JP2736684B2 - Method of manufacturing curved enamel panel - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing a curved plate-shaped enamel panel having a convex portion on the surface side and at least a part of which is curved in a curved plate shape.

[Conventional technology]

Recently, enamel panels in which the surface of a metal plate is coated with an enamel layer have been widely used as interior and exterior materials for buildings. Although this enamel panel is excellent in durability and aesthetics, the demand for patterned enamel panels is increasing because the plain enamel layer has a monotonous appearance. This patterned enamel panel is formed by applying a plastic process such as pressing or roll forming to a metal plate, sandblasting or etching to form a number of convex parts on the metal plate surface, and then applying glaze. It is common to manufacture by glazing and firing.

[Problems to be solved by the invention]

However, in order to obtain a curved enamel panel used for forming a curved wall of a building, a cylindrical surface plate, and the like by the above-described method, as shown in FIGS. 9 and 10, press molding is used. After the projections 2 are formed on the metal plate 1, bending is performed by a bending roll (roll bending machine) 8. The pinch roller 6 and the curved surface adjustment roller 7 of the bending roll always have a large number of projections 2. It is necessary to provide the protrusions 2 densely so as to be in contact. That is, as shown in FIG. 10, unless the contact line 21 with the roller orthogonal to the feed direction (the direction of the arrow X) at the time of bending processing intersects with a large number of convex portions 2, the metal plate is not subjected to roll pressure, Curve molding becomes impossible. Therefore, the shape and arrangement of the protrusions 2 are extremely limited in order to always ensure the contact between the plurality of protrusions 2 and the roll. Height variations must also be kept small. Also, in the case where the projections are formed by sand blasting and etching, the same pattern restrictions as described above are applied, and since the amount of irregularities is small, the pattern is almost conspicuous when coated with an enamel layer, and color unevenness easily occurs. In addition, there is a problem that defects such as burning cracks of the enamel layer are likely to occur due to the sharp edges of the projections. As another method, it is conceivable to simultaneously form a convex portion and a curved surface by press molding with one large mold, but the radius of curvature is limited to a large one and the shape of the convex portion is also limited. In addition, a large and complicated mold must be manufactured every time the specifications of the panel are changed, which increases the cost of the mold and is extremely uneconomical.

SUMMARY OF THE INVENTION The present invention solves the above-mentioned conventional problems. A curved plate-shaped enamel panel having an excellent appearance having a variety of patterns with few restrictions on the shape and arrangement of the projections can be economically obtained. It is intended to provide a method for manufacturing a panel.

[Means for solving the problem]

According to the first invention of this application, a metal sheet having a convex portion on its surface is laminated with a rubber sheet on the convex portion side, and the superposed product of the metal plate and the rubber sheet is bent by a bending roll. A method of manufacturing a curved enamel panel, wherein the enamel layer is applied by applying a glaze to the metal plate and firing it.

Further, the second invention of this application provides a metal sheet having a convex portion on the surface, a rubber sheet having a release hole into which the convex portion is fitted on the convex portion side, and the convex portion being fitted into the release hole. The metal plate and the rubber sheet are bent by a bending roll, and then a glaze is applied to the metal plate, and the enamel layer is applied to the metal plate. This is a method for manufacturing an enamel panel.

In the third invention, in particular, the metal plate is formed of a ferromagnetic material such as a steel plate, and a rubber sheet provided with a flexible rubber magnet layer on a side of the rubber sheet facing the metal plate is used. At the time of laminating the sheets, the rubber sheet is adsorbed to the metal plate by the rubber magnet layer.

According to a fourth invention of this application, a rubber layer is integrally fixed to at least a surface of a metal plate having a convex portion on the surface on the side where the convex portion is formed, and the metal plate with the rubber layer is bent by a bending roll. A method of manufacturing a curved plate-shaped enamel panel, comprising: applying a glaze to the metal plate from which the rubber layer has been peeled off after processing, and applying a glaze to the metal plate to apply an enamel layer. The formation of the rubber layer is performed by spraying a rubber liquid on a metal plate, immersing the metal plate in the rubber liquid, and attaching the rubber liquid to the metal plate, or by bonding a rubber sheet to the metal plate. In the case of immersion in a rubber solution, rubber layers may be formed on both the front and back surfaces of the metal plate.

In the present invention, the projections on the metal plate can be formed by various known methods. However, press molding using a punch and a die is preferable because a projection having a desired height can be easily formed. It is more preferable to use a turret punch press because a metal plate having a large number of convex portions accurately arranged at a desired position can be efficiently obtained.

In the present invention, as the rubber sheet and the rubber layer,
Various rubber materials such as natural rubber and synthetic rubber can be used, but the JIS hardness of the rubber (the hardness of the portion excluding the rubber magnet layer in the case of the third invention) is preferably selected in the range of 40 to 75 mm. If the angle is less than 40 °, the metal plate is too soft to have sufficient force to suppress the substrate portion (except for the convex portion). If the angle exceeds 75 °, it is too hard and brittle, and the durability is insufficient. .

