CN113103677A - 一种具有冲压式拉延型腔的铝合金蜂窝板及其制备方法 - Google Patents
一种具有冲压式拉延型腔的铝合金蜂窝板及其制备方法 Download PDFInfo
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Abstract
本发明属于建筑室内门技术领域,具体涉及一种具有冲压式拉延型腔的铝合金蜂窝板及其制备方法,本铝合金蜂窝板包括有自上而下依次设置的上面板、蜂窝芯和下面板,上面板或\和下面板加工有拉延型腔。本制备方法包括:先将铝板坯材依次经水洗、除油、脱脂、钝化、烘干、喷涂、木纹转印和贴膜的表面处理;再对表面处理后的铝板经一次性冲压成型出拉延型腔;再将两块具有拉延型腔的铝板之间通过胶粘接有铝制蜂窝芯,并压合三者以形成铝合金蜂窝板。本发明的铝合金蜂窝板制造结构的拼接简洁方便,有助于降低生产成本;且其全部采用铝制材质,具有耐潮,不易变形,不易开裂,可回收性高的优点。
Description
技术领域
本发明属于建筑室内门技术领域,具体涉及一种具有冲压式拉延型腔的铝合金蜂窝板及其制备方法。
背景技术
随着消费者对家具个性化需求的不断提高,高端全铝定制门越来越受市场喜爱。室内门是指安装在室内房间入口的门,是所有房间门的总称。现有市面上所使用的室内套装门还是以木制为主、其次是少量的金属套装门。木质室内套装门主要有以下缺点:不防虫、不耐晒;挥发的气味对人员身体健康影响较大;在受潮后有起皮、变形或脱落现象。而金属套装门具有防潮、防虫、耐晒、不开裂、不褪色、不发霉、健康无毒无异味等诸多优点,正被普通百姓接受和广泛应用。但是现有的金属套装门门扇还是存在,如其构件型材的连接方式复杂、安装不便捷、整体采购费用较高等缺陷;另外,其面板多为平板形式,外观造型单一,且欠缺立体、流线型装饰效果。
发明内容
有鉴于此,本发明的目的在于提供一种具有冲压式拉延型腔的铝合金蜂窝板及其制备方法,旨在解决金属门的面板为平面式造型的单一性结构问题。
为达到上述目的,本发明提供如下技术方案:
本发明提及的一种具有冲压式拉延型腔的铝合金蜂窝板,包括有自上而下依次设置的上面板、蜂窝芯和下面板,上面板或\和下面板加工有拉延型腔。
进一步,拉延型腔通过冲压直接加工制成。
进一步,拉延型腔的数量设置为一个以上。
进一步,拉延型腔的横截面呈方形、圆形、椭圆形、梯形、D字形、半圆形、菱形、五边形、六边形、八边形、太极图形、月牙形、十字形、井字形或格栅形中的一种或多种。
本发明还提及一种具有冲压式拉延型腔的铝合金蜂窝板的制备方法,包括如下步骤:先将铝板坯材依次经水洗、除油、脱脂、钝化、烘干、喷涂、木纹转印和贴膜的表面处理;再对表面处理后的铝板经一次性冲压成型出拉延型腔;再将两块具有拉延型腔的铝板之间通过胶粘接有铝制蜂窝芯,并压合三者以形成铝合金蜂窝板。
优选的,采用静电粉末喷涂,且形成的喷涂膜厚为60-70μm,固化温度为210-220℃,固化时间为28-32min。
优选的,木纹转印为将热转印木纹纸放置在喷涂后的铝板坯材表面,并置于炉温为190-200℃之间的加热炉内,保持时长为650-700S。
优选的,采用冷压机实施压合,且压合的时长为8-9小时,温度控制在23±2℃。
本发明的有益效果:本发明的具有冲压式拉延型腔的铝合金蜂窝板能够提高其整体刚性,并可使其边缘平整,且尺寸精度高。而将其作为铝合金冲压门应用是,可具有优美的外观和良好地使用感受,并结构稳定可靠。
本发明的其他优点、目标和特征在某种程度上将在随后的说明书中进行阐述,并且在某种程度上,基于对下文的考察研究对本领域技术人员而言将是显而易见的,或者可以从本发明的实践中得到教导。本发明的目标和其他优点可以通过下面的说明书来实现和获得。
附图说明
为了使本发明的目的、技术方案和优点更加清楚,下面将结合附图对本发明作进一步的详细描述,其中:
图1为本发明铝合金蜂窝板断面结构示意图。
