JP5965325B2 - Method for patterning aluminum profiles - Google Patents

Description

  The present invention relates to a patterning method for an aluminum profile. More specifically, the present invention relates to a method for patterning an aluminum profile that can pattern various designs and can suppress the occurrence of shape defects such as warping and twisting.

There are conventional techniques described in Patent Document 1 and Patent Document 2 as a technique for giving an aluminum shape a texture of natural wood.
The prior art of Patent Document 1 is a technique in which a wood grain film is pasted on the surface of a metal material. However, with this prior art, the finish is flat, so no matter how close the pattern is to natural, the texture of natural wood is lacking.

  The prior art of Patent Document 2 is to form a wood grain-like streak pattern by bringing a cutting tool into contact with the surface of a metal material, and then subjecting the surface to sanding and painting. In this prior art, the texture of wood is given by the streak pattern, but since it is only a concave pattern, it has poor texture and lacks natural texture.

  Further, since there was no technique for applying any pattern other than the conventional technique, the conventional aluminum profile had a problem of poor design.

  In view of the above circumstances, the inventor of the present application has devised a method for patterning an aluminum profile that is patterned by a press machine after the aluminum profile is obtained by extrusion molding and before tempering (Patent Document 3). ). Since the aluminum shape before tempering is soft, the shape of the pattern is easily clearly given by pressurization of the press machine, and various patterns can be affixed with rich irregularities.

  However, since the aluminum profile before tempering is soft, unnecessary warping and twisting are likely to occur due to the pressure applied by the conveyor and press machine, and care was required to prevent the shape from being defective. .

JP-A-9-177238 JP 2004-338153 A JP 2011-218799 A

  In view of the above circumstances, an object of the present invention is to provide an aluminum shape patterning method capable of suppressing the occurrence of shape defects such as warping and twisting.

A patterning method for an aluminum profile according to a first aspect of the present invention is a method for patterning an aluminum profile by a press machine having a male mold and a female mold, wherein the aluminum profile is a main body to be patterned. The portion is a long plate shape and is curved in the width direction, wherein the male mold is disposed on the convex side of the main body and the female mold is disposed on the concave side of the main body, and is pressure-molded. To do.
The patterning method for an aluminum profile according to a second invention is characterized in that, in the first invention, the aluminum profile is formed with a rib projecting from the main body.
The patterning method for an aluminum profile according to a third aspect of the invention is characterized in that, in the first or second aspect of the invention, the aluminum profile is obtained by extrusion molding, tempered, and then patterned by the press machine. .
According to a fourth aspect of the invention, in the first, second, or third aspect, the press machine is a press press.

According to the first invention, since the main body is curved in the width direction, warpage in the longitudinal direction of the aluminum profile can be suppressed. Further, since the male mold is pressed against the convex side of the curved portion of the main body, the convex surface is deformed so as to be depressed, the pattern edge becomes an acute angle, and the pattern appears clearly. Furthermore, the thickness of the aluminum profile is created by the curvature, resulting in a three-dimensional finish.
According to the second invention, since the rigidity of the aluminum profile is increased by the ribs, it can resist the pressing force of the press machine and can suppress the occurrence of shape defects such as warpage and twist.
According to the third invention, since the aluminum profile after tempering is harder than before tempering, it can withstand the pressing force of the press machine and can suppress the occurrence of shape defects such as warping and twisting. . Moreover, handling at the time of conveyance etc. is easy.
According to the 4th invention, generation | occurrence | production of curvature and a twist can be suppressed compared with a roller press by patterning by a press press.

