JPH09225555A - Manufacture of metallic siding material applied with brick pattern - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a metallic siding material applied with the brick pattern that masonry joint corresponding parts parallel to each other in the longitudinal direction are largely recessed among large brick patterns. SOLUTION: A metallic sheet is continuously embossed by an embossing machine comprising two emboss rolls 8a, 8b which are rotated at the same speed in the opposite direction to each other by arranging masonry joint corresponding parts in which each side is inclined around a brick pattern part and orthogonal in the longitudinal direction and pseudo masonry joint corresponding part whose depth is equal to the depth of the joint corresponding part and whose bottom part width is wider than the bottom part width of the masonry joint corresponding parts to be manufactured parallel in the longitudinal direction opposite to each other. A part corresponding to an edge part of a bottom part of the pseudo masonry join corresponding part is restricted at the face and back, and is rolled by a rolling mill 9 comprising two rolls 9a, 9b which are arranged opposite to each other and rotated at the same speed in the opposite direction to each other to the depth of the masonry joint corresponding part whose bottom width is equal to that of the masonry joint corresponding part parallel in the longitudinal direction, and which is >=1.3mm in the depth from the surface of a surface member 1, and parallel in the longitudinal direction.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a metal siding material, which is used as an exterior material for houses and structures and has a brick pattern and which has an excellent design effect.

[0002]

2. Description of the Related Art In recent years, as exterior materials for houses, structures, etc.,
Lightweight and heat-insulating metal siding materials are often used. This metal siding material is a surface material made of a thin metal plate that is formed into a substantially gutter-shaped cross section and provided with engaging portions on both sides along the longitudinal direction, and a synthetic resin foam filled in the gutter-shaped portion of the surface material. The core material is composed of a body, and the back surface material is a sheet-like material that covers the back surface of the core material.

However, the metal siding material is a laminated body of three different materials, that is, a surface material, a core material, and a back surface material, and the degree of expansion and contraction of each material is different, so that the metal siding material as a whole is easily deformed. In order to prevent this defect, it is necessary to give a small embossed pattern to the whole thin coated metal plate used as a surface material to enhance its rigidity, and therefore the surface design is limited.

In recent years, however, demands for high-class designs have become stronger, and large patterns have been favored.
A brick pattern is required as a representative of large patterns, but in the current method of manufacturing metal siding materials, the design of a thin coated metal plate used as a surface material is a relatively small pattern such as a stucco pattern or a pine pattern. Since the entire surface of the metal plate is embossed with an embossing roll, the embossing depth is limited to about 0.8 mm from the surface of the metal plate, which is a surface material, and the edging is irregular and the pattern has cracks in the width direction. However, a pattern such as a brick pattern that requires a joint-corresponding portion having a certain width without an embossed pattern has not been manufactured. In addition, a part of the metal siding material that has an irregular large pattern (iron flat stone pattern) and a joint equivalent part in a different color from the main body is marketed,
In this metal siding material, the embossed pattern is also applied to the joint-corresponding part, and the embossing depth of the joint-corresponding part is shallow. Therefore, painting is performed twice to clearly show the joint-corresponding part, which is expensive. Has become.

[0005]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned drawbacks of conventional metal siding materials and responds to recent demands for high-class designs. The bricks are square or rectangular and have a large pattern with a raised contour. An object of the present invention is to provide a method for producing a metal siding material having a pattern and having an excellent design effect.

[0006]

Means for Solving the Problems As a result of intensive studies to solve the above problems, the inventors of the present invention have found that an embossing machine forms a brick pattern part on a surface of a thin metal plate and a joint corresponding part parallel to the longitudinal direction and a longitudinal direction. In order to form an orthogonal joint-corresponding part and to make it clear and uneven, the embossing depth from the surface of the metal sheet, which is the surface material, to the bottom of one joint-corresponding part is 1.3 mm or more. It was determined that it was necessary to However, if the embossing depth is increased and the convex surface that becomes the brick pattern part is enlarged, cracks occur at the corners of the brick pattern part and in the approximate center of the straight edge, and the bottom surface of the joint-equivalent part is straight. Not only cracks will occur in the approximate center of the edge, but also distortion (wrinkles) will occur from the brick pattern part to the joint-corresponding part, and further, the phenomenon that strain (wrinkles) will also occur in the brick pattern part will occur. I understood. Since this is done by supplying a thin metal plate between the two embossing rolls facing each other, the thin metal plate will be pushed linearly between the two embossing rolls. It is considered that this is due to the fact that there is no phenomenon in which there is a margin in the supply of material due to the flow of material around it when the central part of the blank is fixed and pushed in.

However, rather than supplying a thin metal plate between two opposing embossing rolls for continuous embossing, the blank is fixed and embossing is performed as in ordinary press working. Even if you try to adopt the processing method, if the embossing depth becomes deep, the rigidity of the metal sheet that is the surface material will increase and it will not be possible to bend or coil the embossed metal sheet, but if you do forcefully coil it. Since the embossed surface will be bent and the product value will be lost if it is looped or looped, it is impossible to store the thin metal plate in the embossed state. Since it becomes impossible to manufacture a siding material, a thin metal film must be placed between two opposing embossing rolls. The is the inevitable use embossing machine continuously performing embossing supplied.

