JPH0360819A - Manufacture of metallic roof panel - Google Patents

Abstract

PURPOSE:To improve the productivity and accuracy by adopting roll forming in the manufacture of metallic roof panel with bent parts which are elongated in one direction. CONSTITUTION:When the metallic roof panel 9 with the bent parts 6, 7 which are elongated in one direction is manufactured, the bent parts 6, 7 are passed through between a pair of rotating rolls: the so-called roll forming is performed. By this way, even if the shape of these bent parts are complicated, exact forming is possible and even if it is long-sized, high-speed working is made possible with one roll forming machine and productivity is improved.

Description

DETAILED DESCRIPTION OF THE INVENTION "Industrial Application Field" The present invention relates to a method for manufacturing a metal roof panel, and in particular, a method for manufacturing a metal roof panel, in which a roof panel with high precision can be obtained even if it has a complicated shape.
Furthermore, the present invention relates to a highly productive method for manufacturing metal roof panels.

``Prior Art'' In recent years, Akine panels made of metals such as aluminum are increasingly being used in place of conventional roof tiles and slate boards. These roof panels are shaped so that they can be fitted with each other by providing bent parts at the ends in consideration of rain protection, and are also molded with uneven patterns for a design effect. Alternatively, ribs are molded for structural reinforcement.

``Problem to be Solved by the Invention'' By the way, in order to manufacture the metal roof panel as described above, the bent portions, uneven patterns, reinforcing ribs, etc. are formed by press working on a metal plate cut to a predetermined size. The roof panel is completed by forming the roof panel, but if the shape of these bent parts is complicated, the number of pressing steps must be increased.
This increases costs and makes continuous production difficult. Additionally, there are limits to the shapes of bent parts, etc. that can be accommodated by press processing.
Furthermore, when manufacturing long roof panels, many large press machines are required, resulting in high costs, and the molded roof panels tend to be distorted.

For this reason, it is conceivable to form these bent portions and the like by so-called roll forming processing, which is performed by passing the material between a pair of rotating rolls.

Roll forming processing can accurately form even very complex and complicated shapes extending in the longitudinal direction of hoop materials, and even long parts can be formed in a single process.
Since it can be easily processed with a stand roll forming machine, it can be a means to solve the above problem. However, with the roll forming process, it is impossible to form shapes that extend in the width direction of the hoop material, especially deep drawing such as the reinforcing ribs mentioned above, and forming uneven patterns that spread over almost the entire panel. , conventional roof panels cannot be manufactured solely by roll-forming.

This invention was made in view of the above circumstances, and by taking advantage of the advantages of roll forming and press working, even roof panels with complex shapes can be manufactured with high precision, and work with high productivity can be achieved. The purpose of the present invention is to provide a method for manufacturing metal roof panels that can perform the following steps.

"Means for Solving the Problem" Therefore, when manufacturing a metal roof panel having a folded part extending in at least one direction, the folded part is passed between a pair of rotating rolls. The above-mentioned problem is attempted to be solved by forming the roof panel by press-forming the other roof panel parts.

Embodiment J Hereinafter, a method for manufacturing a metal roof panel according to an embodiment of the present invention will be described with reference to FIGS. 1 to 7.

■Notch cutting process As shown in Fig. 1, after the hoop material 1a, which is a coiled thin aluminum plate, is returned to a plate-like hoop material I by the uncoiler 2, this hoop material 1 is sent to the cutting machine 3. As shown in FIG. 2(a), the cutting machine 3 punches out both ends of the hoop material 1 to form notches 4, 4, . The notches 4 are provided to form folded portions on both sides of the roof panel, which will be described later, and are repeatedly formed in the longitudinal direction of the hoop material I at intervals slightly longer than the entire length of the roof panel. Notches 4.4 provided at both ends of the
are formed so that they face each other. Note that the cutting machine 3 in this process and the machine tools in each process to be described later do not require an equivalent special machine, and well-known and commonly used machine tools can be suitably used.

■Bending part formation As shown in Figure 1, there are notches 4.4 on both ends.

