JP3829234B2 - Panel and manufacturing method thereof - Google Patents

Description

【００２４】
表１の結果は、「比較例２＞比較例１＞発明例」の順による引張剪断強度であったが、実質的には略同等であった。即ち、発明例による接着力は、最大の強度を得るものではないが、所定の接着面積を用いることにより、実用的な接着強度を有するパネルが得られることが判明した。
また、発明例と同じ板片を用い同じ方法及び条件で接着した試験片により、接着面の引張力の加わり方による各種の接着強度を測定した。
その結果を表２に示す。尚、表２中における引張強度は「接着剤の引張強さ試験方法／JIS Ｋ６８４９−１９９４」に基づく角棒引張試験片を用いた。また、引張剪断強度は、前記表１に示した試験方法によって得た。両試験共に５組の試験片に対して行った。
【００２５】
【表２】

【００２６】
表２の結果は、「引張強度＞引張剪断強度」であることが判明した。尚、引き裂き強度の結果は表２に示していないが、引張剪断強度の約１０％程度であり、かなり小さな外力で引き裂かれたり、引き剥がされることが既に知られている。
図１(Ｂ)は、上記試験結果を前提に、アルミニウム合金(Ａ６０６３−Ｔ５)からなる一対の押出形材１０ａ,１０ｂを接着した状態を示す。形材１０ａ,１０ｂは、断面が扁平で矩形の中空部１２を内蔵し、大小の縦端面１４，１６と、これらの間の水平面１５とからなる接着面を有し、表面全体に平均厚さ５μｍの陽極酸化皮膜層２と、平均厚さ１０μｍの電着塗膜４を被覆している。
図１(Ｂ)に示すように、何れかの形材１０における予めアセトンで脱脂した接着面(１４,１５,１６)に前記接着剤８と同様の２液性エポキシ系接着剤１８を塗布し、同様に脱脂した他方の形材１０を図示のように点対称にして接着する。
【００２７】
ところで、図１(Ｂ)において、略断面Ｚ字形に固着し硬化する接着剤１８のうち、形材１０ａ，１０ｂを互いに離間する引張力に実質的に抵抗する引張剪断強度は、水平面１５間に挟まれた水平部分１８ａにより得られる。表２に示したように、接着部では引張剪断強度(τ)よりも引張強度(Ｗ)の方が大きい。即ち、要求される引張強度に対して、接着剤１８により引張剪断強度相当の接着強度が得られた場合、常にそれ以上の引張強度が得られていることになり、係る場合は必要とする接着強度が得られることになる。
従って、図１(Ｂ)において、接着剤１８の図示の水平部分１８ａの長さ及び一対の垂直部分１８ｂの長さの合計値(Σｘ(ｍｍ))と、形材１０ａ，１０ｂの接合部における引張剪断強度(τ(Ｎ／ｍｍ²))との積が、数式５に示すように、接着剤１８に求められる、図１(Ｂ)において紙面奥行き方向に沿う単位長さ当たりの引張強度(Ｗ(Ｎ／ｍｍ))以上であれば、支障ないことが理解される。
【００２８】
【数５】
τ×Σｘ≧Ｗ
【００２９】
更に、図１(Ｂ)において、形材１０ａ，１０ｂにおける中間部における断面の厚みの合計値(ｔ(mm))と形材１０ａ,１０ｂ自体の０.２％耐力(σ_0.2(Ｎ／mm²))との積が、下記の数式６に示すように、上記引張剪断強度(τ(Ｎ／ｍｍ²))と水平部分１８ａ及び各垂直部分１８ｂの長さの合計値(Σｘ(ｍｍ))との積と同じ値か、それ以上の値であれば一層十分な接着強度を有することが理解できる。
【００３０】
【数６】
σ_0.2×ｔ≧τ×Σｘ
【００３１】
一方、図１(Ｂ)に示すように、左側の形材１０ａの接着部Ｅ１の板厚が薄い場合、形材１０ａの中間部Ｅ０に加わる引張力Ｗにより上記接着部Ｅ１が変形し、図示で矢印方向の引き裂き力Ｈが接着部に加わる。係る引き裂き力Ｈに対する接着強度は前述したように低いため、接着剤１８がその上端部から剥離し始め、且つ接着部の全体に伝播して破断に至る、という問題がある。
即ち、形材１０ａ，１０ｂのように引き裂き力Ｈが作用し易い断面形状ではなく、互いに雄・雌嵌合する凹断面形状及び凸断面形状の接合部であって、当該形材の他の部分よりも剛性の高い断面形状とすることが必要となる。
【００３２】
図２(Ａ)は、係る接合部２１ａ,２１ｂを左右両端に有する押出形材２０,２０を接合したパネル２０ａを示す。図２(Ａ)は、各形材２０の押出方向と直交する方向で切断した断面示す。形材２０は、前記同様のアルミニウム合金からなり、断面が扁平で略矩形の中空部２２を内設すると共に、右端の端面２３の中央に凸部２４を有する凸断面形状の雄型接合部２１ａと、左端の端面にて上下一対の凸条２７間に凹部２６を有する凹断面形状の凹雌型接合部２１ｂとを有する。
図２(Ａ)のように、接合部２１ａ，２１ｂの端面２３と凸条２７が当接すると共に、凸部２４と凹部２６とが雄・雌嵌合する。
【００３３】
これらの表面全体には、図２(ａ)に示すように、予め平均厚さ５μｍの陽極酸化皮膜層２と、平均厚さ１０μｍの電着塗膜層４が被覆されている。隣接する形材２０，２０における接合部２１ａ，２１ｂを予めアセトンで脱脂した後、図２(Ａ)に示すように、前記接着剤８と同様の２液性エポキシ系接着剤２８を何れかの接合部に塗布した後、他方の形材２０を図示のように端面２３と凸条２７が当接し、且つ凸部２４と凹部２６とを雄雌嵌合させて接着する。
尚、接合部２１ａ，２１ｂにおける各部の板厚は、中間部分の板厚よりも２〜５倍程度の厚さとし、接合部２１ａ，２１ｂを中間部分よりも剛性の高い断面形状としている。
【００３４】
図２(Ａ)において、接着剤２８は、下記数式７で算出されるその断面全体に渉る長さ(Σｘ)において、形材２０,２０を左右に離間させる引張力Ｗを受ける。
即ち、前記数式５のように、接着部の全長さ(Σｘ)に引張剪断強度(τ)を乗じた値(τ×Σｘ)が引張力(Ｗ)以上であれば、前述したように接着部の単位長さ当たりの引張強さは引張剪断強さより大きいため、所要の引張力(Ｗ)以上の接着強度が得られる。
【００３５】
【数７】
Σｘ＝２×(ｘ₁)＋２×(ｘ₂)＋ｘ₃
【００３６】
また、前記数式６のように、形材２０,２０の中間部の厚み(ｔ＝ｔ/２×２)と形材２０,２０自体の０.２％耐力(σ_0.2)との積が、上記接着部の全長さ(Σｘ)とその引張剪断耐力(τ)との積(τ×Σｘ)以上であれば、所要の接合強度を確実に得ることができる。しかも、形材２０,２０が接着される接合部２１ａ,２１ｂは、中空部２２を内設する他の部分よりも板厚を厚くしているので、剛性の高い断面形状を有し且つ互いに雄・雌嵌合することにより引き裂き力Ｈや引き剥がし力が作用しない。従って、少なくとも前記数式６にて算出される値(τ×Σｘ)を保持するように、予め設計することにより、安定した接合強度を有するパネルを得ることが可能となる。
【００３７】
ここで、上記パネル２０ａの製造方法を説明する。図２(Ｂ)に示すように、先ず形材２０を図示しない押出機を用いて押出成形する。形材２０の断面は、予め前記数式５，６の条件を満たすように設計され、その中空部２２内の中央には中空部２２を２分割するウェブ２５が必要に応じて一体に付設されている。
次に、係る形材２０をパネル２０ａに応じた長さに切断した後、陽極酸化処理を施す。予め表面を脱脂した形材２０，２０を図示しない電極に支持して処理槽内の処理液中に浸漬し、図３(Ａ)に示すように、公知の方法により陽極酸化皮膜層２を形材２０の表面に生成する。係る被膜層２は、５〜２０μｍ程度の厚みとする。処理槽から取り出した係る形材２０は、酸化皮膜層２表面の多数のポアが完全な封孔状態にならないように、８０℃程度の湯により湯洗する。
更に、上記形材２０を別の電極に支持して図示しない電着処理槽内のアクリル系樹脂塗料の電着液中に浸漬し、公知の方法により電着(電気永動)塗装を行う。
