JPH06218439A - Manufacture of metallic panel - Google Patents

Abstract

PURPOSE:To press a long size metallic sheet at a low cost and with high accuracy. CONSTITUTION:Ruggedparts are molded on both upper and lower press dies 11, 12 for pressing so that the rugged parts of similar pattern are molded on the metallic sheet. The rugged part at the end part of one of the pressed surfaces 11a, 12a are molded more shallowly than those at the end part of the other surface. When the metallic sheet 10 is pressed by above dies 11, 12, press works are performed successively in plural times from one end part of the metallic sheet 10 to the other end part. In this case, a part pressed first by the end part of one of the pressed surfaces 11a, 12a should be pressed doubly by the end part of the other surface. Accordingly, a part pressed on the metallic sheet 10 adjacent to the press dies 11, 12 is pressed shallowly once by the end part of one of the pressed surfaces 11a, 12a, then, pressed deeply by the end part of the other of the pressed surfaces 11a, 12a.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a metal panel for roofing materials, roof accessories, exterior wall exteriors, and the like, and particularly to a metal panel suitable for pressing a long metal panel. The present invention relates to a manufacturing method of.

[0002]

2. Description of the Related Art In recent years, roof panels made of metal such as aluminum, steel and copper have been increasingly used in place of conventional ceramic roof tiles and slate plates. Such a roof panel has a bent portion provided at the upper end portion and / or the lower end portion of the water gradient in consideration of the rainy weather so that the roof panel can be fitted to each other, and the roof panel is aimed at its design effect. An uneven pattern is formed on the surface, or ribs for structural reinforcement are formed.

By the way, the present applicant previously applied for a method for producing a metallic roof panel for producing a roof panel having the above-described structure with high accuracy and high productivity (Japanese Patent Application No. 1-196020). . This takes advantage of both roll forming and pressing, forming the bent part of the metal roof panel by passing it between a pair of rotating rolls, and at the same time other roof panel parts are formed. It is formed by press molding.

FIGS. 8 and 9 show an example in which the roof panel 1 that has been subjected to roll forming is subjected to the above-mentioned press work, and reference numerals 2 and 3 in the drawings respectively indicate upper and lower press dies. These press dies 2 and 3 have a press surface 2
a and 3a are formed on a substantially horizontal surface, and these pressing surfaces 2
The protrusions 2b and the recessed grooves 3b are formed in a and 3a, respectively. Then, the upper press die 2 is brought into contact with and separated from the lower press die 3 in the vertical direction, so that the press surfaces 2a, 3
The roof panel 1 is pressed by a and the ribs 4 are formed on the roof panel 1 by engaging the ridges 2b with the grooves 3b.
Are to be molded.

Here, the roof panel 1 will be briefly described. As shown in FIGS. 8 and 9, the roof panel 1 has a left edge portion of a plate-shaped panel body 5 made of an aluminum alloy, that is, a water gradient upper end portion. A fold part 6 that bends inward
Is formed so as to extend in the longitudinal direction of the panel body 5 (direction orthogonal to the plane of the drawing), and is bent at the right edge of the panel body 5, that is, at the lower end of the water gradient, to the side opposite to the bent portion 6. Music part 7
Are formed so as to extend in the longitudinal direction of the panel body 5. Then, in the roof panel 1 having the above-described configuration, with a large number of these arranged on the roof portion of the building, by engaging the hook portion 7a of the bent portion 7 with the convex portion 6a of the bent portion 6, The roof panels 1 arranged vertically are provided on the roof portion while maintaining high water tightness.

The roof panel 1 manufactured as described above
Unlike the above-mentioned ceramic roof tiles and slate plates, it is possible to manufacture a long panel, and a long one has been required from the viewpoint of roof workability.

[0007]

By the way, in the above-mentioned conventional method for manufacturing a roof panel, roll forming and pressing are used. In the roll forming, it is easy to process a long metal plate. However, when attempting to process a long metal plate by pressing, there were the following problems.

For example, when trying to press a long plate at once, a large press die is required,
A large cost is required for the press die, and the press machine itself is also large, which requires a large equipment cost. Further, when pressing one long metal plate, the metal plate is movably arranged in a small press die, and the metal plate is sequentially moved from one end side to the other end side of the metal plate. By pressing and moving the metal plate, it is possible to press one metal plate in plural times.