Therefore, the inventors of the present invention have a coated hot-dip galvanized steel sheet having a plate thickness of 0.27 mm and a plate thickness of 0.35 mm which are usually used as a surface material for producing a metal siding material having a brick pattern. As a result of conducting various experiments using a coated aluminum plate, joint-equivalent portions that are parallel to the longitudinal direction and joint-equivalent portions that are orthogonal to the longitudinal direction are formed around the brick pattern portion of the surface material of the metal siding material, respectively. One embossing roll is used as an embossing machine that forms a side surface with an inclined shape and supplies a thin metal plate between two embossing rolls that rotate in the opposite directions at the same speed and opposite to each other for continuous embossing. A brick pattern portion having a U-shaped cross-section with concave portions formed on the surface to form a pseudo joint corresponding portion parallel to the longitudinal direction of the metal thin plate and a joint corresponding portion orthogonal to the longitudinal direction around the brick pattern portion. If the radius of the planar shape corresponding to the corner is 2.0 to 5.5 mm and the depth is the depth corresponding to the depth of the joint equivalent part orthogonal to the longitudinal direction of the metal siding material to be manufactured, the other embossing roll , In the portion corresponding to the joint-equivalent portion orthogonal to the longitudinal direction of the metal siding material, the width of the top is the same as the width of the bottom of the joint-equivalent portion orthogonal to the longitudinal direction, and the height is the same as the depth of the joint-equivalent portion. In the portion corresponding to the pseudo joint equivalent portion parallel to the longitudinal direction, the width of the top is wider than the bottom width of the joint equivalent portion parallel to the longitudinal direction and corresponds to the pseudo joint equivalent portion parallel to the longitudinal direction. A U-shaped cross-sectional shape that is shorter than the width of the concave portion of the portion and is equal to the U-shaped cross-sectional shape of the portion corresponding to the joint-corresponding portion orthogonal to the longitudinal direction that is shorter than the length obtained by subtracting twice the plate thickness of the surface material. The convex parts of the The depth of the joint-corresponding portion orthogonal to the longitudinal direction of the metal siding material is embossed by using the one formed on the surface so that the joint-corresponding portion orthogonal to the longitudinal direction of the metal siding material to be manufactured Same as the depth and parallel to the longitudinal direction After manufacturing a pseudo joint corresponding portion with a wide bottom at a depth shallower than the depth of the joint equivalent parallel to the longitudinal direction of the metal siding material to be manufactured, this embossing is performed. As a roll processing machine for supplying a thin metal plate between two rolls that rotate in the opposite directions at the same speed and opposite to each other to continuously perform roll processing, one roll has a cross-sectional shape formed on the surface. Equivalent joint portion parallel to the longitudinal direction formed by the embossing A portion corresponding to the edge of the bottom of the back surface and the joint portion whose depth between the portions is parallel to the longitudinal direction of the metal siding material manufactured That has a recess having a U-shaped cross-section with a depth corresponding to the depth obtained by subtracting the depth of the pseudo joint portion from the depth of the other roll, the cross-section formed on the surface of the other roll is the embossed The portion corresponding to the edge of the bottom of the surface of the pseudo joint corresponding to the longitudinal direction formed by and the width of the top between the parts is the same as the width of the bottom of the joint corresponding to the longitudinal direction. A protrusion having a U-shaped cross-section with a height shorter than the length obtained by subtracting twice the plate thickness of the surface material from the width of the concave portion of the roll and the depth obtained by subtracting the depth of the pseudo joint equivalent portion from the joint equivalent portion parallel to the longitudinal direction. The part that is formed so as to fit inside the recess is used to create a joint that is parallel to the longitudinal direction and has a depth of 1.3 mm or more from the surface of the surface material that corresponds to the joint that is parallel to the longitudinal direction. If you roll to the depth of the part,
Continuously manufacture a metal siding material with a brick pattern excellent in design effect that has a brick pattern with unevenness similar to a real brick with a joint equivalent depth of 1.3 mm or more parallel to the longitudinal direction The present invention has been completed by investigating that it is possible.

