KR101416940B1 - Method for forming multi-layer sheet material, and multi-layer sheet material formed using the same - Google Patents

Abstract

A method of forming a multilayer sheet material and a multilayer sheet material produced using the same are disclosed. The method for forming a multilayer sheet material according to an embodiment of the present invention includes two sets of corrugating processes in which two sheets are put into different upper and lower corrugating rolls so that the pitches are the same and the corrugation depths are formed into different corrugations; A lapping step of lapping the two sheets of corrugated webs of different dimensions to secure a closed space of a constant gap due to a difference in depth between corrugations of each sheet; A cutting step of cutting the overlapped two sheets to a predetermined standard; And an embossing forming step of securing the closed space and rotating the two overlapping sheets in a direction (90 DEG) perpendicular to the direction of the corrugating process and putting them in the upper and lower embossing rolls to form a predetermined embossing curved shape And a multilayer sheet member manufactured using the same.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of forming a multi-layer sheet material and a multilayer sheet material produced using the same. BACKGROUND ART < RTI ID = 0.0 >

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of forming a multilayer sheet material and a multilayer sheet material produced using the same, and more particularly, to a method of manufacturing a multilayer sheet material by forming a cover or a cover And a multi-layer sheet material produced by using the same.

An example of an apparatus that generates heat and vibration in general is an internal combustion engine.

The internal combustion engine emits heat, noise, vibration, etc. to the outside through an exhaust system such as a cylinder block or an exhaust manifold connected to a cylinder block.

A heat protector, a heat shield, a heat insulator, or the like is provided to prevent heat and vibration from being radiated to the outside from a heat source or a vibration source such as a cylinder block or an exhaust system of the internal combustion engine. Various covers and covers are used.

In other words, the cover such as the heat protector described above is basically constructed of an engine room in which the space is narrowed by the heat of combustion heat of high temperature or exhaust gas, a heat insulating material for preventing various kinds of sensors and electric parts installed around the exhaust system from being damaged Function at the same time as the function of the heat radiating member to prevent the damage due to the abnormal high temperature of the exhaust system through the smooth heat radiation

In addition, from the other viewpoint of the heat shielding function in the internal combustion engine, the cover such as the heat protector also has a function of shortening the time to reach the activation temperature of the catalyst.

That is, it is prevented that the exhaust gas is discharged from the combustion chamber through the exhaust system by the running wind until the exhaust gas reaches the catalyst through the exhaust system at the beginning of the running of the vehicle, so that the exhaust gas reaches the activation temperature of about 90% It does.

The cover such as the heat protector is manufactured by press molding a sheet material made of a thin steel material along an outer shape of an exhaust manifold or the like, but recently it is a trend to produce a thin sheet of aluminum sheet material having a high thermal conductivity by press molding.

That is, the aluminum sheet material is light in weight, has good moldability, and is easily cooled from the viewpoint of operational safety after it is heated by radiant heat of the exhaust gas. However, since the aluminum sheet material is easily deformed or torn by external force after molding, have.

In order to overcome such disadvantages, in recent years, a multilayer sheet material which is formed by stacking two or more sheets of aluminum sheet material is applied to improve durability, and various bending shapes such as embossing, And the heat dissipation property is also complemented.

However, when the above-mentioned conventional multilayer sheet material is formed into a bent shape such as a simple embossing, a concavo-convex or a corrugated pattern, there is a disadvantage in that the formability is poor such as the sheet material is easily separated from each other during press forming, When the temperature of the exhaust system is higher than a certain temperature, there is no problem in the heat radiation performance of the exhaust system. However, below the activation temperature of the catalyst, in which the thermal efficiency of the exhaust gas must be increased, have.

In addition, the properties of the multilayer sheet material depend on durability, formability, heat resistance, and heat resistance, etc., depending on the material and the bending shape of the material. However, productivity due to complicated bending shape must be taken into consideration. It is urgently required to research and develop a multilayer sheet material which is excellent in durability, moldability, heat radiation property and heat shielding property by being manufactured by the sheet material forming method and the method.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described needs, and it is an object of the present invention to provide a method of manufacturing a laminated sheet having two corrugated sheet- A method of forming a multilayer sheet member by which a hermetically closed space is ensured and an embossed molding process is performed to form a section having a certain embossed curved shape so as to increase durability and heat dissipation as well as heat resistance through the hermetically closed space, Layer sheet material.