この結果、図３(Ｂ)に示すように、形材２０の皮膜層２の表面全体にアクリル系樹脂からなり約１０μｍ程度の厚みを有する電着塗膜層４が被覆される。最後に、形材２０を約１６０〜１９０℃で約３０分間加熱して焼き付け処理を施し、上記塗膜層４を硬化し安定させる。尚、陽極酸化皮膜層２及び電着塗膜層４は、連続した表面処理ラインで処理される。
【００３８】
そして、以上のように酸化皮膜層２と電着塗膜層４とを有する複数の形材２０，２０をアセトンで脱脂した後、互いに接合部２１ａ,２１ｂが対向するように隣接し、接合部２１ａ,２１ｂの何れかに接着剤２８を塗布する。接着剤２８は、エポキシ系又はアクリル系樹脂からなる２液性の常温硬化型の接着剤である。
隣接する形材２０,２０の接合部２１ａ,２１ｂを接着剤２８を介して雄・雌嵌合して接合した状態で、形材２０,２０を、適宜の押さえ治具によって接着剤２８の厚みが適正になるように固定する。係る固定した状態で２，３日程度に渉り保持し、上記接着剤２８を硬化処理しその接着力を安定化させる。これにより、図２(Ａ)に示したように、複数の形材２０を接着剤２８により接合した前記パネル２０ａを得ることができる。
【００３９】
図４(Ａ)は、異なる形態の押出形材３０を示す。この形材３０も前記同様のアルミニウム合金からなり、断面が扁平で略矩形の中空部３２を内設すると共に、右端の端面３３の中央に断面台形の凸部３４を有する雄型接合部３１と、左端の端面に断面略台形で上下対称の凸条３７，３７と、この間に位置する断面台形の凹部３６を有する雌型接合部３５とを有する。図示のように、接合部３１，３５の凸部３４と凹部３６とが雄・雌嵌合可能とされている。尚、これらの表面全体には、図４(ａ)に示すように、平均厚さ５μｍの陽極酸化皮膜層２と、平均厚さ１０μｍの電着塗膜層４とが前述した方法により予め被覆されている。また、接合部３１，３５における各部の板厚は、中間部分よりも厚肉とし剛性を高い断面形状としている。
【００４０】
図４(Ｂ)に形材３０，３０を接合して得られるパネル３０ａの断面を示す。隣接する形材３０,３０における接合部３１,３５を予めアセトンで脱脂した後、図４(Ｂ)に示すように、前記接着剤８と同様の２液性エポキシ系接着剤３８を何れかの接合部に塗布し、他方の形材３０を図示のように端面３３と凸条３７が当接し、且つ凸部３４と凹部３６とが雄雌嵌合させて接着し且つ硬化処理する。これにより、複数の形材３０を接着剤３８により接合した前記パネル３０ａを得ることができる。尚、接着部の全長さΣｘは、図４(Ｂ)に示す２つのｘ₂、１つのｘ₃、及び２つのｘ₄の合計値により算出される。
【００４１】
図５(Ａ)は、異なる形態の押出形材４０の接合部４１，４５の断面を示す。
形材４０も前記同様のアルミニウム合金からなり、図５(Ａ)に示すように、断面が略矩形の中空部４０ａを内蔵する。形材４０の右端には、端面中央に断面三角形状の凹溝４３と、その上下に平行に突出する断面三角形状の凸条４２，４２を有し、且つ外側面との間に段部４４とを有する接合部４１が設けられている。
また、形材４０の左端には、端面中央に断面三角形状の凸条４６と、その上下の断面三角形状で互いに平行な凹溝４７，４７と、これらの上下に連設する屈曲部４８を介して外側面と平行に突出する一対のフランジ４９，４９を有する接合部４５が設けられている。図５(ａ)に示すように、形材４０の表面には、前記同様に陽極酸化皮膜層２と電着塗膜層４とが予め被覆されている。
【００４２】
複数の形材４０における接合部４１，４５を脱脂した後、図５(Ａ)に示すように、接合部４１に前記同様の接着剤Ｓを塗布する。次いで、図５(Ｂ)に示すように、形材４０,４０の接合部４１,４５を接合する。即ち、凹溝４３内に凸条４６を、各凹溝４７内に各凸条４２をそれぞれ嵌合すると共に、段部４４にフランジ４９を位置させている。しかも、接合部４１,４５間は、図５(Ｂ)中のＫ部分において形材４０，４０が当接することにより、適正な間隔で接着剤Ｓを介して左右の形材４０，４０を接合している。これより、複数の形材４０からなるパネルを形成することが可能となる。
尚、図５(Ｂ)に示すように、接合部４１,４５間において、凹溝４３の底部と凸条４６の先端の間、各凹溝４７の底部と凸条４２の先端の間、及び各凸条４２と屈曲部４８との間には、所要断面積の隙間Ｆが位置し、余分となった接着剤Ｓを受け入れる。また、図５(Ｂ)に示すように、接合部４１，４５間における接着剤Ｓの全長さは、前記数式５,６におけるΣｘとして用いられる。但し、図５(Ｂ)中の隙間Ｆの部分では、接着剤Ｓの厚みが適正値よりも大きくなるため、係る隙間Ｆ部分を除いて上記長さΣｘが計算される。
【００４３】
図６(Ａ)は、前記押出形材４０の全体の断面を例示する。即ち、形材４０は両端に接合部４１，４５を有すると共に、これらの間に互いに平行でカーブした一対の湾曲片４０ｂ,４０ｃと、これらに挟まれた扁平な中空部４０ａを有すると共に、図６(ａ)に示すように、その表面には陽極酸化皮膜層２と電着塗膜層４を有している。図６(Ｂ)に示すように、隣接する形材４０,４０の接合部４１,４５を順次接合していく。その結果、図４(Ｃ)に示すように、複数の形材４０を接合したパネル４０ｄを形成することができる。このパネル４０ｄは、図示のように、全体が連続するカーブの湾曲面を形成するので、駅前や商店街において歩行者を雨水から保護するシェルター等の屋根ユニットとして活用することができる。
【００４４】
本発明は以上において説明した各形態に限定されるものではない。
図２乃至図６で示した形材２０,３０,４０は、接合部２１ａ，２１ｂ等の断面形状を中間部分のそれよりも剛性の高いものとしたが、例えば、図７(Ａ)に示す押出形材５０を用いることにより、前記図１(Ｂ)で示した接着面に対する面外方向の引き裂き力Ｈが作用しないパネル５０ａを得ることができる。
形材５０は、図７(Ａ)に示すように、前記同様のアルミニウム合金からなり、断面が扁平な矩形の中空部５１を有し、図示の右端には、厚肉の端壁５３から突設した薄肉で平行な一対の凸条５４，５４からなる接合部５２を有する。また、左端においては端壁５８，５８間の中央の凸部５７の上下に位置する凹溝５６，５６からなる接合部５５を有する。一対の凹溝５６からなる接合部５５は、形材５０の中間部分よりも厚肉とされている。図７(ａ)に示すように、形材５０はその表面に陽極酸化皮膜層２と電着塗膜層４を予め被覆している。
【００４５】
図７(Ａ)に示すように、前記同様に接合部５２，５５間を接着剤５９により接合しパネル５０ａを得る。そして、各凸条５４は最も薄肉であり、且つ形材５０の他の部分よりも剛性の低い断面形状であるため、図７(Ａ)中に示す矢印方向の引き裂き力Ｈや引き剥がし力は作用しなくなる。
即ち、本発明のパネルを形成する押出形材は、接合部で接着した際に、引き裂き力Ｈ等が作用しにくくするため、接合部の断面形状を他の部分より剛性を有する凹・凸断面形状とするか、或いは一方の形材を引き裂き力Ｈ等が作用する前にその形材の本体が変形する柔軟な断面形状を用いることができる。
【００４６】
また、図６(Ａ)で例示した接合部４１,４５の間における湾曲片４０ｂ,４０ｃに替えて、互いに平行で断面略ヘ字形に屈曲した一対の屈曲片を有する押出形材を用い、且つ隣設する形材の屈曲片が連続したジグザク形状を呈するように、接着剤Ｓを介して接合した断面がジグザク形状を呈するパネルを形成することもできる。或いは、棟部分となる中央に上記断面略ヘ字形に屈曲した一対の屈曲片を有する押出形材を用い、その両側に接合部４１，４５間に直線の側片を有する形材を複数接着剤Ｓを介して接合することにより、断面全体が略ヘ字形を呈する屋根用のパネルを形成することも可能である。勿論、接合部４１，４５間には、任意の断面形状の側片を配置することができ、且つその一部を中空部４０ａのない一方の側にのみ側片が位置する形材にすることも可能である。