The hoop material 1 thus formed is sent to a roll-forming machine 5, and the roll-forming machine 5 forms bent portions 6.7 in the longitudinal direction of the hoop material 1 as shown in FIGS. 2(b) and 6. It has elbows at both ends. The shapes of these bent portions 6,7 are different at each side end of the hoop material 1, as shown in FIG. 6, and when the roof panel is placed on the roof of a building, A convex portion 6a that bends inward is formed in the bent portion 6 at one side end (right side in FIG. 6) of the hoop material l located at the bottom end of the hoop material located at the lower end of the roof portion. The other end of 1 (left side in Figure 6)
The bent portion 7 is formed with a hook portion 7a that engages with the convex portion 6a. Therefore, due to the engagement of the convex portions 6a and the hook portions 7a, the vertically connected roof panels are placed on the roof of the building while maintaining high watertightness.

The roll forming machine 5 used in this embodiment is also a well-known and commonly used machine, and is equipped with a large number of rows of rollers (as shown in the figure) that sandwich the hoop material 1 from above and below, and these rollers are provided with unevenness to form the hoop. As the material 1 runs between the rollers, it undergoes plastic deformation corresponding to its unevenness, and the hoop material 1 is bent into a predetermined shape.

■ Hoop material cutting process As shown in Fig. 1, the hoop material ■ with bent portions 6 and 7 formed on both ends is sent to a cutting machine 8, and the hoop material l is cut into a predetermined longitudinal direction by this cutting machine 8. The roof panels 9.9, . . . are formed by cutting at intervals.

The location where the hoop material l is cut by this cutting machine 8 is shown in Figure 2 (
As shown in c), this is the center portion of the cutout portions 4, .

■Formation of reinforcing ribs As shown in FIGS. 1 and 2 (d), tongues 10 and 10 at both ends of the roof panel 9 in the longitudinal direction, corresponding to the notches 4 of the hoop material I, are pressed using a press 11. In addition to bending the roof panel 9 downward, reinforcing ribs 12, 12, and 12, .

The reinforcing ribs 12 are formed in grooves with a rectangular cross section as shown in FIG. It is provided between the bent portions 6 and 7. Such a reinforcing rib 12 is a male type I having a convex portion 13 as shown in FIG.
4 and a female mold 16 having a concave portion 15 corresponding to the convex portion 13
This is formed by deep drawing between the bent portions 6 and 7 of the roof panel 9. In this case, the mold 1 is
4. It is necessary to devise the shape of 16. Therefore, as shown in FIG. 4, the front end 16a (left end in FIG. 4) of the female die 16 is extended to the inside of the hook portion 7a of the bent portion 7, and the hook portion 7a is extended during deep drawing. is held from the sides by the holding temporary I7 and the female die front end I6a, thereby preventing the bending portion 7 from deforming while suppressing movement of the roof panel 9 during deep drawing. Naturally, as shown in Figure 4, male type 1
4 is arranged so as to avoid the bent portion 6 of the roof panel.

■Insulating material attachment A heat insulating material 18 is attached to the back surface of the roof panel 9 on which the reinforcing ribs 12, . . . are formed, and the roof panel 9 as shown in FIG. 5 is completed. The heat insulating material 18 can be attached in any manner. For example, if the insulating material 18 is made of soft foamed plastic, a slightly thicker foamed plastic body is formed by press processing into a shape that matches the shape of the back surface of the roof panel 9. If the insulation material 18 is made of hard urethane foam or phenol foam, it can be pasted on the back of the roof panel 9, or it can be sprayed on the back of the roof panel 9, or it can be pressed and injected using a mold with the back surface treated to release the material. Preferred methods include a method of foaming and subsequent knotting to obtain the heat insulating material 18 of a predetermined thickness.

The roof panel 9 can be manufactured by the method explained above. Here, in this invention, the bent portions 6.7 of the roof panel 9 are formed by the roll forming machine 5, and the other reinforcing ribs 12, etc. are formed by the press AL1, etc., so the roll forming It is possible to take advantage of the advantages of both machining and press working.