That is, according to the present invention, a brick-like embossed pattern is formed by an embossing machine for supplying a thin metal plate between two embossing rolls that rotate in the opposite directions at the same speed and opposite to each other for continuous embossing. After forming the, the engaging parts are formed on both sides of the metal thin plate by the engaging part forming machine to form the surface material having a substantially gutter-shaped cross section, and then the gutter-shaped part of the surface material is made of synthetic resin foam. Inject core material to foam filling,
The back side of the filled core material is covered with a back side material composed of a sheet-like material, and the core material is cured in the process of moving while being sandwiched between double conveyors, and the side surfaces are inclined around the brick pattern part. When manufacturing a metal siding material provided with a brick pattern in which a joint-equivalent portion parallel to the direction and a joint-equivalent portion orthogonal to the longitudinal direction are formed, one embossing roll, as an embossing molding machine, is a brick pattern portion. A concave portion formed on the surface to form a pseudo joint corresponding portion parallel to the longitudinal direction of the thin metal plate and a joint equivalent portion orthogonal to the longitudinal direction in the periphery corresponds to the corner portion of the brick pattern portion with a U-shaped cross section When the radius of the plane shape is 2.0 to 5.5 mm and the depth corresponds to the depth of the joint-corresponding part orthogonal to the longitudinal direction of the metal siding material to be manufactured, the other embossing roll is In the portion corresponding to the joint-equivalent portion orthogonal to the longitudinal direction of the sealing material, the width of the top is the same as the width of the bottom of the joint-equivalent portion orthogonal to the longitudinal direction, and the height is the same as the depth of the joint-equivalent portion. In the portion corresponding to the pseudo joint equivalent portion parallel to the longitudinal direction, the width of the top is wider than the bottom width of the joint equivalent portion parallel to the longitudinal direction, and the portion corresponding to the pseudo joint equivalent portion parallel to the longitudinal direction is formed. A protrusion having a U-shaped cross-sectional shape having the same height as the U-shaped cross-sectional shape of a portion corresponding to a joint-corresponding portion that is shorter than the length obtained by subtracting twice the plate thickness of the surface material from the width of the recess and is orthogonal to the longitudinal direction. Between two rolls that are embossed by using the ones whose surfaces are formed so as to enter the recesses, respectively, and then the embossed thin metal plates are opposed to each other and rotate at the same speed and in opposite directions. Supply to the roll for continuous roll processing. As one of the roll processing machines, one of the rolls has a section corresponding to the bottom edge of the back surface of the pseudo joint corresponding to the longitudinal direction formed by the embossing and the cross-sectional shape formed on the surface and the portion between the sections. The depth of the metal siding material to be manufactured shall have a U-shaped cross-section concave portion having a depth corresponding to the depth obtained by subtracting the depth of the pseudo joint corresponding portion from the depth of the joint corresponding portion parallel to the longitudinal direction. , The other roll has a cross-sectional shape formed on the surface by the embossing and is parallel to the longitudinal direction, the portion corresponding to the edge of the bottom of the pseudo joint corresponding portion surface and the width of the top is long between the portions. The width is equal to the width of the bottom of the joint corresponding to the direction and shorter than the width of the recess of the one roll minus twice the plate thickness of the surface material, and the joint corresponding to the longitudinal direction corresponds to the pseudo joint. Of the height less the depth of the part Use a convex part with a V-shaped cross-section that fits into the concave part, and a depth of 1.3 mm or more from the surface of the surface material at the bottom of the pseudo joint equivalent part parallel to the longitudinal direction. This is a method for producing a metal siding material having a brick pattern, which is characterized by rolling to a depth corresponding to a joint parallel to the direction.

In such a method of the present invention, as a roll processing machine, the opening edge of the concave portion having the U-shaped cross section of one roll has a ten-point average roughness of 3.2 μm when the reference length is 0.8 mm.
With the following finish and a radius of 0.2 to 0.5 mm, the end of the convex part of the U-shaped cross section of the other roll has a 10-point average roughness of 3.2 mm or less at a reference length of 0.8 mm and a radius of 0.2
It was also clarified that the phenomenon of cracks and wrinkles occurring on the slopes and edges of joints can be more significantly prevented by using a taper of ~ 0.5 mm.

Further, in the method for manufacturing a metal siding material having such a brick pattern, embossing is performed so that unfinished portions of the brick pattern portion do not remain on both sides of the surface material formed to have a substantially gutter-shaped cross section. If embossed with a molding machine, joints will be accurately placed between the brick patterns of adjacent metal siding materials that will be joined via the engaging parts when the metal siding material is applied to the wall surface, and the work will be performed well. When the metal siding material to be manufactured is a horizontal metal siding material, the inclination angle of the slope from the brick pattern part to the joint equivalent part parallel to the longitudinal direction of the metal siding material is 110 on the upper surface side. It was also clarified that the appearance can be further improved by embossing at ° to 125 ° and at the lower surface to 130 ° to 140 °.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION A method for producing a brick siding material according to the present invention will be described in detail below with reference to the drawings. FIG. 1 is a perspective view of an embodiment of a metal siding material provided with a brick pattern manufactured by the method of the present invention, FIG. 2 is an enlarged cross-sectional view taken along line XX in FIG. 1, and FIG. 3 is a brick pattern according to the present invention. FIG. 4 is a schematic explanatory view showing an embodiment of an apparatus for carrying out the method for producing a metal siding material having a pattern, and FIG. 4 is used for carrying out the method for producing a metal siding material having a brick pattern according to the present invention. FIG. 5 is a partially enlarged cross-sectional explanatory view of an embossing roll of one embodiment of an embossing machine, and FIG. 5 is one embodiment of a roll processing machine used to carry out the method for manufacturing a metal siding material having a brick pattern according to the present invention. FIG. 3 is a partially enlarged cross-sectional explanatory view of the roll of FIG.

