JP3638782B2 - Embossed metal plate manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing an embossed metal plate for embossing a brickwork pattern or a tilework pattern on the surface.
[0002]
[Prior art]
For example, as a metal plate used for an outer wall material or an inner wall material of a building, a grooved pattern or a tiled pattern (hereinafter referred to as a brick or tiled pattern) is obtained by embossing groove joints vertically and horizontally by press processing or roll processing. ). In recent years, there is a tendency that design feeling and three-dimensional feeling are emphasized as a wall material, and bricks or tiled patterns full of design feeling and three-dimensional feeling are demanded by deeply processing vertical and horizontal groove joints.
[0003]
[Problems to be solved by the invention]
However, according to the press working that presses and embosses the metal plate between a pair of dies whose concavities and convexities are opposite to each other, the longitudinal and lateral groove joints can be embossed relatively deeply to meet the above demands. When a long metal plate is pressed, there are disadvantages that the number of processing steps is very large and the manufacturing cost is high. On the other hand, according to the roll processing in which a metal plate is sandwiched between a pair of embossing rolls and embossed, a long metal plate can be continuously processed to reduce the manufacturing cost. However, if the groove joint is deeply embossed, the metal plate Since the metal plate is easily cracked and the metal plate is likely to meander in the direction perpendicular to the flow direction, only shallow groove joints could be embossed.
[0004]
Therefore, the object of the present invention is to devise a technique for embossing groove joints, making it difficult for cracks and meandering to occur in metal plates, and embossing groove joints deeply by roll processing, and inexpensive in continuous processing. Another object of the present invention is to provide a method for producing an embossed metal plate that can be produced.
[0005]
[Means for Solving the Problems]
As shown in FIG. 1, the present invention passes a strip-shaped metal plate 1 between a pair of embossing rolls 4, 4, and a plurality of horizontal groove joints extending over the entire length in the longitudinal direction of the metal plate 1 at right angles to the axial direction p of the embossing roll 4. 6 and a large number of vertical groove joints 5 parallel to the axial direction p are applied to attach a brick or tile stacking pattern 7 surrounded by vertical and horizontal groove joints 5 and 6, and at the same time, each brick or tile stacking pattern 7 When the uneven pattern 9 shallower than the depth of the vertical and horizontal groove joints 5 and 6 is applied to the surface of the sheet, embossing the uneven pattern 9 by sandwiching the brick or tile stacked pattern 7 portion between the embossing rolls 4 and 4 as shown in FIG. At the same time, the front side of the vertical and horizontal groove joints 5 and 6 is pushed by the joint forming convex part 4a of one embossing roll 4, and the back side of the vertical and horizontal groove joints 5 and 6 is the concave part for joint forming of the other embossing roll 4. 4b and embossing the vertical and horizontal groove joints 5 and 6, and the side walls 11 and 11 of the vertical and horizontal groove joints 5 and 6 are inclined surfaces that gradually become narrower as they reach the groove bottom. In addition to forming, corners 12 where the side walls 11 of the vertical and horizontal groove joints 5 and the brick or tile stacking pattern 7 intersect are rounded.
[0006]
[Action]
The vertical and horizontal groove joints 5 and 6 are not clamped between the joint forming convex part 4a and the joint forming concave part 4b of the embossing rolls 4 and 4, and the surface side of the vertical and horizontal groove joint parts 5 and 6 is the joint. When pressing with the molding convex portion 4a and embossing with the gap g formed between the back surface side and the joint molding concave portion 4b, the vertical and horizontal groove joint portions 5 and 6 are stretched as a whole while the joint molding convex portion 4a is extended. Deep vertical and horizontal groove joints 5 and 6 which are bent and stretched at the tip and are not cracked can be obtained. At the time of overhang forming, the side walls 11 formed on the inclined surfaces of the vertical and horizontal groove joints 5 and 6 are elongated on average, and the rounded corner portions 12 can prevent the bending force from being concentrated.
[0007]
The plurality of lateral groove joints 6 extending over the entire length in the longitudinal direction of the metal plate 1 can suppress the meandering of the metal plate 1.
