JPS6153132B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an improvement in a method for manufacturing patterned aluminum panels used for the interior and exterior of buildings, decoration, etc., using an explosion molding method.

Conventionally, as a method for manufacturing patterned aluminum panels using the explosion molding method, for example,
Publication No. 31726, Publication No. 51-48142, Japanese Unexamined Patent Publication No. 1973-
Many techniques have been disclosed in Publication No. 115067 and the like, and panels obtained using these techniques have been widely used for building interior and exterior materials, decorations, furniture, and the like.

The characteristics of this method are as follows: (1) It does not require large mechanical equipment unlike the die or roll forming method.

(2) Since it is only necessary to have either a male or a female mold, the product can be made at a lower cost.

(3) Any thin-walled product can be obtained, rather than thick-walled products such as aluminum cast panels using the casting method.

(4) Since it is a thin-walled product, electrolytic coloring is possible, increasing its commercial value as a decorative material.

(5) Products made by casting are difficult to bend due to their thick walls, but products made by explosion molding are thin and can be bent at the ends and along the contours of buildings.

These are points such as.

However, even with such an explosion molding method, a method using a conventional steel molding die has the drawback that the molding die becomes large. For example, a mold for forming an aluminum plate measuring 1000 x 2000 mm weighs 1 to 2 tons, and requires large crane equipment to remove the assembly from the water tank each time molding is completed, resulting in poor workability and the number of repetitions per day. is also less restricted.

In addition, even if the mold is made of steel, the uneven pattern surface will be damaged due to repeated use, and the damaged part will have to be repaired. The uneven pattern must be reproduced, and the repair work is not only complicated, but also requires special and advanced techniques.

Therefore, in recent years, easy-to-handle synthetic resin molds have been developed and researched to replace these steel molding molds.

When using this synthetic resin mold, the synthetic resin mold is fitted into a flat box-shaped steel mold with a flat surface and molding is performed.

However, synthetic resin molds are lightweight, and if the uneven pattern surface is damaged, it can be easily repaired with the same type of synthetic resin, but on the other hand, they often break due to the impact during explosive molding, and must be discarded after approximately 2 or 3 uses. There was a drawback that it did not work.

The inventors of the present invention have conducted extensive research to improve the drawbacks of these conventional synthetic resin molds and the steel molds.

That is, the present invention provides a patterned aluminum panel, which is characterized in that an aluminum plate is placed and fixed on a resin mold having a desired uneven pattern on its surface and whose outer periphery is reinforced with a reinforcing frame, and then explode-molded. This is a manufacturing method, and in some cases, a resin mold with a reinforcing material such as glass fiber embedded in layers is used.

In order to manufacture the resin mold used in the present invention, a transfer mold is made by molding the original model with plaster, a metal frame is fitted into the transfer mold, and the resin raw material is poured into it to form the mold. In some cases, glass fibers such as glass cotton, glass woven cloth, and other reinforcing materials are embedded in layers in the resin raw material for reinforcement.

The present invention enables explosion molding of patterned aluminum panels by using a resin mold instead of the conventional steel mold, and by using a mold in which the outer periphery of the resin mold is reinforced with a reinforcing frame. This prevents cracking from the outer peripheral edge of the mold due to instantaneous impact pressure, significantly extending the life of the mold and lowering the unit price of the product. Furthermore, resin molds are easy to manufacture, and although they are inferior to steel molds in terms of durability, they can sufficiently meet the demand for high-mix, low-volume production in response to recent diversification of product demand.

The present invention will be explained in further detail below based on the drawings.

1 to 3 are explanatory diagrams of the manufacturing process of the resin mold used in the present invention.

The reference numeral 1 shown in FIG. 1 is a prototype having a concave-convex pattern surface that is intended to appear on the aluminum panel.
Generally, a steel mold with an uneven pattern engraved or cast is used, but as long as the pattern surface can be transferred to the plaster that flows into the mold, for example, the bottom of a wooden box, plastic box, concrete block frame that can be dismantled, etc. can be made with an uneven pattern by pressing. Other metal plates with patterned surfaces, wooden carved plates, wire mesh, rope, fresh fish, shoe soles,
It may also be used as a prototype for making a transfer mold 2 such as plaster by arranging shaped objects such as formed glass, woven fabric, plants, printing relief plates, etc.