First, the brick siding material produced by the method of the present invention will be described with reference to FIGS. 1 and 2. Numeral 1 is formed in a substantially gutter-shaped cross section on both sides (the upper and lower sides of the illustrated embodiment are horizontal metal siding materials).
Is a surface material made of a thin metal plate provided with engaging portions A and B over its entire length, and this surface material 1 is a coated hot dip galvanized steel sheet, an aluminum alloy coated board, a coated zinc alloy plated steel sheet, or the like. A brick pattern part 1a which is made of a metal plate and has a minute uneven pattern on a part thereof such as a sandstone pattern or a split brick pattern by embossing, if necessary. The depth is shallower than the joint-corresponding part 1b having no concave-convex pattern parallel to the longitudinal direction of the surface material 1 which is largely recessed by mm or more and the joint-corresponding part 1b parallel to the longitudinal direction having no concave-convex pattern (usually about 0.8 mm). ) And a joint-corresponding portion 1c which is orthogonal to the longitudinal direction and has no uneven pattern is formed to form a brick pattern. When constructing a brick pattern in this manner, irregularly-shaped joint-corresponding portions 1c that are parallel to the longitudinal direction and that do not have a concave-convex pattern and that are adjacent to each other and that have no concave-convex joint that are orthogonal to the longitudinal direction are irregular. If it is formed at such intervals, it is possible to obtain a finish that does not feel uncomfortable without having to perform joint alignment of the joint-corresponding portion 1c that does not have a concave-convex pattern that intersects the longitudinal direction at the time of construction on the wall surface, so that construction is easy and This is preferable because material loss can be eliminated.

The shape of the brick pattern of the surface material 1 will be described in more detail. As shown in FIG. 1, a joint-corresponding joint portion which is parallel to the longitudinal direction and has no uneven pattern so as to raise the brick pattern portion 1a which is a convex portion. In order to form 1b deeper than 1.3 mm, a specific method is used for the radius of the planar shape of the corner portion of the brick pattern portion 1a in the embossing process described below and the roll processing method described below after the embossing process. Need to be adopted. When forming the joint-corresponding portion 1b having no uneven pattern parallel to the longitudinal direction by rolling to a depth of 1.3 mm or more from the surface of the surface material 1, the joint-corresponding portion parallel to the longitudinal direction is formed. It is preferable to examine the radius of the bottom edge from 1b to the brick pattern portion 1a, and more preferably the inclination angle of the slope of the joint corresponding portion 1b parallel to the longitudinal direction. Therefore, the inventors of the present invention have, for example, JIS A 671.
_1-1979 in accordance with the "Zhejiang composite metal siding",
As a result of various examinations using a hot-dip galvanized steel sheet with a minimum thickness of 0.27 mm and a relatively large elongation among the steel sheets used, as described below as an embossing roll of an embossing machine and a roll of a roll processing machine. We have determined that it is sufficient to use the ones that meet the conditions.

Reference numeral 2 is a core material made of synthetic resin foam filled in the gutter-shaped portion of the surface material 1 mainly for imparting functions such as heat insulation and soundproofing, and the material thereof is polyurethane foam or poly. The main material is isocyanurate foam, phenol foam, etc., and if necessary flame retardant,
It is composed of a material to which a flame retardant aid is added.

Reference numeral 3 denotes a sheet-like material which covers the back surface of the core material 2 in order to maintain the weather resistance of the core material 2 and prevent the core material 2 from collapsing or forming mold due to dew condensation. It is a back surface material, and as the material, kraft paper, aluminum vapor deposition kraft paper, aluminum foil laminated paper, metal plate, or the like is used.

Next, the method of the present invention for producing a metal siding material having a brick pattern having the above-described structure will be described with reference to FIG.
This will be described with reference to 4 and 5. Reference numeral 4 denotes an uncoiler in which a coil of a metal thin plate constituting the surface material 1 is mounted, and which continuously feeds the metal thin plate. Two uncoilers 4 are arranged side by side and are mounted on one of the uncoilers 4. When the thin plate is consumed, the thin metal plate mounted on the other uncoiler 4 is sent out. Reference numeral 5 is a connector for connecting the rear end of the metal thin plate attached to one uncoiler 4 and the tip of the metal thin plate attached to the other uncoiler 4 by "caulking" when the metal thin plate attached to one uncoiler 4 is consumed, 6 is a pinch roll that continuously feeds the thin metal plate from the uncoiler 4, 7 is a loop of the thin metal plate that is fed out from the pinch roll 6, and then softens the coating film of the thin metal plate to crack into the coating film during the next embossing It is a preheater for heating so as to prevent scratches and cracks. As this heating method, various methods such as a hot air method, an open flame method, a far infrared ray method and a radiant tube method can be adopted.

