Metalworks

Abstract

This invention provides a method for manufacturing metal products and metal products that enable the production of metal products of stable quality while minimizing the amount of work required at the installation site. [Solution] The manufacturing method for this metal product comprises a side plate bending step in which a pair of side plates 13 and 15 are bent with respect to a bottom plate 11 via a first fold line using a bending machine, and a front plate bending step in which a front plate 17 is bent with respect to a bottom plate 11 via a second fold line using a bending machine. The side plate bending step includes a first fillet portion bending step in which fillet portions 23 and 25 are bent with respect to a third fold line so that their inner surfaces overlap and face outward from the bottom plate 11, and then a second fillet portion bending step in which fillet portions 23 and 25 are bent with respect to abutment with the outer surface of the front plate 17 using a bending machine.

Description

Technical Field

[0001] The present invention relates to, for example, a method for manufacturing a metal processed product used as a roofing material and a metal processed product.

Background Art

[0002] Conventionally, long metal roofing materials have been laid side by side from the eaves to the ridge. As such a metal roofing material, for example, a so-called fitting standing flat roofing with fitting portions provided on both side portions in the longitudinal direction is known.

[0003] As the roofing material as described above, for example, it is manufactured by a method for manufacturing a roofing material as shown in Patent Document 1 below. This manufacturing method stepwise bends a long metal plate with a roll forming machine to form a first fitting portion along the longitudinal direction at one side end of the main body, and forms a second fitting portion along the longitudinal direction at the other side end of the main body.

[0004] By the way, in the roofing material as described above, the front end portion in the longitudinal direction is open, and rainwater or the like drips from this opening. Therefore, usually, the front plate portion is bent so as to stand up with respect to the bottom plate. At this time, the plate-like portion between both side portions in the width direction of the front plate portion and the tip portions of the pair of left and right side plate portions is manually bent by an operator using a tool (such as a Yachiyo folding tool) so that the plate-like portions overlap each other from the viewpoint of preventing rain leakage.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, the folding of the front boards of the roofing materials, which involved the Yachiyo fold, was done by workers individually at the roof installation site. This made the process complicated and time-consuming, and the quality of the finished product depended on the skill level of the workers, making it difficult to maintain consistent quality.

[0007] Therefore, the object of the present invention is to provide a method for manufacturing metal products and metal products that can obtain metal products of stable quality while reducing the amount of work required at the installation site. [Means for solving the problem]

[0008] Book invention Reference example The present invention relates to a method for manufacturing a metal product, which involves processing a metal sheet to produce a metal product having a base plate, a pair of side plates erected from the base plate, and a front plate positioned between the pair of side plates, wherein the metal sheet has a fillet portion that extends from the intersection of a first fold line for bending the pair of side plates and a second fold line for bending the front plate toward the leading edge of the front plate and the side edges of the side plates, and comprises a side plate bending step in which the pair of side plates are bent with respect to the base plate via the first fold line using a bending machine, and the front plate being bent with respect to the base plate via the second fold line The invention comprises a front plate bending step in which the front plate bending step or the side plate bending step is performed, wherein the front plate bending step or the side plate bending step includes a first fillet portion bending step in which the fillet portion is bent by a bending machine so that the inner surfaces overlap with each other via a third fold line and face outward from the bottom plate, or so that the outer surfaces overlap with each other via a third fold line and face inward from the bottom plate, and after the first fillet portion bending step, the fillet portion is bent by a bending machine so that it abuts against the outer or inner surface of the front plate.

[0009] the above Reference exampleAccording to this, the Yachiyo fold in the fillet section is performed in a bending machine at a factory or the like through the side plate bending process, front plate bending process, first fillet section bending process, and second fillet section bending process, which have the above configuration. This makes it possible to manufacture metal processed products of stable quality while keeping the number of work hours at the installation site low.

[0010] This invention Reference example In the method for manufacturing metal processed products relating to the above, a cutting step may be included before the front plate bending step and the side plate bending step, in which the corners on the front plate side of the metal plate material are cut with a cutting machine so that the fillet portion remains.

[0011] According to the above embodiment, the cutting process with the above configuration forms a metal sheet material in which a fillet section remains, so that the fillet section can be formed with high precision, and in the process after the cutting process, the fillet section can be bent with high precision, making it possible to manufacture metal processed products of more stable quality.

[0012] This invention Reference example In the method for manufacturing metal processed products relating to the above, during the first bending step of the fillet portion, corner A bending guide portion may be formed to guide the meat portion to bend outward from the bottom plate, or to bend inward from the bottom plate.

[0013] According to the above embodiment, since a bending guide section having the above configuration is formed, the yachiyo fold of the fillet section can be promoted during the first bending process of the fillet section, and it is possible to provide the metal sheet material itself with a yachiyo fold promoting structure derived from the shape of the metal sheet material, thereby simplifying and compacting the yachiyo fold promoting structure on the bending machine side.

[0014] This invention Reference example In the method for manufacturing metal products relating to the above, the side plate bending step includes a step of forming stepped portions on both sides of the front plate adjacent to the side plate, and the bending guide portion is the stepped portion formed on the front plate and the side plate bending step cornerIt may also consist of a stepped portion formed in the meat portion.

[0015] According to the above embodiment, the folding guide portion having the above configuration can effectively promote outward Yachiyo folding, especially in the fillet portion.

[0016] This invention Reference example In the method for manufacturing metal products relating to the above, in the cutting step, the side edge of the front plate is formed along the first fold line, the front edge of the side plate is formed along the second fold line, and the outer edge that connects the first auxiliary fold line extending from the intersection to the first fold line and the second auxiliary fold line extending from the intersection to the second fold line is formed in the fillet portion, and the fillet portion is bent simultaneously with the side plate via the first auxiliary fold line in the side plate bending step when the front plate bending step is performed after the side plate bending step, and the fillet portion in the front plate bending step Department In the first bending process, it is bent via the first auxiliary fold line, the second auxiliary fold line, and the third fold line, or, when the side plate bending process is performed after the front plate bending process, in the front plate bending process, it is bent simultaneously with the front plate via the second auxiliary fold line, and in the side plate bending process, the fillet Department In the first bending step, the material may be bent via the first auxiliary fold line, the second auxiliary fold line, and the third fold line.

