JPH0729162B2 - Metal roof panel manufacturing method - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing a metal roof panel, and in particular, a highly accurate roof panel having a complicated shape can be obtained and productivity is improved. The present invention relates to a method for manufacturing a high metal roof panel.

“Conventional Technology” In recent years, roof panels made of metal such as aluminum have been increasingly used in place of conventional roof tiles and slate plates. Such a roof panel has a shape that can be fitted to each other by providing a bent portion at the end in consideration of the rain finish, and an uneven pattern is formed aiming at its design effect, Alternatively, ribs for structural reinforcement are formed.

[Problems to be Solved by the Invention] By the way, in order to manufacture the above-mentioned metal roof panel, the bent portion, the uneven pattern, the reinforcing rib, etc. are formed by pressing a metal plate body cut into a predetermined size. Although a process of forming a roof panel to complete the roof panel is adopted, if the shape of these bent portions is complicated, the pressing process must be increased,
In addition to high cost, continuous production becomes difficult. In addition, there is a limit to the shape of the bent part that can be processed by pressing,
Further, when manufacturing a long roof panel, there are problems that a large number of large press machines are required, resulting in high cost, and distortion of the molded roof panel is likely to occur.

For this reason, it is conceivable to form these bent portions and the like by so-called roll forming, which is performed by passing between a pair of rotating rolls. With the roll forming process, the shape of the hoop material that extends in the longitudinal direction can be accurately formed even if it is extremely complicated and complicated, and even a long member can be easily formed with one roll forming machine. Since it can be processed into, it can be one means for solving the above problems. However, in the roll forming process, it is impossible to form an uneven shape extending in the width direction of the hoop material, that is, to form a deep drawing such as the reinforcing rib or to form an uneven pattern that spreads over almost the entire panel. Yes,
Traditional roof panels cannot be manufactured by roll forming alone.

The present invention has been made in view of the above circumstances, and by taking advantage of the roll forming process and the press process, it is possible to manufacture a roof panel having a complicated shape with high accuracy, and to perform a highly productive work. It is an object of the present invention to provide a method for manufacturing a metal roof panel capable of performing the above.

"Means for Solving the Problem" Therefore, the present invention provides a metal roof panel having a bent portion extending at both ends in at least one direction of a plate member and an uneven portion extending in a direction orthogonal to the one direction. In manufacturing, the bent portion is a horizontally elongated bent portion that bends inward at the upper surface of the plate material at one end by passing the plate material between a pair of rotating rolls, and the lower surface of the plate material at the other end. Molded into a hook portion that is bent inward and engages with the laterally long bent portion of the one end,
The concavo-convex portion extending in the direction orthogonal to the one direction is a female-type front end portion that abuts the inner surface of the bent portion inside the hook portion on the other end side of the molding material, and a pressing plate from the outer surface corresponding thereto. Therefore, the problem is solved by sandwiching it from the side and pressing it by pressing the press die from the upper and lower surfaces.

[Example] 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 As shown in FIG. 1, the hoop material 1a, which is a coiled aluminum thin plate, is returned to the plate-shaped hoop material (hereinafter simply referred to as "hoop material 1") by the uncoiler 2 and then this hoop The material 1 is sent to the cutting machine 3, and as shown in FIG. 2 (a), the cutting machine 3 punches out both side ends of the hoop material 1 to form the cutouts 4,
4 ... is formed. 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 1 at intervals slightly longer than the entire length of the roof panel, and the hoop material 1 is formed. The notch portions 4 and 4 provided at both side ends are formed so as to face each other. The cutting machine 3 in this step and the machine tool in each step to be described later do not require any special machine, and a well-known and conventional machine tool can be preferably used.

Bent portion formation As shown in FIG. 1, the hoop material 1 having notches 4, 4 ... Formed at both ends is fed to a roll forming machine 5, and by the roll forming machine 5, FIG. Further, bent portions 6 and 7 as shown in FIG. 6 are formed on both side ends of the hoop material 1 in a form extending in the longitudinal direction. The shapes of these bent portions 6 and 7 are different at each side end of the hoop member 1 as shown in FIG. 6, and when the roof panel is arranged on the roof portion of the building, the upper end side of this roof portion is arranged. Hoop material located at
The bent portion 6 at one end (right side in FIG. 6) is formed with a laterally long bent portion 6a that bends inward, and the other end of the hoop member 1 located at the lower end side of the roof portion. The bent portion 7 (left side in FIG. 6) is formed with a hook portion 7a that engages with the laterally long bent portion 6a. Therefore, by the engagement of the laterally long bent portion 6a and the hook portion 7a, the roof panels arranged vertically are arranged on the roof portion of the building while maintaining high watertightness.