【００４７】
【実施例】
ここで、本発明の具体的な実施例を図７(Ｂ)のパネル６０により説明する。
図７(Ｂ)に示すように、パネル６０を形成する押出形材６１は、アルミニウム合金(ＪＩＳ：Ａ６０６３)からなりＴ５熱処理が施されている。この形材６１は、断面扁平で矩形の中空部６２と、その右端にて端壁６５とその中央に細長い凸条６４を有する凸断面形状の雄型接合部６３と、左端にて端壁６７とその中央に細長い凹溝６８を有する凹断面の形状の雌型接合部６６とを有する。図７(Ｂ)において、形材６１の左右方向の全幅は２７０ｍｍ、垂直方向の厚みＴは２５ｍｍ、中間部の板厚ｔは２.５ｍｍ、各接合部６３,６６の板厚は６ｍｍ、凸条６４及び凹溝６８の各傾斜面の左右方向における長さＬは２０ｍｍである。更に形材６１の０.２％耐力は１４５Ｎ／ｍｍ²、引張強さは実測値で１９０Ｎ／ｍｍ²である。
【００４８】
上記形材６１を押出成形した後、硫酸陽極酸化処理により平均膜厚７μｍの陽極酸化皮膜層２を生成し、且つ約８０℃の湯で湯洗した。係る未封孔状態の皮膜層２を有する形材６１に対し、アクリル系熱硬化樹脂による電着塗装を施し、平均膜厚１０μｍの電着塗膜層４を上記皮膜層２の上に被覆した後、約１６０℃〜１９０℃で３０分間加熱する焼き付け処理を行い上記塗膜層４を硬化させた。
上記皮膜層２と塗膜層４を有する形材６１を、図７(Ｂ)に示す押出方向(紙面奥行き方向)に沿って５０ｍｍの長さで１０個切断した。各形材６１の接合部６３，６６をアセトンで脱脂した後、２液性エポキシ系接着剤(長瀬チバ社の商品名:アラルダイト(樹脂:Ａｗ１０６、硬化剤:ＨＶ９５３Ｕ))６９を塗布し、図７(Ｂ)に示すように、一対ずつの形材６１を接合部６３,６６で雄・雌接合して接着した。尚、上記接着剤６９の平均厚さは１００μｍであった。得られた５組の試験片を７日間保持した。
【００４９】
５組の試験片に付き、図７(Ｂ)にて接着された形材６１，６１が互いに離間する左右方向に沿って引っ張る引張試験を行った。その結果、各組の試験片は接着部分で破断し、平均の破断強度は３９２００Ｎ(７８４Ｎ／ｍｍ)であった。尚、各形材６１は、接合部６３，６６を除いた中間部分で伸び変形を生じていた。
ところで、各試験片における接着部の全長Σｘは、図７(Ｂ)で示す接着剤６９の３つの垂直部ｘ₂,ｘ₂,ｘ₃(５ｍｍ×３)と、一対の傾斜部ｘ₄(２０.６ｍｍ×２)の和である。これを前記数式５に基づき剪断強度(τ)との積を求めると、下記数式８の右端に示す値が算出された。
【００５０】
【数８】
τ×Σｘ＝１２.７Ｎ／mm²×((５mm×３)＋(２０.６mm×２))＝７１４Ｎ／mm
【００５１】
一方、形材６１自体の図７(Ｂ)で示す紙面奥行き方向に沿った長さ１ｍｍ当たりの耐力限界は７２５Ｎ／ｍｍで、破断限界強度は９５０Ｎ／ｍｍである。
また、数式８によって算出された剪断耐力(τ)と接着部の全長Σｘとの積の値(７１４Ｎ／ｍｍ)よりも、試験片により測定した実際の強度(７８４Ｎ／ｍｍ)が高くなった。これは数式８では引張剪断強度により強度を算出しているが、係る引張剪断強度よりも引張強度の方が大きいため、その増加分が加味されたことによるものと考えられる。従って、引張剪断強度(τ)を用いる上記数式８により算出される値は、形材６１，６１を接着して得られるパネル６０における接着強度を設計する場合に、その安全性を十分に保証し得ることが確認された。
【００５２】
【発明の効果】
以上において説明した本発明のパネルによれば、接着剤が電着塗膜層の間に介在し且つ両形材が強固に接着され、無地のアルミニウム表面同士の接着の場合と略同等の接着強度が得られるので、複数の押出形材を接着剤のみにより、強固に接合したパネルを形成することが可能となる。しかも、各形材は陽極酸化皮膜層及び電着塗膜層がその表面に被覆されているので、耐食性と外観光沢性の双方が高いパネルを得ることができる。且つ、アルミニウム材に通常用いられる表面処理をそのまま活用することもできる。
また、請求項２乃至４のパネルによれば、引き裂き力や引き剥がし力に対して、強力に抵抗し得る接合部かこれらが作用しにくい接合部を有するので、接着剤による安定した接合を得ることができる。
更に、請求項５，６のパネルによれば、所要の引張り強度や接着剤にて接合される接合部に対し、必要な接着強度や断面形状を有する押出形材を用いることが容易にでき、安定した接着強度を有するパネルとすることができる。
【００５３】
一方、本発明のパネルの製造方法によれば、押出形材間に塗布される接着剤が陽極酸化処理や電着塗装の影響を受けず、無地のアルミニウム表面同士の接着の場合と略同等の接着強度が得られるので、複数の押出形材を接着剤のみにより、強固に接合したパネルを確実に製造することができる。しかも、耐食性と外観光沢性が得られると共に、接着剤が従来のように陽極酸化処理液や電着塗装の溶剤に接触して劣化しないので、所要の接着強度を確実に得られる。加えて、アルミニウム材に通常用いられる表面処理設備・工程をそのまま活用することができる。
また、請求項１０の製造方法によれば、電着塗膜層が封孔されていない陽極酸化皮膜層に強固に密着するので、接合した押出形材間に引張剪断力が働いても、上記皮膜層と塗膜層との間での破断を確実に防止することができる。
【図面の簡単な説明】
【図１】 (Ａ)は本発明のパネルを得るため板片により行った引張試験の状態を示す概略図、(Ｂ)は押出形材間の接合部における接着剤の作用等を示す概略図。
【図２】 (Ａ)は本発明のパネルを示す部分断面図、(ａ)は(Ａ)中の一点鎖線部分ａの拡大図、(Ｂ)はこのパネルを形成する押出形材の断面図。
【図３】 (Ａ)は図２(Ｂ)の形材の表面に形材の表面に陽極酸化処理を施した状態を示す部分断面図、(Ｂ)は電着塗装を施した状態を示す部分断面図。
【図４】 (Ａ)は異なる押出形材の部分断面図、(ａ)は(Ａ)中の一点鎖線部分ａの拡大図、(Ｂ)は(Ａ)の形材同士を接合して得たパネルを示す概略断面図。
【図５】 (Ａ)は異なる形態の押出形材の各接合部を示す部分断面図、(ａ)は(Ａ)中の一点鎖線部分ａを示す拡大図、(Ｂ)は係る接合部を接着剤により接合した状態を示す部分断面図。
【図６】 (Ａ)は図５の接合部を両端に有する押出形材の断面図、(ａ)は(Ａ)中の一点鎖線部分ａを示す拡大図、(Ｂ)は上記形材同士の接合状態を示す部分断面図、(Ｃ)は係る形材を複数枚接合して形成したパネルの断面図。
【図７】 (Ａ)は更に異なる形態の押出形材同士を接合したパネルの部分断面図、(ａ)は(Ａ)中の一点鎖線部分ａを示す拡大図、(Ｂ)は本発明の実施例の押出形材とこれを接合したパネルを示す部分断面図。
【符号の説明】
２………………………………………………………………………陽極酸化皮膜層
４………………………………………………………………………電着塗膜層
１８,２８,３８,Ｓ,５９,６９………………………………………接着剤
１０ａ,１０ｂ,２０,３０,４０,５０,６１………………………押出形材
２０ａ,３０ａ,４０ｄ,５０ａ,６０………………………………パネル
２１ａ,２１ｂ,３１,３５，４１,４５,５２,５５,６３,６６…接合部
Ｈ………………………………………………………………………引き裂き力[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a panel formed by joining a plurality of extruded shapes made of an aluminum alloy and having a flat cross section, and a method for manufacturing such a panel.