Numeral 8 designates two embossing rolls 8a which rotate in the opposite directions at the same speed to each other in order to continuously emboss a thin metal sheet heated to a predetermined temperature by the preheater 7.
8b is an embossing machine, in which one embossing roll 8a has a pseudo joint corresponding to the longitudinal direction of the metal sheet and a long joint around the brick pattern portion 1a to be applied to the metal sheet. The concave portion formed on the surface to form the joint-corresponding portion 1c orthogonal to the direction has a U-shaped cross-sectional shape, and the radius of the plane shape corresponding to the corner portion of the brick pattern portion 1a is 2.0 to 5.5 mm and its depth is A metal siding material having a depth corresponding to the depth of the joint corresponding portion 1c orthogonal to the longitudinal direction, and the other embossing roll 8b corresponds to the joint corresponding portion 1c orthogonal to the longitudinal direction of the metal siding material. In the part to be joined, the joint equivalent part 1c whose top width is orthogonal to the longitudinal direction
Has the same U-shaped cross-sectional shape as the width of the bottom portion and the same height as the depth of the joint corresponding portion 1c, and the width of the top portion is parallel to the longitudinal direction in the portion corresponding to the pseudo joint corresponding portion parallel to the longitudinal direction. The width is shorter than the width of the concave portion of the portion corresponding to the pseudo joint corresponding portion which is wider than the bottom width of the joint corresponding portion 1b and is parallel to the longitudinal direction, and is shorter than the length obtained by subtracting twice the plate thickness of the surface material 1 and orthogonal to the longitudinal direction. Embossing is performed by using protrusions having a U-shaped cross-section having the same height as the U-shaped cross-section of the portion corresponding to the joint-corresponding portion 1c, each of which is formed on the surface so as to enter the recess. Is applied.

At this time, when the metal siding material to be manufactured is a horizontal metal siding material, the metal siding from the brick pattern portion 1a is inserted with the convex portion of the other embossing roll 8b inserted in the concave portion of the one embossing roll 8a. By embossing the slope angle of the slope reaching the joint equivalent part 1b parallel to the longitudinal direction of the material to 110 ° to 125 ° on the upper surface side and 130 ° to 140 ° on the lower surface side, the design effect is further enhanced. It becomes a thing. The embossing machine 8 is embossed so that the unfinished portion of the brick pattern portion 1a does not remain on both sides of the surface material 1 which is formed in a substantially gutter-shaped cross section by the engagement portion forming machine 11 described later. It is preferable that

Reference numeral 9 denotes a roll-working machine for supplying an embossed thin metal plate between two rolls 9a, 9b which rotate at the same speed and in opposite directions at the same speed to perform continuous roll-working. As for this roll processing machine 9, one roll 9a is
The cross-sectional shape formed on the surface is a portion corresponding to the edge of the bottom of the back surface of the pseudo joint corresponding to the longitudinal direction formed by the embossing and the length of the metal siding material manufactured by this depth. One having a concave portion having a U-shaped cross-sectional shape having a depth corresponding to the depth obtained by subtracting the depth of the pseudo joint corresponding portion from the depth of the joint corresponding portion 1b parallel to the direction, the other roll 9b is on the surface. A portion corresponding to the edge of the bottom of the pseudo joint corresponding portion in which the formed cross-sectional shape is formed by the embossing and is parallel to the longitudinal direction, and the joint corresponding portion 1b in which the width of the top is parallel to the longitudinal direction between the portions. The width of the bottom of the one roll 9a is shorter than the width of the recess of the one roll 9a minus twice the plate thickness of the surface material 1 and the depth of the pseudo joint corresponding portion from the joint corresponding portion 1b parallel to the longitudinal direction. The convex part of the U-shaped cross section of the height subtracted A joint corresponding to the longitudinal direction parallel to the bottom of the pseudo joint corresponding to the longitudinal direction and having a depth from the surface of the surface material 1 of 1.3 mm or more is used. Roll processing is performed to a depth of 1b.

In this roll processing machine 9, the opening edge of the concave portion of one roll 9a having a U-shaped cross section has a reference length of 0.
10 mm average roughness at 8 mm 3.2 μm or less and a radius of 0.2 to 0.5 mm, and the edge of the convex portion of the U-shaped cross section of the other roll 9b has a 10 mm average roughness at a reference length of 0.8 mm. It
It is even more preferable that the finish is 3.2 μm or less and the radius is 0.2 to 0.5 mm.

An embossing machine 8 embosses a brick pattern portion 1a, a pseudo joint corresponding portion parallel to the longitudinal direction and a joint corresponding portion 1c orthogonal to the longitudinal direction, and a roll machining machine 9 parallels the longitudinal direction. A joint corresponding to the bottom of the pseudo joint corresponding to a depth of 1.3 mm or more from the surface of the thin metal plate and parallel to the longitudinal direction 1
The leveler 10 is a leveler that corrects the strain of a thin metal material that has been rolled to a depth of b, and this leveler 10 may be installed as necessary. Reference numeral 11 is an engagement portion forming machine for forming the engagement portions A and B on both sides of the thin metal material whose strain is corrected by the leveler 10 as required to form the surface material 1 having a substantially gutter-shaped cross section, 12
Is a surface material 1 having a substantially gutter-shaped cross section having engaging portions A and B on both sides in order to promote foaming of a core material 2 made of a synthetic resin foam injected from a resin injection machine installed next. It is a preheater for heating the preheater, and the preheater 12 may be installed as necessary.

Reference numeral 13 denotes a core material 2 formed of synthetic resin foam in a trough-shaped portion of a surface material 1 which is formed into a substantially gutter-shaped cross section having engaging portions A and B on both sides and which is heated by a preheater 12 if necessary. A resin injecting machine for injecting the resin, 14 is a back surface of the core material 2 in a process in which the core material 2 made of synthetic resin foam injected into the gutter-shaped portion of the surface material 1 is foamed and filled in the gutter-shaped portion. Pay-off reel for supplying the backing material 3 to cover the backing material 3 made of a sheet-like material, and 15 is the core material 2 filled in the gutter-shaped part of the surface material 1.
It is a double conveyor that cures the core material 2 by moving while sandwiching the front surface and the back surface in a state where the back surface is covered with the back surface material 3.

