JP5054887B2 - Drilling roll, multi-fine hole metal material manufacturing apparatus, multi-fine hole metal material manufacturing method, multi-fine hole metal material - Google Patents

Description

  The present invention relates to a perforating roll for manufacturing a multi-microporous metal material constituting a porous soundproof structure, a multi-porous metal material manufacturing apparatus and a multi-porous metal material manufacturing method using the same, and The present invention relates to a manufactured multi-porous metal material.

In the past, various sound absorbing plates and sound insulating plates (hereinafter collectively referred to as “soundproof structures”) have been developed in order to increase the quietness of automobiles and soundproofing houses.
As a soundproof structure used in automobiles, for example, an insulator pad made of foamed urethane, fiber, glass wool, etc. on the back surface of the bonnet, or a silencer pad also made of foamed urethane or fiber between the engine room and the vehicle compartment Are widely used.
Such a soundproof structure reduces sound by diffusing sound in glass wool, fiber, and the like, and repeatedly reflecting the sound energy while converting it into thermal energy accompanied by vibration.

  Recently, in order to achieve higher silence, plate materials made of materials such as iron, aluminum, and synthetic resin that are arranged on the sound source side and have many fine holes (hereinafter referred to as “multi-fine” Of these materials, a plate made of metal is called a “multi-fine porous metal material”.), A plate provided facing the multi-fine porous material, and the multi-fine porous material There has been proposed a porous soundproof structure configured by providing an air layer between a metal plate and a plate material (see, for example, Patent Document 1).

  Further, in this Patent Document 1, if a sound absorption rate of 0.3 or more can be realized in a region where the sound pressure level is high (70 dB or more), sufficient sound absorption performance (a sound volume emitted from a sound source is sufficiently low to some extent). It is described that it is possible to obtain a sound absorbing performance that can be felt. For this reason, in Patent Document 1, a detailed study is made on the relationship between the hole diameter (diameter) of the fine hole (through hole) of the metal plate and the aperture ratio. For example, the diameter of the through hole is changed from φ3 mm to φ0.2 mm. It is described that it is preferable to set the aperture ratio to 3% or less.

  Furthermore, Patent Document 1 suggests that the smaller the hole diameter is, the larger the air viscosity action is, so that an excellent sound absorption effect (that is, sound absorption rate) can be exhibited. For example, it is known that when the hole diameter is close to φ0 mm, the peak of the sound absorption coefficient is theoretically close to 1.0 and excellent sound absorption performance can be exhibited.

For example, Patent Document 2 discloses an invention relating to a metal plate punching apparatus and a metal plate punching method as a technique that can efficiently drill such a multi-fine hole metal material.
An outline of such a metal plate punching apparatus is as follows. As shown in FIG. 6 (a), a disc 101 having a drilling blade portion 102 formed in a predetermined shape on the outer periphery and a disc 103 (so-called spacer) having no blade portion on the outer periphery. A disc-shaped roll 100 for punching metal plates formed by alternately fixing on the same axis, and a disc 111 having a recess 112 that matches the blade portion 102 of the disc 101, and a blade portion. A lower roll 110 is provided that is formed by alternately fixing discs 113 not on the outer periphery on the same axis. Then, the disc-shaped roll 100 for drilling the metal plate and the lower roll 110 are engaged with each other in a pair, and the metal plate 130 interposed between them is drilled by rotating these rolls in the same direction. To do.

  Moreover, as shown in FIG. 6B, the horizontal cross-sectional shape of the drilling blade portion 102 in use is substantially rectangular, and the vertical cross-sectional shape of the drilling blade portion 102 is The blade portion 102 is formed so as to draw a curved line that is high at the front and rear edges and gradually lower at the middle.

In the metal plate punching apparatus (not shown) provided with such a disk-shaped punch 100 for punching the metal plate, the disk-shaped roll 100 for punching the metal plate rotates and the leading edge of the punching blade portion 102 becomes the metal plate 130. A perforated metal plate is manufactured by perforating so as to “cut out” a part of the metal plate by biting, making a cut, and extending the cut along with the rotation of the drilling blade. As an example of this, rectangular holes having a length of 2.6 mm and a width of 1 mm are continuously drilled at intervals of 1.59 mm in a long metal strip having a thickness of 0.035 mm and a width of 65 mm. Specifically, it is specifically shown that a perforated metal plate having 30 rows perforated at intervals of 1.1 mm in the width direction can be manufactured.
JP 2003-50586 (paragraphs 0029, 0030, 0038, 0052, FIGS. 1 and 4) JP 2000-153322 A (paragraphs 0010 to 0016, 0023 to 0026, and FIGS. 1 to 8)

  However, the conventional perforating apparatus, for example, the metal plate perforating apparatus described in Patent Document 2, has the following problems. That is, the perforating blade portion 102 of the disc-shaped roll 100 for perforating a metal plate is characterized by being formed so as to draw a curve that is high at the front edge and the rear edge and gradually lower at the middle (FIG. 6). (See (b)), it was extremely difficult to form the blade portion 102 having such a size that can drill a fine hole having a hole diameter of φ3 mm or less, particularly φ0.5 mm or less.

  Conventionally, as described in Patent Document 1, it is described that it is very difficult to manufacture a micropore having a very small diameter such as φ0.2 mm. Furthermore, since it is not clarified in Patent Document 1 how to provide a fine hole to manufacture as a product, it is possible to continuously and efficiently manufacture a metal plate having such a fine hole. It is not something that can contribute.

  Therefore, the present invention continuously and efficiently manufactures a metal material (multi-fine hole metal material) having fine holes perforated with a maximum hole width exceeding 0 mm and not more than 3 mm, particularly not more than 0.5 mm. An object of the present invention is to provide a perforating roll that can be manufactured, a multi-porous metal material manufacturing apparatus and a multi-porous metal material manufacturing method using the perforating roll, and a multi-porous metal material manufactured by the apparatus.