That is, the roof panel 9 is formed by roll forming.
, that is, a bent portion 6 extending in the longitudinal direction of the hoop material l.
7, even if the shape of the bent portion 6.7 is very complicated and intricate, it can be formed accurately, and even if the roof panel 9 is long, it can be formed using one roll. The forming machine 5 can process easily and at a very high speed. As a result, it is possible to provide a roof panel 9 in which the shape and size of the bent portions 6, 7, which affect the watertightness of the roof, are uniform, and the productivity thereof is also very good.

On the other hand, by forming 5 squares of reinforcing ridges 12, .
It is possible to easily and quickly form a shape along the width direction of the panel 9, particularly deep drawing such as the reinforcing rib 12, and forming an uneven pattern that spreads over almost the entire panel 9.

Note that the details of the method for manufacturing a metal roof panel of the present invention are not limited to the embodiments described above, and various modifications are possible.

As an example, the order of the manufacturing process of the roof panel is arbitrary, and it is also possible to adopt a process order different from the above embodiment. That is, as shown in FIGS. 8(a) to 8(d), after forming the notches 4.4, the hoop material 1 is cut to a predetermined size to form the roof panel 9. Naturally, it is also possible to adopt a process order in which the bent portions 6.7 and the reinforcing ribs 12, . . . are sequentially formed. However, this roof panel 9 needs to be long enough to be formed by the roll forming machine 5.

In addition, in the above embodiment, the hoop material I has notches 4.4,...
The hoop material 1 was cut after forming the notches 4, . . . , but the notches 4, .
It goes without saying that the hoop material 1 may be cut without providing the .

Further, in the above embodiment, the roof panel 9 made of aluminum
Although the present invention has been described, it is not limited thereto, and it goes without saying that it can be suitably applied to well-known and commonly used metal plate roof panels (steel thread, copper-based, etc.).

"Effects of the Invention" As explained in detail above, according to the present invention, when manufacturing a metal roof panel having a bent part extending in at least one direction, the bent part is formed by roll forming. Therefore, even if the shape of the bent part is extremely complex and intricate, it can be formed accurately, and even if the roof panel is long, it can be formed easily and extremely easily with one roll forming machine. Can be processed at high speed. As a result, it is possible to provide f# roof panels whose bent portions are uniform in shape and size, and the productivity thereof is also very good.

On the other hand, by forming other parts of the roof panel by pressing, it is possible to form shapes along the width direction of the hoop material that are difficult to form by roll forming, especially deep drawing such as reinforcing ribs, and to form panels. It is possible to easily and quickly form an uneven pattern that spreads over almost the entire area.

From the above, according to the method for manufacturing a metal roof panel of the present invention, a manufacturing process that takes advantage of both roll forming and press working can be adopted.

[Brief explanation of drawings]

Figures 1 to 7 are diagrams showing a method for manufacturing a metal roof panel according to an embodiment of the present invention, in which Figure 1 is a schematic diagram showing the overall process, and Figures 2 (A) to ( D) is a plan view showing the molding state of the roof panel in each process, Figure 3 is a front view showing the mold of the press machine, Figure 4 is a side view of the same, and Figures 5 to 7 show the roof panel. 5 is a perspective view showing the overall configuration, FIG. 6 is a sectional view taken along the line V[-Vl' in FIG. 5, and FIG. 7 is a cross-sectional view taken along the line ■-■' in FIG. 8(a) to 8(d) are plan views showing other examples of the molding state of the roof panel in each step. 3.8... Cutting machine, 4... Notch,
5...Roll forming machine, 6.7...
...Fold 1tt1 part, 9...ya (Aihafuru,
11...Press machine, 12...Reinforcement rib, 18...Insulating material.

Claims (1)

[Claims] When manufacturing a metal roof panel having a bent portion extending in at least one direction, the bent portion is formed by passing between a pair of rotating rolls, and other parts of the roof panel are pressed. A method for manufacturing a metal roof panel, characterized by forming it.