[0002]
[Prior art]
Shelters for rain protection such as arcades, walking paths, and bus stops in shopping streets include steel structures covered with roof plates, and aluminum plates extruded with aluminum plates that are fitted with resin plates. It has been adopted. However, they require rooftops and resin plates to be attached to the framework of steel frames and profiles, so they require a large number of members and man-hours, and because they are designed and constructed for each subject of the shelter, it takes a long time and cost from design to completion. There is a problem of need.
[0003]
On the other hand, the extruded shape of aluminum alloy can be freely designed in cross section, so it is possible to design and construct a shelter of any size by joining multiple extruded shapes with flat cross sections. is there. However, even in this case, for example, a joint between adjacent extruded profiles is bolted by male-female fitting, and silicon caulking is filled along the joints of both profiles for rain. Since a lot of labor is required, man-hours and costs have not been sufficiently reduced.
[0004]
By the way, various studies have been made so far to join extruded shapes of aluminum alloys with an adhesive. For example, in the patent application of Japanese Patent Application No. 10-21398, the inventors previously disclosed a joining structure and a usage form of a panel for joining extruded shapes of aluminum alloy with an adhesive. According to this, in the longitudinal direction along the extrusion direction of the extruded shape, a long panel can be easily obtained, but on the other hand, since the dimension along the width direction is limited, the adhesive is used between the shapes. It is understood that a panel having a large area can be obtained by using it for the joint portion.
[0005]
In addition, the Sumitomo Light Metal Technical Report (April 1986, pages 69-73) has a research report on the bonding of aluminum materials under the title “Aluminum Bonding Ground Treatment”. This discloses the knowledge about the properties of the porous surface produced by the anodization (alumite) treatment and the relationship between the base treatment and the adhesive strength.
Furthermore, a similar matter is also published in the Aluminum Handbook (1994.7.25) published by the Japan Light Metal Association. For example, it is disclosed that an aluminum cloth is exposed with sandpaper or the like and bonded after a ground treatment with trichlene.
These technologies are mainly aimed at increasing the adhesive strength of aluminum materials, and by using the porous surface of the alumite layer for adhesion, the adhesive strength is achieved by the anchor effect of the adhesive on the porous part. It was about getting.
[0006]
By the way, when a panel is formed by aligning a plurality of extruded shapes made of an aluminum alloy to form a panel, the following two methods (1) and (2) can be considered.
(1) Extruding the shape with an extruder → Adhesion process → Anodizing process → Electrodeposition coating process
(2) Extruding the shape with an extruder → Anodizing process → Adhesion process → Electrodeposition coating process
In the methods (1) and (2), the adhesive deteriorates due to the immersion of the shape material in the anodizing bath and the solvent during electrodeposition coating. Therefore, when manufacturing panels, it becomes difficult to operate with surface treatment equipment. It has the problem that cases arise. Further, in the method (2), there is a problem that the manufacturing process becomes complicated as a whole because an adhesion process is included in the middle of the anodizing treatment process and the electrodeposition coating process performed continuously on the surface treatment line. . In general, an extruded shape is often used after being anodized and electrodeposited. This is to provide a glossy appearance and make it difficult for dirt to adhere to the surface.
[0007]
[Problems to be Solved by the Invention]
The present invention solves the problems in the prior art as described above, and provides a panel capable of strongly and surely joining a plurality of aluminum alloy extruded shapes with an adhesive, and a manufacturing method for obtaining such a panel. This is the issue.
[0008]
[Means for Solving the Problems]
In order to solve the above-mentioned problems, the present inventors have conducted intensive research and investigations, and as a result, the adhesive strength between extruded shapes of aluminum alloys whose surfaces are coated with an anodized film layer and an electrodeposition film layer, This was obtained by finding the knowledge that the profile of the plain aluminum surface is only slightly lower than that of the shape members on the surface.
That is, the panel of the present invention is formed by joining a plurality of extruded shapes made of an aluminum alloy and having a flat cross section, and an anodized film layer is formed on the outer surface including the surfaces of the joint portions facing each other. Is formed, and the electrodeposition coating layer is coated thereon, and the electrodeposited coating layers are bonded together with an adhesive, whereby the above-mentioned shapes are bonded to each other. .
[0009]
According to this, since the adhesive is interposed between the electrodeposition coating layers and the two shape members are firmly bonded to each other, substantially the same adhesive strength as that in the case of bonding the plain aluminum surfaces can be obtained. Therefore, it is possible to form a strongly bonded panel only with the adhesive. In addition, since each shape has an anodized film layer formed on the surface and an electrodeposition coating layer is further coated thereon, a panel having high performance in both corrosion resistance and appearance gloss is obtained. be able to.
[0010]
Moreover, the panel which each has a concave cross-sectional shape and a convex cross-sectional shape which fit each other so that each joint part which the said shape members oppose with each other so that tearing force or peeling force may not act with respect to the said adhesive agent is also contained.
In general, the tearing force and tearing force are significantly smaller than the tensile strength and tensile shearing force among the breaking strengths of the bonded portion by the adhesive. However, according to the panel, even if a pair of extruded extruded members are subjected to a tensile load in a direction away from each other, a tearing force or a peeling force does not act on the joint where the adhesive is located. There is no breakage at the joint. Rather, depending on the case, it is possible to ensure that the joint has a high strength to such an extent that breakage occurs in the middle of any extruded profile, and it is possible to ensure safety as a panel structure. .
Note that the tearing force is the case where the plate materials are bonded together, and the external force that pulls each plate material in the out-of-plane direction of the bonding surface with respect to the bonding surface, the peeling force is bonded repeatedly. This is an external force that peels one plate member between the two plate members in the direction out of the bonding surface.
[0011]
Further, each of the joint portions facing each other has a cross-sectional shape having rigidity higher than that of other portions of the shape member, so that the tearing force or the peeling force acts on the joint portion. Also included is a panel that makes it harder to do.
According to this, since the adhesive is applied along the tensile shear surface in the direction of separating the extruded profiles to be joined, for example, as a joint having a male / female fitting-type cross section having high rigidity, the tearing force is applied. Or it becomes possible to set it as the panel which has big adhesive strength without peeling force acting.
On the other hand, when any one of the joined sections has a cross-sectional shape having rigidity lower than that of the other part of the profile, the tearing or peeling force is applied to the joint. Panels made difficult to work are also included.
According to this, before the tensile shearing force acts, one of the bonded members is deformed at an intermediate portion other than the joining portion, so that the tearing force or the peeling force acts on the joining portion (adhesive). Can be avoided.
[0012]
Moreover, the panel by which the junction part joined by the said adhesive agent satisfy | fills following Numerical formula 3 with respect to the tensile strength W calculated | required by the panel is also contained.
[0013]
[Equation 3]
τ × Σx ≧ W
[0014]
According to this, it is possible to easily form a panel having a bonded portion having an adhesive strength higher than the tensile strength that separates the joined shapes from each other, and to make a safe panel. In Equation 3, τ is the tensile shear strength (N / mm at the joint between the profiles).²), Σx is the total value (mm) of the length of the bonded portion in the cross section of the bonded portion, and W is the tensile strength per unit length required for the direction in which the bonded shapes are separated from each other (N / mm).
[0015]
Furthermore, the panel by which the junction part joined by the said adhesive satisfy | fills following Numerical formula 4 with respect to the cross-sectional shape of each said joined shape member is also contained.
[0016]
[Expression 4]
σ_0.2× t ≧ τ × Σx
[0017]
According to this, even if a pair of extruded profiles to be joined receive a tensile load in a direction away from each other, it is possible to easily and reliably obtain a panel that is not easily broken at the joint where the adhesive is located.