The invention according to claim 1, which has solved the above problem, is composed of a pair of a metal metal roll having a protrusion and a receiving roll that receives a pressing force generated by the protrusion of the metal roll, and the metal roll and the metal roll A drilling roll for producing a multi-fine holed metal material constituting a soundproof structure in which a drilled metal material is interposed between a receiving roll and a shear hole is drilled in the drilled metal material, The height of the protrusion is 120% or more of the thickness of the metal material to be perforated, the rising angle of the protrusion from the surface of the metal roll is 90 to 135 °, and the tip of the protrusion of the metal roll is The maximum length of the width is greater than 0 mm and less than or equal to 3 mm, and the laying ratio of the metal roll is 1 to 3%. The receiving roll includes a metal axis, paper fibers around the axis, and Mixed cotton The metal roll is softened by adding water to the body, and then the metal roll on which the protrusion is formed is pressed to transfer the shape of the protrusion, and is dried and cured. It is configured as a perforating roll for producing a multi-porous metal material that constitutes a soundproof structure, which is a woolen roll provided with a recess that meshes with the projection of the above.
The invention according to claim 2, soundproof structure according to claim 1, characterized in that the maximum length of a width of the tip of the protrusion of the metal roll is formed below 0.5mm exceed 0mm It is constituted as a perforating roll for producing a multi-fine porous metal material constituting the body .

Here, the “perforated metal material” in the present invention refers to a metal foil or a metal thin plate, and the “metal foil” in the present invention refers to a metal material having a thickness of 0.2 mm or less. The “metal thin plate” means a metal material having a thickness exceeding 0.2 mm.
Further, in the present invention means a projection of the piercing rolls, the recesses of the receiving roll meshing with this drilled been pruning cross, the hole in the state with a burr or bulge as "pruning Dan'ana", such pruning a large number perforated metal material the Dan'ana referred to as a "multi-pruning Dan'ana metal material". A relatively flat hole after flattening such burrs and bulges is referred to as a “micro hole”, and a metal material provided with a large number of such micro holes is referred to as a “multi-fine hole metal material”.

In this way, in the piercing roll of the present invention constituted by a pair of metal rolls having protrusions and a receiving roll provided with a recess that meshes with the protrusions, the protrusions provided on the surface of the metal rolls The rise angle from the surface of the metal is set within an appropriate range, and the height of the protrusion is set to be 20% or more higher than the thickness of the metal material to be drilled. it can be drilled pruning Dan'ana by pruning cross to produce a multi-pruning Dan'ana metal material. In this case, the maximum length of the width of the tip of the protrusions 3mm less than the 0 mm, because more preferably is formed by 0.5mm or less, pruning provided been pruning cross by the take projections and recesses Dan'ana In this case, the maximum length of the hole width exceeds 0 mm and is 3 mm or less, more preferably 0.5 mm or less. Maximum length of the width of the hole is less than 3mm beyond the 0 mm, and more preferably be formed of the following pruning Dan'ana 0.5 mm, it flattened without eventually remove burrs or bulges by other means or processes, it is possible to form a smaller micropores than the pruning Dan'ana.
By thus flattening without removing burrs from a metal material with drilled pruning Dan'ana, can be provided with smaller micropores, it is possible to increase the viscosity effect of the air in such micropores It is possible to form a multi-fine porous metal material having high sound absorption performance.

  According to a third aspect of the present invention, the metal roll is configured as the punching roll on which a Cr plating film having an average film thickness of 5 to 20 μm is formed.

By forming a Cr plating film on the surface of the metal roll, it is possible to improve the surface of the metal roll, particularly the strength of the protrusions. Therefore, it is possible to prevent the protrusion of chipping and breaking drilling a pruning Dan'ana, it is possible to perforate the pruning Dan'ana while maintaining the predetermined size and predetermined shape over a long period of time.

According to a fourth aspect of the present invention, the soundproof structure according to any one of the first to third aspects is formed on the perforated metal material that has been transported by a transport means that transports the perforated metal material. Drilling a shear hole having a maximum hole width of more than 0 mm and not more than 3 mm with an opening ratio of 1 to 3% using a punch for punching a multi-fine hole metal material to produce a multi-shear hole metal material And flattening means for flattening a shear hole having a burr including a bulge portion bulging from a plane of the multi-shear hole metal material perforated by the perforation means to form a multi-hole metal material , in which burrs are configured as a multi-microporous metallic material for a manufacturing apparatus constituting the soundproof structure characterized by having a receiving means for receiving the multi-micropores metallic material having a flattened by the flattening means is there.

Thus, in the manufacturing apparatus for multi-porous metal material constituting the soundproof structure of the present invention, the metal material to be drilled, which is the object to be drilled by the transfer means, is transferred to the drilling means, and claims 1 to 3. A shear hole having a predetermined size and a predetermined shape is drilled in the drilled metal material by a punching means using the punch for manufacturing the multi-fine hole metal material constituting the soundproof structure according to any one of the above. Thus, a multi-shear pore metal material can be obtained. Then, by flattening without removing burrs including a bulging portion that bulges from the plane of the multi-shear hole metal material generated by the perforating means, the flattening means has micropores of a desired size. A multi-porous metal material can be manufactured continuously and efficiently.

The invention according to claim 5 is the transfer process of transferring the drilled metal material to the drilling process, and the drilled metal material transferred from the transfer process, according to any one of claims 1 to 3. A multi-shearing product in which a shear hole having a maximum hole width of more than 0 mm and not more than 3 mm is drilled at an aperture ratio of 1 to 3% using a multi-porous metal material manufacturing perforating roll constituting the soundproof structure described above The perforating step as a perforated metal material, and a shear hole having a burr including a bulging portion that bulges from the plane of the multi-shear perforated metal material by perforation in the perforating step is made into a fine hole by flattening the multi-porous metal material A multi-porous metal material constituting a soundproof structure , comprising: a flattening step for receiving the multi-porous metal material having a burr flattened in the flattening step ; It is a manufacturing method.

Thus, in the manufacturing method of the multi-fine hole metal material which constitutes the soundproof structure of the present invention, the metal material to be drilled is transferred to the drilling process in the transfer process, and has a predetermined size and a predetermined shape in the drilling process. Shear holes can be drilled. Then, in the flattening step, the shear holes formed at the flattened positions are flattened without removing the burrs including the bulging portion that bulges from the plane of the multi-shear hole metal material generated by the drilling. A multi-porous metal material can be continuously and efficiently produced by re-forming the micro-holes.