It is process drawing (I-IV) of the patterning method of this invention. It is process drawing (V-VII) of the patterning method of this invention. It is explanatory drawing of the patterning method by a press press, Comprising: (A) is a front view, (B) is a side view. The aluminum profile A in which the square pattern was formed is shown, (A) is a front perspective view, (B) is a rear perspective view, and (C) is an end view. It is explanatory drawing of the patterning method by another press press, Comprising: (A) The front view before pressurization, (B) The front view in pressurization. It is a front view of the aluminum shape member B in which the wood grain pattern was formed. Furthermore, it is explanatory drawing of the patterning method by another press press, Comprising: (A) The front view before pressurization, (B) The front view in pressurization. It is a front view of the aluminum shape material C in which the checkerboard pattern was formed. It is explanatory drawing of the state which attached the aluminum profile to the fence, Comprising: (A) is a front view, (B) is a longitudinal cross-sectional view. It is sectional drawing of the aluminum profile D in other embodiment.

Next, an embodiment of the present invention will be described with reference to the drawings.
The method for patterning an aluminum profile according to the present invention will be described based on the process diagrams of FIGS.
In the figure, the extrusion process I, the cooling process II, the tension correction process III, the cutting process IV, the tempering process V, and the surface treatment process VII are not particularly different from the conventional extrusion process of an aluminum profile. What is important in the present invention is that a patterning step VI by a press machine is included between the tempering step V and the surface treatment step VII.

In the extrusion process I, a billet made of aluminum or an aluminum alloy is extruded using a known extruder 1. By this step, the billet becomes the aluminum profile A.
In the cooling step II, the aluminum profile A is cooled on the cooling bed 2 by air cooling or water cooling.

In the tension straightening process III, both ends of the aluminum profile A are held by the grab of the stretcher 3 and pulled in the longitudinal direction. This corrects bending and the like.
In the cutting step IV, the aluminum profile A is cut to a desired length with a cutter.

  The tempering step V refers to a step of artificial age hardening after cooling (cooling step II) from high temperature processing (extrusion step I). A known heat treatment furnace 5 or the like is used for the tempering process.

  In the patterning step VI, various designs are patterned on the aluminum profile A by the press machine 10. By this step, a patterned aluminum profile A is obtained. This step will be described in detail later.

  In the surface treatment step VII, anodizing treatment, coloring treatment, and the like are performed. The anodizing treatment is performed by immersing the aluminum profile A in an electrolytic solution such as sulfuric acid, oxalic acid, or chromic acid. By forming an oxide film on the surface of the aluminum profile A by anodizing treatment, corrosion resistance and wear resistance are improved. Moreover, you may perform the coloring process which colors the aluminum shape material A by secondary electrolytic coloring after an anodizing process.

In the present invention, the reason why the patterning step VI is performed after the tempering step V is as follows.
The tensile strength and proof stress of the aluminum profile A change as follows according to the progress of the machining process.
a) Immediately after the extrusion step I, it is in a very soft state. For example, in the case of an aluminum shape of alloy number 6063, the tensile strength is 90 N / mm ² and the proof stress is 50 N / mm ² .
b) From the cooling process II to the cutting process IV, it corresponds to the one that has been naturally aged after cooling from high temperature processing. If the aluminum shape is alloy number 6063, the tensile strength is 150 N / mm ² and the proof stress is 90 N / mm. ²
c) Finished after the tempering step V is equivalent to the product that has been subjected to artificial age hardening after cooling from high-temperature processing. If the aluminum shape is alloy No. 6063, the tensile strength is 185 N / mm ² mm ²

  As described above, the tensile strength and yield strength of the aluminum profile A increase in the order of a) → b) → c). Therefore, if the patterning process is performed after the tempering process, the aluminum profile A after the tempering process is harder than before the tempering process, so that it can resist the pressing force of the press machine 10, and warp, twist, etc. The occurrence of shape defects can be suppressed. In addition, since the aluminum profile A after tempering is hard, it is easy to handle without being deformed during conveyance. Therefore, the patterning process becomes easy.

  Note that the patterning step VI may be performed after the surface treatment step VII in terms of suppressing the occurrence of shape defects. However, if the patterning step VI is performed after the surface treatment step VII, the anodized film or the colored coating film formed on the surface may be destroyed due to the deformation of the aluminum profile A. Therefore, the patterning step VI is preferably performed before the surface treatment step VII.