图2为本发明铝合金蜂窝板制备过程中的分步结构示意图,a为上面板的内表面(非装饰面)向上,b为在上面板的拉延型腔背面上设置的蜂窝芯,c为在上面板的内表面并围绕拉延型腔外设置蜂窝芯,d为压合下面板后的整体结构且下面板的外表面(装饰面)向上。
附图标记:上面板1、蜂窝芯2、下面板3、拉延型腔4。
具体实施方式
以下通过特定的具体实例说明本发明的实施方式,本领域技术人员可由本说明书所揭露的内容轻易地了解本发明的其他优点与功效。本发明还可以通过另外不同的具体实施方式加以实施或应用,本说明书中的各项细节也可以基于不同观点与应用,在没有背离本发明的精神下进行各种修饰或改变。需要说明的是,以下实施例中所提供的图示仅以示意方式说明本发明的基本构想,在不冲突的情况下,以下实施例及实施例中的特征可以相互组合。
其中,附图仅用于示例性说明,表示的仅是示意图,而非实物图,不能理解为对本发明的限制;为了更好地说明本发明的实施例,附图某些部会有省略、放大或缩小,并不代表实际产品的尺寸;对本领域技术人员来说,附图中某些公知结构及其说明可能省略是可以理解的。
请参阅图1所示,本实施例中提及的具有冲压式拉延型腔的铝合金蜂窝板,包括有自上而下依次设置的上面板1、蜂窝芯2和下面板3,且上面板1、蜂窝芯2和下面板3的相互之间是通过胶粘接及压合而形成的整体结构,而上面板1或\和下面板3加工有拉延型腔4,以使得所形成铝合金蜂窝板具有外形装饰结构,能够解决金属门的面板为平面式造型的单一性结构问题,并且通过拉延型腔的设计结构,还能够提高其整体刚性。
在本实施例中的拉延型腔4通过冲压直接加工制成,具有成型速度和质量好的效果,有助于提升生产效率。相应的,为获取不同结构、形状的拉延型腔,其配备有不同的冲压模具来匹配生产。
在本实施例中的拉延型腔4的数量设置为一个以上。可根据生产工艺、客户需求、产品美观度进行综合考量;同时,拉延型腔4的横截面可以是呈方形、圆形、椭圆形、梯形、D字形、半圆形、菱形、五边形、六边形、八边形、太极图形、月牙形、十字形、井字形、格栅形或其他类似变形结构中的一种或多种。
下面详细阐述下本具有冲压式拉延型腔的铝合金蜂窝板的制备工艺,包括如下步骤:
1)、原始数据收集,为模具设计做准备。
铝板坯材原料成分包括:Si:0.2%、Fe:0.35%、Cu:0.15%、Mn:0.21-0.5%、Mg:4.2-5.0%、Cr:0.1%、Zn:0.25%、Ti:0.1%其余为铝。
铝合金冲压门所用铝面板原始设计参数见下表1。
表1
板材状态 | 板厚/mm | 最小R角/mm | 最大冲压深度/mm |
自由状态 | 1 | 2 | 10 |
2)、铝板材坯料准备:将铝板坯材依次经水洗、除油、脱脂、钝化、烘干、喷涂、木纹转印和贴膜等表面处理后,采用数控激光切割机裁切,裁剪后尺寸为长度2250mm,宽度1150mm,尺寸公差±1mm;其中,水洗采用二至三道工序;烘干温度在50℃;喷涂采用静电粉末喷涂,且形成的喷涂膜厚为65μm,固化温度为210℃,固化时间为30min;木纹转印为将热转印木纹纸放置在喷涂后的铝板坯材表面,并置于炉温为190℃之间的加热炉内,保持时长为680S。
3)、准备模具:根据冲压门面板设计图纸及技术要求,采用有限元方式,设计凸模、凹模及压边圈,针对不同规格的冲压门面板,共用一套压边圈。模具制作材料采用45号钢,淬火温度840℃,硬度58-62HRC。凸模、凹模及压边圈制作要求见下表2。
表2
表面粗糙度/μm | 加工尺寸公差/mm | 配合间隙/mm | 冲压R角/mm |
0.8 | ±0.05 | ±0.02 | 2 |
4)、拉延:选用1250吨压力机,凸模及压边圈固定于压力机下工作平台上,凹模固定压力机滑块上,机床顶杆把压边圈顶起,压料面比凸模最高点高20MM,顶杆力设置为120T,剪切后的铝板坯材放置压边圈上并定位,启动压力机,滑块与凹模下行,凹模与压边圈压住铝板坯材,滑块继续下行,模具使铝板坯材在压力作用下拉伸变形,铝板坯材最大减薄率10%,形成冲压门面板半成品。拉延工艺参数见下表3。