The material of the transfer mold 2 must be able to faithfully transfer the pattern surface of the master mold 1, and must be free from air bubbles on the surface, cracks during solidification, poor conformability of uneven parts, and aging temperature. Materials are selected from those that are less prone to expansion and contraction distortion due to changes, and gypsum is the most suitable, but depending on the size of the mold and the degree of complexity of the pattern surface, for example, paraffin, synthetic resin, asphalt compound, low melting point metal, etc. Any material can be selected from among concrete, cement, etc. Furthermore, these injection materials for the transfer mold 2 can be used alone or in combination, for example, by using plaster only for the layer near the pattern surface and paraffin for the other layers, if necessary. Furthermore, a suitable filler may be mixed in and used. Paraffin and the like can be collected and reused after use.

In Figure 2, a metal reinforcing frame 3 is placed on the top surface of the transfer mold 2 which has been dried and solidified and removed from the master mold 1, and liquid resin is poured into the inside of this metal reinforcing frame 3, so that the outer periphery is reinforced with metal. Molding resin mold 4 reinforced with frame 3
FIG. At this time, instead of using the liquid resin alone, reinforcing materials such as glass fibers are embedded in the liquid resin in a layered manner, which can prevent the intricate and delicate patterns on the surface of the molding resin mold 4 from deforming during explosive molding. Defects such as end face cracking and end face missing of the molding resin mold 4 can be improved. The reinforcing frame 3 protects the aluminum panel from cracking or breaking when it collides with the resin mold during explosive molding. All you need to do is design a metal frame.

Alternatively, liquid resin may be poured directly onto the upper surface of the transfer mold 2 made of plaster or the like, but if you want to prevent the pattern surface from deforming and use it repeatedly, apply a surface treatment agent such as resin to the pattern surface. It is preferable.

The resin to be injected must have appropriate hardness and ductility; for example, polyester resin, vinyl ester resin, epoxy resin, phenolic resin, etc. are used. Preferably, a resin is further injected onto the surface treatment agent via a release agent such as a water-soluble coating film based on vinyl acetate resin.

The reinforcing material embedded in the resin may be any material such as glass fiber, glass woven cloth, asbestos, chemical fiber, vinyl rope, vinyl net, wire mesh, wire, metal coil, hard rubber, or a combination of these materials. suitable.

Figure 3 shows a molding resin mold 4 with a metal reinforcing frame 3 removed from the transfer mold 2 after the resin has polymerized and solidified.
shows.

Figure 4 shows using the molding resin mold 4 shown in Figure 3.
FIG. 2 is an explanatory diagram when implementing the present invention. In the figure, 5 is a flat-bottom molding table, into which a molding resin mold 4 with a metal reinforcing frame 3 is fitted, an aluminum plate 6 is placed on the table, and a tightening frame 12 is tightened with bolts 7. Then, the vacuum pump 8 exhausts the air inside the molding table 5 through the exhaust pipe 9, and the valve 13 is closed to keep the inside vacuum.

The explosive 11 may be a string explosive, a detonating wire, a sheet explosive, a net explosive, or the like, and is submerged in water together with the molded assembly with the detonator 10 attached.

After that, the detonator 10 is ignited and the explosive 1 is released.
1 is exploded, and the energy is used to explode the aluminum plate 6.
is caused to collide with the surface of the molding resin mold 4 to faithfully transfer the uneven pattern on the surface of the molding resin mold 4.

The present invention employs the above manufacturing method,
The usage life of the molding resin mold 4 is approximately 10 to 20 times depending on the size of the mold and the degree of complexity of the pattern surface, and if reinforcing material is used, it can be used repeatedly approximately 15 to 30 times. Compared to conventional resin molds, which can be used approximately 3 to 10 times, the lifespan is greatly improved.

