1277464 九、發明說明： 【發明所屬之技術領域】 本發明系關於一種金屬板立體成型的方法與裝置，主要利用加溫 與加壓的方式將金屬板成型，成型後金屬板可完全貼合於模面上，成 爲一片立體浮雕的薄板或異型、倒邊的機殼或工件。 【先前技術】 以金屬浮雕、立體板殼及各類機彀的製程技術，現有成型方法 約分有9類，大要說明如下： 産 品 成型原理 效 果 沖 β 産 品 成型原理 效 果 滾 壓 産 品 成型原理 效 果 壓 缚 產 品 成型原理 效 果 擠 壓 産 品 成型原理 效 果 4k 刻 産 品 成型原理 效 果 金屬浮雕防火門 金屬液體直接澆鑄於雕模上β 笨重、有砂孔，表面粗糙。 金屬飾板、機殼。 重力沖製金屬工件： 立體感不佳，紋路不細緻，表面不平滑 金屬飾板 重力塵滾雕模加注於工件 紋路需對稱、單調。 機殼、飾件。 ^隹，麵效果不良；成品薄度有限 銘板、標牌。 重力擠麼金屬工件於模具面。 表面不平滑。 銘板、標牌。 1277464 機殼 成型模腔抽真空後注入金屬液體。 ^料強度高、重#輕，_合金產品為主。但是 粗糙，需經過多次研磨、拋光'塗裝處理”過程 =，瑕鱗高，且越設備昂責、成本高。市場佔 有率約一成左右，始終無法提高。 銘板、標牌《1277464 IX. Description of the Invention: [Technical Field] The present invention relates to a method and a device for three-dimensional forming of a metal plate, which mainly uses a heating and pressing method to form a metal plate, and the formed metal plate can be completely adhered to On the die surface, it becomes a three-dimensional relief plate or a profiled, inverted casing or workpiece. [Prior Art] With the metal embossing, three-dimensional shell and all kinds of machine process technology, the existing molding methods are divided into 9 categories, the major explanations are as follows: Product molding principle effect punching β Product molding principle effect Rolling product molding principle effect The principle of molding the product of the binding product The effect of the molding principle of the extrusion product 4k The principle of the molding principle of the metal embossed fire door metal liquid is directly cast on the carving mold β is bulky, has sand holes, and the surface is rough. Metal plaque, case. Gravity stamping of metal parts: The three-dimensional feeling is not good, the grain is not fine, the surface is not smooth. Metal plaque Gravity dust roll embossing is added to the workpiece. The grain needs to be symmetrical and monotonous. Case, trim. ^隹, the surface effect is poor; the thinness of the finished product is limited. Nameplate, signage. Gravity squeezes the metal workpiece on the mold surface. The surface is not smooth. Nameplate, signage. 1277464 Enclosure The molding cavity is vacuumed and injected with metal liquid. The material strength is high, the weight is # light, and the _ alloy is the main product. However, it is rough and needs to be polished and polished 'painting process' =, the scale is high, and the equipment is high and the cost is high. The market share is about 10%, which can't be improved.
電解原理經4至6小時，使模型表面鍍上一層金屬q 表面精細、光滑、品質佳。但是成型一模耗時4孚時以 上’速度過慢，而且成型後仍需做金屬表面處理，交貨 速度慢、成本高，在市場上無法獲得大量採用流通。 產 品：防電磁波金屬外殼。 成型原理：金屬板外覆娜膜，經加溫後氣壓加麼成型^ 效果：工气外覆塑膠膜，成型精細度受限；溫度無法提高，約 15^°C以上，塑膠膜即起變化、燃燒；無起模裝置，大面 積薄殼工件脫模會變形。此法已公佈多年，目前未有市 场應用實例βThe electrolysis principle is 4 to 6 hours, so that the surface of the model is coated with a layer of metal. The surface of the metal q is fine, smooth and of good quality. However, the molding time is too slow for 4 hours, and the metal surface treatment is still required after molding. The delivery speed is slow and the cost is high, and it is impossible to obtain a large amount of circulation in the market. Product: Anti-electromagnetic metal casing. Molding principle: the metal plate is covered with a film, and the air pressure is added after heating. Effect: The plastic film is covered by the working gas, the molding fineness is limited; the temperature cannot be increased, about 15^°C or more, the plastic film changes. , burning; no die-cutting device, large-area thin-shell workpiece demoulding will be deformed. This law has been published for many years and there is currently no market application example.