In Equation 4, σ_0.2Is the 0.2% proof stress of the profile itself (N / mm²), T is the minimum value (mm) of the total thickness values in the cross section perpendicular to the spacing direction of the shapes excluding the joint, and τ is the tensile shear strength (N / mm²), Σx represents the total value (mm) of the length of the bonded portion in the cross section of the bonded portion.
[0018]
In addition, a panel is also included in which the electrodeposition coating layer is obtained by coating the shape material with the anodized coating layer and washing with hot water, and then electrodepositing an acrylic resin and baking. Thereby, since the electrodeposition coating layer is formed on the anodic oxide coating layer in the unsealed state, the coating layer can be firmly coated. Therefore, a panel in which the tensile shear strength and the like of the adhesive for joining the shape members is the same as that in the case of the aluminum substrate can be obtained.
In addition, a panel in which the adhesive is a two-component room-temperature curable adhesive made of an epoxy resin or an acrylic resin is also included. According to this, it becomes possible to reliably give the above-described tensile strength between the joint portions of the extruded profiles joined by the adhesive.
[0019]
On the other hand, the method for producing a panel of the present invention is a method for producing a panel formed by joining a plurality of extruded shapes made of an aluminum alloy and having a flat cross section, and an anodized film layer is formed on the surface of the shaped material. The anodizing step to be generated, the electrodeposition coating step for coating the surface of the anodized film layer in the above shape with the electrodeposition coating layer, and the electrodeposition coating layers on the surface of the joint portion facing each other And an adhesive step in which the adhesive is cured after the adhesive is applied and the profiles are brought into close contact with each other.
According to this, the adhesive applied between the adjacent extruded profiles is not affected by anodizing treatment or electrodeposition coating, and a shear strength, etc., substantially equal to that in the case of bonding between plain aluminum surfaces can be obtained. Therefore, it is possible to reliably manufacture a panel in which a plurality of extruded shapes are firmly joined only by an adhesive. In addition, excellent corrosion resistance and appearance gloss can be obtained, and the adhesive does not deteriorate when it comes into contact with the anodizing solution or electrodeposition solvent as in the past, so the required adhesive strength can be obtained reliably. It becomes.
[0020]
In addition, the electrodeposition coating process includes a panel manufacturing method that is performed after the anodized film layer generated by the anodizing treatment process is washed with hot water.
According to this, since the electrodeposition coating layer is firmly adhered to the unsealed anodic oxide coating layer, even if a tensile shear force acts between the joined extruded shapes, the coating layer and the coating layer Can be reliably prevented. Accordingly, high tensile shear strength can be provided between the extruded profiles in the panel.
[0021]
DETAILED DESCRIPTION OF THE INVENTION
In the following, preferred embodiments of the present invention will be described with reference to the drawings.
FIG. 1 (A) shows the state of a tensile test performed to obtain the panel of the present invention.
First, a pair of plate pieces (length 100 mm × width 25 mm × plate thickness 1.5 mm) 1a and 1b are prepared from an aluminum alloy (A6063-T5) based on JIS K6850 “Tensile shear bond strength test method for adhesive”. did. As shown in FIG. 1 (A), a two-component epoxy adhesive (trade name: Araldite (resin: Aw106, curing agent: HV953U) of Nagase Ciba) on the adhesive surface 6 having a length of 12.5 mm in the left-right direction. 8 was applied to adhere the plate pieces 1a and 1b.
The plate pieces 1a and 1b are preliminarily coated with an anodic oxidation (sulfuric acid) film layer 2 having an average thickness of 5 μm and an electrodeposition coating film layer 4 made of an acrylic resin and having an average thickness of 10 μm. The electrodeposition coating layer 4 is coated in an unsealed state where the coating layer 2 is formed and washed with hot water, and is baked at 180 ° C. for 30 minutes.
[0022]
Further, the adhesive surfaces 6 and 6 of the plate pieces 1a and 1b of the invention example to which the adhesive 8 is applied are degreased with acetone, and then the thickness of the adhesive 8 is made constant between the adhesive surfaces 6 and 6. Therefore, a pair of steel wires having a wire diameter of 0.1 mm was inserted in parallel and the adhesive 8 was applied. The curing condition of the adhesive 8 was maintained at room temperature for 3 days.
On the other hand, the plate piece of Comparative Example 1 having the same material and size as the plate pieces 1a and 1b has an aluminum base on the surface without the coating layer 2 or coating layer 4, and is preliminarily made of 240 mesh sandpaper. After the adhesive surface 6 was finish-polished, the adhesive 8 was applied and adhered under the same conditions as described above. Further, the plate piece of Comparative Example 2 having the same material and size as the plate pieces 1a and 1b is similar to the above in the unsealed state in which only the oxide film layer 2 is coated on the surface and washed with hot water. The adhesive 8 was applied and adhered under the conditions.
Based on the tensile shear strength test method for adhesive (JIS K6850-1994) for each of the five pieces of the invention example and each of the plate pieces (1a, 1b) of Comparative Examples 1 and 2, the arrows in FIG. Along the direction, the tensile speed was 2 mm / min. The results are shown in Table 1.
[0023]
[Table 1]

[0024]
The results in Table 1 were tensile shear strengths in the order of “Comparative Example 2> Comparative Example 1> Invention Example”, but were substantially equivalent. That is, it has been found that, although the adhesive strength according to the invention example does not obtain the maximum strength, a panel having a practical adhesive strength can be obtained by using a predetermined adhesive area.
In addition, various adhesive strengths according to the method of applying the tensile force on the bonding surface were measured using test pieces that were bonded using the same plate pieces as in the inventive examples and bonded under the same method and conditions.
The results are shown in Table 2. In addition, the tensile strength in Table 2 used the square bar tensile test piece based on "The tensile strength test method of an adhesive / JISK6849-1994". The tensile shear strength was obtained by the test method shown in Table 1 above. Both tests were performed on 5 sets of specimens.
[0025]
[Table 2]

[0026]
The results in Table 2 were found to be “tensile strength> tensile shear strength”. Although the tear strength results are not shown in Table 2, it is about 10% of the tensile shear strength, and it is already known that the tear strength can be torn or peeled off with a considerably small external force.
FIG. 1 (B) shows a state where a pair of extruded shape members 10a and 10b made of an aluminum alloy (A6063-T5) are bonded on the basis of the test results. The shape members 10a and 10b have a flat hollow rectangular portion 12 with a flat cross section, and have an adhesive surface composed of large and small vertical end surfaces 14 and 16 and a horizontal surface 15 between them, and have an average thickness over the entire surface. An anodized film layer 2 having a thickness of 5 μm and an electrodeposition coating film 4 having an average thickness of 10 μm are coated.
As shown in FIG. 1 (B), a two-component epoxy adhesive 18 similar to the adhesive 8 is applied to the adhesive surfaces (14, 15, 16) previously degreased with acetone in any of the shapes 10. Similarly, the other degreased member 10 is bonded point-symmetrically as shown.
[0027]
By the way, in FIG. 1 (B), among the adhesive 18 that is fixed and cured in a substantially Z-shaped cross section, the tensile shear strength that substantially resists the tensile force separating the members 10a and 10b from each other is between the horizontal planes 15. Obtained by the sandwiched horizontal portion 18a. As shown in Table 2, the tensile strength (W) is larger than the tensile shear strength (τ) at the bonded portion. In other words, when an adhesive strength equivalent to the tensile shear strength is obtained by the adhesive 18 with respect to the required tensile strength, a tensile strength higher than that is always obtained. Strength will be obtained.
Accordingly, in FIG. 1B, the total value (Σx (mm)) of the length of the illustrated horizontal portion 18a and the length of the pair of vertical portions 18b of the adhesive 18 and the joint portion of the profile members 10a and 10b. Tensile shear strength (τ (N / mm²)), As shown in Formula 5, the tensile strength per unit length (W (N / mm)) along the depth direction in FIG. It will be understood that there will be no problem.
[0028]
[Equation 5]
τ × Σx ≧ W
[0029]
Further, in FIG. 1 (B), the total thickness (t (mm)) of the cross section in the middle part of the shape members 10a and 10b and the 0.2% proof stress (σ of the shape members 10a and 10b themselves._0.2(N / mm²))), The tensile shear strength (τ (N / mm²)) And the total value (Σx (mm)) of the lengths of the horizontal portions 18a and the vertical portions 18b, it can be understood that the adhesive strength is more sufficient if the value is equal to or greater than the product.
