CA2757375C - Producing single sheet metal from two separate sheets - Google Patents

Producing single sheet metal from two separate sheets Download PDF

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Publication number
CA2757375C
CA2757375C CA2757375A CA2757375A CA2757375C CA 2757375 C CA2757375 C CA 2757375C CA 2757375 A CA2757375 A CA 2757375A CA 2757375 A CA2757375 A CA 2757375A CA 2757375 C CA2757375 C CA 2757375C
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CA
Canada
Prior art keywords
sheet
metal sheets
metal sheet
sheets
zones
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA2757375A
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French (fr)
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CA2757375A1 (en
Inventor
Ali Torabi
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Individual
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Individual
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Priority to CA2757375A priority Critical patent/CA2757375C/en
Publication of CA2757375A1 publication Critical patent/CA2757375A1/en
Application granted granted Critical
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Expired - Fee Related legal-status Critical Current
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21CMANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/02Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of sheets
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21HMAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
    • B21H8/00Rolling metal of indefinite length in repetitive shapes specially designed for the manufacture of particular objects, e.g. checkered sheets
    • B21H8/005Embossing sheets or rolls
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21KMAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K23/00Making other articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/02Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00Articles made by soldering, welding or cutting
    • B23K2101/18Sheet panels
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/02Iron or ferrous alloys
    • B23K2103/04Steel or steel alloys
    • B23K2103/05Stainless steel
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/08Non-ferrous metals or alloys
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/08Non-ferrous metals or alloys
    • B23K2103/10Aluminium or alloys thereof
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/08Non-ferrous metals or alloys
    • B23K2103/12Copper or alloys thereof
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/18Dissimilar materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/18Dissimilar materials
    • B23K2103/20Ferrous alloys and aluminium or alloys thereof
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/18Dissimilar materials
    • B23K2103/22Ferrous alloys and copper or alloys thereof
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/12Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of metal or with an outer layer of metal or enameled metal

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

The most common method and apparatus for embossing of sheet metal (whole cross and longitudinal) is using a roll mill and roll forming machine producing profile shape along the length of sheet. This proposed invention presents a new "UNIQUE" metal sheet made from two separate sheets that are pressed and punched (embossed and/ or coined) together (cold welding procedure) to make a single sheet .The embossing shape is not profile type and can be produced in longitude and cross pattern. Also these two sheets can be made of different materials to obtain the desired characteristics of each metal sheet . These sheets can be used in wall ,roof or deck panels and other areas that metal sheets metal are used.