產 品 成型原理 效 果Product molding principle effect
成型原理： 效果： 【發明内容】 本發明的目的在於提供一個結構簡單合理，成型速度快捷，成型 後的産品表面光滑均勻，無細孔與磨痕，品質優良的金屬板立體成型 的方法與裝置。 本發明的目的可以通過以下的措施達到：使用一金屬板及成型裝 置，金屬板採用加溫軟化後易於延伸成型的超塑性合金材料，如： Ζη-5Α1、Ζη-ΠΑΙ、Ζη-22Α1、Ζη-50Α1之鋅基合金或其他之鋁基合金。 已知具有超塑性材料有數十種以上，本發明所敘述，取Ζη_5Α1為例做 說明ν成型裝置包括雕刻模、起模裝置、密封模、加壓裝置。起模裝 置位於雕刻模之上，將金屬板置於起模裝置之上，密封模覆蓋於金屬 板之上’加壓裝置通過壓力開關或壓力閥與密封模相通。在金屬板加 1277464 溫之後，利用氣壓或液壓之加壓裝置將金屬板於成型模腔内加壓成 塑，成型過程是：固體—軟化—延伸—成型。 本成型法最大的特色是採用金屬板材，經加壓而成型。成型面積 可達500mm X 500麵以上，成型面積大，一次可成塑之工件數量多， 這是本成型方法最具優勢所在。另外，本成型法也有一個特色，即使 用母模具，無公模具，對於一些倒邊、異型件，有退模考量的產品， 成型無問題°本發明即是根據以上特性，研發設計出一套合理、穩定、 順利的成型方法與裝置，以達到市場應用的目的。 本發明的重要核心在於起模裝置，該裝置不但具有脫模的作用， 同時也是成型腔組合的一部分，視實際需要可以是板狀(如圖4所示成 型裝置2)，或是各類型立體狀(如圖5、圖11所示成型裝置2)，可以 是單塊或多塊組合，與底模結合成整個成型腔。底模可以是雕刻模， 雕刻模也可以是底模或底模的一部份，底模亦可以設計成多塊組合與 活動式的設置，可以說整個成型模腔即是一套起模裝置。為方便說明， 本發明以雕刻模與起模裝置分別敘述。模具如此靈活設置，可以充分 發揮本發明成型方法無公模具的特性，使整個成型工序順利許多，並 且對產品的精細度與變化幫助許多，其特點如下： A·脫模容易：金屬板成型後可經由起模裝置的作用，輕易脫模(如圖9 所示）。 B.排氣容易：無須另開排氣孔穴，模腔内氣體可經由起模裝置與雕刻 模組合相接處(如圖6所示A部位)排出，排氣是多方向性的，排氣 容易得多，並免除模具内排氣孔穴位置空間的浪費。 C·成型精細：由於排氣容易，解決了模内包氣問題，成型的工件可達 到紋路精細，角度立體等各種高標準的要求。 D·異型工件成型：各類異型工件成型，可一次完成、一體成型。如： 起模裝置内框壁加工成内凹型態，可製成倒邊工件（如囷1〇所 示），或者是内寬出口窄的異型工件(如圖11所示）。 大面積成型： 1277464 a·大面積成型，可以一次取得大量之工件〇 b·厚度〇· 1腿~ 〇· 3 HUD之薄板，成型時若是面積過大，如果沒有 起模裝置合理的支樓，工件脫模會產生變形、破裂的間題。起 模裝置的設計可以如圖12所示，可在起模裝置之内框空位處 加以連結起模條狀或其他形狀的補助設置，以利於起模。 本發明與現有技術相比，具有如下優點： 1、結構合理，採用光潔的金屬板材，在加溫軟化之後經由壓力裝置精 密成型，成型後的産品完全貼合於雕刻模面上，由於雕刻鋼模可進 行精細雕刻、拋光，致使成型產品同樣具有精細的雕紋及光亮平滑 的表面，無細孔與磨痕，品質優良。 2、 成型速度快，只需1〜5分鐘，比電鑄法快50倍以上。適合於金屬 銘板、標牌、浮雕板畫、機殼等精緻產品，厚度要求可由〇. 1腦〜3 刪，精細如電鑄銘板之類的產品到大如金屬浮雕防火門皆可輕易成 型。 3、 無用公模具，所以無退模問題，對於成型對象有退模考量的產品， 完全可妥善解決，因此產品的設計空間报寬廣。 【實施方式】 取一片Zn-5A1合金板材，其尺寸大於起模裝置2内框尺寸。起模 裝置2分為兩片合成(如圖2所示），加壓裝置5採用氣壓加壓裝置或 液壓加壓裝置。本實施例中加壓裝置5採用氣壓加壓裝置。雕刻模1 刻有各種精細的文字、圖案等(如圖3所示）。起模裝置2放置於雕刻 模1之上，金屬板7放置於起模裝置2之上，密封模3覆蓋於金屬板7 之上，加壓裝置5及加壓開關6通過管路4與密封模3相通(如圖4、 圖5所示）。開啟氣壓加壓開關6，氣體加壓裝置5經由管路4注入氣 體於密封模3腔内，產生氣脹壓力，其壓力推向金屬板，使其完全貼 於雕刻模1壁上成型（如囷7所示）。成型後經由起模裝置2之起模 作用，使金屬板7脫離雕刻模1，然後起模裝置2抽離金屬板7(如 所示）。 1277464 本實施方式’金屬板材與模具預先加熱至成型完成，溫度控制在 150C〜380C °加工過程將起模裝置2置於離刻模1腔上，然後放置 金屬板7於起模裝置2上，覆蓋密封模3，壓力為〇. 1〇一〇. 70kg/咖2。 然後對密封模3腔内注入氣體，壓力設定為〇· 〇卜〇· 6〇kg/麵2，使金 屬板7在雕刻模腔内氣脹成型（如圖6、圖7所示）；保壓1〜5分鐘，開 啟密封模蓋，可視實際需要對成型工件進行氣吹冷卻(如圖8所示）， 經由起模裝置2的作用，使金屬板7脫離雕刻模1，然後起模裝置2抽 離金屬板7(如圖9所示）。取出成型工件進行裁切、金屬表面處理（電 鍍、電泳或烤漆）。 【圖式簡單說明】 實際工作，除特殊件、異型工件之外，大部分工件的邊框(如圖4 所示Η部位)都不高，為方便圖示說明，特將模腔邊框(如圖5所示H 部位)加高，以方便清楚看出成型過程。 圖1為金屬板的平面結構示意圖。 圖2為起模裝置的平面結構示意圖。 圖3為雕刻模的平面結構示意圖。 圖4、圖5為成型裝置的内部組合結構示意圖。 圖6、圖7為金屬板成型的工作過程示意圖。 圖8為金屬板成型工件吹氣冷卻示意圖。 圖9為工件脫模狀態示意圖。 圖、圖11為異型工件成型示意圖。 圖12為大型工件所使用的起模裝置輔助組合的平面結構示意圖。 【主要元件符號說明】 1雕刻模。 2起模板。 3密封模。 4管路。Molding principle: Effect: [Draft] The object of the present invention is to provide a method and a device for three-dimensional forming of a metal plate with simple and reasonable structure, fast forming speed, smooth and uniform surface after molding, no fine holes and wear marks, and excellent quality. . The object of the present invention can be achieved by the following measures: using a metal plate and a molding device, the metal plate is a superplastic alloy material which is easily stretched and