The invention according to claim 6 is manufactured using the perforating roll for manufacturing the multi-fine porous metal material constituting the soundproof structure according to any one of claims 1 to 3, and for sound absorption. A multi-porous metal material used, which is formed by drilling a shear hole having a burr including a bulging portion that swells from the flat surface of the metal material to be drilled at an aperture ratio of 1 to 3% and flattening the shear hole. The fine hole metal material constituting the soundproof structure is provided with a fine hole having a maximum length of a width of more than 0 mm and not more than 3 mm.

  With the multi-porous metal material having such a configuration, a large number of micro-holes having a small maximum hole width are provided in the metal material, so that a large air viscous action can be generated. . Therefore, the sound passing through the fine hole is attenuated by vibration of the air due to the viscous action of the air, so that the volume of the sound can be reduced.

If the perforating roll for manufacturing a multi-fine hole metal material constituting the soundproof structure according to the present invention is used, the maximum length of the hole width in the perforated metal material such as metal foil or metal thin plate is more than 0 mm and not more than 3 mm. It is possible to continuously and efficiently drill a shear hole, that is, a fine hole, at an opening ratio of 1 to 3%.
According to the manufacturing apparatus for multi-fine hole metal material constituting the soundproof structure according to the present invention, the maximum length of the hole width in the metal material to be perforated such as metal foil or metal thin plate by using this perforating roll. It is possible to produce a multi-sheared hole metal material (that is, a multi-fine hole metal material) by continuously and efficiently drilling fine holes having a diameter of more than 0 mm and not more than 3 mm at an opening ratio of 1 to 3%.
According to the method for producing a multi-fine hole metal material constituting the soundproof structure according to the present invention, the maximum length of the hole width in the perforated metal material such as metal foil or metal thin plate is more than 0 mm and less than 3 mm. A multi-porous metal material can be produced by continuously and efficiently drilling holes with an aperture ratio of 1 to 3%.
In the multi-porous metal material constituting the soundproof structure according to the present invention, the maximum length of the width of the hole exceeds 0 mm and is 3 mm or less, and the generated air has an opening ratio of 1 to 3%. Due to the viscous action, the volume of the sound passing there can be reduced (that is, sound absorption).

Next, the best embodiment of the perforating roll, the multi-microporous metal material manufacturing apparatus, the multi-microporous metal material manufacturing method, and the multi-microporous metal material according to the present invention will be described with reference to the drawings as appropriate. In the drawings to be referred to, FIG. 1 is an explanatory view of a piercing roll and a multi-porous metal material of the present invention. FIG. 2 is an explanatory view illustrating an example of the configuration of the multi-porous metal material manufacturing apparatus of the present invention. Figure 3 (a) ~ (c) is a pruning sectional hole and micropores to form an explanatory diagram for step-by-step instructions. FIG. 4 is a flowchart for explaining the method for producing a multi-porous metal material of the present invention.

[1. Drilling roll]
As shown in FIG. 1, a perforating roll 1 according to the present invention is configured by a pair of a metal metal roll 2 having a protrusion 3 and a receiving roll 4 that receives a pressing force generated by the protrusion 3 of the metal roll 2. Has been. Then, puncturing the pruning Dan'ana 6 to be perforated metal material 5 by interposed between the roll 4 receives a pierceable metal member 5 and the metal roll 2 to produce a multi-pruning Dan'ana metal member 7.

(Metal roll and protrusion)
Here, it is preferable that the protrusion 3 formed on the metal roll 2 has a height of 120% or more of the thickness of the metal material 5 to be perforated. If the height of the projection 3 is less than 120% of the thickness of the metal material 5 to be drilled, the metal material 5 to be drilled 5 even if the metal material 2 having the projection 3 is drilled using the metal roll 2. of the pierceable metal material 5 will extend the ductility, which can not be pruning disconnection, there may not be able to drill pruning Dan'ana 6. Here, the shape of the protrusion 3 can be a circular shape, an elliptical shape, a triangular shape, a quadrangular shape, a crescent shape, or the like in the cross-sectional shape in the direction parallel to the receiving roll 3, but is preferably a circular shape. That is, it is preferable that the protrusion 3 has a three-dimensional shape such as a cone shape, a truncated cone shape, or a cylindrical shape.

Moreover, it is preferable that the protrusion 3 formed on the metal roll 2 sets the rising angle from the surface of the metal roll 2 to 90 to 135 °. When the rising angle of the projection 3 is less than 90 ° from the surface of the metal roller 2, omission of the projection 3 from the perforated metal material 5 after perforation is poor, multi pruning Dan'ana metal member 7 to the metal roller 2 There is a risk of wrapping around. In contrast, when the rising angle of the projection 3 is more than 135 ° from the surface of the metal roller 2, the angle forming the projections 3 will be too loose, pruning shear force does not act effectively even if the perforations, the It extends perforated metal material 5 there is a possibility that it is impossible to drill pruning Dan'ana 6 occurs.

Also, the smaller the maximum length in the width of the projection 3 to be formed on the metal roller 2, the maximum length of a width of pruning Dan'ana 6 of the perforated metal material 5 is pierced by such projections 3, that is, multi-fine The maximum length of the width of the fine hole 8 of the hole metal material 9 can be reduced.

In addition, the fine hole 6 pierced by the protrusion 3 is more excellent in sound absorbing performance as its size is smaller. The maximum length of the width of the tip of the projection 3 (portion), the maximum length of a width of pruning Dan'ana 6 and micropores 8.
Therefore, the maximum length of the width of the tip of the protrusion 3 is preferably more than 0 mm and 3 mm or less, more preferably 1 mm or less, still more preferably 0.5 mm or less, and It is even more preferable to form with 3 mm or less, and most preferable to form with 0.2 mm or less. When the maximum length of the width of the pruning Dan'ana 6 which is perforated by the tip of the projection 3 is too large beyond 3 mm, is not stabilized perforated shape pruning Dan'ana 6, it tends to become distorted shape. For this reason, it is difficult to design a product including calculation of an aperture ratio for obtaining a desired sound absorption performance. In contrast, the perforated pruning Dan'ana 6 maximum as the length is smaller the pruning Dan'ana 6 shape of the width of the can be made close to a desired shape. In addition, product design and aperture ratio calculation for obtaining desired sound absorption performance are facilitated.
In addition, what is necessary is just to adjust suitably the installation ratio of the protrusion 3 which occupies per unit area of the metal roll 2 by the sound absorption performance and the sound absorption characteristic calculated | required in the location which uses a multi-fine hole metal plate.