[0017] According to the above embodiment, the Yachiyo fold in the fillet section can be performed more reliably and accurately by utilizing the first auxiliary fold line, the second auxiliary fold line, and the third fold line.

[0018] This invention Reference example In the method for manufacturing metal products relating to the above, the front plate bending process is performed after the side plate bending process, the fillet portion is bent simultaneously with the side plate via the first auxiliary fold line in the side plate bending process, and the front plate bending process cornerIn the first bending step of the gusset part, it may be bent through the first auxiliary crease line, the second auxiliary crease line, and the third crease line so that the inner surfaces overlap and face outward from the bottom plate, and in the second bending step of the gusset part, it may be bent so as to contact the outer surface of the front plate.

[0019] According to the above aspect, a metal processed product having a gusset part with an outward Hachijyo fold can be manufactured accurately and stably.

[0020] The present invention Reference example In the method for manufacturing a metal processed product according to the present invention, the outer edge portion may include a first inclined portion that extends while inclining so as to gradually approach the first auxiliary crease line from the tip edge portion side of the side plate toward the tip edge portion of the front plate, and a second inclined portion that extends while inclining so as to gradually approach the second auxiliary crease line from the side edge portion side of the front plate toward the side edge portion of the side plate.

[0021] According to the above aspect, by using the first inclined portion and the second inclined portion provided on the outer edge portion, it becomes easier to form a gusset part having a polygonal shape.

[0022] The present invention Reference example In the method for manufacturing a metal processed product according to the present invention, it may include a tip bending step of bending the tip portion of the front plate with a bending machine in a direction approaching the base end portion of the front plate.

[0023] According to the above aspect, by the tip bending step having the above configuration, a so-called water return portion can be formed on the front plate, suppressing the outflow of moisture such as rainwater from the tip of the front plate and making it easier to retain moisture inside the metal processed product.

[0024] On the other hand, the present invention AkiraThe metalwork is made of a metal plate and comprises a bottom plate, a pair of side plates erected from the bottom plate, and a front plate positioned between the pair of side plates, wherein the outer or inner surface of the front plate, on both sides adjacent to the pair of side plates, is made of overlapping metal plates, and when the front plate is viewed from the outer or inner side, it is provided with a polygonal shape having four or more corners.

[0025] According to the above invention, a metal product having a so-called Yachiyo-folded portion (fillet section) can be obtained, and since the Yachiyo-folded fillet section has a polygonal shape with four or more corners, the contact area with the front plate can be increased compared to a triangular plate-shaped fillet section, thereby improving the rigidity of the metal product on the front plate side. In the metal product according to the present invention, the polygonal portion may have polygonal shapes that are different in shape from each other on both sides in the width direction of the front plate. In the metal product according to the present invention, the polygonal portion may be a polygon having a plurality of side edges that are inclined with respect to the base plate. In the metal product according to the present invention, the plurality of side edges may be inclined to be spaced apart from the side plate. In the metal processed product according to the present invention, the metal processed product may be used as a roofing material for a building. In the metal processed product according to the present invention, the metal sheet material may be made of a metal selected from aluminum-zinc alloy plated steel sheet, galvanized steel sheet, and copper sheet. [Effects of the Invention]

[0026] According to the present invention, the Yachiyo fold in the fillet section is performed in a bending machine at a factory or the like by the side plate bending process, front plate bending process, first fillet section bending process, and second fillet section bending process configured as described above. Therefore, metal processed products of stable quality can be manufactured while reducing the amount of work required at the installation site. [Brief explanation of the drawing]

[0027] [Figure 1] This is a perspective view showing one embodiment of a metal processed product according to the present invention. [Figure 2] This diagram shows one embodiment of the method for manufacturing a metal product according to the present invention, and is a process diagram thereof. [Figure 3] This is a block diagram of the various machines used in the manufacturing method of the metal processed product. [Figure 4] This is a plan view (unfolded view) of a metal sheet material used in the method for manufacturing metal processed products according to the present invention. [Figure 5] This is a plan view of a metal sheet material used in the same manufacturing method, when cut while leaving the fillet section intact. [Figure 6] This is an enlarged plan view of the main parts in sections A and B of Figure 5. [Figure 7] This is a perspective view of the side plate bending process in the method for manufacturing metal processed products according to the present invention. [Figure 8] This is a perspective view of the front plate bending process in the same manufacturing method. [Figure 9] This is a perspective view of the first bending process for the fillet section in the same manufacturing method. [Figure 10] This is a perspective view of the tip bending process in the same manufacturing method. [Figure 11] This shows another embodiment of the method for manufacturing metal products according to the present invention, and is a perspective view of the side plate bending process. [Figure 12] This is a perspective view of the first bending process for the fillet section in the same manufacturing method. [Figure 13] This is a perspective view of the tip bending process in the same manufacturing method. [Figure 14] This is a perspective view when a metal processed product according to the present invention is converted into a design registration application. [Figure 15] This is a front view of the same object. [Figure 16] This is the rear view. [Figure 17] This is a right side view of the same object. [Figure 18] This is a left side view of the same object. [Figure 19] The same plane diagram. [Figure 20] The same base view. [Figure 21] This is a reference perspective showing the names of the parts of the body used. [Modes for carrying out the invention]

[0028] (One embodiment of a method for manufacturing metal products) Hereinafter, an embodiment of the method for manufacturing metal processed products according to the present invention will be described with reference to Figures 1 to 10.

[0029] The manufacturing method for metal products in this embodiment (hereinafter also simply referred to as the "manufacturing method") involves processing a metal sheet material 30 as shown in Figures 4 and 5 to produce a metal product 10 as shown in Figure 1, which has a bottom plate 11, a pair of side plates 13 and 15 erected from the bottom plate 11, and a front plate 17 (which can also be called an end plate) positioned between the pair of side plates 13 and 15.