In order to manufacture a metal siding material having a brick pattern by the apparatus having such a structure, first, a thin metal plate to be the surface material 1 is uncoiled from the uncoiler 4 to the pinch roll 6.
When the metal thin plate mounted on one of the uncoilers 4 is consumed, the rear end of the metal thin plate and the tip of the metal thin plate mounted on the other uncoiler 4 are connected by the connecting machine 5 Since the connection is made by caulking, it is possible to continuously send out the metal thin plate. Thus, when connecting the trailing end of the preceding metal thin plate and the leading end of the next metal thin plate by the connecting device 5, The loop-shaped thin metal plate at the tip of the pinch roll 6 is consumed.

Thereafter, the thin metal plate is heated to a predetermined temperature by the preheater 7 to soften the coating film, and the two embossing rolls 8 are rotated at the same speed and in opposite directions to each other.
The embossing machine 8 composed of a and 8b embosses the brick pattern portion 1a, the pseudo joint corresponding portion parallel to the longitudinal direction of the metal sheet, and the joint equivalent portion 1c orthogonal to the longitudinal direction,
This embossing is performed by forming the pseudo joint corresponding portion parallel to the longitudinal direction of the thin metal plate and the joint corresponding portion 1c orthogonal to the longitudinal direction in the concave portion formed on the surface of one embossing roll 8a and the other embossing roll. The convex portion formed on the surface of 8b enters and is continuously performed on the surface material 1. At this time, one embossing roll 8a is a surface for forming a joint corresponding portion 1c orthogonal to the longitudinal direction and a pseudo joint corresponding to the longitudinal direction of the metal thin plate around the brick pattern portion 1a to be applied to the metal thin plate. The concave portion formed in has a U-shaped cross-section and the radius of the plane shape corresponding to the corner of the brick pattern portion 1a is 2.0.
Since it is ~ 5.5 mm, a large stress concentration does not occur when forming the corner portion of the brick pattern portion 1a.
Since the phenomenon such as cracking does not occur at the corners of the metal thin plate, the depth of the pseudo joint corresponding portion parallel to the longitudinal direction of the metal sheet and the joint corresponding portion 1c orthogonal to the longitudinal direction is the longitudinal direction of the metal siding material manufactured. Since it is shallow at a depth (usually about 0.8 mm) corresponding to the depth of the joint-corresponding portion 1c orthogonal to, there is no occurrence of cracks, wrinkles or strains in both joint-corresponding portions.

Since the convex portion formed on the surface of the other embossing roll 8b is inserted into the concave portion formed on the surface of the one embossing roll 8a to perform embossing, the brick pattern portion 1a to the thin metal plate is formed. The metal thin plate is not in contact with any of the embossing rolls 8a and 8b in the part forming the slope extending to the bottom of the joint corresponding portion 1c orthogonal to the longitudinal direction and the joint corresponding to the longitudinal direction, that is, the material is restrained. Although it will be stretched in the state of not being formed, it is formed on the surface of one embossing roll 8a in the part which becomes the bottom of each pseudo joint corresponding portion parallel to the longitudinal direction of the metal thin plate and the joint corresponding portion 1c orthogonal to the longitudinal direction. The embossing is performed in a state in which the bottom of the concave portion and the top of the convex portion formed on the surface of the other embossing roll 8b are constrained to cause almost no elongation.

Next, the embossed thin metal plate is supplied between two rolls 9a and 9b of the roll processing machine 9 which are rotated at the same speed and in opposite directions, and are continuously rolled. However, with this roll processing machine 9,
A portion corresponding to the edge of the bottom of the pseudo joint equivalent portion formed by the embossing parallel to the longitudinal direction is held on its back surface by one roll 9a, and its front surface by the other roll 9b, in the longitudinal direction. The U-shaped cross section in which the convex portion of the U-shaped cross-sectional shape formed on the surface of the other roll 9b is formed on the surface of the other roll 9b between the portions corresponding to the edges of the bottom of the parallel pseudo joint corresponding portion Entering into the concave portion of the shape, the width of the bottom portion at the bottom of the pseudo joint corresponding to the longitudinal direction parallel to the longitudinal direction in which the expansion hardly occurs in the embossing of the joint equivalent portion 1b parallel to the longitudinal direction of the metal siding material manufactured. That is, a part having the same width as that having slopes on both sides thereof is formed.
As a result, the depth of the bottom of this portion from the surface of the surface material 1 becomes the depth of the joint corresponding portion 1b parallel to the longitudinal direction of 1.3 mm or more, and the edge of the bottom of the pseudo joint corresponding portion formed by embossing is formed. A slight step is formed on the part corresponding to the part 1.
The joint-corresponding portion 1b having a depth of 3 mm or more and parallel to the longitudinal direction can be formed.

