DETAILED DESCRIPTION

[0021] Referring in more detail to the drawings, FIGS. 1 and 2 illustrate a vehicle 10 having various body panels 12 , doors 14 , a trunk 16 and a hood 18 wherein each may be formed from inner and outer sheet metal panels 20 , 22 connected together by a hem 24 embodying the invention. As best shown in FIGS. 3 and 4 , the various body panels 12 , 14 , 16 , 18 of the vehicle 10 may each comprise an outer sheet metal panel 22 that is slightly larger than an inner sheet metal panel 20 and has a border flange 25 along the periphery of the outer panel 22 that is folded or hemmed over the peripheral edge 40 of the inner panel 20 to form the hem 24 connecting inner and outer panels 20 , 22 together. A smooth and fair hem outer edge 26 is required to avoid blemishes on the finished, painted panel and to ensure a consistent gap between adjacent panels 20 , 22 .

[0022] FIGS. 5 and 6 illustrate a method and a first apparatus embodiment of the invention for forming a flat hem 24 in the outer sheet metal panel 22 onto the inner sheet metal panel 20 to connect the panels 20 , 22 together. A second hemming method and second and third flange hemming apparatus embodiments for producing flat modified hems are shown in FIGS. 9 - 11 . Reference numerals with the subscript “a” in FIGS. 9 and 10 indicate alternative configurations of elements that also appear in the first embodiment. Likewise, reference numerals with the subscript “b” in FIG. 11 indicate alternative configurations of elements that also appear in the first or second embodiments. Unless indicated otherwise, where a portion of the following description of the first embodiment uses a reference numeral to refer to the figures, that portion of the description applies equally to elements designated by the subscripts “a” and “b” in FIGS. 9 - 11 . Likewise, unless indicated otherwise, where a portion of the description of the second apparatus embodiment uses a reference numeral to refer to the figures, that portion of the description applies equally to elements designated by the subscript “b” in FIG. 11 .

[0023] The hemming method and apparatus provide a smooth and fair fold line defining the outer edge 26 of the outer panel 22 having a reduced outside bend diameter 27 that is less than three times the thickness of a sheet metal panel 20 or 22 , desirably less than about twice the thickness of a sheet metal panel 20 or 22 , and preferably generally equal to or less than the thickness of a single sheet metal panel 20 or 22 , to improve the appearance of the outer edge 26 and of the automotive vehicle body in general. To achieve the reduced outside bend radius or diameter 27 , the hemming apparatus and method produce a hemmed flange 24 that has an inner portion 28 adjacent the outer edge 26 that is generally flat and inclined relative to an outer portion 30 folded flat against the inner sheet metal panel 20 .

[0024] The improved hem 24 may be produced with a standard hemming press using an improved hemming tool 32 ( FIG. 6 ) with an end forming face 33 having a first, generally planar section 34 constructed to form the outer portion 30 of the flange and a second portion 36 inclined relative to the first section 34 to form the inner portion 28 of the flange 24 . As best shown in FIGS. 5 and 6 , to form the hem, the inner sheet metal panel 20 is disposed on the outer sheet metal panel 22 that in turn is received on a locating and support fixture 42 in a press. A prehem tool 44 having an inclined forming face 46 is preferably carried by an upper platen of a press (not shown) and is advanced toward and engages the upstanding flange 25 ′ of the outer sheet metal panel 22 to bend it from an initial included angle of approximately 90 degrees to a prehemmed acute included angle of between 25 and 75 degrees, and preferably about 45 degrees, to form a prehemmed flange 25 ″. Thereafter, as shown in FIG. 6 , the final hem tool 32 also carried by an upper platen of the press, is advanced toward the prehemmed flange 25 ″ to bend the flange into its final, hemmed position and form the flange 25 having an outside bend diameter 27 that is less than three times the thickness of a sheet metal panel 20 or 22 .