[0030] Furthermore, the front plate 17 is located at one end of the base plate 11 in the longitudinal direction and is positioned between the pair of side plates 13 and 15. The pair of side plates 13 and 15 and the front plate 17 are erected at an angle perpendicular to the base plate 11.

[0031] Furthermore, the metal product 10 of this embodiment has a gutter shape extending in a predetermined direction, and is used as a roofing material laid in a row from the eaves to the ridge, and is a so-called interlocking standing seam roof, with fitting parts 19 and 21 provided on both sides in the extension direction L.

[0032] When used as roofing material, the metal product 10 is installed with the front plate 17 facing downwards (towards the eaves) and the portion opposite to the front plate 17 in the longitudinal direction facing towards the ridge. However, the metal product may be used for purposes other than roofing material and is not particularly limited.

[0033] As shown in Figure 2, the manufacturing method of this embodiment includes a cutting step S1, a side plate bending step S2, a front plate bending step S3, a fillet section first bending step S4 included in the front plate bending step S3, a fillet section second bending step S5, and a tip bending step S6. Each step will be described in detail below.

[0034] Furthermore, as shown in Figure 3, this manufacturing method is carried out using a well-known cutting machine 1, a first bending machine 3 installed downstream of the metal product 10 manufacturing line in the cutting machine 1, and a second bending machine 5 installed downstream of the first bending machine 3.

[0035] The first bending machine 3 bends a pair of side plates 13 and 15 so that they rise up relative to the bottom plate 11 while transporting the metal sheet material 30, and is equipped with rollers for transporting the metal sheet material 30, as well as punches, dies, and pressing parts for bending the side plates 13 and 15. The second bending machine 5 bends the front plate 17 and the fillet portions 23 and 25 as shown in Figures 4 and 5, and is equipped with punches, dies, and pressing parts for bending.

[0036] (Cutting process S1) This cutting process S1 is a process in which, with respect to the unfolded metal plate material 30 as shown in Figure 4, the cutting machine 1 cuts both corners on the front plate 17 side of the metal plate material 30 from the intersections P1 and P2 where the first fold lines 31 and 33 for folding the pair of side plates 13 and 15 and the second fold line 35 for folding the front plate 17 intersect, so that fillet portions 23 and 25 that extend toward the leading edge 17a of the front plate 17 and the side edges 13a and 15a of the side plates 13 and 15 remain.

[0037] In this embodiment, the metal sheet material 30 is in the form of a long plate extending for a predetermined length. As the metal sheet material 30, for example, galvalume steel sheet (registered trademark, aluminum-zinc alloy plated steel sheet), galvanized iron (zinc plated steel sheet), copper sheet, etc. can be used.

[0038] A pair of side plates 13 and 15 are arranged along the extension direction L (which can also be called the longitudinal direction) of the metal plate 30, and on both sides in the width direction W, which is perpendicular to the extension direction L in a plan view. A front plate 17 is positioned at one end of the metal plate 30 in the extension direction L, between the pair of side plates 13 and 15. The portion of the metal plate 30 enclosed by the pair of side plates 13 and 15 and the front plate 17 forms the bottom plate 11.

[0039] Furthermore, the edge of the front plate 17 located at one end in the extension direction L is designated as the front edge 17a. In addition, the edges of the side plates 13 and 15 in the width direction W extending along the extension direction L are designated as the side edges 13a and 15a.

[0040] Furthermore, first fold lines 31 and 33 are provided at the boundary between the base plate 11 and the pair of side plates 13 and 15, respectively, for folding the pair of side plates 13 and 15 upwards (standing upright) relative to the base plate 11. In this embodiment, the pair of first fold lines 31 and 33 extend parallel to each other along the extension direction L of the metal plate material 30.

[0041] Furthermore, a second fold line 35 is provided at the boundary between the bottom plate 11 and the front plate 17, for folding the front plate 17 upwards relative to the bottom plate 11. In this embodiment, the second fold line 35 extends along the width direction W of the metal plate material 30 and perpendicular to the first fold lines 31 and 33.

[0042] Furthermore, a fillet portion 23 is provided that extends outwards from the intersection P1 of the first fold line 31 and the second fold line 35 toward the leading edge 17a of the front plate 17 and the side edge 13a of the side plate 13, and a fillet portion 25 is provided that extends outwards from the intersection P2 of the first fold line 33 and the second fold line 35 toward the leading edge 17a of the front plate 17 and the side edge 15a of the side plate 15.

[0043] Then, as shown in Figures 5 and 6, the metal sheet material 30 is cut by the cutting machine 1 at both corners on the front plate 17 side (the part where one side of the front plate 17 in the width direction W intersects with the tip of the side plate 13 in the extension direction L, and the part where the other side of the front plate 17 in the width direction W intersects with the tip of the side plate 15 in the extension direction L) so that the fillet portions 23 and 25 remain.

[0044] Furthermore, in the cutting process S1 described above, the side edges 17b and 17c of the front plate 17 are formed along the first fold lines 31 and 33, and the front edges 13b and 15b of the side plates 13 and 15 are formed along the second fold line 35. In addition, outer edges 49 and 51 are formed on the fillet portions 23 and 25, respectively, connecting to the first auxiliary fold lines 41 and 43 extending from the intersections P1 and P2 onto the first fold lines 31 and 33, and to the second auxiliary fold lines 45 and 47 extending from the intersections P1 and P2 onto the second fold line 35.

[0045] To elaborate on the fillet portions 23 and 25, the fillet portion 23 on the side plate 13 side has an outer edge portion 49 that connects to a first auxiliary fold line 41 extending from intersection P1 onto the first fold line 31 and a second auxiliary fold line 45 extending from intersection P1 onto the second fold line 35. On the other hand, the fillet portion 25 on the side plate 15 side has an outer edge portion 51 that connects to a first auxiliary fold line 43 extending from intersection P2 onto the first fold line 33 and a second auxiliary fold line 47 extending from intersection P2 onto the second fold line 35.