Further, the undercut portions are formed at both sides of the embossed curved shape so as to have a bonding force by undercut between the two thin sheet sheets by a multi-stage embossing process in a state in which two thin sheet sheets whose corrugated shapes are formed in different dimensions To ensure a bonding force between the sheets to thereby improve the moldability, and to provide a multilayer sheet material produced using the same.

The present invention also provides a method of forming a multilayer sheet material and a multilayer sheet material produced by using the method, wherein the corrugating process and the embossing process are performed in multiple stages to increase the molding speed of the material.

The method for forming a multilayer sheet material according to an embodiment of the present invention includes two sets of corrugating processes in which two sheets are put into different upper and lower corrugating rolls so that the pitches are the same and the corrugation depths are formed into different corrugations; A lapping step of lapping the two sheets of corrugated paper of different dimensions to secure a closed space of a certain gap due to a difference in depth between corrugations of each sheet; A cutting step of cutting the overlapped two sheets to a predetermined standard; And an embossing forming step of securing the closed space and rotating the two overlapping sheets in a direction (90 DEG) perpendicular to the direction of the corrugating process and putting them in the upper and lower embossing rolls to form a predetermined embossing curved shape can do.

Further, the two sheets may be formed of a thin sheet of aluminum material.

Further, the two sheets may have different thicknesses.

Each of the two sets of corrugating processes is composed of at least two stages of upper and lower corrugating rolls, and the corrugations formed on each sheet are sinusoidal waveforms so that the corrugation depths of the corrugations are gradually deeper Can be molded.

Further, the upper and lower corrugated rolls may be formed of at least two or more stages of gears to be engaged with each other along the outer circumferential surface, and the height of the gears may be gradually increased from the first stage to the last stage.

Wherein the embossing forming step is constituted by at least two stages of upper and lower embossing rolls at a plurality of stages and the pressing portions are formed at regular intervals in the longitudinal direction of the corrugated shape formed in the two sheets, So that the depth of the pressing portion can be deepened.

The gap between the upper and lower embossing rolls is formed by at least two stages of gears that are engaged with each other along the outer periphery of the upper and lower embossing rolls, Among the two sheets, the corrugated depth of the corrugation is set to be larger than the corrugated depth of the small sheet, and the height of the gear from the first stage to the last stage may be gradually increased.

In addition, the two sheets are formed by forming the pressing portion at predetermined intervals along the longitudinal direction of the corrugated shape by the embossing forming process in a state of being wave-shaped in the two sets of corrugating processes, And a constant undercut portion that is pushed by the pressing portion is formed on both side portions.

Further, the multilayer sheet material produced by the method of forming a multilayer sheet material according to the embodiment of the present invention is formed by forming a sealed space portion of a certain gap due to the difference in the depth of the bore between two sheets of mutually superimposed one- The pressing part is formed at regular intervals along the longitudinal direction of the corrugated part and the undercut part pushed by the pressing part is formed constantly on both sides of the curved shape between the pressing parts.

According to the method for forming a multilayer sheet material according to the embodiment of the present invention, two sheets of aluminum foil sheets formed into corrugated shapes having different bone depth dimensions are stacked one upon the other by means of two corrugating processes, Shaped portion is formed to have a certain embossed curved cross-section through the embossing molding process, thereby providing durability and heat dissipation by the two-ply aluminum sheet material and enhancing heat resistance through the closed space portion.

Further, in the process of forming the pressed portion between the two sheet metal sheets by a multi-stage embossing process in a state in which the two wave-shaped thin sheet sheets are overlapped with each other using the corrugated pattern, the undercut portion So that the sheet member has a bonding force due to undercut, thereby improving moldability.

Further, the two wave forming processes and the embossing forming processes are each implemented in a multi-stage, thereby increasing the molding speed of the material, thereby improving the productivity.

1 is a process block diagram of a method for forming a multilayer sheet material according to an embodiment of the present invention.
2 is a process diagram of a method for forming a multilayer sheet material according to an embodiment of the present invention.
3 is a conceptual diagram of a corrugating process in the method of forming a multilayer sheet material according to an embodiment of the present invention.
4 is a conceptual diagram of an embossing molding process in a method of molding a multilayer sheet material according to an embodiment of the present invention.
5 is a partial perspective view of a multilayer sheet material produced using the method of forming a multilayer sheet material according to an embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

It is to be understood, however, that the present invention is not limited to the illustrated embodiments, and that various changes and modifications may be made without departing from the spirit and scope of the invention. .