In this roll processing, as described above, the portion to be processed is a portion where the embossing hardly causes expansion, and the pseudo joint corresponding to the longitudinal direction parallel to the longitudinal direction where the embossing is severely processed. Since the portion corresponding to the edge of the bottom of the roll is constrained by both rolls 9a and 9b, cracks and wrinkles do not occur. Then, the opening edge of the concave portion having a U-shaped cross section of one roll 9a has a reference length.
10-point average roughness at 0.8 mm Finishing with 3.2 μm or less and radius of 0.2 to 0.5 mm, the edge of the convex part of the U-shaped cross section of the other roll 9b has a 10-point average roughness at a reference length of 0.8 mm 3.2μ
If the finish is m or less and the radius is 0.2 to 0.5 mm, the finish is good and the stress concentration due to bending is small, so there is a slope formed on both sides of the edge formed at the bottom edge of the pseudo joint equivalent part. Even when the width of the portion is narrow, the phenomenon that cracks, wrinkles, and the like occur is further reduced, which is preferable.

Thus, the embossing machine 8 and the roll processing machine 9 form a surface around the brick pattern portion 1a on which the joint corresponding portion 1b parallel to the longitudinal direction of the thin metal plate and the joint corresponding portion 1c orthogonal to the longitudinal direction are formed. The material 1 is straightened after its distortion is corrected by a leveler 10 which is installed as required, and is formed into a gutter-shaped cross section by forming engaging portions A and B on both sides thereof by an engaging portion forming machine 11. It is heated by a preheater 12 installed as needed, and a core material 2 made of synthetic resin foam is injected into the gutter-shaped portion by a resin injecting machine 13, and the core material 2 is foamed and filled in the gutter-shaped portion. The back material 3 is supplied from the payoff reel 14 so as to cover the back surface of the core material 2 with the back material 3 made of a sheet in the process of being in a state, and the back surface of the core material 2 filled in the gutter-shaped portion of the surface material 1. The front and back sides are sandwiched by the double conveyors 15 and 15 with the back side material 3 covered. Core 2 in the process of moving and is cured, producing a predetermined length in the cut is transverse clad metal siding material brick pattern was subjected to is to complete after exiting between double conveyor 15, 15.

[0030]

EFFECTS OF THE INVENTION According to the method for manufacturing a metal siding material provided with a brick pattern according to the present invention, an uneven pattern is formed between brick pattern portions which are large patterns that meet the requirements of recent high-class designs. A metal with a brick pattern that has an excellent design effect in the state where the joint-corresponding part is parallel to the longitudinal direction and the joint-corresponding part is formed at a depth of 1.3 mm or more than the brick part and the brick pattern part is clearly raised. The siding material can be manufactured.

The produced brick-patterned metal siding material is formed such that the joint-corresponding portion parallel to the longitudinal direction is recessed more than the brick-patterned portion and has no uneven pattern. Since it can be clearly distinguished from the brick pattern part, there is no need to color-code the brick pattern part and the joint-equivalent part, and the surface material can be made inexpensive because it is possible to use a monocolor, so it is a high-class design. Nevertheless, it is possible to provide an inexpensive metal siding material.

Further, a brick pattern produced by embossing with a embossing machine is applied so that uncompleted portions of the brick pattern portion do not remain on both sides of the surface material formed into a substantially gutter-shaped cross section. The appearance of the metal siding material does not deteriorate in the installed state, and if the metal siding material with a brick pattern that is manufactured is a horizontal metal siding material, the horizontal joints will be removed from the brick pattern part. The slope angle of the slope reaching the horizontal joint is 110 on the top side.
If it is formed so that it is in the range of ° to 125 ° and 130 ° to 140 ° on the lower surface side, the inclination angle on the lower surface side that is often noticeable at the time of viewing becomes tight and the appearance is very excellent. Of.

The industrial value of the method for producing a brick siding material having a brick pattern according to the present invention having various effects as described above is very great.

[Brief description of drawings]

FIG. 1 is a perspective view of an embodiment of a brick siding material produced by a method of the present invention.

FIG. 2 is an enlarged cross-sectional explanatory view taken along line XX in FIG.

FIG. 3 is a schematic explanatory view showing one embodiment of an apparatus for carrying out the method for manufacturing a metal siding material having a brick pattern according to the present invention.

FIG. 4 is a partial enlarged cross-sectional explanatory view of an embossing roll of one embodiment of an embossing machine used to carry out the method for manufacturing a metal siding material having a brick pattern according to the present invention.

FIG. 5 is a partially enlarged cross-sectional explanatory view of a roll of an example of a roll processing machine used for carrying out the method for manufacturing a metal siding material having a brick pattern according to the present invention.