The roll forming machine 5 in this embodiment is also a well-known one, and a large number of rollers (not shown) for interposing the hoop material 1 from above and below are arranged in a row, and the rollers are provided with irregularities. As the hoop material 1 travels between the rollers, the hoop material 1 is plastically deformed corresponding to the unevenness, and the hoop material 1 is bent into a predetermined shape.

Hoop material cutting process As shown in FIG. 1, the hoop material 1 having the bent portions 6 and 7 formed on both ends is sent to a cutting machine 8, and the hoop material 1 is cut by the cutting machine 8 at predetermined longitudinal intervals. Everything is cut to form roof panels 9, 9, .... The cutting position of the hoop material 1 by the cutting machine 8 is, as shown in FIG. 2 (c), the central portion of the cutouts 4, ... Formed at both ends of the hoop material 1 in the above-described process.

Reinforcement rib formation As shown in FIGS. 1 and 2 (d), the tongue portions 10, 10 at both ends in the longitudinal direction of the roof panel 9 corresponding to the cutout portion 4 of the hoop material 1 are moved downward by a press machine 11. And a reinforcing rib 12, 12, ... Which is a form of unevenness in the width direction at a predetermined interval in the longitudinal direction of the roof panel 9 while being bent into a press machine.
Similarly formed by 11.

As shown in FIG. 5, the reinforcing rib 12 is formed in a groove having a rectangular cross section, and is formed in a direction orthogonal to the extending direction of the bent portions 6 and 7, that is, along the width direction of the roof panel 9. It is provided between the bent portions 6 and 7. Such reinforcing ribs 12
Is deep-drawn between the bent portions 6 and 7 of the roof panel 9 by the male die 14 having the convex portion 13 and the female die 16 having the concave portion 15 corresponding to the convex portion 13 as shown in FIG. Is formed by. In this case, it is necessary to devise the shapes of the molds 14 and 16 so that the bent portions 6 and 7 are not deformed as the reinforcing ribs 12 are formed. Therefore, as shown in FIG. 4, the front end portion 16a (left end in FIG. 4) of the female die 16 is connected to the hook portion 7a of the bent portion 7.
It is extended until it comes in contact with the inner surface of the inner bent portion, and during deep drawing, it is laterally clamped by the female front end 16a at the inner part of the hook 7a and the corresponding outer surface from the holding plate 17. The deformation of the bent portion 7 is prevented while suppressing the movement of the roof panel 9 during deep drawing. Naturally, as shown in FIG. 4, the male mold 14 is arranged so as to avoid the bent portion 6 of the roof panel 9.

Insulation Material Attachment The heat insulation material 18 is attached to the back surface of the roof panel 9 on which the reinforcing ribs 12, ... Are formed to complete the roof panel 9 as shown in FIG. The method of attaching the heat insulating material 18 is arbitrary. For example, in the case of the heat insulating material 18 made of soft foamed plastic or the like, a slightly thicker foamed plastic body is formed by pressing into a shape that matches the back surface shape of the roof panel 9, If this is attached to the back of the roof panel 9 or if it is a heat insulating material 18 made of hard urethane foam or phenol foam,
This is sprayed on the back surface of the roof panel 9, or the back surface is suppressed by a mold with a mold release treatment, and after injecting and foaming, the heat insulating material having a predetermined thickness is removed.
A suitable method is to obtain 18.

The roof panel 9 can be manufactured by the method described above. Here, in the present invention, the bent portions 6 and 7 of the roof panel 9 are formed by the roll forming machine 5, and the other reinforcing ribs 12, ... It is possible to take a manufacturing process that makes use of the advantages of both press and press working.

That is, by forming the roof panel 9, that is, the bent portions 6 and 7 extending in the longitudinal direction of the hoop material 1 by roll forming, the bent portions 6 and 7 have a very complicated and complicated shape. However, even if the roof panel 9 is long, it can be easily and very rapidly processed by one roll forming machine 5. As a result, the roof panel 9 in which the bent portions 6 and 7 that influence the watertightness of the roof are uniform in shape and size
And the productivity is very good.