In order to clearly illustrate the embodiments of the present invention, parts that are not related to the description are omitted.

3, the direction from left to right in FIG. 3 is referred to as "the width direction of the waveform" and the direction perpendicular to the width direction of the waveform in FIG. 3 (90 DEG) The direction from the left to the right in Fig. 4 is defined as "the longitudinal direction of the waveform ".

FIG. 1 is a process block diagram of a method of forming a multilayer sheet material according to an embodiment of the present invention, FIG. 2 is a process diagram of a method of forming a multilayer sheet material according to an embodiment of the present invention, Fig. 4 is a conceptual diagram of an embossing molding process in a method of molding a multilayer sheet material according to an embodiment of the present invention. Fig.

A method of forming a multilayer sheet material according to an embodiment of the present invention is a method of forming a multilayer sheet material by forming a two-ply sheet, which is a material for producing a heat protector through press molding along one side of a heat generating portion of a cylinder block of an internal combustion engine, Layered sheet material can be formed.

1 and 2, a method of forming a multilayer sheet material according to an embodiment of the present invention includes two wave forming steps S1, an overlapping step S2, a cutting step S3, and an embossing step S4. .

First, two sheets are provided. For convenience of explanation, the two sheets are divided into an upper sheet 11 and a lower sheet 13.

Here, the upper sheet 11 and the lower sheet 13 may be made of a thin aluminum sheet having a high thermal conductivity, and an aluminum thin sheet of A1050-0 having 99% purity aluminum may be used as a specific material.

The upper sheet 11 and the lower sheet 13 are aluminum thin plates having a thickness of approximately 0.3 mm or less. In the embodiment of the present invention, the thickness t1 of the upper sheet 11 is 0.3 mm, The thickness t2 of the sheet 13 is 0.13 mm, but the present invention is not limited thereto. The upper sheet 11 and the lower sheet 13 may be formed to have a thickness of 0.2 mm The same thickness may be applied to each other.

That is, in the two sets of corrugating processes, the upper sheet 11 and the lower sheet 13 are put into different upper and lower corrugating rolls R1 and R2, respectively, so that the respective pitches Pt are the same, (D1, D2) are formed into different waveform shapes.

At this time, the upper sheet 11 to be formed in the corrugating step S1 of the first set SP1 forms the corrugation with the corrugation pitch Pt of 12 mm and the corrugation depth D1 of the corrugation 4 mm , The bottom sheet 13 formed in the wave forming step S1 of the second set SP2 has a waveform Pt of 12 mm which is the same as the top sheet 11 but the corrugation depth D2 of the corrugation is 6 mm To form a deeper wave.

Each of the wave shaping steps S1 of the two sets SP1 and SP2 constitutes six stages of upper and lower corrugating rolls R1 and R2 and is formed into upper and lower sheets 11 and 13, Is formed of a sinusoidal waveform.

3, each waveform forming step S1 is formed so as to gradually deepen the corrugated depths D1 and D2 of the corrugations in six steps. For this purpose, as shown in FIG. 3, The upper and lower corrugating rolls R1 and R2 are configured in six stages P1 to P6 by forming gear teeth which are engaged with each other along the outer circumferential surface.

At this time, the height of the gear is gradually increased from the first stage P1, which is the first stage, to the sixth stage P6, which is the last stage, so that the upper and lower sheets 11, The corrugation depths D1 and D2 of the corrugations are gradually deepened.

As described above, in the wave forming step S1 of the second set (SP1, SP2), the pitches Pt of the upper sheet 11 and the lower sheet 13 are the same, while the valleys D1 and D2 are 2 mm.

Then, in the lapping step (S2), the upper and lower sheets 11, 13 formed with different depths D1 and D2 of the corrugations are overlapped with each other so that the corrugation depth D1, and D2, and is transferred to the cutting step S3, which is the next step, with the closed space portion S having a constant gap secured.

In the lapping step S2, the upper sheet 11 and the lower sheet 13 are simultaneously inserted between the upper roll R3 and the lower roll R4, 11 are inserted and overlapped.