  Further, the patterning step VI may be performed before the tempering step V. In this case, since the aluminum shape A is soft, the shape of the pattern can be clearly attached by pressurization of the press machine 10.

Next, each embodiment of the patterning step VI will be described.
(Square pattern)
First, an aluminum profile A having a square pattern will be described.
3 is a press machine for patterning a square pattern on an aluminum profile A. The press press moves the ram up and down above the bed, puts the lower mold on the bed, attaches the upper mold to the lower end of the ram, and can press the upper or lower mold against the material manually or by power Any type of press may be used.

  FIG. 4 shows an aluminum profile A patterned with the press 10, and the surface shown in FIG. 4A is a processed aluminum profile A with a square-shaped (rectangular) recess g, (B ) The back surface shown in the figure is an aluminum shape A before processing without a square-shaped recess.

  (C) As shown in the figure, the aluminum profile A is composed of a long plate-shaped main body a1 to which a patterning process is applied, and a pair of ribs a2 and a2 suspended from both edges of the main body a1. . The main body a1 is curved in the width direction, and the convex side of the curve (upper side in (C) figure) is the surface, and the concave side of the curve (lower side in figure (C)) is the back side. The pair of ribs a <b> 2 and a <b> 2 protrude substantially perpendicularly to the back surface side of the main body portion a <b> 1. The width of the main body a1 is, for example, 100 mm and the radius of curvature is, for example, 500 mm, but is not limited to these dimensions. In the extrusion process I, the aluminum profile A having such a shape is formed.

Returning to FIG. 3, reference numeral 11 denotes an upper mold, which is a block-shaped member made of die steel or the like. The reference surface 11a, which is the lower surface of the upper die 11, is curved so as to be recessed upward with substantially the same curvature radius as that of the main body portion a1 of the aluminum profile A. The upper mold 11 is a male mold, and has a square-shaped convex portion 11b that protrudes substantially at the center of the reference surface 11a.
The “reference surface” is a surface that presses the aluminum shape member so as not to move during pressure molding. In the present specification, the “male mold” means a mold having a portion protruding from the reference surface.

Reference numeral 12 denotes a lower mold, which is a block-shaped member made of die steel or the like. The reference surface 12a, which is the upper surface of the lower mold 12, is curved so as to protrude upward with substantially the same curvature radius as the main body portion a1 of the aluminum profile A. The lower mold 12 is a female mold, and a square-shaped concave portion 12b that fits with the convex portion 11b of the upper mold 11 is formed in the approximate center of the reference surface 12a.
In the present specification, “female mold” means a mold having a portion that is recessed from a reference surface or a portion that is deformed and recessed during pressure molding.

  The aluminum profile A is subjected to patterning by placing the upper die 11 which is a male die on the convex side of the main body a1 and the lower die 12 which is a female die on the concave side of the curve, and press molding. Is given.

  If the main body portion of the aluminum profile is not formed in a curved shape in advance and is flat, warping may occur in the longitudinal direction of the aluminum profile due to pressure molding. However, in the aluminum profile A according to the present embodiment, since the main body portion a1 is curved in the width direction in advance, warpage in the longitudinal direction of the aluminum profile A can be suppressed.

  Further, since the male mold 11 is pressed against the curved convex side of the main body a1, the convex surface is deformed so as to be recessed, and the pattern edge becomes an acute angle. Therefore, the pattern appears more clearly than when the male mold 11 is pressed against the concave side of the main body a1.

  Furthermore, since the aluminum profile A has high rigidity due to the ribs a <b> 2, it can resist the pressing force of the press press 10. For this reason, it is possible to suppress the occurrence of shape defects such as warping and twisting, as compared with the case of pressing a simple flat aluminum shape.