When drilling such a maximum length pierceable metal substrate using a projection 3 having a width of 5 (see FIG. 3 (a)), pruning Dan'ana 6 drilled by the projections 3 in FIG. 3 (b) as shown, it will have a burr 61 including a bulge portion 62 in the plane of the multi pruning Dan'ana metal member 7. Note that pruning Dan'ana 6 drilled, for example, as shown in FIG. 1, may form a pruning Dan'ana 6 of relatively appointed shape, metal pieces when drilled multi micropores metal it may become an pruning Dan'ana 6 having a shape connected to the timber 9. Then, as shown in FIG. 3 (c), the flattening means and the flattening step to be described later, formed by flattening the multi pruning Dan'ana metal member 7 comprising a pruning Dan'ana 6 having a burr 61 minute Since the hole 8 is affected by the shape of the burr 61 and the bulging portion 62 generated by the protrusion 3, a vertical cross section in which the width of the fine hole 8 is different between one surface and the other surface of the multi-porous metal material 9. In addition to presenting the fine holes 8 having a substantially trapezoidal surface shape, there may be formed fine holes (not shown) partially covered in the longitudinal sectional shape of the fine holes 8.

Already maximum length and width of the projection 3 to be formed on the metal roll 2 described laying percentage of protrusions 3 occupied per unit area of the metal roller 2 is pruning Dan'ana 6 to be drilled directly into the multi-pruning Dan'ana metal member 7 In addition, the maximum width of the fine holes 8 perforated in the multi-porous metal material 9 and the aperture ratio are reflected, and the sound absorbing performance is greatly affected. Therefore, the maximum width of the protrusions 3 and the laying ratio of the protrusions 3 per unit area of the metal roll 2 may be appropriately selected and provided within the restricted range according to the sound range where sound absorption is desired. preferable.
For example, when the perforation roll 1 is provided with the protrusions 3 having a large maximum width at a low laying ratio, the multi-porous metal material 9 perforated by this has fine holes 8 having a large maximum length. Since it has a sparse ratio, the sound absorption performance on the low-frequency range side is excellent. On the other hand, when the perforation roll 1 is provided with the protrusions 3 having a small maximum width in many laying ratios, the multi-porous metal material 9 perforated thereby has a small width and a maximum length. Since the holes 8 are provided at a dense ratio, the sound absorption performance on the high sound range side is excellent.
In addition, such an arrangement of the protrusions 3 may be such that the protrusions 3 are closely gathered to form one group, and the group is distributed on the outer peripheral surface of the metal roll 2 at an arbitrary interval.

  For example, the protrusion 3 of the metal roll 2 can be suitably shown by implanting and providing a needle-like or columnar protrusion 3 having a predetermined diameter on a cylindrical soft iron serving as a core, but is not limited thereto. For example, it can be suitably formed by pressing, stamping or the like using a mold having a hardness higher than that of soft iron. For example, it can be suitably formed by mechanical grinding, and can also be suitably formed by chemical etching. Furthermore, it is also possible to cast by using a mold for forming the protrusion 3.

The metal roll 2 is preferably made of soft iron in order to facilitate the formation of the protrusions 3, and a Cr (chromium) plating film having an average film thickness of 5 to 20 μm is preferably formed on the surface thereof. By using soft iron having a low hardness, it is possible to provide the projection 3 with high accuracy without missing the projection 3 when the projection 3 having a small maximum width is provided. Further, the Cr plating film is formed to improve the strength of the surface of the metal roll 2. Thus, the strength of the projections 3 can be improved, even if the perforations of the pruning Dan'ana 6 to be perforated metal material 5 prevents chipping or bending of the projection 3, allows the long-term use . When the average film thickness of the Cr plating film is less than 5 μm, the effect of preventing the protrusion 3 from being chipped or broken cannot be obtained. On the other hand, even if the average thickness of the Cr plating film exceeds 20 μm, the strength of the protrusions 3 is the same as that of 20 μm and hardly improves.

(Receiving roll)
Receiving roll 4 is in cooperation with the metal roll 2 drilled pruning Dan'ana 6 to be perforated metal material 5, to produce a multi-pruning Dan'ana metal member 7. Therefore, it is preferable that the receiving roll 4 can form a concave portion in the body portion in accordance with the maximum length and shape of the protrusion 3 of the metal roll 2 and the ratio of the protrusion 3 occupying per unit area of the metal roll 2. In such a configuration, the receiving protruding 3 meshing metal roll 2 in the recess of the roll 4, drilling a pruning Dan'ana 6 to be perforated metal material 5 by using the pruning shear force arising when the Can do.

As the receiving roll 4 having a configuration in which a concave portion is formed in the body portion, for example, a woolen roll or a metal roll can be preferably exemplified. Incidentally, when the recess of the roll 4 receiving the projections 3 of the metal roll 2 is perforated so as to mesh, in the perforated metal material 5 in contact with the projection 3, so pruning shear force is generated, the pruning Dan'ana 6 Perforations can be drilled in a relatively neat shape. Therefore, it is preferable to appropriately adjust each shape and rotation so that the protrusion 3 of the metal roll 2 and the recess of the receiving roll 4 are engaged with each other.

The woolen roll is a roll having a metal shaft center and a body portion in which paper fibers and cotton are mixed (not shown). This body portion is a roll that is hard at the time of drying, can be softened by including water, and can be hardened by drying again. Therefore, if a woolen roll is used, the metal roll 2 is softened by adding water, and then pressing the metal roll 2 on which the protrusions 3 are formed to transfer the shape of the protrusions 3 and drying and curing the metal roll 2. It is possible to easily produce a recess that matches the protrusion 3. Then, after preparing the recess matching the projection 3 of the metal roller 2, thereby again dried and cured the wool down roll surface is very hard, generate strong pruning shear force when the protrusion 3 and the recess are engaged Therefore, it can be particularly suitably used as the receiving roll 4 used in the present invention.
The woolen roll configured as described above can be suitably used when drilling a metal material 5 (metal foil) having a thickness of 0.2 mm or less.