[0008]
【The invention's effect】
Therefore, according to the present invention, while the metal plate 1 can go straight without meandering, the vertical and horizontal groove joints 5 and 6 can be deeply embossed between the embossing rolls 4 and 4, so that the brick or the like has excellent three-dimensional feeling and design feeling. The tile stacking pattern 7 can be attached, and it has been possible to manufacture the tiles at a low cost by continuous roll processing.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
1 is a plan view of an embossed metal plate obtained by the method of the present invention, FIG. 2 is an enlarged plan view of a part of the embossed metal plate, and FIG. 3 is a cross-sectional view showing a state of forming a groove joint portion of the embossed metal plate. FIG. 4 is an enlarged sectional view of a part of the embossed metal plate.
[0010]
As the metal plate 1 of the embossed metal plate, a painted galvanized steel plate, a painted aluminum plate, or the like is used. In particular, the raw sheet is preferably a cold-rolled steel sheet for deep drawing (SPCE material) excellent in workability having an elongation of 36% or more, or an aluminum alloy sheet having an elongation of 23% or more with uncauterized (type O). The plate thickness of the metal plate 1 is about 0.3 to 1 mm.
[0011]
As shown in FIG. 4, an epoxy resin paint or a polyester resin paint primer 2 is applied and baked to a film thickness of 1 to 15 μm on the surface of the metal plate 1, and a top coat film 3 is formed on the surface of the primer 2. . As the top coat film 3, a polyester resin paint or a fluorine resin paint is baked to a film thickness of 7 to 30 μm.
[0012]
In addition to the resin paint, the top coat film 3 is preferably a high-molecular polyester resin paint having a number average molecular weight of 5,000 to 50,000 with good bending workability. More preferable. A paint having the following composition is used as the paint for forming the shrink-pattern coating film. The reaction mixture of sulfonic acid and amine is sulfonic acid based on 100 parts by weight of the sum of 65 to 95 parts by weight of high molecular polyester resin having a hydroxyl value of 5 to 110 and 5 to 35 parts by weight of low-nuclear methylated melamine resin. 0.1 to 3 parts by weight in amount, 1 to 15 parts by weight of silica fine particles having an average particle size of 10 μm or less for reducing gloss and stabilizing the shrinkage pattern, polyacrylonitrile for improving weather resistance, polymethyl methacrylate, etc. Acrylic resin: Fluorine resin such as vinylidene fluoride: A paint containing 1 to 20 parts by weight of organic resin particles such as polyester resin.
[0013]
The coated metal plate 1 wound in a coil shape is continuously embossed by passing between a pair of embossing rolls 4 and 4 having irregularities opposite to each other on the peripheral surface. The embossing roll 4 is made of a carbon steel material for mechanical structure, and the surface is plated with hard chrome. By this embossing, a number of vertical groove joints 5 parallel to the axial direction p of the embossing roll 4 and a plurality of horizontal groove joints 6 extending over the entire length in the longitudinal direction of the metal plate 1 perpendicular to the axial direction p, as shown in FIG. Is formed, and a brick or tiled pattern 7 surrounded by the vertical and horizontal groove joints 5 and 6 is attached to the entire surface of the metal plate 1.
[0014]
At that time, in order to prevent the metal plate 1 from bending over the entire length in the width direction, the vertical groove joints 5 are preferably the vertical groove joints 5 and 5 adjacent to each other in the width direction of the metal plate 1, preferably all the vertical groove joints 5. Are arranged in a zigzag pattern with unequal pitches in a direction perpendicular to the axial direction p of the embossing roll 4 (longitudinal direction of the metal plate 1) so that they are not arranged on the same straight line in the width direction.
[0015]
The surface of the vertical and horizontal groove joints 5 and 6 is assumed to have no uneven pattern. However, all the surfaces of the brick or tile stacked pattern 7 group surrounded by the vertical and horizontal groove joints 5 and 6 are sandstone patterns to enhance the design effect. A shallow fine uneven pattern 9 is applied (see FIG. 2). The depth d ₁ (see FIG. 3) of the concave portion 10 of the uneven pattern 9 is set to 0.05 to 2 mm. On the other hand, the depth d ₂ (see FIG. 3) of the vertical and horizontal groove joints 5 and 6 is about 2 to 7 mm.