[0046] Furthermore, as shown in Figure 6, the outer edges 49 and 51 have first inclined portions 53 and 55 that extend from the front edge portions 13b and 15b of the side plates 13 and 15 toward the front edge portion 17a of the front plate 17, inclined so as to gradually approach the first auxiliary fold lines 41 and 43, and second inclined portions 57 and 59 that extend from the side edge portions 17b and 17c of the front plate 17 toward the side edge portions 13a and 15a of the side plates 13 and 15, inclined so as to gradually approach the second auxiliary fold lines 45 and 47.

[0047] In this embodiment, the outer edge 49 of the fillet portion 23 has a first inclined portion 53 that extends from the front edge 13b side of the side plate 13 toward the front edge 17a of the front plate 17, inclined to gradually approach the first auxiliary fold line 41, and a second inclined portion 57 that extends from the side edge 17b side of the front plate 17 toward the side edge 13a of the side plate 13, inclined to gradually approach the second auxiliary fold line 45.

[0048] Furthermore, the outer edge 51 of the fillet portion 25 has a first inclined portion 55 that extends from the tip edge 15b side of the side plate 15 toward the tip edge 17a of the front plate 17, inclining as it gradually approaches the first auxiliary fold line 43, and a second inclined portion 59 that extends from the side edge 17c side of the front plate 17 toward the side edge 15a of the side plate 15, inclining as it gradually approaches the second auxiliary fold line 47.

[0049] Furthermore, the fillet portion 23 is provided with a third fold line 37 that extends diagonally along the diagonal of the fillet portion 23, connecting the intersection point P1 of the first fold line 31 and the second fold line 35 to a predetermined portion of the outer edge 49 (in this case, the connecting portion R1 between the first inclined portion 53 and the second inclined portion 57).

[0050] Furthermore, the fillet section 25 is provided with a third fold line 39 that extends diagonally along the diagonal of the fillet section 25, connecting the intersection point P2 of the first fold line 33 and the second fold line 35 to a predetermined portion of the outer edge 51 (in this case, the connecting portion R2 between the first inclined portion 55 and the second inclined portion 59).

[0051] Furthermore, of the pair of left and right side plates 13 and 15, a notch 61 is formed in the side plate 15, on the other end side in the extension direction L, closer to the side edge 15a of the side plate 15, beyond the tip edge 15b.

[0052] Furthermore, the base end 53a of the first inclined portion 53 of the outer edge portion 49 of the fillet portion 23 has a different inclination angle (an angle close to right with respect to the second auxiliary fold line 45) than the base end 53a, and the base end 57a of the second inclined portion 57 also has a different inclination angle (an angle close to right with respect to the first auxiliary fold line 41) than the base end 57a.

[0053] Furthermore, the base end 55a of the first inclined portion 55 on the outer edge 51 of the fillet portion 25 has a different inclination angle (an angle close to right with respect to the second auxiliary fold line 47) than the other ends 55a, and the base end 59a of the second inclined portion 59 also has a different inclination angle (an angle close to right with respect to the first auxiliary fold line 43) than the other ends 59a.

[0054] Then, in cutting step S1, the cutting machine 1 cuts along one end of the extension direction L of the first fold line 31, the outer edge 49 including the first inclined portion 53 and the second inclined portion 57, and one side of the width direction W of the second fold line 35. In addition, the cutting machine 1 cuts along one end of the extension direction L of the first fold line 33, the outer edge 51 including the first inclined portion 55 and the second inclined portion 59, the other side of the width direction W of the second fold line 35, and the outer edge shape of the notch 61.

[0055] As a result, a metal plate 30 is formed in which fillet portions 23 and 25 remain at both corners of the front plate 17 of the metal plate 30, as shown in Figures 5 and 6.

[0056] (Side panel bending process S2) This side plate bending process S2 is a process in which, after the cutting process S1, a pair of side plates 13 and 15 are bent relative to the bottom plate 11 via the first fold lines 31 and 33 using a bending machine (see arrow F1 in Figure 5).

[0057] In the side plate bending process S2 of this embodiment, the metal plate material 30, with fillet portions 23 and 25 remaining as shown in Figures 5 and 6, is bent by the first bending machine 3 so that the side plate 13 rises upward relative to the bottom plate 11 via the first fold line 31, as shown by arrow F1 in Figure 5, and the top of the side plate is folded downward to form a fitting portion 19 that is roughly mountain-shaped. At this time, the fillet portion 23 is bent upward simultaneously with the side plate 13 via the first auxiliary fold line 41 on the first fold line 31 (see Figure 7).

[0058] Similarly, the first bending machine 3 bends the side plate 15 upwards relative to the bottom plate 11 via the first fold line 33, as shown by arrow F1 in Figure 5, and then folds it back downwards from its top to form a roughly mountain-shaped fitting portion 21. At this time, the fillet portion 25 is bent upwards simultaneously with the side plate 15 via the first auxiliary fold line 43 on the first fold line 33 (see Figure 7).

[0059] During the side plate bending process S2 described above, the punches, dies, and pressing parts of the first bending machine 3 bend the side plates 13 and 15, including the fillet portions 23 and 25, along the first fold lines 31 and 33 and the first auxiliary fold lines 41 and 43 relative to the bottom plate 11.

[0060] Furthermore, in this embodiment, during the first fillet bending process S4, as shown in Figure 8, a bending guide portion is formed to guide the bending direction of the fillet portions 23 and 25 so that they face outward from the bottom plate 11 (in a direction that does not overlap with the bottom plate 11 in a plan view). The bending guide portion will be described in detail below.

[0061] In other words, during the side plate bending process S2, in which a pair of side plates 13 and 15 are bent relative to the bottom plate 11, stepped portions 18, 18 (see Figure 7) extending in the extension direction L are formed near both sides of the front plate 17 in the width direction W, close to the side plates 13 and 15. That is, the side plate bending process S2 of this embodiment includes the process of forming stepped portions 18, 18 near both sides of the front plate 17 in the width direction W.