formed after warming and softening, such as: Ζη-5Α1, Ζη-ΠΑΙ, Ζη-22Α1, Ζη -50Α1 zinc-based alloy or other aluminum-based alloy. It is known that there are dozens or more of superplastic materials, and the present invention is described by taking Ζη_5Α1 as an example. The ν forming apparatus includes an engraving mold, a mold releasing device, a sealing mold, and a pressurizing device. The ejection device is located above the engraving mold, and the metal plate is placed on the ejection device, and the sealing mold covers the metal plate. The pressing device communicates with the sealing mold through a pressure switch or a pressure valve. After the metal plate is added with 1277464 temperature, the metal plate is press-formed into the molding cavity by a pneumatic or hydraulic pressing device, and the molding process is: solid-softening-extension-forming. The biggest feature of this molding method is the use of sheet metal, which is formed by pressing. The molding area can reach 500mm X 500 or more, the molding area is large, and the number of workpieces that can be molded at one time is large. This is the most advantageous part of this molding method. In addition, this molding method also has a special feature, that is, the use of the mother mold, no public mold, for some inverted, shaped parts, there are no mold considerations, the molding is no problem. The invention is based on the above characteristics, research and development design Reasonable, stable and smooth molding methods and devices to achieve market applications. An important core of the invention lies in the die-cutting device, which not only has the function of demolding, but also is part of the combination of the molding cavity, and may be plate-shaped according to actual needs (such as the molding device 2 shown in Fig. 4), or various types of three-dimensional The shape (such as the molding apparatus 2 shown in Figs. 5 and 11) may be a single piece or a plurality of pieces combined with the bottom mold to form the entire molding cavity. The bottom mold may be an engraving mold, and the engraving mold may also be a part of the bottom mold or the bottom mold. The bottom mold may also be designed in a plurality of combinations and movable arrangements. It can be said that the entire molding cavity is a set of the mold release device. . For convenience of explanation, the present invention is described separately by an engraving die and a die-cutting device. The mold is so flexible that the molding method can be fully utilized without the characteristics of the male mold, so that the entire molding process is much smoother, and the product fineness and variation are greatly improved. The characteristics are as follows: A·Ease of demoulding: after metal sheet molding It can be easily demolded by the action of the die-cutting device (as shown in Figure 9). B. Exhaust is easy: no need to open the exhaust hole, the gas in the cavity can be discharged through the combination of the die-cutting