[0030]
[Formula 6]
σ_0.2× t ≧ τ × Σx
[0031]
On the other hand, as shown in FIG. 1B, when the thickness of the bonding portion E1 of the left shape 10a is thin, the bonding portion E1 is deformed by the tensile force W applied to the intermediate portion E0 of the shape 10a. Then, a tearing force H in the direction of the arrow is applied to the bonded portion. Since the adhesive strength with respect to the tearing force H is low as described above, there is a problem that the adhesive 18 starts to peel off from the upper end portion thereof and propagates to the entire adhesive portion to break.
That is, it is not a cross-sectional shape in which the tearing force H is likely to act like the shape members 10a and 10b, but a joint portion having a concave cross-sectional shape and a convex cross-sectional shape that are fitted with each other, and the other part of the shape member It is necessary to have a cross-sectional shape with higher rigidity.
[0032]
FIG. 2 (A) shows a panel 20a in which extruded shape members 20, 20 having such joint portions 21a, 21b at both left and right ends are joined. FIG. 2A shows a cross section cut in a direction orthogonal to the extrusion direction of each profile 20. The profile 20 is made of the same aluminum alloy as described above, and has a hollow section 22 having a flat cross section and a substantially rectangular shape, and a male joint 21a having a convex cross section having a convex section 24 at the center of the right end face 23. And a concave female joint portion 21b having a concave cross-sectional shape having a concave portion 26 between a pair of upper and lower convex ridges 27 on the left end face.
As shown in FIG. 2 (A), the end surfaces 23 of the joint portions 21a and 21b and the projections 27 come into contact with each other, and the projections 24 and the recesses 26 are fitted into a male and a female.
[0033]
As shown in FIG. 2A, the entire surface is preliminarily coated with an anodic oxide coating layer 2 having an average thickness of 5 μm and an electrodeposition coating layer 4 having an average thickness of 10 μm. After degreasing the joints 21a and 21b in the adjacent shape members 20 and 20 with acetone in advance, as shown in FIG. 2 (A), a two-component epoxy adhesive 28 similar to the adhesive 8 is applied to either After the application to the joint portion, the other shape member 20 is bonded with the end face 23 and the projection 27 contacting each other as shown in the figure, and the projection 24 and the recess 26 are fitted to each other.
In addition, the plate | board thickness of each part in junction part 21a, 21b is made into thickness about 2 to 5 times the plate | board thickness of an intermediate part, and makes junction part 21a, 21b cross-sectional shape higher in rigidity than an intermediate part.
[0034]
In FIG. 2A, the adhesive 28 receives a tensile force W that separates the shape members 20 and 20 left and right in the length (Σx) that extends over the entire cross section calculated by the following mathematical formula 7.
That is, if the value (τ × Σx) obtained by multiplying the total length (Σx) of the bonded portion by the tensile shear strength (τ) is equal to or greater than the tensile force (W) as shown in Equation 5, the bonded portion as described above. Since the tensile strength per unit length is greater than the tensile shear strength, an adhesive strength greater than the required tensile force (W) can be obtained.
[0035]
[Expression 7]
Σx = 2 × (x₁) + 2 × (x₂) + X_Three
[0036]
In addition, as shown in Equation 6, the thickness (t = t / 2 × 2) of the middle part of the shape members 20 and 20 and the 0.2% proof stress (σ_0.2) Is equal to or greater than the product (τ × Σx) of the total length (Σx) of the bonded portion and its tensile shear strength (τ), the required bonding strength can be reliably obtained. In addition, since the joint portions 21a and 21b to which the shape members 20 and 20 are bonded are thicker than other portions in which the hollow portion 22 is provided, the joint portions 21a and 21b have a highly rigid cross-sectional shape and are mutually male.・ Tearing force H and peeling force do not act by fitting female. Therefore, it is possible to obtain a panel having a stable bonding strength by designing in advance so as to retain at least the value (τ × Σx) calculated by Equation 6.
[0037]
Here, a method for manufacturing the panel 20a will be described. As shown in FIG. 2B, the shape member 20 is first extruded using an extruder (not shown). The cross section of the shape member 20 is designed in advance so as to satisfy the conditions of Equations 5 and 6, and a web 25 that divides the hollow portion 22 into two is integrally attached to the center of the hollow portion 22 as necessary. Yes.
Next, after cutting the shape member 20 into a length corresponding to the panel 20a, anodizing treatment is performed. The shape members 20 and 20 whose surfaces have been degreased in advance are supported by an electrode (not shown) and immersed in a treatment liquid in a treatment tank, and an anodized film layer 2 is formed by a known method as shown in FIG. It is generated on the surface of the material 20. The coating layer 2 has a thickness of about 5 to 20 μm. The shaped member 20 taken out from the treatment tank is washed with hot water of about 80 ° C. so that a large number of pores on the surface of the oxide film layer 2 are not completely sealed.
Further, the shape member 20 is supported on another electrode and immersed in an electrodeposition liquid of an acrylic resin paint in an electrodeposition treatment tank (not shown), and electrodeposition (electropermanent) coating is performed by a known method.
As a result, as shown in FIG. 3B, the entire surface of the coating layer 2 of the profile 20 is coated with the electrodeposition coating layer 4 made of acrylic resin and having a thickness of about 10 μm. Finally, the shape member 20 is heated at about 160 to 190 ° C. for about 30 minutes to be baked to cure and stabilize the coating layer 4. The anodic oxide coating layer 2 and the electrodeposition coating layer 4 are processed by a continuous surface treatment line.
[0038]
And after degreasing the shape materials 20 and 20 which have the oxide film layer 2 and the electrodeposition coating film layer 4 with acetone as mentioned above, it adjoins so that junction part 21a, 21b may mutually oppose, Adhesive 28 is applied to either 21a or 21b. The adhesive 28 is a two-component room temperature curable adhesive made of an epoxy or acrylic resin.
In a state where the joint portions 21a and 21b of the adjacent shape members 20 and 20 are male-female-fitted and joined via the adhesive 28, the shape members 20 and 20 are bonded to the thickness of the adhesive 28 by an appropriate pressing jig. Fix so that is appropriate. In such a fixed state, the adhesive 28 is held for about 2 to 3 days, and the adhesive 28 is cured to stabilize its adhesive force. Thereby, as shown in FIG. 2A, the panel 20a in which a plurality of shapes 20 are joined by the adhesive 28 can be obtained.
[0039]
FIG. 4A shows an extruded profile 30 of a different form. This profile 30 is also made of the same aluminum alloy as described above, and has a male section 31 having a flat section and a substantially rectangular hollow section 32, and a convex section 34 having a trapezoidal section in the center of the end face 33 at the right end. The left end face has protrusions 37, 37 that are substantially trapezoidal in cross section and symmetrical in the vertical direction, and a female joint portion 35 having a trapezoidal concave section 36 located therebetween. As shown in the drawing, the convex portions 34 and the concave portions 36 of the joint portions 31 and 35 can be fitted into a male and a female. In addition, as shown in FIG. 4 (a), the entire surface is previously coated with the anodic oxide coating layer 2 having an average thickness of 5 μm and the electrodeposition coating layer 4 having an average thickness of 10 μm by the method described above. Has been. In addition, the plate thickness of each part in the joint portions 31 and 35 is thicker than the intermediate portion, and has a cross-sectional shape with high rigidity.
[0040]
FIG. 4B shows a cross section of a panel 30a obtained by joining the shape members 30,30. After degreasing the joints 31 and 35 in the adjacent shape members 30 and 30 with acetone in advance, as shown in FIG. 4 (B), a two-component epoxy adhesive 38 similar to the adhesive 8 is applied to any one of them. The other profile 30 is applied to the joint, and the end face 33 and the projection 37 are brought into contact with each other as shown in the figure, and the projection 34 and the recess 36 are fitted into a male and female to be bonded and hardened. Thereby, the said panel 30a which joined the some shape material 30 with the adhesive agent 38 can be obtained. Note that the total length Σx of the bonded portion is the two x shown in FIG.₂One x_Three, And two x_FourIt is calculated by the total value of
[0041]
FIG. 5A shows a cross section of the joint portions 41 and 45 of the extruded shape member 40 having a different form.