(Wood grain pattern)
Next, an aluminum profile B with a woodgrain pattern will be described.
The press 20 of FIG. 5 is a press machine for patterning a woodgrain pattern on the aluminum profile B. The aluminum profile B is composed of a long plate-like main body portion b1 on which a patterning process is performed, and a pair of ribs b2 and b2 depending from both edges of the main body portion b1. Before the patterning process, the aluminum profile B and the aluminum profile A have the same shape.

  In FIG. 5, the code | symbol 21 is an upper mold | type and is a block-shaped member manufactured with die steel etc. FIG. Both edge portions of the lower surface of the upper die 21 are reference surfaces 21a, and are curved so as to be recessed upward with substantially the same bending radius as the main body portion b1 of the aluminum profile B. The upper die 21 is a male die, and a plurality of ridges 21b protruding from the reference surface 21a are formed on the lower surface thereof.

  Reference numeral 22 denotes a lower mold, which is a block-shaped member made of die steel or the like. Both edge portions of the upper surface of the lower mold 22 are reference surfaces 22a, which are curved so as to protrude upward with substantially the same bending radius as the main body portion b1 of the aluminum profile B. The lower mold 22 is a female mold, and a plurality of concave stripes 22b that fit into the convex stripes 21b of the upper mold 21 are formed on the upper surface thereof.

The aluminum shape member B is subjected to pressure forming by placing the upper die 21 which is a male die on the convex side of the curve of the main body b1 and the lower die 22 which is a female die on the concave side of the curve. Is given.
FIG. 6 shows an aluminum profile B patterned by the press press 20. On the surface of the aluminum profile B, a wood grain pattern g is patterned.

Since the aluminum profile B has high rigidity due to the rib b2, the aluminum profile B can resist the pressing force of the pressing press 20, and can suppress the occurrence of shape defects such as warping and twisting.
Moreover, since the main-body part b1 has curved in the width direction previously, the aluminum profile B can suppress the curvature in the longitudinal direction of the aluminum profile C.

  Further, since the male mold 21 is pressed against the convex side of the curve of the main body b1, the convex surface is deformed so as to be depressed, the pattern edge becomes an acute angle, and the pattern appears clearly.

(Stone pattern)
Next, an aluminum shape member C having a grid pattern will be described.
The press 30 in FIG. 7 is a press machine for patterning a grid pattern on the aluminum shape C. The aluminum profile C is composed of a long plate-like main body c1 to which a patterning process is applied, and a pair of ribs c2 and c2 that hang down from both edges of the main body c1. Before the patterning process, the aluminum profile C and the aluminum profile A have the same shape.

  In FIG. 7, reference numeral 31 denotes an upper mold, which is a block-shaped member made of die steel or the like. The upper mold 31 is a male mold, and a plurality of convex portions 31b constituting a grid pattern are formed on the lower surface thereof. The width of the upper mold 31 is narrow and the same width as the width on which the convex portions 31b are formed. Therefore, although the reference surface 31a of the upper mold 31 does not physically exist, the position indicated by the imaginary line passing through the vicinity of the edges at both ends of the upper mold 31 is the reference surface 31a. The reference surface 31a is a surface that is at the same level as the surface of the main body c1 before deformation when the upper die 31 is lowered to the lowest point (FIG. 7B). The convex portion 31b protrudes from the virtual reference surface 31a. Thus, the “male mold” includes a mold having a portion protruding from a virtual reference plane.

  Reference numeral 32 denotes a lower mold, which is a block-shaped member made of die steel or the like. Both edge portions of the upper surface of the lower mold 32 are reference surfaces 32a, and are curved so as to protrude upward with substantially the same bending radius as the main body portion c1 of the aluminum profile C. The lower die 32 is a female die, and a plurality of concave portions 32b that fit into the convex portions 31b of the upper die 31 are formed on the upper surface thereof.

The aluminum shape member C is subjected to pressure forming by placing a male upper die 31 on the curved convex side of the main body c1 and a female lower die 32 on the concave concave side. Is given.
FIG. 8 shows an aluminum profile C patterned by the press press 30. On the surface of the aluminum profile C, a grid pattern g is patterned.