[Explanation of symbols]

 1 surface material 1a brick pattern part 1b joint part parallel to the longitudinal direction 1c joint part orthogonal to the longitudinal direction 2 core material 3 backing material 4 uncoiler 5 splicer 6 pinch roll 7 preheater 8 embossing machine 8a embossing roll 8b Embossing roll 9 Roll processing machine 9a Roll 9b Roll 10 Leveler 11 Engaging section forming machine 12 Preheating machine 13 Resin injection machine 14 Payoff reel 15 Double conveyor A Engaging section B Engaging section

Claims (4)

[Claims] 1. A brick by means of an embossing machine (8) for supplying a thin metal plate between two embossing rolls (8a, 8b) that rotate in the opposite directions at the same speed and opposite to each other for continuous embossing. After forming the embossed pattern of the pattern,
By forming the engaging portions (A, B) on both sides of the thin metal plate by 1) to form a surface material (1) having a substantially gutter-shaped cross section, and then forming the surface material.
A core material (2) made of synthetic resin foam is injected into the trough-shaped portion of (1) to foam-fill, and the back surface of the filled core material (2) is covered with a back surface material (3) made of a sheet-like material. Then double conveyor (1
The core material (2) is hardened in the process of moving while sandwiching it between (5, 15) to form joint portions (1b) parallel to the longitudinal direction whose side surfaces are inclined around the brick pattern portion (1a). When manufacturing a metal siding material having a brick pattern formed with joint corresponding portions (1c) orthogonal to the longitudinal direction, one embossing roll (8a) is used as an embossing machine (8). Around the periphery of (1a), a concave part formed on the surface to form a pseudo joint corresponding part parallel to the longitudinal direction of the thin metal plate and a joint corresponding part (1c) orthogonal to the longitudinal direction is a brick pattern with a U-shaped cross section. The radius of the planar shape corresponding to the corner of part (1a) is 2.0.
A depth of ~ 5.5 mm corresponding to the depth of the joint equivalent part (1c) orthogonal to the longitudinal direction of the metal siding material to be manufactured, the other embossing roll (8b) is In the portion corresponding to the joint-equivalent portion (1c) orthogonal to the longitudinal direction, the width of the top portion is the joint-equivalent portion (1c) orthogonal to the longitudinal direction.
Has the same U-shaped cross-section as the width of the bottom of the joint and the same height as the depth of the joint-corresponding portion (1c), and the width of the top is longitudinal in the portion corresponding to the pseudo joint-corresponding portion parallel to the longitudinal direction. From the width of the concave portion of the portion corresponding to the pseudo joint corresponding portion which is wider than the bottom of the parallel joint corresponding portion (1b) and parallel to the longitudinal direction, the surface material
A convex portion having a U-shaped cross-sectional shape that is shorter than the length obtained by subtracting twice the plate thickness of (1) and has the same height as the U-shaped cross-sectional shape of the portion corresponding to the joint corresponding portion (1c) orthogonal to the longitudinal direction. Are embossed by using the ones formed on the surface so as to enter the recesses, respectively, and then two rolls (9a , 9b) to perform continuous roll processing as a roll processing machine (9), one of the rolls (9a) has a cross-sectional shape formed on the surface parallel to the longitudinal direction formed by the embossing. The portion corresponding to the edge of the bottom of the pseudo joint corresponding portion and the depth between the portions is the depth of the joint corresponding portion (1b) parallel to the longitudinal direction of the metal siding material manufactured from the depth of the pseudo joint corresponding portion. It has a recess with a U-shaped cross section with a depth corresponding to the depth subtracted. Do what the other roll (9
b) is a portion corresponding to the edge of the bottom of the surface of the pseudo joint corresponding to the longitudinal direction in which the cross-sectional shape formed on the surface is parallel to the longitudinal direction formed by the embossing and the width of the top in the longitudinal direction between the portions. It is the same as the width of the bottom of the parallel joint corresponding part (1b) and shorter than the length of the width of the recess of the one roll (9a) minus twice the plate thickness of the surface material (1) and parallel to the longitudinal direction. Using a protrusion having a U-shaped cross-section with a height obtained by subtracting the depth of the pseudo joint corresponding part from the joint corresponding part (1b) is formed so as to enter the concave part, parallel to the longitudinal direction. The bottom of the pseudo joint corresponding part has a brick pattern characterized by being rolled to a depth of 1.3 mm or more from the surface of the surface material (1) to the depth of the joint corresponding part (1b) parallel to the longitudinal direction. Method for producing metal siding material. 2. One roll as a roll processing machine (9)
The opening edge of the U-shaped cross section of (9a) has a standard length of 0.8 mm.
10-point average roughness of 3.2 μm or less and a radius of 0.
2 to 0.5 mm, the edge of the convex part of the U-shaped cross section of the other roll (9b) has a 10-point average roughness of 3.2 when the reference length is 0.8 mm.
The method for producing a metal siding material provided with a brick pattern according to claim 1, wherein the metal siding material having a finish of not more than μm and a radius of 0.2 to 0.5 mm is used. 3. An embossing machine (8) for embossing so that uncompleted portions of the brick pattern portion (1a) do not remain on both sides of the surface material (1) formed in a substantially gutter-shaped cross section. Item 3. A method for producing a metal siding material having a brick pattern according to item 1 or 2. 4. When the metal siding material to be produced is a horizontal metal siding material, the inclination angle of the slope from the brick pattern portion (1a) to the joint equivalent portion (1b) parallel to the longitudinal direction of the metal siding material is set. The embossing is performed at 110 ° to 125 ° on the upper surface side and 130 ° to 140 ° on the lower surface side.
The method for producing a metal siding material having a brick pattern according to any one of items 1 to 6 above.