At this time, the upper sheet 11 and the lower sheet 13 have the same pitch Pt so that the bottom portion of the lower sheet 13 contacts the valley portion of the upper sheet 11, Has a shallow depth D1 of the corrugation compared to the lower sheet 13 and is formed between the floor portion of the upper sheet 11 and the valley portion of the lower sheet 13 by a gap G of 2 mm, ).

As described above, the upper sheet 11 and the lower sheet 13, which are overlapped with each other by the corrugated shape, are cut to a certain standard in the cutting step (S3) in the overlapped state.

At this time, cutting can be performed in various ways in the cutting step (S3), but a cutter using a blade or the like can be used in view of the fact that it is an aluminum sheet of a thin plate.

Subsequently, in the embossing molding step S4, the two sheets overlapped with each other while securing the closed space portion S by the difference of the valleys D1 and D2 of the corrugations of the upper sheet 11 and the lower sheet 13 The embossing rolls R5 and R6 are pressed into a predetermined embossing bending shape in the longitudinal direction of the corrugated sheet (i.e., in a direction perpendicular to the width direction of the corrugated sheet).

4, the embossing step S4 includes upper and lower embossing rolls R5 and R6 of five stages (E1 to E5), and the upper and lower sheets 11 and 13 The pressing portions PR are formed at regular intervals in the longitudinal direction of the corrugated shape with respect to the formed corrugated shape.

At this time, the pressing portion PR is formed so as to deepen its depth sequentially in five stages. To this end, the upper and lower embossing rolls R5 and R6 form gears which are engaged with each other along the outer circumferential surface .

The gaps G2 between the gears of the upper and lower embossing rolls R5 and R6 are set so that the corrugation depths D1 and D2 of the corrugated corrugations D1 and D2 D1), and the height of the gear is gradually increased from the first end (E1) as the first end to the fifth end (E5) as the last end.

Of course, the clearance G2 between the gears of the upper and lower embossing rolls R5 and R6 may be set such that each gear of the upper and lower corrugating rolls R1 and R2 applied in the corrugating process S1 Is set larger than the clearance (G1).

As a result, the upper and lower sheets 11 and 13 are formed while deepening the depth of the pressing portion PR sequentially in the embossing molding step S4.

Therefore, in the above-described method for forming a multilayer sheet material, the corrugated sheet forming process S1 and the embossing forming process S4 of the two sets (SP1 and SP2) are performed in six stages P1 to P6 and five stages E1 to E5 So that the forming speed of the material can be increased, thereby improving the productivity.

On the other hand, in the embodiment of the present invention, the six corrugating rollers and the embossing rollers S4 are formed by five stages of forming rolls in the two corrugating steps S1, If the molding speed considering the productivity is satisfied, it can be applied variously within the range of 1 to 10 stages.

5 is a partial perspective view of a multilayer sheet material produced using the method of forming a multilayer sheet material according to an embodiment of the present invention.

The multilayer sheet material 10 shown in Fig. 5 can be manufactured by the method of forming the multilayer sheet material according to the embodiment of the present invention as described above.

That is, in the method of forming the multilayer sheet material according to the embodiment of the present invention, the upper and lower sheets 11, 12 formed in the corrugated shapes having different bore depths D1, D2, respectively, 13 are mutually overlapped (S2) so that a closed space portion S of 2 mm gap G is secured therebetween, and the embossed molding step S4 is carried out to form a section having a certain embossed curved shape Respectively.

In addition, the durability is improved by roll-forming the two-ply sheet material, and the heat-sealing performance is enhanced by the aluminum thin plate having high thermal conductivity. The regular sealed space portion S ).

That is, when the temperature of the exhaust system is equal to or higher than a predetermined temperature during running of the vehicle, the heat radiation performance of the exhaust system is improved. When the temperature of the exhaust system is higher than the activation temperature of the catalyst, Heat storage performance of the exhaust system is improved.

Further, the upper and lower sheets 11 and 13 are subjected to the embossing molding process S4 (Fig. 1) in a state where the upper and lower sheets 11 and 13 are corrugated in the two corrugation forming steps S1 by the method of forming the multilayer sheet material according to the embodiment of the present invention. In the process of forming the pressing portion PR at predetermined intervals along the longitudinal direction of the corrugated shape by the pressing portion PR, the pressing portion PR is pressed by the pressing portion PR on both sides of the embossed curved shape between the pressing portions PR Thereby forming a constant undercut portion UC.