Description

BACK GROUND OF INVENTION:
it is known that embossed or coined sheet metal has advantages such as increased strength, rigidity ,and aesthetics. Many improvements to the process have been made over the years.
Resolution in many patents being issued. Some examples of related patents are:
3,769,129 10/1973 Alvin R. William 4,027,517 6/1977 Bodnar 4,092,842 6/1978 Natham Oser 4,579,785 4/1986 Karousbas 5,111,572 3/1992 Haim!
US 7,114,363 B2 10/2006 Varis US 7,363,791 B2 4/2008 Bodnar US 7,234,336 B2 6/2007 Braunetal US 2009/0301015 A1 12/2009 Simms US 2002/0148269 A1 10/2002 Ruck US 2005/0000262 A1 1/2005 Schreiberetal US 2005/0069603 A1 5/2005 Vaughn et al US 2005/0138981 A1 6/2005 Wilhelm Most of these patterns are related to embossing sheet metal and some of them are about making composite sheet metals. For embossing all of them produce a single sheet and most of
-2-them use roll mill and roll forming machines for embossing. For composite sheets, they use adhesives to attach sheets.
Use of a roll mill machine for embossing or coining has limits of shape and depth, and cannot provide patterns, and the dies are very expensive. Also a roll forming machine can just can create longitudinal profile .For composite sheet metals, using an adhesive for attachment makes the product expensive ,and also these methods haven't too much affect on the mechanical features of the final product.
This invention overcomes some of these limitations, and introduces a new kind of metal sheet that is made of two separate metal sheets that are attached together physically.
DESCRIPTION.
The main section of this invention, is that it produces a "UNIQUE(single) metal sheet by pressing (embossing and coining) two separate metal sheets together. The basis of this invention, is contact or cold welding, where the force of adhesion following first contact can be augmented by pressing (embossing and coining) two metal sheets tightly together (at the embossing or coining zone).
When two surfaces are pressed together metal to metal contact occurs. The interface between the sheets transfers the tensile strain while the two sheet are under pressure and this permits two sheet contact during the deforming ,and the sheets are bonded together fig(1-a) and fig(1-b). By repeating this process at each embosses or coin deformation, and spreading these-3-deformations in the entire surface, a very large force for keeping the two sheet together is created. Finally we have a single sheet from two separate sheets that attached together physically. The final product with this method is several times stronger, more rigid, and much better appearance than traditional methods. With this method rigidity and strength are increased in two ways:
1- embossing (and or coining) 2-combination of two sheets Each of the above methods increases the rigidity and strength separately and when these methods are combined, these advantages multiply. This method one allows to decrease the thickness of sheet metal and consequently decrease the weight of materials.
For example, in wall and roof panels ,where rigidity and strength are important, the sheet metal has to be at least 1mm thick. With this method we can use two sheets with thickness0.3mm each and a final have sheet of 0.6mm ,which is stronger than the sheet single of lmm.
This point is going to be very important when the volume of sheet metals in some cases is huge or in some places where weight is an important factor, like a roof, ceiling ,wall or deck panels.
Another option that can be used with this method is to produce a "UNIQUE"
sheet metal from two different materials for attaining the best combination of the advantages of each two sheets. With this method, one sheet metal is base and another sheet is outer layer. The base usually is strong and inexpensive steel. The outer layer can be any kind of metal such as aluminum, copper or stainless steel. The base is thicker and the outer layer is thinner. The product is a Unique(single) product with good strength and rigidity, less cost, and better appearance, corrosion resistance, and heat reflection .
This product is not expensive compared to a single sheet (such as aluminum, copper or stainless) with the same strength and rigidity. As an example, aluminum or stainless steel have very good resistance against corrosion ,but aluminum is expensive and very light and usually soft whereas stainless steel is expensive and hard to work. But the combination of a thin layer of each one of them, the final product will give the same features ,without the disadvantages of each.
Comparison Unique sheet with regular metal panel One of the most intensive uses of sheet metal is as metal panels. The "unique"
sheet can be used as a metal panel too. At fig (2) I show some examples of Unique and embossed sheet metal. This kind of sheet metal in comparison with regular wall, roof and deck panels ,has better characters :
1-Material :
To produce this panel we need less material in two ways:
a)As explained with "unique "sheet method we can use thinner sheets metal with more strength.
b) In regular type panels, the sheet is made by roll mill and roll forming machines (bending work),then cover surfaces are decreased(depend on profile of panel up to 25%
the surface cover is going to be less than the original plain sheet).But with this method the sheet is embossed (stretching)and, consequently the covering surface is not considerably different than the original sheet Fig(3).
2-Heat Transfer: Heat transfer is a very important factor in any building.
This panel has better performance regarding heat transfer in comparison with regular panels.
a) this kind of sheet metal has less surface, consequently heat transfer (both conductive and radiant) is less.
b)Because of no longitude profile shape, the embodiment surface with this method is an obstacle against surface flow. As shown in fig (5) embossed deformation can produce zones like (A) in fig( 5 ) and also with changing surface flow direction towards out of surface (B).
With simulations we can create a special form with the best performance in heat transfer for surface flow.
c) With the "UNIQUE "method of two sheets combined, we can use a metal such as aluminum or stainless steel as an outer layer ,that has good ability to reflect.
d) With the "UNIQUE "method, using a perforated sheet metal as a base with a thin layer of any kind of sheet metal as a outer layer, with filling inside (between the holes of perforated sheet) using different kinds of insulation material, can give a panel with added insulation. It is ideal for use as an exterior panel (wall, siding or roof).
3- Shape and form: A regular panel can only produce profile shape lengthwise and this has limitations in shape , form and pattern, but the proposed method is more flexible in shape ,form and pattern. This helps to make shapes with better features for strengthening ,more resistance against buckling and better performance for heat transfer. It helps the panels to be used for more decorative purposes and architectural designs.
4-Better assembly: The regular panels can just be used in one direction, because the longitude profile shape for assembling together needs special trims. But with this kind of sheet metal, four sides or any places of the sheet can be plain(with any size that is needed)fig(4). This helps to make multiple shapes for better sealing and by assembly. This kind sheet can be used in any directions. Also by changing the arrangement of pattern shape with any angle (straggle), it can be used for non-squared surfaces more easily.
Description of apparatus:
For producing the "Unique" metal sheet, depending on size and thickness of the sheet we can use any press machine . But for producing this kind of sheet in unlimited length sizes (with width up to 48), the following apparatus ( schematic is shown in fig(6)) is suggested .This apparatus is comprised two of coil openers (6-1), a cleaning unit (6-2), a dryer unit (6-3), a feeding system (6-4), a heating unit (6-5), a press unit (6-6), coining rollers (6-7), (6-8) and a cutting unit (6-9). After the sheets are opened from a coil, they pass through the cleaning unit. At this stage rust-7-' ,grease and another contaminates are removed from the surfaces that will be connected together. Then the sheets pass through the dryer system. The feeding unit then feeds the sheets in the desired length to the press machine.
Before pressing, they pass through a heating unit. The preheating gives better forming and cold welding performance. In the press machine two separate sheets are punched (embossed and coined) together. After this step the new sheet passes through two rollers for coining the longitudinal edges(6-8) and another roller is for coining the cross edges (6-9) (section A-A in fig (4)). The Cutting unit then cuts the sheet into the desired size.
Also this machine can be used for producing a single sheet with embossing form. (Some of the examples are shown in fig(2)and fig(4) ).