[0025] The final hem tool 32 has a forming face 33 with a generally planer first section 34 constructed to form the outer portion 30 of the flange 25 substantially flat onto the inner sheet metal panel 20 and thus provide a so called “closed hem” without any gap between an outside edge 54 of the flange 25 and the inner panel 20 . The second section 36 of the forming face 33 is inclined at an obtuse included angle relative to the first section 34 and is also preferably generally planer to form the generally flat, inclined inner portion 28 of the hemmed flange 25 immediately adjacent to the outer edge 26 or bend in the outer sheet metal panel 22 . Desirably, the second section 36 is disposed at an included angle of about 100 to 160 degrees relative to the first section 34 and preferably about 135 degrees. The angle may be varied to permit the location of the peripheral edge 40 of the inner sheet metal panel 20 to be varied relative to the outer edge 26 or hem line. Preferably, the second section 36 of the final hem tool 32 does not immediately overlie and is spaced outboard of the inner sheet metal panel 20 to prevent the inner sheet metal panel 20 from being unduly pinched by the inclined second section 36 of the hemming tool 32 and inner portion 28 of the flange 25 . Thus, as shown in FIG. 4 , the longitudinal distance “a” from the peripheral edge 40 of the inner panel 20 to the outer edge 26 of the outer panel 22 is preferably greater than the longitudinal distance “b” from the fold or bend 56 between the inner portion 28 of the flange 25 and the outer portion 30 and the outer edge 26 of the outer panel 22 .

[0026] A modified hem flange embodiment is illustrated at 70 in FIG. 7 . The modified hemmed flange 70 has an outer bend diameter 27 ′ equal to about twice the thickness of the outer sheet metal panel 22 ′. An inner portion 71 of the flange 70 is folded flat onto the outer sheet metal panel 22 ′ and an outer portion 72 of the flange 70 is folded flat or closed on the inner sheet metal panel 20 ′. To prevent creasing of the flange 70 and to provide the outer portion 72 above the inner sheet metal panel 20 ′, a smooth or generally arcuate transition or ramp section 74 is preferably provided between the inner and outer portions 71 , 72 of the hemmed flange 70 .

[0027] In either hemmed flange embodiment 25 , 70 , the outer bend diameter 27 , 27 ′ at the outer edge of the flange 25 , 70 is substantially less than in the prior art, as shown in FIG. 8 , wherein the outer bend diameter 80 of an outer panel 82 is equal to the sum of the thickness of the inner panel 82 and twice the thickness of the outer panel 84 . If the panels 82 and 84 are of equal thickness the radius of the bend 80 is equal to three times the thickness of either panel. Desirably, the outer bend diameter 27 may be generally equal to one or two times the thickness of the outer sheet metal panel 22 or less. The reduced bend diameter 27 , 27 ′ of the present invention provides an improved appearance of the finished hemmed panels by themselves, and in assembly relative to the prior art hemmed panels they appear to have a substantially more uniform and smaller gap and a flush alignment.

[0028] As with the first method and apparatus embodiment of FIGS. 1 - 6 , the second embodiment shown in FIGS. 9 and 10 and the third embodiment shown in FIG. 11 are for forming a flat hem 24 a , 24 b in an outer sheet metal panel 22 a , 22 b onto an inner sheet metal panel 20 a , 20 b to connect the panels 20 a , 20 b ; 22 a , 22 b together.

[0029] According to the second embodiment shown in FIGS. 9 and 10 , the apparatus includes a support fixture in the form of a die ring 42 a . The die ring 42 a is shaped to receive and hold a sheet metal panel, such as the outer sheet metal panel shown at 22 a , having an upstanding border flange 25 a formed along at least a portion of the panel 22 a . The border flange 25 a of the outer sheet metal panel 22 a is bendable to the flanged position shown in FIG. 9 . The inner sheet metal panel 20 a is stacked on top of the outer sheet metal panel 22 a in a layered disposition.