The undercut portion UC functions to maintain a firm fastening force between the upper sheet 11 and the lower sheet 13 in the up-and-down, front-back, and left-right directions.

The bonding force between the upper and lower sheets 11 and 13 prevents the cover such as the heat protector and the like from being easily separated during the press forming process, thereby improving the moldability.

That is, as shown in Fig. 5, the multi-layer sheet material 10 produced by the method for forming a multilayer sheet material according to the embodiment of the present invention is formed by forming unidirectionally corrugated wave- And the lower sheet (11, 13), the closed space (S) is formed by the difference of the valleys (D1, D2).

The pressing portion PR is formed at regular intervals along the longitudinal direction of the corrugation, and on both sides of the curved shape between the pressing portions PR, an undercut portion PR pushed inward by the pressing portion PR (UC) are regularly formed.

In the embodiment of the present invention, the multi-layer sheet material composed of only two sheets is exemplified. However, the number of sheets is not necessarily limited to two, and the two wave forming processes mentioned in the embodiment of the present invention are not limited to three or more. It is possible to apply the same molding method to the molding of a three-ply or four-ply multi-layer sheet material by applying three sheets or four sheets by widening the four corrugating steps.

At this time, depending on the number of sheets, the thickness of the sheet, the pitch of the corrugation, the depth of the corrugation, and the like may be changed as needed.

While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, And all changes to the scope that are deemed to be valid.

10: Multilayer sheet material
11: upper sheet
13: Lower sheet
S: closed space part
UC: undercut portion
PR:
Pt: pitch of waveform

Claims (9)

In the method for forming a multilayer sheet material,
Two wave forming processes in which two sheets are put into different upper and lower wave forming rolls so that the pitches are the same and the groove depths are formed into different waveforms;
A lapping step of lapping the two sheets of corrugated webs of different dimensions to secure a closed space of a constant gap due to a difference in depth between corrugations of each sheet;
A cutting step of cutting the overlapped two sheets to a predetermined standard; And
An embossing forming step of securing the closed space and rotating the two overlapping sheets in a direction perpendicular to the direction of the corrugating step, into an upper and lower embossing roll to form a predetermined embossing curved shape;
And a step of forming the multilayer sheet member. The method according to claim 1,
The two sheets
Wherein the sheet member is made of a thin sheet of an aluminum material. The method according to claim 1,
The two sheets
Wherein the thickness of the multilayer sheet member is different from the thickness of the multilayer sheet member. The method according to claim 1,
The two sets of waveform shaping steps
Characterized in that each of the upper and lower corrugated rolls comprises at least two stages of upper and lower corrugating rolls, and each corrugated shape formed in each sheet is formed in a sinusoidal waveform so that the corrugated depth of the corrugation is gradually deepened, Molding method. The method according to claim 1,
The upper and lower corrugating rolls
And at least two or more stages of gears are formed to be engaged with each other along the outer circumferential surface,
And the height of the gear is gradually increased from the first stage to the rearmost stage. The method according to claim 1,
The embossing molding process
Wherein the pressurizing portions are formed at regular intervals in the longitudinal direction of the corrugated shape formed on the two sheets, and the depth of the pressurizing portions is sequentially Wherein the forming of the multi-layer sheet material is performed so as to be deep. The method according to claim 1,
The upper and lower embossing rolls
And at least two stages of multi-stages are formed by gears which are engaged with each other along the outer circumferential surface,
The gap between the gears of the upper and lower embossing rolls is set to be larger than the valley depth of the sheet having the smallest depth of corrugation of the corrugated two sheets, Wherein the forming of the multi-layer sheet material comprises: The method according to claim 1,
The two sheets
Wherein the pressing portion is formed at regular intervals along the longitudinal direction of the corrugated shape by the embossing forming process in the waveform forming process in the two sets of corrugating process steps, And forming a predetermined undercut portion which is pushed by the first and second molds. The multilayer sheet material according to any one of claims 1 to 8,
A closed space having a constant gap due to the difference in the depth of the bore is formed between the two sheets which are mutually superimposed on one another and the corrugated depth is differently formed and the pressurizing part is formed at regular intervals along the longitudinal direction of the corrugated part, And the undercut portion pushed by the pressing portion is uniformly formed on both side portions of the curved shape between the upper and lower portions.

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