表3
顶杆数量 | 底缸力 | 闭合高度 |
40根 | 100-120吨 | 636MM |
5)、切外轮廓:采用数控激光切割机裁切冲压门面板半成品外轮廓达到设计尺寸。数控激光切割工艺参数为:切割功率1800-2200W;切割速度2000-4000mm/min;保护气体为氮气;气压10Kpa。
6)、蜂窝板压合:
6.1)铝合金冲压门面板成品的上面板1放置工作平台上,其内表面(非装饰面)向上,如图2a所示,并在内表面涂抹双组份聚氨酯胶水,涂胶量600-800g/㎡;
6.2)蜂窝芯2根据图纸尺寸裁切成若干块,放置上面板1的拉延型腔4(凸起区域)背面的双组份聚氨酯胶水部位,使蜂窝芯2应充分填满上面板1的凸起区域,如图2b所示;
6.3)另一蜂窝芯2(较前一步工序中的蜂窝芯2增厚18mm)根据图纸尺寸裁切成若干块,放置上面板1的外凹陷区域的双组份聚氨酯胶水部位,且该蜂窝芯应充分填满上面板1的外凹陷区域,如图2c所示;
6.4)铝合金冲压门面板成品的下面板3(为与上面板1镜像件)在内表面(非装饰面)涂抹双组份聚氨酯胶水;
6.5)下面板3(内表面向下)放置蜂窝芯2上部,如图2d所示;
6.6)将上述组合好的铝合金蜂窝板半成品放置在冷压机的压合平台上,压合8小时,温度23±2℃。待胶水完全固化后取出蜂窝板。
本发明采用蜂窝芯分别填充的方式进行带有冲压外观效果的铝合金蜂窝板制作,使蜂窝板具有立体感、流线型装饰效果。同时,1mm薄铝合金板材,其刚性差,而在拉延过程中,通过压边圈固定铝合金板材坯料四周,在拉延过程中,使板材充分拉伸、产生硬化作用,从而提高成品铝合金冲压门面板刚性,有助于提高其抗变形能力;另外,本工艺中设计的专用压边圈结构,使板材拉延过程中材料流动均匀,保证铝合金冲压门面板成型后四周边缘平整无皱曲变形,从而使铝合金冲压门面板整体尺寸控制精确,为铝合金冲压门装配达到精密配合提供保障,达到铝合金冲压门成品外观优美的效果。
最后说明的是,以上实施例仅用以说明本发明的技术方案而非限制,尽管参照较佳实施例对本发明进行了详细说明,本领域的普通技术人员应当理解,可以对本发明的技术方案进行修改或者等同替换,而不脱离本技术方案的宗旨和范围,其均应涵盖在本发明的权利要求范围当中。
Claims (8)
1.一种具有冲压式拉延型腔的铝合金蜂窝板,其特征在于,包括有自上而下依次设置的上面板(1)、蜂窝芯(2)和下面板(3),所述的上面板或\和下面板加工有拉延型腔(4)。
2.根据权利要求1所述的具有冲压式拉延型腔的铝合金蜂窝板,其特征在于,所述的拉延型腔通过冲压直接加工制成。
3.根据权利要求1所述的具有冲压式拉延型腔的铝合金蜂窝板,其特征在于,所述的拉延型腔的数量设置为一个以上。
4.根据权利要求1所述的具有冲压式拉延型腔的铝合金蜂窝板,其特征在于,所述的拉延型腔的横截面呈方形、圆形、椭圆形、梯形、D字形、半圆形、菱形、五边形、六边形、八边形、太极图形、月牙形、十字形、井字形或格栅形中的一种或多种。
5.一种具有冲压式拉延型腔的铝合金蜂窝板的制备方法,其特征在于,包括如下步骤:先将铝板坯材依次经水洗、除油、脱脂、钝化、烘干、喷涂、木纹转印和贴膜的表面处理;再对表面处理后的铝板经一次性冲压成型出拉延型腔;再将两块具有拉延型腔的铝板之间通过胶粘接有铝制蜂窝芯,并压合三者以形成铝合金蜂窝板。
6.根据权利要求5所述的制备方法,其特征在于,采用静电粉末喷涂,且形成的喷涂膜厚为60-70μm,固化温度为210-220℃,固化时间为28-32min。
7.根据权利要求5所述的制备方法,其特征在于,木纹转印为将热转印木纹纸放置在喷涂后的铝板坯材表面,并置于炉温为190-200℃之间的加热炉内,保持时长为650-700S。
8.根据权利要求5所述的制备方法,其特征在于,采用冷压机实施压合,且压合的时长为8-9小时,温度控制在23±2℃。
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