[0030] A roll hemming tool 60 is movably supported adjacent the fixture 42 a and includes a forming roller 68 that engages and bends the border flange 25 a while rolling along a length of the border flange 25 a . The forming roller 68 is supported by a bearing 70 that is, in turn, supported on a forming roller axle 72 . The forming roller 68 includes an outer circumferential forming face 62 that actually engages the border flange 25 a . The forming face 62 includes a frusto-conical first portion 64 shaped to bend the upstanding border flange 25 a of the outer sheet metal panel 22 a along a first fold line 26 a of the border flange 25 a into a position forming an acute angle relative to an underlying portion of the inner sheet metal panel 20 a as shown in FIG. 9 . The forming face 62 of the hemming tool 60 forming roller 68 also has a cylindrical second portion 66 shaped and positioned to bend an outer portion 30 a of the border flange 25 a into a position over and generally parallel to the underlying portion of the inner sheet metal panel 20 a . The second portion 66 of the forming face 62 bends the outer portion 30 a of the border flange 25 a along a second fold line 56 a that is generally parallel to and spaced from the main fold line 26 a.

[0031] The apparatus may also include a pre-hem tool such as the pre-hem tool 44 shown in FIG. 5 , that pre-bends the border flange 25 a to an acute included angle relative to the underlying portion of the panel before the forming roller 68 is used to form the final hem. When such a pre-hem tool 44 is used, it bends the border flange 25 a to a pre-hem angle of between 25 and 75 degrees relative to the underlying portion of the panel.

[0032] Whether or not a pre-hem tool is to be employed, the forming roller 68 is shaped such that the frusto-conical first portion 64 of the forming surface 62 is shaped to incline relative to the cylindrical second portion 66 of the forming surface 62 at an obtuse included angle of between 110 and 160 degrees depending on, among other considerations, the thickness of the outer sheet metal panel.

[0033] In fabricating the roller 68 , the angle of the frusto-conical first portion 64 of the forming surface 62 is selected to provide a border flange angle that meets requirements specified for an intended application. Depending on the selected angle of the frusto-conical first portion 64 of the forming surface 62 , a border flange 25 a that is hemmed by the hemming tool 60 may end up having an outer bend diameter 26 a that's less than three times the thickness of the outer sheet metal panel 22 a , less than twice the thickness of the outer sheet metal panel 22 a , or that's approximately equal to the thickness of the outer sheet metal panel 22 a.

[0034] The forming roller 68 is supported in a position to hem the border flange 25 a over a peripheral edge 40 a of the inner sheet metal panel 20 a as shown in FIG. 9 . When the forming roller 68 engages the border flange 25 a , the frusto-conical first portion 64 of the forming surface 62 of the forming roller 68 is disposed outboard of the peripheral edge 40 a of the inner panel 20 a such that the cylindrical second portion 66 of the forming surface 62 of the forming roller 68 overlies the peripheral edge 40 a of the inner sheet metal panel 20 a.

[0035] To support the forming roller 68 for rotational and translational motion relative to the inner and outer sheet metal panels 20 a , 22 a , the apparatus includes a forming roller support arm 76 . The forming roller support arm 76 may extend from any suitable manipulating means known in the art to include a robot arm or a roll form hemming machine. The support arm 76 and manipulating means support the roller axle 72 in such a way as to allow the roller 68 to be moved along a path that will cause the roller 68 to engage and hem the outer panel border flange 25 a as described above and shown in FIGS. 9 and 10 .

[0036] An inner end of the forming roller 68 includes a radially-extending annular rim 78 configured to guide the forming roller 68 along a periphery 79 of the fixture 42 a . The radially-extending annular rim 78 is axially biased against the fixture 42 a by a spring 86 disposed axially around the forming roller axle 72 . The spring 86 is disposed between the forming roller 68 and a spring retainer portion 88 of the forming roller support arm 76 . The spring 86 may be a coil spring, a gas spring or any other suitable biasing device known in the art.