The receiving roll 4 for punching the metal foil is not limited to this, and for example, a roll having an elastic body such as a synthetic resin roll or a rubber roll can be used. By using the elastic body portion, when pressed by the protrusion 3 of the metal roll 2, a concave portion having substantially the same shape as the shape of the protrusion 3 is formed, and the metal foil can be perforated. As the receiving roll 4 that can be used in the present invention, a concave portion may not be formed in advance, and such a configuration may be used. And it is preferable to use a synthetic resin roll or a rubber roll having a rubber hardness of 40 to 120 degrees according to an A type rubber hardness meter defined by JIS K 6301 (new JIS K 6253), and a rubber hardness of about 80 degrees (60 to 60 degrees). (100 degrees) is more preferable. If it is less than 40 degrees, the receiving roll 4 is too soft, the followability of the shape of the protrusions 3 is deteriorated, and there is a possibility that drilling cannot be suitably performed. On the other hand, when it exceeds 120 degrees, for receiving the roll 4 is too hard, in order to follow-up property of the shape of the projection 3 is poor, less prone to pruning sectional, not only it is impossible to drill pruning Dan'ana 6, the projections 3 It can be a cause of chipping and bending.
Examples of the synthetic resin used for the synthetic resin roll include urethane resin, silicon resin, nylon resin, EPT resin, and NBR resin. Moreover, natural rubber and synthetic rubber can be used as rubber used for the rubber roll.

As described above, the receiving roll 4 can be appropriately selected and used from a woolen roll, a synthetic resin roll, a rubber roll, or a metal roll . Among them, it is preferable to use a woolen roll . By appropriately selecting and using according to the conditions for drilling, such as the thickness of the metal material 5 to be drilled and the shape of the fine holes 8, the fractured hole 6 can be suitably drilled.

[2. Multi-porous metal material manufacturing equipment]
Next, the multi-porous metal material manufacturing apparatus 10 according to the present invention will be described with reference to the explanatory diagram of FIG.
As shown in FIG. 2, the multi-porous metal material manufacturing apparatus 10 according to the present invention includes a transfer means 11, a perforating means 12 using the perforating roll 1 described above, a flattening means 13, and a receiving means. And means 14.
Multi microporous metal material manufacturing apparatus 10 having such a configuration, the pierceable metal material 5 long-strip pruning Dan'ana 6 suitably for drilling to a multi-microporous metallic material 9 (micropores 8) Can be used.
Will be specifically described a case where a multi-microporous metallic material 9 by puncturing the pruning Dan'ana 6 (micropores 8) to be perforated metal material 5 long strip.

(Transport means)
The transfer means 11 is for transferring the elongated band-shaped metal material 5 to be punched toward the punching means 12. As this transfer means 11, for example, when the long strip-shaped metal material 5 to be perforated is wound in a roll shape, the wound metal material 5 to be wound is unwound and transferred to the perforation means 12. It can be shown suitably.
In addition, it is preferable that the transfer means 11 is provided with a tension reel and unwinds while adjusting the tension as appropriate. This is to prevent wrinkles from occurring when the long strip-shaped metal material 5 to be punched wound in a roll is transferred to the punching means.

(Perforation means)
The punching means 12 includes a punching roll 1 constituted by a pair of a metal roll 2 and a receiving roll 4. In this metal roll 2, in order to pierce the metal material 5 to be drilled, the protrusion 3 is formed with the predetermined shape described in the above-described drilling roll 1 and a predetermined ratio per unit area of the metal roll 2. . Therefore, the punching means 12 inserts the drilled metal material 5 transferred by the transfer means 11 between the metal roll 2 and the receiving roll 4 so that the metal roll 2 and the receiving roll 4 are put into the covered roll. while rotating in the direction of delivering the perforated metal material 5 performs perforation of pruning Dan'ana 6 with projections 3 formed on the surface of the metal roller 2, to produce a multi-pruning Dan'ana metal member 7. Note that the pruning Dan'ana 6 at this time, since burrs 61 including a bulge portion 62 is present, the surface of the multi-pruning Dan'ana metal member 7 is uneven state (see Figure 3 (b)).
In addition, as described above, when the recess of the shape matching the protrusion 3 of the metal roll 2 is formed in the body portion of the receiving roll 4, the protrusion 3 of the metal roll 2 and the recess of the receiving roll 4 are engaged with each other. It is preferable to appropriately set the position and rotation speed of each roll. In addition, it is preferable that the clearance between the metal roll 2 and the receiving roll 4 is substantially the same as these thicknesses so as not to cause wrinkles when the perforated metal material 5 is perforated.

(Flattening means)
Flattening means 13, by flattening without removing burr 61 including a bulge portion 62 that bulges from the plane generated in the multi-pruning Dan'ana metal member 7 by perforation means 12, the multi-pruning Dan'ana metal member 7 Prepare a flat surface. As the flattening means 13, for example, sandwiching the multi pruning Dan'ana metal member 7 which is perforated with two rubber nip rolls at appropriate pressing force, it is suitably illustrating the configuration of flattening the burr 61 it can. The nip roll, it is preferable to use those 40-120 degrees rubber hardness by type A durometer specified in J IS K 6301 (New JIS K 6253), a rubber hardness of 80 degrees before and after the (60-100 degrees) It is more preferable to use one. If it is less than 40 degrees, the nip roll is too soft and it may be difficult to flatten the burr 61. If it exceeds 120 degrees, the nip roll is too hard and the burr 61 may be scraped or chipped to generate cutting powder. There is a risk that the fine hole metal material 9 may be broken.
The material of the nip roll can be appropriately selected from urethane resin, silicon resin, nylon resin, EPT resin, NBR resin, natural rubber, synthetic rubber, and the like.

In this way, the maximum length of a width of the tip of the projection 3 of the perforated roll 1 used in punching means 12 as described above is formed below 3mm beyond the 0 mm, pruning sectional depending on such projections 3 pruning Dan'ana 6 provided is would maximum length of the width of the hole is drilled to 3mm or less. By forming the pruning Dan'ana 6 maximum length less than 3mm of the width of the tip of the projection 3, by the flattening means 13, by flattening without removing the burrs 61 and the bulge 62, the pruning Dan'ana 6 It is possible to form the fine hole 8 having the maximum length with a smaller width. As a result, it is possible to increase the viscous action of air in the fine holes 8, so that it is possible to form the multi-fine hole metal material 9 having high sound absorption performance.