Next, examples will be described.

Example 1 In Figure 1, the prototype 1 is a 5 mm thick iron plate with a vertical
A box measuring 600 mm, width 400 mm, and depth 100 mm was assembled, and an uneven pattern of an arbitrary design was formed on the inside plane using rubber clay. Gypsum plaster was injected into the inside of this prototype 1 to a thickness of 50 mm. After air drying, remove the side plate of the master model 1, take out the transfer mold 2 to be made of plaster, and then apply the second
As shown in the picture, thickness 10mm, height 50mm, width 350
An iron frame 3 with a length of 550 mm is placed, and a surface treatment agent based on epoxy resin is applied as a joint agent to the surface of the transfer mold 2. After drying, a vinyl acetate-based surface treatment agent is applied to the surface of the transfer mold 2 to facilitate mold release. After applying a water-soluble paint to form a thin film, a liquid polyester resin is injected and dried to obtain a molding resin mold 4 having an iron frame 3 attached to its outer periphery as shown in FIG.

Next, as shown in FIG. 4, this molding resin mold 4 is fitted into the inside of a flat-bottom molding table 5, and an aluminum plate 6 (5 mm x 600 mm x 800 mm) is placed on the table and the clamping frame 1 is fitted.
2. Tighten the bolts 7, and use the vacuum pump 8 to exhaust the air inside the forming table 5 and the aluminum plate 6 into the exhaust pipe 9.
Then, close the valve 13 to maintain a vacuum inside.

Detonating wires 11 are formed in a mesh shape at appropriate intervals on the upper surface of the aluminum plate, and detonators 10 are attached.

Explosive molding was carried out by detonating the detonating wire with the molding assembly assembled as described above and explosives submerged in water.

As a result, the pattern of the molding resin mold was faithfully transferred to the surface of the aluminum plate 6, and the molding resin mold had no cracks from the outer peripheral end surface or loss of the uneven pattern surface.

Example 2 In the method of Example 1, when forming the molding resin mold 4 shown in FIG. 2, instead of injecting only polyester resin as in Example 1, glass fiber was layered into the polyester resin. The embedded resin mold has been strengthened.

Other than this, explosion molding was carried out in exactly the same manner as in Example 1. As a result, the pattern surface was faithfully transferred to the aluminum plate, and the molding resin mold had no cracks from the outer peripheral end surface or loss of the uneven pattern surface. Nakatsuta.

After that, explosion molding was performed repeatedly using the resin molds of Example 1 and Example 2, and the molding resin mold of Example 1 lost part of the uneven pattern on the surface after the 6th time, so polyester resin was used. As a result of repairing and repeating explosive molding, a slight crack appeared on the outer peripheral end face after the 10th try, and it became unusable after the 12th try.

In addition, in the molding resin mold of Example 2, a part of the uneven pattern surface was damaged at the 11th time, so it was repaired in the same manner as above, and the first crack on the outer peripheral end surface occurred at the 16th time, but at the 18th time.
I was able to withstand it until the second use.

[Brief explanation of the drawing]

1 to 3 are explanatory diagrams of the manufacturing process of a molding resin mold used in the present invention, and FIG. 4 is an explanatory diagram of an embodiment of the method of the present invention. 1... Master model, 2... Transfer mold, 3... Metal reinforcing frame, 4... Resin mold for molding, 5... Flat bottom molding table, 6
... Aluminum plate, 7 ... Bolt, 8 ... Vacuum pump, 9 ... Exhaust pipe, 10 ... Detonator, 11 ...
Explosives, 12... tightening frame, 13... valve.

Claims (1)

[Claims] 1. Patterned aluminum, which has a desired uneven pattern on its surface and is explosively formed by placing and fixing an aluminum plate on a resin mold whose outer periphery is reinforced with a reinforcing frame. How to manufacture panels. 2. A method for manufacturing a patterned aluminum panel according to claim 1, which uses a resin mold in which a reinforcing material such as glass fiber is embedded in layers.