device and the engraving mold (as shown in Figure 6A), the exhaust is multi-directional, exhaust It is much easier and eliminates the waste of the venting hole in the mold. C·Molding fine: Due to the easy exhausting, the problem of in-mold gas entrapment is solved, and the formed workpiece can reach various high standards such as fine lines and three-dimensional angle. D· Shaped workpiece forming: All kinds of shaped workpieces can be formed in one time and integrated. For example, the inner frame wall of the demoulding device is processed into a concave shape, which can be made into a reversed workpiece (as shown by 囷1〇) or a profiled workpiece with a narrow inner outlet (as shown in Fig. 11). Large-area molding: 1277464 a· Large-area molding, can obtain a large number of workpieces at a time 〇b·thickness 〇·1 leg~ 〇· 3 HUD thin plate, if the area is too large during molding, if there is no reasonable branch of the mold-making device, the workpiece Demolding can cause deformation and cracking. The squeezing device can be designed as shown in Fig. 12, and can be attached to a mold strip or other shape in the frame vacancy of the ejector device to facilitate the mold release. Compared with the prior art, the invention has the following advantages: 1. The structure is reasonable, and the smooth metal sheet is used, and after being softened and softened, it is precisely molded by a pressure device, and the formed product is completely adhered to the engraving mold surface, due to the engraving steel. The mold can be finely engraved and polished, so that the molded product also has fine embossing and bright and smooth surface, no fine holes and wear marks, and excellent quality. 2, the molding speed is fast, only 1 to 5 minutes, 50 times faster than the electroforming method. It is suitable for exquisite products such as metal nameplates, signs, embossed board paintings, casings, etc. The thickness requirements can be easily changed from 〇.1 brain~3, fine products such as electroformed nameplates to large metal embossed fire doors. 3, useless male mold, so there is no problem of mold-removal, for the molding object has a model to consider the product, can be properly solved, so the design space of the product is widely reported. [Embodiment] A piece of Zn-5A1 alloy sheet is taken, and its size is larger than the inner frame size of the die-cutting device 2. The ejector unit 2 is divided into two pieces (as shown in Fig. 2), and the pressurizing unit 5 is a pneumatic pressurizing device or a hydraulic pressurizing device. In the present embodiment, the pressurizing device 5 employs a pneumatic pressurizing device. The carving mold 1 is engraved with various fine characters, patterns, etc. (as shown in Figure 3). The ejector device 2 is placed on the engraving mold 1, the metal plate 7 is placed on the ejector device 2, the sealing dies 3 are overlaid on the metal plate 7, and the pressing device 5 and the pressure switch 6 are sealed through the pipe 4 