(Receiving means)
The receiving means 14 receives the multi-porous metal material 9 obtained by flattening the burr 61 including the bulging portion 62 by the flattening means 13 while preparing it for shipment.
As the receiving means 14 in the case of the long strip-like multi-fine hole metal material 9, for example, it can be suitably shown that this is wound in a coil shape and wound.

(Film formation means)
In the multi-porous metal material manufacturing apparatus 10 according to the present invention, in consideration of the purpose of use of the multi-porous metal material 9, the surface of the multi-porous metal material 9 has, for example, corrosion resistance and heat dissipation. A means (film forming means 15) for forming a film for enhancing the functionality of the film may be provided.

  The film forming means 15 may be provided between the transfer means 11 and the punching means 12 or between the flattening means 13 and the receiving means 14 as necessary. In addition, the film forming means 15 may be provided as a separate process before drilling by the multi-porous metal material manufacturing apparatus 10 of the present invention. After the punching and receiving by the receiving means 14, the film forming means 15 is provided as a separate process. It may be provided.

  As described above, the multi-porous metal material manufacturing apparatus 10 of the present invention continuously applies the multi-porous metal material 9 provided with a large number of micro-holes 8 having a maximum hole width exceeding 0 mm and not more than 3 mm. And it can manufacture efficiently. Since the viscous action of air is generated in the fine holes 8 of the multi-fine hole metal material 9, it is possible to attenuate the vibration of the air passing therethrough and reduce the volume.

[3. Method for producing multi-porous metal material]
Next, the manufacturing method of the multi-porous metal material according to the present invention will be described with reference to the flowchart shown in FIG. In addition, the manufacturing method of the multi-microporous metal material of the present invention can be suitably used for perforating a long strip-shaped metal material to be perforated to obtain a multi-microporous metal material. Hereinafter, with reference to FIG. 4 and FIGS. 2 and 3 as appropriate, a manufacturing method for manufacturing a multi-porous metal material 9 by perforating a long strip-shaped metal material 5 to be perforated will be described.

  The manufacturing method of the multi-porous metal material of the present invention includes a transfer process (step S1), a drilling process (step S2), a flattening process (step S3), and a receiving process (step S4).

First, in the transfer process, the drilled metal material 5 is transferred to the drilling process of the next process in order to drill the drilled metal material 5 (step S1).
Next, in the perforating process, the perforated roll 1 constituted by the metal roll 2 and the receiving roll 4 described above is rotated in the direction in which the perforated metal material 5 is fed out, and is transported by the transporting process. the metal material 5, 3 mm or less beyond the 0mm maximum length in the width of the hole, more preferably continuously perforating a pruning Dan'ana 6 under the following conditions 0.5mm exceed 0mm, multi pruning Dan'ana metal member 7 Is manufactured (step S2). As described above, the pruning Dan'ana 6 of such multi pruning Dan'ana metal member 7 has a burr 61 including a bulge portion 62, its surface is uneven state.

Then, in the planarization process, which is perforated by perforation step, a burr 61 which surface comprises a bulge 62 occurring in multiple pruning Dan'ana metal member 7 of the uneven state, holding down that sandwich using two nip rolls Thus, it is flattened without removing the fine holes 8 and a multi-hole metal material 9 is manufactured (step S3). In addition, by performing flattening, the multi-porous metal material 9 may be broken or deformed when it is wound in a roll shape in the receiving process of the next process or when the wound multi-porous metal material 9 is used. Can be prevented.

  Next, in the receiving process, the long strip-shaped multi-fine hole metal material 9 with the burr 61 flattened is wound and received in a roll shape (step S4).

  As described above, according to the method for producing a multi-fine hole metal material according to the present invention, a large number of fine holes 8 having a maximum hole width exceeding 0 mm and not more than 3 mm, more preferably not more than 0.5 mm are provided. The produced multi-porous metal material 9 can be manufactured continuously and efficiently. In addition, since the viscous action of air arises in the fine hole 8 of this multi-fine porous metal material 9, it is possible to attenuate the vibration of the air of the sound which passes through this, and to make the sound volume small.

  In the method for producing a multi-porous metal material of the present invention, for example, a film for improving functionality such as corrosion resistance and heat dissipation may be formed on the surface of the multi-porous metal material 9 to be manufactured. Is possible.

As a manufacturing method of the multi-microporous metal material 9 on which such a film is formed, for example, a transfer process for transferring the metal material 5 to be drilled to the drilling process, and drilling the metal material 5 to be drilled transferred in this transfer process. with use roll 1, a piercing process in which the maximum length of a width of the hole is a multi pruning Dan'ana metal member 7 was drilled pruning Dan'ana 6 below 3mm beyond the 0 mm, multi pruning Dan'ana in drilling boring step A flattening step of flattening the burr 61 including the bulging portion 62 generated in the metal material 5 to obtain a multi-hole metal material 9 having fine holes 8 having a maximum hole width exceeding 0 mm and not more than 3 mm; For example, a film forming process for forming a film for improving corrosion resistance and heat dissipation on the multi-porous metal material 9 in which the burr 61 including the bulging portion 62 is flattened in the forming process, and a film is formed in the film forming process. A receiving method for receiving the multi-porous metal material 9; It can gel.

Note that this film forming step may be performed between the transfer step and the perforating step, in addition to being performed between the flattening step and the receiving step as described above.
It is also possible to form a film in a step different from the step for performing perforation according to the present invention. For example, after rolling a metal foil or a thin metal plate (perforated metal material 5), such a film may be formed and then used for the multi-porous metal material manufacturing apparatus 10 according to the present invention. Such a film may be formed after the step is completed and the multi-porous metal material 9 is manufactured.

  Thus, by forming a film by the film forming step, for example, the multi-porous metal material 9 with improved corrosion resistance and heat dissipation can be obtained.

Next, since the selection of the conditions for the piercing roll of the present invention and the confirmation test of the multi-porous metal material in which the fine holes were drilled / formed using the piercing roll selected for the conditions were performed, the following examples It will be described while showing.
In this example, the conditions related to the perforating roll for forming the desired multi-fine holes in the present invention were selected.
<A. Length of protrusion on the roll for drilling>
First, a truncated cone-shaped protrusion (metal) having a maximum tip width of 3 mm (i.e., φ3 mm) with a 10 μm thick Cr plating film formed on a cylindrical soft iron (metal roll) serving as a core The rising angle from the roll surface: 100 °) was formed at a height of 100% of the thickness of the metal material to be perforated and at a height of 130% of the thickness of the metal material to be perforated. Three types of perforation roll B and perforation roll C formed at a height of 150% of the thickness of the metal material to be perforated were prepared (all have a projection laying ratio of 3%).

