Contact surface for a crimping roller in a roll forming tool

Abstract

A roll-forming tool for deforming a flange cap from a splayed configuration to engage a vehicle flange, the tool includes a polymeric contact surface disposed about a rigid drum. The polymeric contact surface can be in the form of a sleeve and integrally formed to the metal drum, or alternatively, the sleeve can be removeably attached to the drum for allowing replacement. The drums can be metal and configured for eccentric rotation relative to a corresponding drive shaft, thereby accommodating further variations in flange thickness.

1 . A roll forming tool comprising: 
 (a) a housing;    (b) a motor within the housing;    (c) a guide roller and a drive roller, the guide roller rotatably connected to the housing, the drive roller including a rigid drum having a contact surface defined by a polymeric contact sleeve; and    (d) a drive shaft connecting the drive roller to the motor.    
   
   
       2 . The roll forming tool of  claim 1 , wherein the polymeric contact sleeve is permanently connected to the drum.  
   
   
       3 . The roll forming tool of  claim 1 , wherein the polymeric contact sleeve is releasably connected to the rigid drum.  
   
   
       4 . The roll forming tool of  claim 1 , wherein the polymeric contact sleeve is bonded to the rigid drum.  
   
   
       5 . The roll forming tool of  claim 1 , wherein the polymeric contact sleeve is molded to the rigid drum.  
   
   
       6 . The roll forming tool of  claim 1 , wherein the rigid drum is metal.  
   
   
       7 . The roll forming tool of  claim 1 , further comprising a resilient core connecting the drive shaft to the rigid drum.  
   
   
       8 . The roll forming tool of  claim 1 , wherein the rigid drum includes a plurality of apertures, the polymeric contact sleeve projecting through the apertures.