If the press working is carried out in this way, a large press die and a press machine are required, so that the equipment cost can be kept low. However, when the metal plate is pressed, distortion may occur at the edge of the pressed part of the metal plate. Then, when a single metal plate is divided into a plurality of times and pressed, the boundary between the previous pressing and the subsequent pressing becomes an edge in the two pressings. In the case of two times, double distortion occurs, and in one press, even a small distortion that is not a problem as a product can be a large distortion by pressing the metal plate in multiple times. There was a nature.

Therefore, when the metal plate is pressed in a plurality of times, it becomes difficult to perform the high-precision pressing, and the appearance of a plurality of pressings is not preferable. There was a problem. The present invention has been made in view of the above circumstances, and provides a method for manufacturing a metal panel in which a boundary between presses is not distorted even when a single metal plate is pressed multiple times. That is the purpose.

[0011]

According to the method of manufacturing a metal panel of the present invention, a long metal plate is sequentially pressed in a plurality of times from one end side to the other end side of the metal plate. By applying, it is to produce a metal panel having irregularities of the same shape repeatedly in the length direction, the left and right ends of the pressing surface of the press die for pressing the metal plate, to the metal panel The unevenness is formed so as to form the unevenness of the same shape, and the unevenness at one end is formed shallower than the unevenness at the other end, and the metal plate is first pressed by the press die. The metal plate is sequentially pressed so that a part of the pressed part that is pressed to one end of the pressing surface is pressed by the other end of the pressing surface in an overlapping manner. It was used as a solution to the problem.

[0012]

According to the above structure, when one metal plate is sequentially pressed from one end side, first, one end side of the metal plate is pressed by the press die. Next, the part of the metal plate adjacent to the already pressed part is pressed. At this time, the part pressed on one end of the press surface of the press die and the other part of the press surface of the press die are pressed. Press so that the edges overlap.

That is, the portion pressed on one end of the pressing surface of the metal plate is then overlapped and pressed by the other end of the pressing surface. Then, as described above, a part of the first pressed part of the metal plate and a part of the later pressed part are overlapped and pressed so that the metal plate is pressed from one end to the other end. Repeat towards the side.

The left and right ends of the pressing surface are formed with concavities and convexities so as to form the same concavities and convexities on the metal plate, and one end is formed with a concavity and convexity shallower than the other end. Therefore, the part of the metal plate that is pressed in duplicate by the first press and the second press is first shallowly unevenly pressed by one end of the pressing surface, and then deeply by the other end. The unevenness will be pressed.

That is, the overlappingly pressed portions of the metal plate are formed to have an unevenness shallower than the depth of the unevenness of the metal panel of the final finished product by the first pressing, and the finished product of the finished product is pressed by the second pressing. It is formed in the depth of the unevenness of the metal panel. Therefore, in the overlappingly pressed portions of the metal plate, the amount of deformation of the metal plate by one pressing is small, so that distortion is less likely to occur despite being pressed by the end portion of the pressing surface.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the metal panel manufacturing method of the present invention will be described below with reference to FIGS. 1. The roll forming process and the roll forming process are performed by a known method similar to the conventional one. First, after returning the hoop material (not shown), which is a coiled aluminum thin plate, to the plate hoop material with an uncoiler, the folded-back portions (not shown) at the left and right ends of the roof panel 1 (shown in FIGS. 5 to 7). ) Is formed, and a hoop material corresponding to the length of the roof panel is cut.

Next, the hoop member is bent by a roll forming machine (not shown) into bent portions 6 and 7 as shown in FIG.
Is molded in a form extending in the longitudinal direction of the hoop material to form a panel material (metal plate) 10 including the bent portions 6 and 7 and the panel body 5. The shape of the bent portions 6 and 7 is different at each edge of the panel body 5, and the left edge of the panel body 5 (in FIG. 1), that is, the bent portion 6 formed at the upper end of the water gradient is Convex portion 6a bent inwardly at an acute angle
And a folded-back portion 6b extending outward from the root of the convex portion 6a and folding back the tip side.