The shape member 40 is also made of the same aluminum alloy as described above, and includes a hollow portion 40a having a substantially rectangular cross section as shown in FIG. At the right end of the shape member 40, there is a groove 43 having a triangular cross section at the center of the end surface, and convex ridges 42, 42 protruding in parallel with the upper and lower sides thereof, and a step 44 between the outer surface. Are provided.
Further, at the left end of the shape member 40, a ridge 46 having a triangular cross section at the center of the end face, concave grooves 47, 47 parallel to each other in the upper and lower cross section of the cross section, and a bent portion 48 connected to the upper and lower sides thereof. A joint portion 45 having a pair of flanges 49 and 49 protruding in parallel with the outer surface is provided. As shown in FIG. 5A, the surface of the shape member 40 is previously coated with the anodic oxide coating layer 2 and the electrodeposition coating layer 4 in the same manner as described above.
[0042]
After degreasing the joint portions 41 and 45 in the plurality of shape members 40, the same adhesive S as described above is applied to the joint portion 41 as shown in FIG. Next, as shown in FIG. 5B, the joint portions 41 and 45 of the shape members 40 and 40 are joined. That is, the ridge 46 is fitted in the groove 43, the ridge 42 is fitted in each groove 47, and the flange 49 is positioned on the step 44. In addition, between the joint portions 41 and 45, the shape members 40 and 40 come into contact with each other at a portion K in FIG. 5B, so that the left and right shape members 40 and 40 are joined with the adhesive S at an appropriate interval. is doing. As a result, it is possible to form a panel composed of a plurality of shape members 40.
5B, between the joints 41 and 45, between the bottom of the groove 43 and the tip of the ridge 46, between the bottom of each groove 47 and the tip of the ridge 42, and A gap F having a required cross-sectional area is located between each protrusion 42 and the bent portion 48, and the excess adhesive S is received. Further, as shown in FIG. 5B, the total length of the adhesive S between the joint portions 41 and 45 is used as Σx in the equations 5 and 6. However, since the thickness of the adhesive S is larger than the appropriate value in the gap F in FIG. 5B, the length Σx is calculated excluding the gap F.
[0043]
FIG. 6A illustrates the entire cross section of the extruded profile 40. That is, the shape member 40 has joint portions 41 and 45 at both ends, a pair of curved pieces 40b and 40c that are curved in parallel with each other, and a flat hollow portion 40a sandwiched between them. As shown to 6 (a), it has the anodic oxide film layer 2 and the electrodeposition coating film layer 4 on the surface. As shown in FIG. 6B, the joint portions 41 and 45 of the adjacent shape members 40 and 40 are sequentially joined. As a result, as shown in FIG. 4C, a panel 40d in which a plurality of shape members 40 are joined can be formed. As shown in the figure, the panel 40d forms a curved surface with a continuous curve, and can be used as a roof unit such as a shelter for protecting pedestrians from rainwater in front of a station or in a shopping street.
[0044]
The present invention is not limited to the embodiments described above.
In the shape members 20, 30, and 40 shown in FIGS. 2 to 6, the cross-sectional shapes of the joint portions 21a and 21b and the like are higher in rigidity than that of the intermediate portion. For example, as shown in FIG. By using the extruded shape member 50, the panel 50a in which the tearing force H in the out-of-plane direction with respect to the bonding surface shown in FIG.
As shown in FIG. 7A, the shape member 50 is made of the same aluminum alloy as described above, and has a rectangular hollow portion 51 with a flat cross section, and protrudes from a thick end wall 53 at the right end in the figure. It has the joint part 52 which consists of a pair of thin and parallel ridges 54 and 54 provided. Further, at the left end, there is a joint portion 55 composed of concave grooves 56 and 56 positioned above and below the central convex portion 57 between the end walls 58 and 58. The joint portion 55 composed of the pair of concave grooves 56 is thicker than the intermediate portion of the shape member 50. As shown in FIG. 7 (a), the shape member 50 is preliminarily coated with an anodic oxide coating layer 2 and an electrodeposition coating layer 4 on its surface.
[0045]
As shown in FIG. 7A, a panel 50a is obtained by joining the joints 52 and 55 with an adhesive 59 in the same manner as described above. Since each ridge 54 is the thinnest and has a cross-sectional shape having a lower rigidity than the other portions of the shape member 50, the tearing force H and the peeling force in the direction of the arrow shown in FIG. No longer works.
In other words, the extruded shape forming the panel of the present invention has a concave / convex cross section having a rigid cross-sectional shape than the other parts in order to make it difficult for the tearing force H or the like to act when bonded at the joint. It is possible to use a flexible cross-sectional shape in which the main body of the shape is deformed before the tearing force H or the like acts on one shape.
[0046]
Further, instead of the curved pieces 40b and 40c between the joint portions 41 and 45 illustrated in FIG. 6A, an extruded shape member having a pair of bent pieces that are parallel to each other and bent into a substantially H-shaped cross section, and It is also possible to form a panel in which the cross section joined through the adhesive S exhibits a zigzag shape so that the adjacent bent pieces of the shape members have a continuous zigzag shape. Alternatively, an extruded shape member having a pair of bent pieces bent in the above-mentioned substantially H-shaped cross section at the center serving as a ridge portion, and a plurality of shape members having straight side pieces between the joint portions 41 and 45 on both sides thereof are used. By joining via S, it is also possible to form a roof panel whose entire cross section has a substantially square shape. Of course, a side piece having an arbitrary cross-sectional shape can be disposed between the joint portions 41 and 45, and a part of the side piece is formed into a shape in which the side piece is located only on one side without the hollow portion 40a. Is also possible.
[0047]
【Example】
Here, a specific embodiment of the present invention will be described with reference to the panel 60 of FIG.
As shown in FIG. 7B, the extruded shape member 61 forming the panel 60 is made of an aluminum alloy (JIS: A6063) and subjected to T5 heat treatment. This shape member 61 has a flat hollow rectangular portion 62, a male joint portion 63 having a convex cross-sectional shape having an end wall 65 at its right end and an elongated ridge 64 at its center, and an end wall 67 at its left end. And a female joint portion 66 having a concave cross-sectional shape having an elongated concave groove 68 at the center thereof. In FIG. 7B, the overall width of the shape member 61 is 270 mm, the thickness T in the vertical direction is 25 mm, the thickness t of the intermediate portion is 2.5 mm, the thickness of each joint 63, 66 is 6 mm, and convex. The length L in the left-right direction of each inclined surface of the strip 64 and the concave groove 68 is 20 mm. Furthermore, the 0.2% proof stress of the shape member 61 is 145 N / mm.²The tensile strength is 190 N / mm as measured.²It is.
[0048]
After the above-described shape member 61 was extrusion-molded, an anodized film layer 2 having an average film thickness of 7 μm was generated by sulfuric acid anodizing treatment, and washed with hot water at about 80 ° C. The shape member 61 having the unsealed film layer 2 was subjected to electrodeposition coating with an acrylic thermosetting resin, and the electrodeposition coating layer 4 having an average film thickness of 10 μm was coated on the film layer 2. Then, the said coating layer 4 was hardened by performing the baking process which heats at about 160 to 190 degreeC for 30 minutes.
Ten sections 61 having the coating layer 2 and the coating layer 4 were cut at a length of 50 mm along the extrusion direction (the depth direction on the paper surface) shown in FIG. After degreasing the joints 63 and 66 of each shape member 61 with acetone, a two-component epoxy adhesive (trade name of Nagase Ciba: Araldite (resin: Aw106, curing agent: HV953U)) 69 is applied, and FIG. As shown in FIG. 7 (B), a pair of shape members 61 were joined by male and female joints at joints 63 and 66. The average thickness of the adhesive 69 was 100 μm. The obtained 5 sets of test pieces were held for 7 days.
[0049]
A tensile test was performed in which the shape members 61 and 61 adhered in FIG. 7B were pulled along the left and right directions apart from each other on the five sets of test pieces. As a result, each set of test pieces was broken at the bonded portion, and the average breaking strength was 39200 N (784 N / mm). In addition, each shape member 61 produced elongation deformation at an intermediate portion excluding the joint portions 63 and 66.