[0037] According to the third flange hemming apparatus embodiment shown in FIG. 11, a ball roller 90 is supported on a collar 92 that is fixed to a forming roller axle 72 b immediately adjacent a forming roller 68 b . The ball roller 90 serves the same purpose as the radially extending annular rim 78 of the roller 68 in the second flange hemming apparatus embodiment of FIGS. 9 and 10 in that the ball roller 90 is disposed in a position to guide the forming roller 68 b along a periphery 79 b of a die ring fixture 42 b . However, the ball roller 90 of the third embodiment accomplishes this by rolling along an outer side wall 94 of the die ring fixture 42 b rather than turning against the side wall 94 .

[0038] In practice, the second and third apparatus embodiments may be used to hem two sheet metal panels together by first providing an outer sheet metal panel 22 a , 22 b having a generally upstanding border flange 24 a , 24 b along a periphery 26 a , 26 b of the outer panel 22 a , 22 b . An inner sheet metal reinforcing panel 20 a , 20 b , that is slightly smaller than the outer panel 22 a , 22 b , is then positioned against the outer sheet metal panel 22 a , 22 b . The inner panel 20 a , 20 b is positioned against an inner surface of the outer panel 22 a , 22 b such that a peripheral edge 40 a , 40 b of the inner panel 20 a , 20 b is disposed adjacent and generally parallel to the border flange 24 a , 24 b of the outer panel 22 a , 22 b.

[0039] The forming roller 68 , 68 b is fabricated so that the frusto-conical first portion 64 , 64 b of its forming surface 62 , 62 b is angled to accommodate the thickness of the inner panel 20 a , 20 b and to provide a desired outer panel border flange fold radius. The forming roller 68 , 68 b is then mounted on a support arm 76 , 76 b of a robot or a roll hemming machine that is then programmed or otherwise configured to roll the forming roller 68 , 68 b along the hem. As the forming roller 68 , 68 b rolls along the border hem, the frusto-conical first portion 64 , 64 b of the forming surface 62 , 62 b of the roller 68 , 68 b folds the border flange 24 a , 24 b into its inclined position over the underlying portion of the outer panel 22 a , 22 b while the cylindrical second portion 66 , 66 b of the forming surface 62 , 62 b simultaneously folds the outer portion 30 a , 30 b of the border flange 24 a , 24 b into a position flat against the inner surface of the inner panel 22 a , 22 b . This is done by rolling the forming roller 68 , 68 b along the border flange 24 a , 24 b such that the frusto-conical first portion 64 , 64 b of the forming surface 62 , 62 b rolls along an inner portion 98 , 98 b of the border flange 24 a , 24 b and the cylindrical second portion 66 , 66 b of the forming surface 62 , 62 b rolls along the outer portion 30 a , 30 b of the border flange 24 a , 24 b . In its inclined position the border flange 24 a , 24 b forms an acute angle relative to the underlying portion of the panel.

[0040] Alternatively, a pre-hem roller or steel 44 may be used to fold the border flange 24 a , 24 b until the border flange is inclined against the peripheral edge 40 a , 40 b of the inner panel 20 a , 20 b such that a distal edge of the panel is spaced from the inner surface of the inner panel 20 a , 20 b as shown in phantom in FIG. 5 . One of the two forming roller embodiments is then employed to further fold the border flange 24 a , 24 b such that the portion of the border flange 24 a , 24 b disposed generally parallel to the underlying portion of the outer panel 22 a , 22 b lies flat against the inner surface of the inner panel 20 a , 20 b , securing the inner panel to the outer panel.

[0041] This description is intended to illustrate certain embodiments of the invention rather than to limit the invention. Therefore, it uses descriptive rather than limiting words. Obviously, it's possible to modify this invention from what the description teaches. Within the scope of the claims, one may practice the invention other than as described.