The right edge portion of the panel body 5 (in FIG. 1),
That is, the bent portion 7 formed at the lower end of the water gradient is bent to the opposite side of the bent portion 6 and is bent while being bent substantially parallel to the panel body 5, and the hook portion 7a. Hook part 7
and a folded-back portion 7b formed by folding back the front end side of a. The panel material 10 having the above-described structure is formed into a roof panel (metal panel) 1 by press working described later, and a heat insulating material 13 is attached to the panel material 10. As shown in FIG. In the state in which the roof panel 1 is vertically arranged by engaging the hook portion 7a of the bent portion 7 with the convex portion 6a of the bent portion 6 in the state of being arranged in the portion P, the roof panel 1 that is vertically connected maintains high watertightness. It is designed to be installed on the roof.

2. Pressing After the panel material 10 is formed as described above, the panel body 5 of the panel material 10 is pressed by the manufacturing method according to the present invention to form an uneven pattern that also serves as a reinforcing rib. To do. Here, the shape of the concavo-convex pattern formed by pressing will be described before the pressing method is described.

As shown in the completed view of the roof panel 1 shown in FIG. 5, the panel body 5 is provided with a plurality of downwardly convex concave grooves 5a ... At predetermined intervals in the longitudinal direction of the roof panel 1. Is formed by. The concave grooves 5a are provided along the direction of the water gradient of the panel body 5, and are formed so as to widen and deepen from the upper end side to the lower end side of the water gradient, and are formed in a triangular shape in plan view. Has been done. Further, the concave grooves 5a ... Are formed in a substantially V shape in a cross-sectional view.

Then, these recessed grooves 5 are provided continuously.
A convex portion 5b is formed between a. The convex portion 5b
, Are formed so as to spread from the lower end side of the water gradient of the panel body 5 toward the upper end side, contrary to the concave grooves 5a. The concave grooves 5a and the convex portions 5b serve as reinforcing ribs and also serve as a decorative appearance of the roof panel 1.

2 and 4 (A) when the concave grooves 5a ... And the convex portions 5b ... Are processed by press working.
Upper and lower press dies 11 and 12 as shown in (B) are used. The upper press die 11 is a block-like member that is provided so as to be vertically movable, and its length (the length in the left-right direction of the upper press die 11 shown in FIG. 4) is the length of the panel material 10. The width of the panel material 10 is slightly wider than 1/4 of the width of the panel material 10. By moving the panel material 10 in the length direction with respect to the upper and lower press dies 11 and 12, as shown in FIG.
It is designed to be pressed in a batch. In FIG. 3, the panel material 10 includes upper and lower press dies 1.
The portions pressed adjacent to Nos. 1 and 12 are shown by dividing them by diagonal lines in the opposite direction.

The lower surface of the upper press die 11 is a press surface 11a, as shown in FIG.
The upper press die 11 is inclined at a predetermined angle with respect to the pressing direction (vertical direction). On the press surface 11,
As shown in FIG. 4, a plurality of protrusions 11b ... Is formed. The protrusions 11b are for press-molding the recessed grooves 5a, and are formed at predetermined intervals in the length direction of the upper press die 11 (left-right direction in FIG. 4).

That is, on the pressing surface 11a, there are formed protrusions 11b having a shape corresponding to the triangular recessed grooves 5a of the finished roof panel 1. Further, the protrusion 11b provided within the predetermined distance a from the left end (in FIG. 4) of the pressing surface 11a of the upper press die 11 is formed lower than the other protrusions 11b. Further, the protrusion 11b provided within the predetermined distance b (distance equal to the predetermined distance a) from the right end (in FIG. 4) of the upper press die 11 is the pressing surface 11
The protrusion 11b is basically the same pattern as the protrusion 11b provided within a predetermined distance a from the left end of a, and the protrusion is formed high.

On the other hand, the lower press die 12 has a block shape, and its length (horizontal direction in FIG. 4) is formed similarly to the upper press die 11. Lower press die 1
The upper surface of 2 is a press surface 12a.
Are formed in parallel with the press surface 11a of the upper press die 11 and substantially in the same shape and area as the press surface 11a. A plurality of recessed grooves 12b ... Engaging with the above-mentioned ridges 11b ... Are formed on the pressing surface 12a so as to face the ridges 11b.