Since the aluminum profile C has high rigidity due to the rib c2, it can withstand the pressing force of the pressing press 30 and can suppress the occurrence of shape defects such as warping and twisting.
Moreover, since the main body part c1 is previously curved in the width direction, the aluminum profile C can suppress warpage in the longitudinal direction of the aluminum profile D.

  Furthermore, since the male mold 31 is pressed against the curved convex side of the main body c1, the convex surface is deformed so as to be depressed, the pattern edge becomes an acute angle, and the pattern appears clearly.

The aluminum shape B having the woodgrain pattern and the aluminum shape C having the woodgrain pattern are repeatedly provided with patterns in the longitudinal direction. When processing such a repeating pattern, a roll press may be used instead of the press press. If a roll press is used, patterning can be continuously performed on long aluminum shapes B and C, and the working time can be shortened.
The roll press may be either manual pressurization or power pressurization as long as the material can be pressure-molded between a pair of rolls, and various types of presses such as hydraulic pressure and pneumatic pressure are used as the power. be able to.

  However, even in the case of processing a repeated pattern, it is preferable to use a press press because the warpage and twisting of the aluminum shapes B and C can be suppressed compared to a roll press. When patterning with a roll press, a press load is locally applied to the aluminum profile, and it is not possible to press the aluminum profile so that it does not move in order to feed the aluminum profile while applying pressure. The bending in the longitudinal direction cannot be suppressed. On the other hand, when patterning is performed with a press press, the aluminum shape, the upper die, and the lower die are in contact with each other on the surface, so there is no fear of bending in the longitudinal direction.

  In addition, when processing a repeated pattern with a press press, the upper mold and the lower mold are long along the long direction of the aluminum profile, and have irregularities that give a pattern of at least one cycle of the repeated pattern. The formed one is used. Then, the pressure forming is repeated while moving the aluminum profile in the longitudinal direction.

The aluminum profiles A to C described above are used as materials for fences, gates, and the like.
FIG. 9 shows an example in which a fence is formed using the aluminum profile A. A large number of aluminum profiles A are arranged side by side in parallel, and their upper and lower ends are fixed to the upper rail 41 and the lower rail 42.

  Since the aluminum shapes A to C are curved in the width direction, when assembled as a fence, a gate, or the like, a thickness on the appearance is born. For this reason, a three-dimensional finish is obtained.

  In addition, it is also possible to use together with an aluminum shape without a pattern other than using aluminum shape AC with a pattern as mentioned above. In this case, the patterned aluminum shapes A to C serve as design accent members.

(Other embodiments)
Like the aluminum profile D shown in FIG. 10, in addition to a pair of ribs d2 and d2 depending from both edges of the main body part d1, a rib d3 protruding from the center of the back surface of the main body part d1 may be provided. Thus, by increasing the number of ribs, the rigidity of the aluminum profile D becomes higher, and the occurrence of shape defects such as warping and twisting can be further suppressed.

A Aluminum profile a1 Main body a2 Rib 10 Press press 11 Upper mold 12 Lower mold BD Aluminum profile 20, 30 Press press

Claims (4)

A method of patterning an aluminum profile by a press machine comprising a male mold and a female mold,
In the aluminum profile, the main body to be patterned is a long plate and is curved in the width direction,
A patterning method for an aluminum shape, comprising: molding the male mold on the convex side of the main body and the female mold on the concave side of the main body, and performing pressure molding. 2. The patterning method for an aluminum profile according to claim 1, wherein the aluminum profile is formed with a rib protruding from the main body. 3. The method for patterning an aluminum profile according to claim 1 or 2, wherein the aluminum profile is obtained by extrusion molding and tempered, and then patterned by the press machine. 4. The method for patterning an aluminum profile according to claim 1, wherein the press machine is a press press.

Images