[0062] Furthermore, the parts of the front plate 17 where the stepped portions 18, 18 are formed have higher bending strength and are less prone to bending compared to the parts of the front plate 17 where the stepped portions 18, 18 are not formed.

[0063] Furthermore, during the side plate bending process S2, the bottom plate 11 is configured to have stepped portions 11a, 11a that extend along the extension direction L, continuous with the stepped portions 18, 18.

[0064] Furthermore, during the side plate bending process S2, stepped portions 24 and 26 are formed in the fillet portions 23 and 25 along the first auxiliary fold lines 41 and 43. In other words, the side plate bending process S2 of this embodiment includes the step of forming stepped portions 24 and 26 in the portions of the fillet portions 23 and 25 along the first auxiliary fold lines 41 and 43.

[0065] Furthermore, the parts of the fillet sections 23 and 25 where the stepped sections 24 and 26 are formed have higher bending strength and are more difficult to bend compared to the parts of the fillet sections 23 and 25 where the stepped sections 24 and 26 are not formed.

[0066] The bending guide section described above consists of stepped sections 18, 18 formed on the front plate 17 and stepped sections 24, 26 formed on the fillet sections 23, 25 during the side plate bending process S2. The function of this bending guide section will be described in detail in the explanation of the front plate bending process S3.

[0067] As shown in Figure 10, each side plate 13, 15 has stepped portions 14, 16 formed on it so as to be continuous with the fillet portions 23, 25. In addition, the roughly mountain-shaped fitting portions 19, 21 provided on each side plate 13, 15 have stepped portions 13c, 15c formed on them at positions corresponding to the stepped portions 14, 16.

[0068] Furthermore, the fitting portion 19 of a predetermined metal product 10 fits into the fitting portion 21 of another metal product 10 that is positioned adjacent to it, while the fitting portion 21 of a predetermined metal product 10 fits into the fitting portion 19 of another metal product 10 that is positioned adjacent to it, so that multiple metal products 10 are joined together in parallel.

[0069] (Front plate bending process S3 and fillet section first bending process S4) This front plate bending process S3 is a process in which, after the cutting process S1, the front plate 17 is bent relative to the bottom plate 11 via the second fold line 35 using a bending machine (see arrow F2 in Figure 7).

[0070] Furthermore, this front plate bending process S3 includes a first fillet portion bending process S4 in which the fillet portions 23 and 25 are bent by a bending machine so that their inner surfaces overlap via the third fold lines 37 and 39 and face outward from the bottom plate 11. In addition, the fillet portions 23 and 25 are bent in the front plate bending process S3 via the first auxiliary fold lines 41 and 43, the second auxiliary fold lines 45 and 47, and the third fold lines 37 and 39.

[0071] By the way, in this embodiment, as described above, during the first fillet bending process S4, as shown in Figure 8, bending guide portions (stepped portions 18, 18 formed on the front plate 17, and stepped portions 24, 26 formed on the fillet portions 23, 25) are formed to guide the bending direction of the fillet portions 23, 25 so that they face outward from the bottom plate 11.

[0072] Furthermore, in this embodiment, the front plate bending process S3 and the fillet portion first bending process S4 are performed by the second bending machine 5. The second bending machine 5 is provided with a bending restriction portion on the inner surface side of the fillet portions 23 and 25 that restricts bending of the fillet portions 23 and 25 inward of the bottom plate 11 (in the direction overlapping the bottom plate 11 in a plan view), while a bending allowance portion is provided on the outer surface side of the fillet portions 23 and 25 that allows bending of the fillet portions 23 and 25 outward of the bottom plate 11.

[0073] Then, as shown by arrow F2 in Figure 7, the metal plate material 30 with the pair of side plates 13 and 15 bent is bent so that the front plate 17 rises upwards from the bottom plate 11 via the second fold line 35 (front plate bending process S3, see Figure 8).

[0074] Furthermore, in conjunction with the front plate bending process S3 described above, the fillet portion 23 on the side plate 13 is bent so that the outer edge 49 protrudes outward toward the metal product 10 via the first auxiliary fold line 41, the second auxiliary fold line 45, and the third fold line 37. In other words, the fillet portion 23 is folded in such a way that it forms valley folds at the first and second auxiliary fold lines 41 and 45, and mountain folds at the third fold line 37, resulting in a so-called outward Yachiyo fold.

[0075] In this process, the bend-guiding portions (stepped portions 18, 24) described above guide the fillet portion 23 to face outward from the bottom plate 11.

[0076] In other words, in this embodiment, the fillet portion 23 is positioned between the stepped portions 18 and 24, which have high bending strength. Therefore, even if the fillet portion 23 tries to bend inward into the bottom plate 11, the stepped portions 18 and 24 prevent this bending deformation. As a result, the fillet portion 23 is guided to bend outward into the bottom plate 11 rather than inward. In other words, because the stepped portions 18 and 24 resist the bending stress associated with the bending deformation of the front plate 17, the fillet portion 23 is less likely to bend inward into the bottom plate 11, while it is more likely to bend outward into the bottom plate 11. Consequently, an outward Yachiyo fold is naturally formed on the fillet portion 23.

[0077] Furthermore, the bending restriction section and bending allowance section of the second bending machine 5 also assist in the outward Yachiyo fold of the fillet section 23.

[0078] Subsequently, the inner surfaces of the fillet section 23 (the surfaces facing the internal space of the metal product 10) are folded so that they overlap, and the first inclined section 53 and the second inclined section 57 are aligned with each other, that is, the edges of both inclined sections 53 and 57 are aligned, and the fillet section 23 is bent so that it faces outward from the bottom plate 11 (see Figure 8).