[Action]

In the first aspect of the invention, the rubber sheet is elastically deformed by being pressed between the metal plate and the roller of the bending roll during bending, and acts as a cushion material for absorbing irregularities on the surface side of the metal plate. Prevents the roll pressure from dropping to zero or fluctuating significantly with respect to a metal plate with protrusions,
Bending is performed smoothly.

In the second aspect of the present invention, the convex portion of the metal plate fits into the escape hole, so that the pressing force by the roller of the bending roll does not apply to the convex portion at all, but is applied to the substrate portion of the metal plate via the rubber sheet. , The clamping pressure, and therefore the roll pressure, is kept almost constant during the bending process, and the height is, for example, 5 m.
Even a metal plate having a high convex portion of about m can be accurately bent with a uniform bending radius.

Further, in the third invention, the rubber sheet is positioned at a predetermined position on the metal plate by the attraction force of the rubber magnet layer, so that the separation of the rubber sheet from the metal plate and the displacement of the relief hole during bending by the bending roll can be prevented. Since it is prevented, the bending process can be performed smoothly and reliably, and the handling of the metal sheet and rubber sheet overlapping (fitting into the relief hole of the convex part) and loading into the bending roll is also easy. Work efficiency is improved.

In the fourth invention, the rubber layer is elastically deformed by being pressed between the metal plate and the roller of the bending roll during bending, and acts as a cushion material for absorbing irregularities on the surface of the metal plate. The roll pressure is prevented from becoming zero or greatly fluctuating with respect to the metal plate having the portion, and the bending is performed smoothly.

〔Example〕

Hereinafter, a first embodiment of the present invention will be described with reference to FIGS.

In FIG. 1, reference numeral 1 denotes a metal plate made of an enameled steel plate, which is press-formed on a flat metal plate material.
A shallow partially spherical convex portion 2 protruding from the surface 1a side is formed, and a large number of convex portions 2 scattered on the substrate portion 3 are arranged in a pattern. As shown in FIG. 1 (a), the rubber sheet 4 thicker than the convex portion 2 and the height h is placed on the surface of the metal plate 1 as shown in FIG.
1a side, and pinch roller as shown in Fig.
A bending process is performed by a bending roll 8 having a curved surface adjusting roller 7 and 5,6. When the convex portion 2 passes through the pinch roller 6 and the curved surface adjusting roller 7 due to the movement of the metal plate 1, the rubber sheet 4
When the substrate 3 is opposed to the pinch roller 6 and the curved surface adjusting roller 7, the rubber sheet 4 is clamped between these rollers and the substrate 3. As a result, the convex portion 2 is allowed to pass smoothly, and the roller pressure is constantly generated, so that the bending process is performed without any trouble. As shown in FIG. 2, a narrow strip-shaped flange portion 9 is welded to both longitudinal edges of the bent metal plate 1 by bending or welding at both edges in the width direction. The flanges 10 of partial annular shape are connected to each other, and a clip 11 having an L-shaped cross section for attachment to a building body is welded to these flanges. Thus, the curved enamel panel 12 can be obtained.

In the above embodiment, the outer bending is performed so that the surface 1a of the metal plate 1 becomes a curved outer surface. By bending into 8
An inner bent product in which the surface 1a of the metal plate 1 is a curved inner surface can also be formed.

Next, FIG. 3 shows a second embodiment of the present invention. As a rubber sheet 14, a rubber magnet sheet 16 having flexibility is bonded to a side of the rubber sheet main body 15 facing the metal plate 1 with an adhesive. The only difference is that a punched release hole 17 into which the convex portion 2 of the metal plate 1 is fitted is used in this laminated rubber sheet.
Different from the above embodiment. The relief hole 17 is provided at a position facing each convex portion 2, and has a diameter larger than the outer diameter D of the convex portion 2. In the drawings, the same parts as those in FIGS. 1 and 2 are denoted by the same reference numerals. (The same applies to other drawings hereinafter.) In this embodiment, when the rubber sheet 14 is overlaid on the metal plate 1, the rubber sheet 16 is magnetized by the rubber magnet sheet 16.
Since 14 is adsorbed on the substrate portion 3 of the metal plate 1 and is integrated with the metal plate 1, the hanging down of the rubber sheet 14 and the displacement of the escape hole 17 can be prevented without using an adhesive tape or the like, and the bending roll 8 smoothly. Since the convex portion 2 is fitted in the escape hole 17, a rubber sheet
14 is a pinch roller 6 or a curved surface adjustment roller 7 and a projection 2
As a result, the roll pressure is always kept substantially constant without being excessively deformed due to local pinching, and accurate bending can be performed with a uniform bending force. In this embodiment, as shown in the figure, the height of the convex portion 2 can be made larger than that in the above embodiment, and a curved panel having a clearer pattern can be obtained.