The concave grooves 12b are formed by press-molding the triangular concave grooves 5a and the convex portions 5b on the panel material 10 together with the protrusions 11b, and the lower press die 1 is formed.
2 are formed at predetermined intervals in the length direction (left-right direction in FIG. 4). Further, the groove 12b provided on the pressing surface 12a within the same predetermined distance a from the left end of the lower press die 12 as the upper press die 12 corresponds to the protrusion 11b at the left end of the upper press die 11. Are formed shallower than the other concave grooves 12b.

The right end of the lower press die 12 (in FIG. 4)
The groove 12b provided within a predetermined distance b (equal to the predetermined distance a) basically has the same pattern as the groove 12b provided within the predetermined distance a from the left end of the pressing surface 12a. In addition, the groove is deeply formed. The upper and lower press dies 11 and 12 have the shape of the press surfaces 11a and 12a as described above, and the panel material 10
When pressing to form irregularities, press dies 11, 1
The portion corresponding to the left end of 2 has a shallower unevenness than the other portions.

Next, such upper and lower press dies 11, 1
A method of pressing the panel material 10 using No. 2 will be described. First, as shown in FIG. 4 (A), the panel material 10 to be pressed has its length direction relative to the press dies 11 and 12 perpendicular to the direction of the ridges 11b ... Of the upper press surface 11a, That is, they are arranged in accordance with the left-right direction in FIG. 4 and are arranged so as to be movable along the length direction.

Then, with the right end portion side of the panel material 10 being raised, the upper press die 11 is aligned with the right end portion of the lower press die 12 and placed on the lower press die 12. Then, the upper press die 11 is lowered to move the panel material 10 to 1 /
The part slightly longer than 4 is pressed.

At this time, the portion from the left end of the pressed portion of the panel material 10 to the predetermined distance a is the pressed surface 11
a, 12a corresponding to the low ridges 11b and the shallow groove 12b, and are pressed shallowly, and the pressing surface 11
Strain is less likely to occur in the pressed material 10 as compared with the case where the end portions of a and 12a are pressed to the same depth as other portions.

Next, the panel material 10 is moved in the direction of the arrow D (in FIGS. 4A and 4B, the positions of the upper and lower press dies 11 and 12 are moved for illustration purposes). . At this time, the moving distance of the panel material 10 is shorter than the length of the upper and lower press dies by a predetermined distance a and b, and the shallowly pressed portions (the portions of the predetermined distance a) on the upper and lower press dies 11 and 12. The length is duplicated and pressed.
That is, the portion of the panel material 10 that is pressed at the portion from the left end of the pressing surfaces 11a and 12a to the predetermined distance a is overlapped and pressed at the portion from the right end of the pressing surfaces 11a and 12a to the predetermined distance b. Become.

The overlappingly pressed portion is pressed shallower than the other portions by the portion from the left end of the pressing surfaces 11a, 12a to the predetermined distance a in the previous pressing, and in the subsequent pressing, Press surfaces 11a, 1
The portion from the right end of 2a to the predetermined distance b is pressed to the same depth as other portions.

Therefore, since the amount of deformation of the panel material by a single press is small in the part where the boundary between the previous press and the subsequent press overlaps, the amount of deformation of the panel material is the same as in the other parts. Even if it becomes, distortion is hard to occur. That is, even if the end portions of the pressing surfaces 11a and 12a, which are apt to be distorted, are pressed twice in the overlappingly pressed portions, the distortion is not generated.

Then, as described above, the boundary between the previous press and the subsequent press has a predetermined distance a, b as shown in FIG.
The roof panel 1 is completed by performing the third and fourth pressing processes so that the roof panels 1 are overlapped and pressed.

3. Installation of heat insulating material A heat insulating material 13 is attached to the back surface of the completed roof panel 1 as shown in FIGS. 5 to 7. The method of attaching the heat insulating material 13 is arbitrary. For example, in the case of the heat insulating material 13 made of soft foam plastic, a slightly thick foam plastic body is formed by pressing into a shape that matches the back surface shape of the roof panel 1. , A method of sticking this to the back surface of the roof panel 1 or a heat-insulating material 13 made of hard urethane foam, phenol foam, etc. Insulation is injected and fired, then removed and a heat insulating material of specified thickness 1
The method of obtaining 3 is preferably raised.