[0079] Similarly, in conjunction with the bending process of the front plate 17 described above, the fillet portion 25 on the side plate 15 is bent so that the outer edge 51 protrudes outward toward the metal product 10 via the first auxiliary fold line 43, the second auxiliary fold line 47, and the third fold line 39. In other words, the fillet portion 25 is folded in such a way that it forms valley folds at the first and second auxiliary fold lines 43 and 47, and mountain folds at the third fold line 39, resulting in a so-called outward Yachiyo fold.

[0080] Furthermore, the bending guide sections (stepped sections 18, 26) described above guide the fillet section 25 to face outward from the bottom plate 11 (the reason for this is the same as in the case of the fillet section 23 and will be omitted), naturally creating an outward Yachiyo fold for the fillet section 25, and the bending regulating section and bending allowance section of the second bending machine 5 further assist in creating an outward Yachiyo fold for the fillet section 23.

[0081] Subsequently, the fillet portion 25 is folded so that its inner surfaces overlap, and the first inclined portion 55 and the second inclined portion 59 are aligned with each other, that is, the edges of both inclined portions 55 and 59 are aligned, and the fillet portion 25 is bent so that it faces outward from the base plate 11 (see Figure 8).

[0082] (Second bending process for fillet section S5) This second fillet bending process S5 is a process in which the fillet portions 23 and 25 are bent using a bending machine after the first fillet bending process S4 so that they come into contact with the outer surface of the front plate 17 (see arrow F3 in Figure 8).

[0083] In this embodiment, the second fillet bending step S5 involves bending the fillet portion 23 facing outward from the bottom plate 11 in the first fillet bending step S4 above, via the first and second auxiliary fold lines 41 and 45, using the second bending machine 5 so that it contacts one side in the width direction W of the outer surface of the front plate 17 (the side opposite to the surface facing the internal space of the metal product 10) (see Figure 9).

[0084] Similarly, the fillet portion 25 facing outward from the bottom plate 11 is bent by the second bending machine 5 via the first and second auxiliary fold lines 43 and 47 so that it abuts against the other side in the width direction W of the outer surface of the front plate 17 (see Figure 9).

[0085] As a result, as shown in Figure 10, when the front plate 17 is viewed from the outside (or from the front), it is provided with fillet sections 23 and 25 that have a polygonal shape with four or more corners.

[0086] In this embodiment, the fillet portion 23 is constructed by folding and overlapping the first inclined portion 53 and the second inclined portion 57 so that they are aligned, and the base end 53a of the first inclined portion 53 and the base end 57a of the second inclined portion 57 are aligned, and the shape of the stepped portion 24, etc., so that one side in the width direction W is inclined to protrude toward the center of the width direction W, the upper side 73 is horizontal, and the other side in the width direction W has a stepped portion 74 that fits the stepped portion 24, forming a polygonal shape with four or more corners (see Figure 10).

[0087] On the other hand, the fillet section 25 is constructed such that the first inclined section 55 and the second inclined section 59 are aligned, and the base end 55a of the first inclined section 55 and the base end 59a of the second inclined section 59 are aligned, and the shape of the stepped section 26, etc., results in a polygonal shape with four or more corners, where one side in the width direction W is inclined to protrude toward the center of the width direction W, and the other side in the width direction W has a stepped section 79 that fits the stepped section 26.

[0088] Furthermore, this fillet section second bending process S5 is performed using the same second bending machine 5 as the one used in the front plate bending process S3 and the fillet section first bending process S4.

[0089] (Tip bending process S6) This tip bending process S6 is a process in which the tip portion 27 of the front plate 17 is bent using a bending machine in a direction that is close to the base portion 29 of the front plate 17.

[0090] In other words, as shown by arrow F4 in Figure 9, the tip 27 of the front plate 17, which is bent relative to the base plate 11, is folded back so that it is in a direction close to the base end 29. Here, the tip 27 of the front plate 17 is folded back so that it is perpendicular to the intermediate part 28 of the front plate 17, which rises upward perpendicular to the base plate 11. As a result, a metal product 10 as shown in Figure 1 is manufactured.

[0091] (One embodiment of a metal product) As described above, this metal product 10 has a trough shape extending in a predetermined direction, having a bottom plate 11, a pair of side plates 13 and 15, and a front plate 17. On the outer surface of the front plate 17, on both sides adjacent to the pair of side plates 13 and 15, metal plate material 30 is superimposed, and when the front plate 17 is viewed from the outer side (which can also be called the front side), it is provided with polygonal parts (fillet portions 23 and 25) having four or more corners.

[0092] As described above, the fillet section 23 has a polygonal shape with a pair of upper and lower side edges 71, 72, a horizontal upper edge 73, and a stepped section 74, while the fillet section 25 has a polygonal shape with multiple side edges 75, 76, 77, 78 and a stepped section 79. Thus, the metal product 10 has fillet sections 23 and 25 on both sides of the front plate 17 in the width direction W, each having a different polygonal shape.

[0093] (Other embodiments of the method for manufacturing metal products) Referring to Figures 11-13, other embodiments of the method for manufacturing metal products according to the present invention will be described. Parts substantially identical to those in the above embodiments are denoted by the same reference numerals, and their descriptions are omitted.

[0094] Figure 11 shows the state of the metal sheet material 30 after the side plate bending process S2. From this state, the front plate bending process S3 and the fillet section first bending process S4 are performed.

[0095] Furthermore, in this embodiment, during the first fillet bending process S4, as shown in Figure 12, a bending guide portion is formed to guide the bending direction of the fillet portions 23 and 25 so that they face inward towards the bottom plate 11 (in the direction overlapping the bottom plate 11 in a plan view).

[0096] In this embodiment, unlike the previous embodiment, no stepped portions 18, 18 are formed on the front plate 17. Instead, stepped portions 24, 26 are formed on the fillet portions 23, 25 along the first auxiliary fold lines 41, 43 during the side plate bending process S2. These stepped portions 24, 26 constitute the bending guide portions described above.