Claims (7)

What is claimed?
1. A method of making a composite unitary metal sheet by pressing two separate metal sheets together; wherein the two separate metal sheets of the composite unitary metal sheet are pressed and bonded together by:
a) embossing and stretching the two separate metal sheets, both together as one, to form a plurality of discrete stretched zones in the composite unitary metal sheet; wherein the plurality of discrete stretched zones form a pattern which substantially covers an entire surface of the composite unitary metal sheet;
b) coining the two separate metal sheets, both together as one, to form: (i) one or more first coined zones in the composite unitary metal sheet between, and within the pattern formed by, the discrete stretched zones; and (ii) one or more second coined zones in the composite unitary metal sheet outside the pattern formed by the discrete stretched zones; and c) coining the two separate metal sheets, both together as one, to form coined edge portions around edges of the composite unitary metal sheet.
2. The method of claim 1, wherein the composite unitary metal sheet is made with each of the two separate metal sheets being formed of a different metal material than each other.
3. The method of any one of claims 1 and 2, wherein one of the two separate metal sheets is perforated to define holes and, after pressing two separate metal sheets together as aforesaid, filling the holes in the perforated sheet with insulating material.
4. The method of any one of claims 1 to 3 adapted to produce a single one said composite unitary metal sheet, comprising further steps of:
using a cleaning unit to remove any rust or contaminates from surfaces of the two separate metal sheets, using a feeding system to feed the two separate metal sheets, using a heating system before pressing to heat the two separate metal sheets, using a press machine for said pressing of the two separate metal sheets together, using a longitude and cross roller for coining the edges as aforesaid, and using a cutting unit to cut the composite unitary metal sheet in any desired size.
5. The method according to claim 4, wherein before using the cutting unit as aforesaid, the composite unitary metal sheet is produced with an unlimited length.
6. An apparatus for carrying out the method of any one of claims 1 to 3 to produce said composite unitary metal sheet, wherein the apparatus comprises:
a press machine which performs (a) said embossing and stretching of said two separate metal sheets, both together as one, to form said discrete stretched zones, and (b) said coining of said two separate metal sheets, both together as one, to form said first coined zones and said second coined zones; and a longitude and cross roller which performs (c) said coining of said two separate metal sheets, both together as one, to form said coined edge portions.
7.
A composite unitary metal sheet produced according to the method of any one of claims 1 to 5, wherein the composite unitary metal sheet comprises said two separate metal sheets, said plurality of discrete stretched zones, said first coined zones, said second coined zones, and said coined edge portions.
CA2757375A 2011-10-28 2011-10-28 Producing single sheet metal from two separate sheets Expired - Fee Related CA2757375C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA2757375A CA2757375C (en) 2011-10-28 2011-10-28 Producing single sheet metal from two separate sheets

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA2757375A CA2757375C (en) 2011-10-28 2011-10-28 Producing single sheet metal from two separate sheets

Publications (2)

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CA2757375A1 CA2757375A1 (en) 2013-04-28
CA2757375C true CA2757375C (en) 2016-09-06

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11787149B2 (en) 2018-07-20 2023-10-17 10856479 Canada Inc. Combined sheets and method and system for producing same

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Effective date: 20140917

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Effective date: 20181029