[0016]
The vertical and horizontal groove joints 5 and 6 are rolled with a deep groove depth d ₂ , and as shown in FIG. 3, the brick or tile stack pattern 7 portion is sandwiched between embossing rolls 4 and 4 to form fine irregularities such as sandstone patterns. Although the pattern 9 is embossed, the surface side of the vertical and horizontal groove joints 5 and 6 is pressed by the joint forming convex portion 4a of one embossing roll 4, and the back side of the vertical and horizontal groove joints 5 and 6 is the other embossing roll 4. A gap g is formed between the joint forming recesses 4b and the longitudinal and transverse groove joints 5 and 6 are embossed. By such embossing, the vertical and horizontal groove joints 5 and 6 are stretched and bent at the tip of the joint forming convex portion 4a while being stretched as a whole, and can be deeply embossed without breaking the vertical and horizontal groove joints 5 and 6. it can.
[0017]
The both side walls 11 and 11 of the vertical and horizontal groove joints 5 and 6 are averagely stretched so that cracks do not occur. A tilt angle α of 60 ° is applied. The corner 12 where the side wall 11 of the vertical and horizontal groove joints 5 and the brick or tile stacking pattern 7 portion intersects is bent with a curvature radius of 1 to 3 mm so that bending stress does not concentrate and break. Turn on.
[0018]
【Example】
As the metal plate 1, a coated hot-dip galvanized steel plate (plate thickness 0.35 mm) using a cold-drawn steel plate (SPCE material) for deep drawing is used. The pattern of the vertical and horizontal groove joints 5 and 6 is as shown in FIG. The depth d ₁ of the concave portion 10 of the fine concavo-convex pattern 9 embossed on the surface of the brick or tile pattern 7 is set to 0.05 to 2 mm. The width W of the vertical and horizontal groove joints 5 and 6 is 15 mm, the inclination angle α of the side wall 11 of the vertical and horizontal groove joints 5 and 6 is 50 °, and the radius of curvature of the radius attached to the corner 12 of the vertical and horizontal groove joints 5 and 6 is 2 mm. The diameter of the embossing roll 4 is 210 mm.
[0019]
As a result of roll processing under the above conditions, the metal plate 1 was able to go straight without meandering, and the vertical and horizontal groove joints 5 and 6 could be deeply embossed to a depth of 5 mm so that they were not cracked.
[Brief description of the drawings]
FIG. 1 is a plan view of an embossed metal plate obtained by the method of the present invention.
FIG. 2 is an enlarged plan view of a part of an embossed metal plate.
FIG. 3 is a cross-sectional view showing a forming state of a groove joint portion of an embossed metal plate.
FIG. 4 is an enlarged cross-sectional view of a part of an embossed metal plate.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Metal plate 4 Embossing roll 4a Embossing roll joint forming convex part 4b Embossing roll joint forming concave part 5 Vertical groove joint 6 Horizontal groove joint 7 Brick or tile stacking pattern 9 Shallow uneven pattern

Claims (1)

A plurality of transverse groove joints 6 extending through the entire length of the metal plate 1 in the longitudinal direction at right angles to the axial direction p of the embossing roll 4 through the strip-shaped metal plate 1 between the pair of embossing rolls 4 and 4, and parallel to the axial direction p By embossing a large number of vertical groove joints 5, a brick or tile stacking pattern 7 surrounded by the vertical and horizontal groove joints 5 and 6 is applied, and at the same time, the vertical and horizontal groove joints 5 are formed on the surface of each brick or tile stacking pattern 7. -When applying the uneven pattern 9 shallower than the depth of 6,
At the same time as embossing the shallow concavo-convex pattern 9 by sandwiching the brick or tile stacked pattern 7 part between the embossing rolls 4 and 4, the surface side of the vertical and horizontal groove joints 5 and 6 is the joint forming convex part 4a of one embossing roll 4. The back side of the vertical and horizontal groove joints 5 and 6 is formed with a gap g between the other embossing roll 4 and the joint forming recess 4b to emboss the vertical and horizontal groove joints 5 and 6,
The side walls 11 and 11 of the vertical and horizontal groove joints 5 and 6 are formed on an inclined surface having a gradually narrower groove width toward the groove bottom, and the side walls 11 of the vertical and horizontal groove joints 5 and 6 and the brick or tile stacking pattern 7 portion, A method for manufacturing an embossed metal plate, wherein a corner 12 is rounded.

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