[0097] Furthermore, in this embodiment, the second bending machine 5 is provided with a bending restriction portion on the outer surface side of the fillet portions 23, 25 that restricts the outward bending of the fillet portions 23, 25 to the metal workpiece 10, while a bending allowance portion is provided on the inner surface side of the fillet portions 23, 25 that allows the inward bending of the fillet portions 23, 25 to the metal workpiece 10.

[0098] Then, with respect to the metal plate material 30 in which the pair of side plates 13 and 15 have been bent as shown by the arrows in Figure 12, the front plate 17 is bent upwards with respect to the bottom plate 11 via the second fold line 35 (front plate bending process S3).

[0099] Furthermore, in conjunction with the front plate bending process S3 described above, the fillet portion 23 on the side plate 13 is bent so that the outer edge 49 is pulled inward into the metal product 10 via the first auxiliary fold line 41, the second auxiliary fold line 45, and the third fold line 37 (see Figure 12). In other words, the fillet portion 23 is folded in such a way that it forms a mountain fold at the first and second auxiliary fold lines 41 and 45, and a valley fold at the third fold line 37, resulting in a so-called inward Yachiyo fold.

[0100] In this process, the bend-guiding portion (stepped portion 24) guides the fillet portion 23 to face inward towards the bottom plate 11.

[0101] In other words, unlike the embodiment described above which has two high-bending-strength sections (stepped sections 18, 24), during the front plate bending process S3, the high-bending-strength stepped section 24 presses the fillet section 23 toward the inside of the bottom plate 11, thus guiding the fillet section 23 toward the inside of the bottom plate 11. To put it another way, a single stepped section 24 is not enough to withstand the bending stress associated with the bending deformation of the front plate 17, so the fillet section 23 is prone to bending and deforming toward the inside of the bottom plate 11. As a result, an inward Yachiyo fold is naturally formed on the fillet section 23.

[0102] Furthermore, the bending restriction section and bending allowance section of the second bending machine 5 also assist in the inward Yachiyo fold of the fillet section 23.

[0103] Subsequently, the outer surfaces of the fillet portion 23 (the surfaces opposite to the inner surface facing the internal space of the metal product 10) are folded so that they overlap, and the first inclined portion 53 and the second inclined portion 57 are aligned with each other, that is, the edges of both inclined portions 53 and 57 are aligned, and the fillet portion 23 is bent so that it faces inward into the bottom plate 11.

[0104] Similarly, in conjunction with the bending process of the front plate 17 described above, the fillet portion 25 on the side plate 15 is bent so that the outer edge 51 is pulled inward into the metal product 10 via the first auxiliary fold line 43, the second auxiliary fold line 47, and the third fold line 39. In other words, the fillet portion 25 is folded in such a way that it forms a mountain fold at the first and second auxiliary fold lines 43 and 47, and a valley fold at the third fold line 39, resulting in a so-called inward Yachiyo fold.

[0105] Furthermore, the bending guide portion (stepped portion 26) described above guides the fillet portion 25 to face outward from the bottom plate 11 (for the same reason as the fillet portion 23), and an inward Yachiyo fold is naturally applied to the fillet portion 25. In addition, the bending regulating portion and bending allowance portion of the second bending machine 5 assist in the inward Yachiyo fold of the fillet portion 23.

[0106] Subsequently, the fillet portion 25 is folded so that its inner surfaces overlap, and the first inclined portion 55 and the second inclined portion 59 are aligned with each other, that is, the edges of both inclined portions 55 and 59 are aligned, and the fillet portion 25 is bent so that it faces inward into the base plate 11.

[0107] Subsequently, in the second fillet bending step S5, the fillet portions 23 and 25 after the first fillet bending step S4 are bent by a bending machine so that they come into contact with the inner surface of the front plate 17. Furthermore, in the tip bending step S6, the tip portion 27 of the front plate 17 is bent by a bending machine toward the base portion 29 of the front plate 17, thereby producing a metal product 10A as shown in Figure 13.

[0108] (modified version) In the embodiments shown in Figures 1-10 and Figures 11-13, the front plate bending process S3 is performed after the side plate bending process S2, and the front plate bending process S3 includes the fillet section first bending process S4. However, in the method for manufacturing metal processed products according to the present invention, the side plate bending process including the fillet section first bending process may be performed after the front plate bending process. Furthermore, the fillet section first bending process in this case includes either an outward Yachiyo fold process or an inward Yachiyo fold process.

[0109] (Effects and Benefits) Next, we will explain the manufacturing method of the metal processed product having the above configuration and the effects of the metal processed product.

[0110] In other words, as described above, this manufacturing method includes a side plate bending step S2 and a front plate bending step S3, and the front plate bending step S2 or the side plate bending step S3 includes a fillet section first bending step S4, and further includes a fillet section second bending step S5.

[0111] According to this, the Yachiyo fold in the fillet sections 23 and 25 is performed in a bending machine 3 and 5 at a factory or the like by the side plate bending process S2, front plate bending process S3, first fillet section bending process S4, and second fillet section bending process S5, which have the above configuration. As a result, metal processed products 10 and 10A of stable quality can be manufactured while keeping the number of work hours at the installation site low.

[0112] In other words, while conventionally the Yachiyo fold in the fillet section was performed manually by workers at the installation site, this manufacturing method allows it to be performed mechanically and industrially by bending machines 3 and 5 through a side plate bending process S2, a front plate bending process S3, a first fillet section bending process S4, and a second fillet section bending process S5.

[0113] Therefore, since workers do not need to perform the Yachiyo-fold on the fillet sections 23 and 25 at the installation site, the amount of work required at the installation site can be reduced, thereby controlling the overall work load. At the same time, it is possible to stably manufacture high-quality metal processed products 10 and 10A with less variation in quality.

[0114] Furthermore, in the above embodiment, prior to the front plate bending process S3 and the side plate bending process S2, there is a cutting process in which the corners on the front plate side of the metal plate material are cut with a cutting machine so that fillet portions 23 and 25 remain.

