RU2408547C1 - Method of making mould for controlling glass surface geometry - Google Patents

Abstract

FIELD: chemistry.

SUBSTANCE: invention relates to the glass industry, in particular to production of curved glass used in motor-car construction, furniture production and other industries. The method of making a mould for controlling surface geometry and size of glass involves making a frame having the same shape as the mould, layer-by-layer deposition of composite material onto the said frame, preparation of the working surface which repeats the outline and surface o the glass, and mechanical finishing the working surface of the mould in accordance with its mathematical model.

EFFECT: invention reduces labour input in manufacturing, metal consumption and weight of the mould.

2 cl, 3 dwg

Description

The invention relates to the glass industry, in particular to the production of molded glasses, and can be used to control the geometry of the surface and dimensions of curved glass used in the automotive industry, in the manufacture of furniture and in other fields.

The problem of controlling the geometry of the surface and dimensions of curved glass is quite relevant, since there are strict requirements for the final product to correspond to theoretical parameters, for example, for the correspondence of the surface geometry of the finished glass to its mathematical model.

Currently known methods for the manufacture of templates to control the geometry of the surface and the contour of curved glass, for example of wood, plastic, metal.

The disadvantage of this method is the complexity of manufacturing, the fragility of the patterns, the loss of accuracy of the working surfaces during operation.

Closest to the claimed technical essence and the achieved result, selected as a prototype, is a method of manufacturing a template for controlling the geometry of the surface and dimensions of curved glass, described in the patent of the Russian Federation for utility model No. 81193, cl. C03B 23/025, publ. 03/10/2009

The template is made of one-piece aluminum, using the method of a burned-out model, with subsequent processing of the working surfaces in accordance with the mathematical model.

The disadvantages of this method are the high complexity of the manufacturing process, due to the multi-stage process, including the manufacture of a burnable model, technological processes of metal casting, subsequent processing; significant metal consumption and product weight.

The problem solved by the invention is the improvement of the method of manufacturing a template for controlling the geometry of the glass surface.

The technical result from the use of the invention is to reduce the complexity of manufacturing, reducing metal consumption and reducing the weight of the template.

This result is achieved by the fact that in the method of manufacturing a template for controlling the geometry of the surface and dimensions of the glass, including the manufacture of a work surface that repeats the contour and the surface of the glass, a frame is made that repeats the shape of the template, then layer-by-layer composite material is applied to the resulting frame and the machining of the working template surface in accordance with its mathematical model.

As a composite material, adhesive material is used (polyester resins, epoxy resins, urethane resins, phenol resins, melamine resins, acrylic resins) and reinforcing material (fiberglass, nylon, glass mat, etc.).

The template is made as follows.

According to the mathematical model of glass, a frame model is made.

The frame is a blank of polyurethane foam, made on the basis of a mathematical model of the glass surface. The surface of the frame repeats the surface of the future template, with a constant understatement of several millimeters, which is due to further manufacturing technology. The frame can be made of wood, plastic, polyurethane foam, wire frame, etc.

The reinforcing material (fiberglass, capron, glass mat) is layered in layers on all sides, connecting the layers with adhesive (polyester resins, epoxies, urethane resins, phenol resins, melamine resins, acrylic resins). The number of layers should be sufficient for further machining of the working surfaces of the template.

After drying, the working surfaces of the resulting structure are processed, for example, on a machine with numerical control according to the mathematical model of the glass surface, achieving the required shape accuracy and geometric parameters.

The template is painted and installed on a light frame for the convenience of further work with it.

Example 1

Model: Mitsubishi Lancer

Product: Template for controlling surface geometry and curvature of the windshield

Figure 1 presents a mathematical model of the windshield.

A lightweight polyurethane foam frame is made on a numerically controlled machine, which repeats the shape of a future product with a constant understatement of 5-7 mm.

The resulting framework is glued with layers of composite materials (glass mat CSM-E450 and polyester resin Polylite 33545-60) and dried. The number of layers is calculated by the formula:

,

,

where S _arm - the thickness of the reinforcing material, mm;

S _cells - the thickness of the adhesive layer, mm;

S _borrow - the understatement of the frame relative to the finished product, mm;

S _CR - the amount of allowance for mechanical finishing, mm

If the number of layers according to the formula is fractional (non-integer), then it is rounded to the whole in a larger direction. In this example, S _arm = 1.2 mm, S _CL = 0.5 mm, S _zan = 5 mm, S _CR = 2 mm. Thus, the number of layers N = (1.2 + 0.5) / (5 + 2) = 4.11. Take the number of layers equal to 5, rounding the result to an integer in a larger direction.

Then, a machine with numerical control is used to finish machining the working surface of the template according to the mathematical model of the surface of the windshield, achieving the required shape accuracy and geometric parameters.

Figure 2 shows the appearance of the resulting product.

Figure 2 indicates: 1 - the working surface of the template, made in accordance with its mathematical model; 2 - stiffeners; 3 - mounting hole.

Figure 3 presents a section aa of one of the walls of the template (see figure 2), where the frame of the product made of polyurethane foam and layers of the composite material (polyester resins and glass mat) are visible.

Thus, the invention offers, in contrast to the prototype, a faster method of manufacturing a template for glass control. This significantly reduces the complexity of manufacturing due to the exclusion of the technological process of casting metals with the manufacture of the corresponding foundry equipment, the metal consumption of the product and the weight of the template due to its performance from a light and durable composite material.

Claims (2)

1. A method of manufacturing a template to control the geometry of the surface and dimensions of the glass, including the manufacture of a work surface that follows the contour and the glass surface, characterized in that they make a frame that follows the shape of the template, then apply composite layers of material to the resulting frame and carry out the final mechanical processing of the work surface template in accordance with its mathematical model. 2. The method according to claim 1, characterized in that the adhesive material and the reinforcing material are used as the composite material.

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