By the way, the total length Σx of the adhesive portion in each test piece is the three vertical portions x of the adhesive 69 shown in FIG.₂, x₂, x_Three(5mm × 3) and a pair of inclined parts x_FourIt is the sum of (20.6 mm × 2). When the product of this and the shear strength (τ) was obtained based on the above Equation 5, the value shown at the right end of the following Equation 8 was calculated.
[0050]
[Equation 8]
τ × Σx = 12.7N / mm²× ((5 mm × 3) + (20.6 mm × 2)) = 714 N / mm
[0051]
On the other hand, the yield strength limit per 1 mm in length along the paper surface depth direction shown in FIG. 7B of the shape member 61 itself is 725 N / mm, and the breaking limit strength is 950 N / mm.
In addition, the actual strength (784 N / mm) measured with the test piece was higher than the product value (714 N / mm) of the shear strength (τ) calculated by Expression 8 and the total length Σx of the bonded portion. This is because the strength is calculated by the tensile shear strength in Formula 8, but the tensile strength is larger than the tensile shear strength, and it is considered that the increase is taken into account. Therefore, the value calculated by Equation 8 using the tensile shear strength (τ) sufficiently guarantees the safety when designing the adhesive strength in the panel 60 obtained by adhering the shape members 61 and 61. Confirmed to get.
[0052]
【The invention's effect】
According to the panel of the present invention described above, the adhesive is interposed between the electrodeposition coating layers, and both shapes are firmly bonded, and the adhesive strength is substantially equal to the case of bonding between plain aluminum surfaces. Therefore, it is possible to form a panel in which a plurality of extruded shape members are firmly joined only by an adhesive. In addition, since each of the shapes is coated with the anodic oxide coating layer and the electrodeposition coating layer, a panel having both high corrosion resistance and appearance gloss can be obtained. And the surface treatment normally used for an aluminum material can also be utilized as it is.
Moreover, according to the panel of Claims 2 thru | or 4, since it has the junction part which can resist strongly with respect to tearing force or peeling force, or these junction parts cannot act easily, the stable joining by an adhesive agent is obtained. be able to.
Furthermore, according to the panels of claims 5 and 6, it is possible to easily use an extruded profile having a required adhesive strength and cross-sectional shape for a joint portion to be joined with a required tensile strength or adhesive. It can be set as the panel which has the stable adhesive strength.
[0053]
On the other hand, according to the method for producing a panel of the present invention, the adhesive applied between the extruded shapes is not affected by anodizing treatment or electrodeposition coating, and is substantially equivalent to the case of bonding between plain aluminum surfaces. Since the adhesive strength can be obtained, it is possible to reliably manufacture a panel in which a plurality of extruded shapes are firmly joined only with an adhesive. In addition, corrosion resistance and appearance gloss can be obtained, and since the adhesive does not deteriorate upon contact with the anodizing solution or the electrodeposition coating solvent as in the prior art, the required adhesive strength can be reliably obtained. In addition, the surface treatment facilities and processes normally used for aluminum materials can be utilized as they are.
Further, according to the manufacturing method of claim 10, since the electrodeposition coating layer adheres firmly to the unsealed anodic oxide coating layer, even if a tensile shear force acts between the joined extruded shapes, Breakage between the coating layer and the coating layer can be reliably prevented.
[Brief description of the drawings]
FIG. 1A is a schematic diagram showing a state of a tensile test performed with a plate piece to obtain a panel of the present invention, and FIG. 1B is a schematic diagram showing an action of an adhesive and the like at a joint between extruded profiles. .
2A is a partial cross-sectional view showing a panel of the present invention, FIG. 2A is an enlarged view of an alternate long and short dash line portion a in FIG. 2A, and FIG. 2B is a cross-sectional view of an extruded profile forming this panel; .
3A is a partial cross-sectional view showing a state in which the surface of the shape member in FIG. 2B is subjected to anodizing treatment, and FIG. 3B shows a state in which electrodeposition coating is applied. FIG.
4A is a partial cross-sectional view of different extruded shapes, FIG. 4A is an enlarged view of a dashed line portion a in FIG. 4A, and FIG. 4B is obtained by joining the shapes of (A) together. FIG.
5A is a partial cross-sectional view showing joints of extruded shapes having different forms, FIG. 5A is an enlarged view showing an alternate long and short dash line part a in FIG. 5A, and FIG. The fragmentary sectional view which shows the state joined by the adhesive agent.
6A is a cross-sectional view of an extruded profile having the joint portion of FIG. 5 at both ends, FIG. 6A is an enlarged view showing an alternate long and short dash line portion a in FIG. 5A, and FIG. The fragmentary sectional view which shows the joining state of (C), (C) is sectional drawing of the panel formed by joining a plurality of the shape materials concerned.
7A is a partial cross-sectional view of a panel in which extruded shapes having different forms are joined to each other, FIG. 7A is an enlarged view showing an alternate long and short dash line portion a in FIG. 7A, and FIG. The fragmentary sectional view which shows the extruded shape material of an Example, and the panel which joined this.
[Explanation of symbols]
2 ………………………………………………………………………… Anodized film layer
4 ……………………………………………………………………… Electrodeposition coating layer
18,28,38, S, 59,69 ……………………………………… Adhesive
10a, 10b, 20, 30, 40, 50, 61 ……………………… Extruded profile
20a, 30a, 40d, 50a, 60 ……………………………… Panel
21a, 21b, 31, 35, 41, 45, 52, 55, 63, 66 ... junction
H ……………………………………………………………………… Tear force

Claims (10)

Formed by joining a plurality of extruded shapes made of aluminum alloy and having a flat cross section,
An anodized film layer is formed on the outer surface including the surface of each joint portion facing each other, and an electrodeposition coating layer is coated thereon, and the electrodeposition coating layer is bonded with an adhesive. By doing so, the above-mentioned shape members are joined to each other. The respective joint portions facing each other between the shape members have a concave cross-sectional shape and a convex cross-sectional shape that are fitted to each other so that a tearing force or a peeling force does not act on the adhesive. The panel according to 1. Each of the joint portions facing each other has a cross-sectional shape having rigidity higher than that of other portions of the shape member, so that the tearing force or the peeling force hardly acts on the joint portion. Become
The panel according to claim 1 or 2, characterized in that Any one of the joined parts has a cross-sectional shape having rigidity lower than that of the other part of the shape, so that the tearing force or the peeling force acts on the joint part. Made difficult
The panel according to claim 1 or 2, characterized in that The joint joined by the adhesive satisfies the following formula 1 with respect to the tensile strength W required for the panel.
The panel according to claim 1, wherein:
[Expression 1]
τ × Σx ≧ W
Here, τ is the tensile shear strength (N / mm ² ) at the joint between the profiles, Σx is the total length (mm) of the bonded portion in the cross section of the joint, and W is the shape between the joined profiles. The tensile strength (N / mm) per unit length required for the directions away from each other is shown. The joint joined by the adhesive satisfies the following mathematical formula 2 with respect to the cross-sectional shape of each joined shape.
The panel according to any one of claims 1 to 5, wherein
[Expression 2]
σ _0.2 × t ≧ τ × Σx
Here, σ _0.2 is the 0.2% proof stress (N / mm ² ) of the profile itself, t is the minimum value (mm) of the total values of the thicknesses in the cross section perpendicular to the separation direction of the profiles, τ represents the tensile shear strength (N / mm ² ) at the joint between the shape members, and Σx represents the total value (mm) of the length of the bonded portion in the cross section of the joint. The electrodeposition coating layer is an anodized coating layer formed on the shape and washed with hot water, and then electrodeposited with an acrylic resin and baked.
A panel according to any one of claims 1 to 6, wherein The adhesive is a two-component room temperature curable adhesive made of an epoxy or acrylic resin,
The panel according to any one of claims 1 to 7, characterized in that A method of manufacturing a panel formed by joining a plurality of extruded shapes made of an aluminum alloy and having a flat cross section,
An anodizing treatment step for generating an anodized film layer on the surface of the shape material;
An electrodeposition coating process for coating the surface of the anodized film layer of the above-mentioned shape material with an electrodeposition coating layer;
An adhesive step between the electrodeposition coating films on the surfaces of the joints facing each other, and an adhesive step for curing the adhesive after the shapes are brought into close contact with each other.
A method for producing a panel, characterized by the above. The electrodeposition coating step is performed after washing the anodized film layer generated by the anodizing treatment step with hot water,
The panel manufacturing method according to claim 9.

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