Next, FIGS. 4 and 5 show a third embodiment of the present invention, in which the shape of the convex portion 2 is a flat ellipse having a flat top, and a bending roll 8 , And the remaining portion is left as a flat plate portion 18 as shown in FIG. As the rubber sheet 14, a laminated rubber magnet sheet 16 similar to that shown in FIG. 3 is used, and an oval shaped relief hole 17 is formed in the rubber sheet.

FIG. 6 shows a fourth embodiment of the present invention. A rubber solution is spray-coated on the surface 1a side of the metal plate 1 having the same convex portions 2 as the third embodiment, and if necessary, After performing a vulcanization process to form a rubber layer 20 integrally fixed to the metal plate 1, the metal plate 1 with the rubber layer 20 is charged into a bending roll 8 and bent. After the bending, the rubber layer 20 is peeled off, and the clip 11 is attached and the glaze is baked in the same manner as in the first embodiment to obtain the curved enamel panel shown in FIG.

The present invention is not limited to the above embodiments,
For example, instead of providing the rubber magnet sheet 16 on the rubber sheet 14, the rubber sheet main body 15 with the relief holes 17 is temporarily fixed to the metal plate 1 with an adhesive or an adhesive tape and the like, and is superposed. Alternatively, in the embodiment shown in FIG. 1, the rubber sheet 4 may be temporarily fixed to the metal plate 1 by this method. Also, the present invention provides curved enamels of various shapes and patterns, such as those having a large bending radius as shown in FIG. 7 and those having a plurality of types of convex portions 2A and 2B having different shapes as shown in FIG. Applicable to manufacture of panel 12. In the above embodiment, the enamelling process is performed after the flanges 9, 10 and the like are continuously provided on the edge of the metal plate 1 after the bending process. However, the enamelling process is performed with the curved plate-shaped body without these flanges. In this case, it can be used as an interior panel material or the like which is used with the peripheral edge portion suppressed by the edge material.

〔The invention's effect〕

As described above, according to the present invention, it is possible to smoothly and reliably perform bending by a bending roll via a rubber sheet or a fixed rubber layer superimposed on a metal plate, and the shape of the convex portion provided on the metal plate. A curved enamel panel with a variety of patterns can be economically obtained, in which there are few restrictions on the arrangement and the convex portions of various shapes are arranged in various patterns. In addition, a metal plate having a convex portion formed by press working can be used, and there is less occurrence of defects at the time of enamel layer deposition than an etching or sand blast product, and the pattern by the convex portion after enamel layer deposition is excellent. A curved enamel panel having the appearance and quality is obtained.

[Brief description of the drawings]

FIG. 1 is a process explanation (cross section) showing a first embodiment of the present invention.
FIG. 2 is a perspective view of the curved enamel panel, FIG. 3 is an explanatory view of a main step showing a second embodiment of the present invention, and FIG. 4 is a third view showing a third embodiment of the present invention. Figure equivalent, fifth
FIG. 2 is a diagram corresponding to FIG. 2, FIG. 6 is a diagram corresponding to FIG. 3 showing a fourth embodiment of the present invention, and FIGS. 7 and 8 are other drawings of a curved enamel panel obtained by the present invention. FIG. 9 is a view corresponding to FIG. 3 showing a conventional method for manufacturing a curved plate-shaped enamel panel, and FIG. 10 is a plan view of a metal plate in the same manner. 1 ... metal plate, 1a ... surface, 2, 2A, 2B ... convex part, 4 ...
Rubber sheet, 5: Pinch roller, 6: Pinch roller, 7: Curved surface adjustment roller, 8: Bending roll, 12: Curved enamel panel, 14: Rubber sheet,
15 …… Rubber sheet body, 16 …… Rubber magnet sheet, 17 ……
Escape hole, 20 ... rubber layer.

Claims (4)

(57) [Claims] 1. A metal sheet having a convex portion on its surface, a rubber sheet is superimposed on the convex portion side, and a superposed product of the metal plate and the rubber sheet is bent by a bending roll, and then the metal sheet is formed on the metal sheet. A method for manufacturing a curved enamel panel, comprising applying an enamel layer by applying a glaze and firing. 2. A metal sheet having a convex portion on its surface, a rubber sheet having a release hole into which the convex portion is fitted, on a side of the metal plate having the convex portion fitted into the release hole. A method of manufacturing a curved plate-shaped enamel panel, comprising: laminating an overlapped product of a metal sheet and a rubber sheet with a bending roll, applying a glaze to the metal sheet and firing the metal sheet to form an enamel layer. Method. 3. A metal sheet is made of a ferromagnetic material, and a rubber sheet is provided with a flexible rubber magnet layer on a side facing the metal sheet. 3. The method according to claim 1, wherein the rubber sheet is adsorbed to the metal plate by the layer. 4. A metal plate having a convex portion on its surface, a rubber layer is integrally fixed to at least the surface on the side where the convex portion is formed, and the metal plate with the rubber layer is bent by a bending roll. A method for manufacturing a curved plate-shaped enamel panel, wherein a glaze is applied to the metal plate from which the rubber layer has been peeled off and fired to apply an enamel layer.