Mode 3 is connected (as shown in Figure 4 and Figure 5). The pneumatic pressure switch 6 is turned on, and the gas pressurizing device 5 injects gas into the cavity of the sealing mold 3 via the pipeline 4 to generate an inflation pressure, and the pressure is pushed toward the metal plate to be completely attached to the wall of the engraving mold 1 (for example)囷7)). After the molding, the metal plate 7 is released from the engraving die 1 by the ejection of the mold releasing device 2, and then the ejection device 2 is pulled away from the metal plate 7 (as shown). 1277464 In the present embodiment, the metal plate and the mold are preheated until the molding is completed, and the temperature is controlled at 150 C to 380 C. During the processing, the mold release device 2 is placed on the cavity of the die, and then the metal plate 7 is placed on the die release device 2, Covering the sealing die 3, the pressure is 〇. 1〇一〇. 70kg/coffee 2. Then, the gas is injected into the cavity of the sealing mold 3, and the pressure is set to 〇·〇卜〇·6〇kg/face 2, so that the metal plate 7 is inflated and formed in the engraving cavity (as shown in Fig. 6 and Fig. 7); Pressing for 1 to 5 minutes, opening the sealing mold cover, and performing air blowing cooling on the molded workpiece according to actual needs (as shown in FIG. 8), the metal plate 7 is separated from the engraving mold 1 by the action of the mold releasing device 2, and then the mold releasing device is 2 Pull away from the metal plate 7 (as shown in Figure 9). The molded part is taken out for cutting, metal surface treatment (electroplating, electrophoresis or baking). [Simple description of the diagram] In actual work, except for special parts and special-shaped workpieces, the frame of most workpieces (such as the Η part shown in Figure 4) is not high. For the convenience of illustration, the cavity frame is specially designed. The H part shown in Figure 5 is raised to make it easier to see the molding process. Figure 1 is a schematic plan view of a metal plate. 2 is a schematic plan view showing the structure of the mold release device. Fig. 3 is a schematic plan view showing the structure of the engraving mold. 4 and 5 are schematic views showing the internal combined structure of the molding apparatus. Fig. 6 and Fig. 7 are schematic diagrams showing the working process of forming a metal plate. Fig. 8 is a schematic view showing the blowing cooling of a metal plate forming workpiece. Fig. 9 is a schematic view showing the state of demolding of the workpiece. Fig. 11 is a schematic view showing the forming of a profiled workpiece. Figure 12 is a plan view showing the planar structure of the auxiliary assembly of the die-cutting device used for the large workpiece. [Main component symbol description] 1 Engraving mode. 2 templates. 3 sealing mold. 4 pipelines.
9 1277464 5加壓裝置。 6加壓開關。 7金屬板。 Η模腔邊框。 Α排氣口。9 1277464 5 Pressurizing device. 6 pressure switch. 7 metal plates. Η cavity border. Α Vent.