  A multi-porous metal material manufacturing apparatus was manufactured by mounting the above-described piercing roll and woolen roll on a mold rolling apparatus. Then, a metal foil made of an aluminum alloy having a thickness of 0.1 mm, which had been manufactured in advance, was passed between a piercing roll and a woolen roll, and a large number of fine holes were rolled to produce a multi-fine hole metal material ( Opening ratio 3%).

As a result of observation, in the drilling roll A (the height of the protrusion was 100% of the thickness of the metal material), the height of the protrusion was insufficient and the metal material could not be punched. As a result, a multi-porous metal material could not be produced (x).
On the other hand, in the perforating roll B and the perforating roll C (the height of the protrusion is 130% and 150% of the thickness of the metal material), since the height of the protrusion is appropriate, a good circular hole is formed in the metal material. Could be perforated. As a result, it was possible to produce a good multi-porous metal material (◯).
From the above results, it was found that the height of the protrusion provided on the perforating roll only needs to be about 130% of the thickness of the metal material to be perforated.

<B. Rising angle of protrusion from metal roll surface>
Next, the influence of the rising angle of the protrusion from the metal roll surface was examined. A metal roll having a frustoconical protrusion with a rising angle from the surface of the metal roll of 90 °, 115 °, 130 °, and 150 ° with a Cr plating film having a thickness of 10 μm formed is prepared. Drilling rolls D, E, F, and G were prepared in the order described above (protrusion laying ratio 3%). The maximum length of the width of the tip of the protrusion was 3 mm (that is, φ3 mm), and the height of the protrusion was 130% of the thickness of the metal material.

  These drilling rolls D, E, F and G are mounted on a multi-fine hole metal material manufacturing apparatus, and a number of fine holes are drilled in a metal foil made of aluminum alloy having a thickness of 0.1 mm which has been manufactured in advance. Thus, a multi-porous metal material was produced (opening ratio: 3%). And the shape of the formed micropore was observed.

As a result of observation, the punching rolls D, E, and F (the rising angles of the protrusions from the surface of the metal roll are 90 °, 115 °, and 130 °) have the appropriate rising angles of the protrusions from the surface of the metal roll. Moreover, the shape of the fine holes was also good circular shape, and a good multi-fine hole metal material could be manufactured (◯).
In contrast, perforations roll G (rising angle 150 ° of the projection from the surface of the metal roll), since the rising angle of the projections is too loose, insufficient pruning shear force for perforating the metal material, the fine A hole could not be formed (x).
When the rising angle of the protrusion from the surface of the metal roll is 89 ° or less, the rising angle of the protrusion from the surface of the metal roll is an acute angle (that is, the diameter of the protrusion increases toward the tip portion). In addition, the protrusions of the projections after drilling the fine holes are not easily removed, and metal foil is sometimes involved. Therefore, it was not possible to produce a multi-porous metal material (x).
From the above results, it was found that the rising angle of the protrusion from the surface of the metal roll is preferably 90 ° or more and 135 ° or less.

<C. Maximum length of protrusion tip width>
Next, the influence of the maximum length of the width of the tip of the protrusion was examined. With a 10 μm-thick Cr plating film formed, the height of the protrusion is 130% of the thickness of the metal foil, the rising angle of the protrusion from the surface of the metal roll is 115 °, and the maximum width of the tip A metal roll having a truncated cone-shaped protrusion having a length of 0.15 mm, 0.5 mm, 1 mm, 3 mm, and 4 mm (that is, φ0.15 mm, φ0.5 mm, φ1 mm, φ3 mm, and φ4 mm) is manufactured ( Protrusion rolls H, I, J, K, and L were prepared in the order described above, with a projection laying ratio of 3%.

  Then, these perforating rolls H, I, J, K, and L are mounted on a multi-fine hole metal material manufacturing apparatus, and a large number of fine holes are made in a metal foil made of aluminum alloy having a thickness of 0.1 mm that has been manufactured in advance. A multi-porous metal material was produced by perforation (opening ratio: 3%). And the shape of the formed micropore was observed.

As a result of observation, the perforating rolls H, I, and J (the maximum width of the tip end of the protrusion is 0.15 mm, 0.5 mm, and 1 mm) are appropriate because the maximum length of the end of the protrusion is appropriate. In addition, the shape of the fine holes became a good circular shape, and a good multi-fine hole metal material could be manufactured (◯).
Although the perforating roll K (maximum length of the tip width of the projection is 3 mm), the maximum length of the tip width of the projection was slightly large, so the shape of the microhole was not a good circular shape, A relatively good multi-porous metal material could be produced (Δ).
On the other hand, the perforating roll L (maximum length of the tip end of the projection is 4 mm) is too large because the maximum length of the tip end of the projection is too large. The metal material was extended, and the fine holes could not be drilled. Therefore, it was not possible to produce a multi-porous metal material (x).
From the above results, it was found that the maximum length of the tip width of the protrusion in the present invention is preferably 3 mm or less.

Next, a multi-porous metal material having an aperture ratio of 3% and a multi-porous metal material having an aperture ratio of 1% were prepared under the condition that the maximum length of the width of the tip of the protrusion was constant. Rate).
First, the conditions of the piercing roll I (protrusion length: 130% of the thickness of the metal foil, the rising angle of the protrusion from the surface of the metal roll: 115 °, and the maximum length of the width of the tip of the protrusion: In the case of 0.5 mm, that is, φ0.5 mm), a punching roll I _{3 in} which the opening ratio of the multi-porous metal material is 3% and a punching roll I _{1 in} which the opening ratio of the multi-porous metal material is 1% Produced. Then, using these, a large number of fine holes were drilled in the metal material to be punched to produce a multi-porous metal material a (opening ratio 3%) and a multi-porous metal material b (opening ratio 1%).
Using such a multi-porous metal material a and a multi-porous metal material b, a porous soundproof structure having the structure shown in FIG. 1 of Japanese Patent Application Laid-Open No. 2003-50586 was produced and the sound absorbing performance was confirmed. It was confirmed that any of the multi-porous metal materials (corresponding to the interior plate of JP-A-2003-50586) has good sound absorption performance.