On the other hand, by forming the reinforcing ribs 12, ... Which extend in the width direction of the roof panel 9 by pressing, forming a shape along the width direction of the hoop material 1 which is difficult to form by roll forming, particularly a reinforcing rib. Deep drawing such as 12 or
It is possible to easily and rapidly form a concavo-convex pattern that spreads over almost the entire panel 9.

The details of the method for manufacturing a metal roof panel according to the present invention are not limited to those in the previous embodiment, and various modifications are possible.

As an example, the order of steps for manufacturing the roof panel is arbitrary, and it is also possible to adopt a step order different from that in the above-mentioned embodiment. That is, as shown in FIGS.
After the cutouts 4, 4, ... Are formed, the hoop material 1 is cut into a predetermined size to form a roof panel 9, and bent portions 6, 7 and reinforcing ribs 12, ... Are sequentially formed on the roof panel 9. Of course, it is possible to adopt the order of steps. However, the roof panel 9 needs to have a length such that it can be molded by the roll forming machine 5.

Further, in the above embodiment, the hoop material 1 was cut after forming the cutout portions 4, 4, ... In the hoop material 1. However, the cutout portion 4, ... Is not essential, and the cutout portion 4 ,. Needless to say, the hoop material 1 may be cut without providing the ...

Further, in the above embodiment, the roof panel 9 made of aluminum is used.
However, it is needless to say that the present invention is not limited to this, and can be suitably applied to a well-known and commonly used metal sheet roof panel (steel-based, copper-based, etc.).

[Advantages of the Invention] As described in detail above, according to the present invention, when manufacturing a metal roof panel having a bent portion extending in at least one direction, the bent portion is formed by roll forming. Therefore, even if the shape of this bent part is very complicated and complicated, it can be accurately formed, and even if the roof panel is long, it can be easily and very easily performed with one roll forming machine. It can be processed at high speed. As a result, it is possible to provide a roof panel in which the bent portion has a uniform shape and size, and the productivity is also very good.

On the other hand, by forming the other part of the roof panel by pressing, forming the shape along the width direction of the hoop material that is difficult to form by roll forming, especially forming deep drawing such as reinforcing ribs, It is possible to easily and rapidly form a concavo-convex pattern that spreads almost all over.

From the above, according to the method for manufacturing a metal roof panel of the present invention, it is possible to take a manufacturing process that makes use of the advantages of both roll forming and pressing.

[Brief description of drawings]

1 to 7 are views showing a method for manufacturing a metal roof panel according to an embodiment of the present invention, in which FIG. 1 is a schematic view showing the whole process, and FIGS. D) is a plan view showing the roof panel molding state in each process, FIG. 3 is a front view showing the mold of the press machine, FIG. 4 is a side view of the same, and FIGS. 5 to 7 show roof panels. 5 is a perspective view showing the entire structure, FIG. 6 is a sectional view taken along the line VI-VI ′ of FIG. 5, and FIG. 7 is a line VII-VII ′ of FIG. Sectional views taken along the arrows and FIGS. 8A to 8D are plan views showing another example of the molded state of the roof panel in each step. 3, 8 ... Cutting machine, 4 ... Notch section, 5 ... Roll forming machine, 6, 7 ... Bending section, 9 ... Roof panel, 11 ...
… Press machine, 12 …… Reinforcing ribs, 18 …… Insulation material.

Claims (1)

[Claims] 1. When manufacturing a metal roof panel having bent portions extending at both ends of a plate material in at least one direction and uneven portions extending in a direction orthogonal to the one direction, the bent portions are By passing the plate material between a pair of rotating rolls, a horizontally elongated bent portion is bent inward at the upper surface of the plate material at one end side, and the one end portion is bent inward at the lower surface of the plate material at the other end. The concavo-convex portion that is formed in the hook portion having a shape that engages with the laterally long bent portion and that extends in the direction orthogonal to the one direction contacts the inner surface of the bent portion inside the hook portion on the other end side of the molding material. A method for producing a metal roof panel, which is press-molded by laterally sandwiching a female die front end portion and a corresponding holding plate from the outer surface, and pressing the press die from the upper and lower surfaces. .