is made of soft material,
the hole is not necessarily formed in advance. In this case,
the sheet-like member fixing device can be passed through the
sheet-like member by hitting the hook with a tool. Thus,
since there is no need to conduct the step of forming a hole,
workability can be improved.
According to the sheet-like member fixing device of the
present invention characterized in that a handle is provided
to the other end of the male thread, the sheet-like member
can be easily supported by holding the handle with hand or
tool, and therefore the sheet-like member_ can be easily
pulled out, positioned, and temporarily fixed by holding the
handle.
According to the sheet-like member f_fixing device of the
present invention characterized in that the handle is shaped
like a ring, great force can be easily applied to the fixing
device fixed to the sheet-like member by putting a finger
into the ring-like handle. Thus, the sheet-like member can
be easily pulled out, positioned, and teanporarily fixed by
applying great force to the fixing device.
According to the sheet-like mea~nber fixing device of the
present invention characterized in that the female thread can
49
- CA 02463667 2004-04-28
be screwed down by hand, the female thread of such sheet-like
member fixing device has wings that makes it easier to apply
force, so that the female thread can be easily screwed down
by hand. Furthermore, the female thread can be easily and
firmly tightened from the surface side of the sheet-like
member by holding the handle with one hand and by screwing
down the female thread with the other hand.