  The perforating roll 1 of the present invention, the multi-porous metal material manufacturing apparatus 10 using the same, the manufacturing method of the multi-porous metal material 9, and the preferred embodiments of the multi-porous metal material 9 will be described in detail. However, the contents of the present invention are not limited to these, and can be appropriately changed and modified without departing from the spirit of the present invention.

  For example, in the above description of the best mode for carrying out the present invention, the case where the multi-porous metal material 9 is manufactured by perforating the long-band-shaped metal material 5 to be perforated has been specifically described. Alternatively, a single sheet-like perforated metal material 25 formed with a relatively short length can be used.

  FIG. 5 illustrates another example of the configuration of the multi-porous metal material manufacturing apparatus 20 according to the present invention in the case of punching a single sheet-like metal material 25 having a relatively short length. It is explanatory drawing to do. As shown in FIG. 5, it is preferable that the transfer means 21 of the multi-porous metal material manufacturing apparatus 20 in such a case is configured to transfer sheet-like metal materials 25 to be punched one by one. Can show. As the transfer means 21 when applied to the single sheet-like perforated metal material 25 formed with a relatively short length, for example, a mode in which the transfer means 21 is placed on the rotation roller 21a that rotates and is transferred is preferable. Can be shown.

Further, the receiving means 24 of the multi-porous metal material manufacturing apparatus 20 in this case preferably shows a configuration in which the perforated sheet-like multi-porous metal material 26 is collected and received on the pallet 24a. be able to.
In addition, the transfer means 21, the punching means 22, the flattening means 23, and the receiving means 24 in the other example of the configuration of the multi-porous metal material manufacturing apparatus 20 of the present invention shown in FIG. 5 are the transfer means described above. 11, the punching means 12, the flattening means 13, and the receiving means 14 are the same, and the description thereof is omitted.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. It is explanatory drawing explaining an example of a structure of the multi-porous metal material manufacturing apparatus of this invention. (A) ~ (c) is a pruning sectional hole and micropores to form an explanatory diagram for step-by-step instructions. It is a flowchart for demonstrating the manufacturing method of the multi-porous metal material of this invention. It is explanatory drawing explaining another example of a structure of the multi-porous metal material manufacturing apparatus of this invention. (A) is a partial cross-sectional view of a conventional disc-shaped roll for punching a metal plate, and (b) is a diagram for explaining the shape of the blade portion of the disc-shaped roll for punching a metal plate.

Explanation of symbols

1 perforated roll 2 metal rolls 3 projections 4 receiving roll 5 to be perforated metal material 6 pruning Dan'ana 7 and 27 multi pruning Dan'ana metal material 8 micropores 9, 29 multi-microporous metal members 10 and 20 multi-microporous metal material manufacturing Apparatuses 11, 21 Transfer means 12, 22 Perforation means 13, 23 Flattening means 14, 24 Receiving means 15 Film forming means

Claims (6)

A metal roll made of metal having protrusions;
It consists of a pair of receiving rolls that receive the pressing force generated by the protrusions of this metal roll,
A drilling roll for producing a multi-fine holed metal material that constitutes a soundproof structure in which a metal material to be drilled is interposed between the metal roll and the receiving roll to drill a shear hole in the metal material to be drilled. ,
The height of the protrusion of the metal roll is 120% or more of the thickness of the metal material to be perforated, and
The rising angle of the protrusion from the surface of the metal roll is 90 to 135 °, and
The maximum length of the width of the tip of the protrusion of the metal roll is more than 0 mm and 3 mm or less,
The laying ratio of the protrusion is 1 to 3%,
The receiving roll is made by softening by adding water to the body part mixed with paper fibers and cotton, and then pressing the metal roll on which the protrusions are formed to transfer the shape of the protrusions, and then drying and curing the metal roll. It is a woolen roll provided with a recess that meshes with the projection of the metal roll. The maximum length of the width of the tip of the protrusion of the metal roll is more than 0 mm and not more than 0.5 mm, for producing a multi-porous metal material constituting a soundproof structure according to claim 1 Drilling roll. 3. The perforated hole for producing a multi-porous metal material constituting the soundproof structure according to claim 1, wherein the metal roll is formed with a Cr plating film having an average film thickness of 5 to 20 μm. Rolls. A perforation for producing a multi-microporous metal material constituting the soundproof structure according to any one of claims 1 to 3, wherein the perforated metal material transported by a transport means for transporting the perforated metal material comprises the soundproof structure according to any one of claims 1 to 3. Drilling means for punching a shear hole having a maximum hole width of more than 0 mm and not more than 3 mm at an opening ratio of 1 to 3% using a roll for a multi-shear hole metal material;
Flattening means for flattening a shear hole having a burr including a bulging portion bulging from a plane of the multi-shear hole metal material perforated by the perforation means to form a multi-hole metal material;
The planarization means burrs flattened said a receiving means for receiving a multi-microporous metallic material, multi-microporous metallic material for a manufacturing apparatus constituting the soundproof structure characterized by having. A transfer process for transferring the drilled metal material to the drilling process;
The perforated metal material transported from the transporting step is perforated using a perforating roll for producing a multi-fine hole metal material constituting the soundproof structure according to any one of claims 1 to 3. The perforating step as a multi-shear hole metal material having a maximum length of a width exceeding 0 mm and 3 mm or less perforated with an opening ratio of 1 to 3%;
A flattening step for flattening a shear hole having a burr including a bulging portion that bulges out from a plane of the multi-shear hole metal material by perforation in the perforation step to form a multi-hole metal material,
A receiving step of receiving the multi-porous metal material having a burr flattened in the flattening step;
The manufacturing method of the multi-porous metal material which comprises the soundproof structure characterized by having. A multi-porous metal material that is manufactured using a perforating roll for manufacturing a multi-porous metal material that constitutes the soundproof structure according to any one of claims 1 to 3, and is used for sound absorption. Then, a shear hole having a burr including a bulging portion that bulges from the flat surface of the metal material to be drilled is drilled at an opening ratio of 1 to 3%, and the shear hole is flattened, and the maximum width of the drilled hole is A multi-porous metal material constituting a soundproof structure , wherein a fine hole having a length exceeding 0 mm and not exceeding 3 mm is provided.

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