If the roof panel 1 is manufactured as described above,
The press cost of the roof panel 1 can be reduced without requiring a press working device and a press die corresponding to the length of the roof panel 1, and the roof panel 1 is pressed in a plurality of times. Even in the configuration, there is no distortion at the boundary between the press workings, and the accuracy of the press working can be improved.

In the above embodiment, the present invention is applied to the production of the roof panel 1, and after the hoop material is formed into a plate shape, the notch is formed, the hoop material is cut, and the hoop material is roll-formed. Although it is configured to perform press working, the above-mentioned press working can be applied to other than manufacturing roof panels, so that the same uneven pattern is repeated along the length direction on a relatively long metal plate. The present invention can be applied to the production of any metal panel as long as it is a production of a metal panel that needs to be pressed.

In the above embodiment, the pressing surfaces 11a and 12a of the pressing dies 11 and 12 are inclined, but this is because the roof panel 1 has the bent portion 7, and thus the panel body 5 Part of the panel body 5 is hidden by the bent portion 7. Therefore, if the pressing surfaces 11a and 12a are made horizontal, the vertical movement of the upper press die 11 alone will result in the panel body 5 as shown in FIGS. This is because it is impossible to press the part hidden in the bent portion 7. That is, by forming the pressing surfaces 11a and 12a into inclined surfaces, as shown in FIG. 2, even the portion hidden by the bent portion 7 of the panel body 5 is pressed by the vertical movement of the upper press die 11. It is possible. Therefore, when the metal plate not provided with the bent portion 7 is pressed by the method of the present invention, it is not necessary to incline the press surfaces 11a and 12a.

Further, in the above embodiment, the roof panel 1 is configured to be pressed four times, but the number of times of pressing is determined by the length of the metal plate to be pressed, the press working apparatus and the press die. And the shape of the concave and convex pattern formed by press working.

[0040]

As described above in detail, according to the method for manufacturing a metal panel of the present invention, a long metal plate is formed with a concavo-convex pattern which is repeated along the lengthwise direction by press working. At this time, even if a long metal plate is pressed multiple times, even if it is pressed with a press die shorter than the metal plate, distortion may occur at the boundary between the press works. Without, high precision press working can be performed. Therefore, in order to perform highly accurate press working on a long metal plate, it is not necessary to install a large press working apparatus and a large press die, and it is possible to perform highly accurate press working with low equipment cost.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a panel material serving as a metal plate in a method for manufacturing a metal panel according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a press die for press working used in the method for manufacturing a metal panel.

FIG. 3 is a plan view of a panel material for explaining a press working method in the method for manufacturing a metal panel.

FIG. 4 is a cross-sectional view of the press die for explaining the press working method.

FIG. 5 is a perspective view showing a roof panel manufactured by the method for manufacturing a metal panel.

FIG. 6 is a cross-sectional view showing the roof panel.

FIG. 7 is a cross-sectional view showing a roof configured by the roof panel.

FIG. 8 is a cross-sectional view of a press die for explaining a conventional method for manufacturing a metal panel.

FIG. 9 is a cross-sectional view of a press die for explaining a conventional method for manufacturing a metal panel.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Roof panel (metal panel) 5a Groove (unevenness) of roof panel 5b Convex part (unevenness) of roof panel 11 Upper press die 11a Press surface of upper press die 11b Pressed ridge (unevenness) 12 Lower press Mold 12a Press surface of lower press mold 12b Recessed groove (uneven) on press surface

Claims (1)

[Claims] 1. A long metal plate is repeatedly pressed in a plurality of times from one end side to the other end side of the metal plate, thereby repeating the same shape in the length direction. A method of manufacturing a metal panel for manufacturing a metal panel having irregularities, wherein the metallic panel is formed with irregularities of the same shape on both left and right end portions of a pressing surface of a press die for pressing the metal plate. In addition to forming unevenness on the metal plate, the unevenness at one end is formed shallower than the unevenness at the other end, and the press surface of the portion of the metal plate that is pressed first by the press die is pressed. A method of manufacturing a metal panel, wherein the metal plate is sequentially pressed so that a portion to be pressed on one end is overlapped by the other end of the pressing surface.