[0115] According to the above embodiment, the cutting process S1 with the above configuration forms a metal sheet material 30 in which fillet portions 23 and 25 remain (see Figures 5 and 6). As a result, the fillet portions 23 and 25 can be formed with high precision, and in the process after the cutting process S1, the fillet portions 23 and 25 can be bent with high precision, making it possible to manufacture metal processed products 10 and 10A of more stable quality.

[0116] Furthermore, in the above embodiment, a bending guide portion is formed that, during the first fillet bending process S4, guides the fillet portions 23 and 25 to bend outward from the bottom plate 11, or to bend inward from the bottom plate 11.

[0117] According to the above embodiment, since a bending guide section having the above configuration is formed, the yachiyo fold of the fillet sections 23 and 25 can be promoted during the first fillet section bending process S4, and it is possible to provide the metal sheet material 30 itself with a yachiyo fold promoting structure derived from the shape of the metal sheet material 30, thereby simplifying and compacting the yachiyo fold promoting structure on the second bending machine 5 side.

[0118] Furthermore, in the above embodiment, the side plate bending process S2 includes the step of forming stepped portions 18, 18 on both sides of the front plate 17 that are close to the side plates 13, 15, and the bending guide portion consists of the stepped portions 18, 18 formed on the front plate 17 and the stepped portions 24, 26 formed on the fillet portions 23, 25 during the side plate bending process S2.

[0119] According to the above embodiment, the folding guide portion having the above configuration can effectively promote outward Yachiyo folding, in particular, in the fillet portions 23 and 25.

[0120] Furthermore, in the above embodiment, in the cutting step S1, the side edges 17b, 17c of the front plate 17 are formed along the first fold lines 31, 33, the front edges 13b, 15b of the side plates 13, 15 are formed along the second fold line 35, and the outer edges 49, 51 are connected to the first auxiliary fold lines 41, 43 extending from intersection points P1, P2 onto the first fold lines 31, 33 and the second auxiliary fold lines 45, 47 extending from intersection point P2 onto the second fold line 35. The fillet portions 23 and 25 are formed in the fillet portions 23 and 25. In the side plate bending process S2, when the front plate bending process S3 is performed after the side plate bending process S2, the fillet portions 23 and 25 are bent simultaneously with the side plates 13 and 15 via the first auxiliary fold lines 41 and 43, and in the fillet first bending process S4 of the front plate bending process S3, they are bent via the first auxiliary fold lines 41 and 43, the second auxiliary fold lines 45 and 47, and the third fold lines 37 and 39.

[0121] According to the above embodiment, the Yachiyo fold in the fillet portions 23 and 25 can be performed more reliably and accurately by utilizing the first auxiliary fold lines 41 and 43, the second auxiliary fold lines 45 and 47, and the third fold lines 37 and 39.

[0122] Furthermore, the same effect as described above can be obtained even if the fillet sections 23 and 25 are bent simultaneously with the front plate 17 via the second auxiliary fold lines 45 and 47 during the front plate bending process S3 when the side plate bending process S2 is performed after the front plate bending process S3, and are bent via the first auxiliary fold lines 41 and 43, the second auxiliary fold lines 45 and 47, and the third fold lines 37 and 39 during the first fillet bending process S4 in the side plate bending process S2.

[0123] Furthermore, in the above embodiment (the embodiment shown in Figures 1 to 10), the front plate bending process S3 is performed after the side plate bending process S2. The fillet portions 23 and 25 are bent simultaneously with the side plates 13 and 15 via the first auxiliary fold lines 41 and 43 in the side plate bending process S2. In the first thin-walled portion bending process S4 of the front plate bending process S3, they are bent so that their inner surfaces overlap and face outward from the bottom plate 11 via the first auxiliary fold lines 41 and 43, the second auxiliary fold lines 45 and 47, and the third fold lines 37 and 39. In the second fillet portion bending process S6, they are bent so that they abut against the outer surface of the front plate 17.

[0124] According to the above embodiment, a metal product 10 having fillet portions 23 and 25 with outward-facing Yachiyo folds can be manufactured accurately and stably.

[0125] Furthermore, in the above embodiment, the outer edges 49 and 51 of the fillet portions 23 and 25 have first inclined portions 53 and 55 that extend inclined from the leading edge portions 13b and 15b of the side plates 13 and 15 toward the leading edge portion 17a of the front plate 17, so as to gradually approach the first auxiliary fold lines 41 and 43, and second inclined portions 57 and 59 that extend inclined from the side edge portions 17b and 17c of the front plate 17 toward the side edge portions 13a and 15a of the side plates 13 and 15, so as to gradually approach the second auxiliary fold lines 45 and 47.

[0126] According to the above embodiment, the first inclined portion 53, 55 and the second inclined portion 57, 59 provided on the outer edges 49, 51 of the fillet portions 23, 25 make it easier to form polygonal fillet portions 23, 25.

[0127] Furthermore, in the above embodiment, there is a tip bending step S6 in which the tip portion 27 of the front plate 17 is bent by a bending machine (second bending machine 5) in a direction approaching the base portion 29 of the front plate 17.

[0128] According to the above embodiment, the tip bending process S6 with the above configuration can form a so-called water-repellent portion on the front plate 17, thereby suppressing the outflow of moisture such as rainwater from the tip of the front plate 17 and making it easier to retain moisture inside the metal processed products 10 and 10A.

[0129] Furthermore, the metal processed products 10 and 10A are made of metal sheet material 30 and have a bottom plate 11, a pair of side plates 13 and 15 erected from the bottom plate 11, and a front plate 17 positioned between the pair of side plates 13 and 15. On the outer or inner surface of the front plate 17, on both sides adjacent to the pair of side plates 13 and 15, the metal sheet material 30 is overlapped, and when the front plate 17 is viewed from the outer or inner side, it is provided with polygonal portions (fillet portions 23 and 25) having four or more corners.

[0130] According to the above invention, metal processed products 10 and 10A having so-called Yachiyo-folded portions (fillet portions 23 and 25) can be obtained. Furthermore, since the Yachiyo-folded fillet portions 23 and 25 have a polygonal shape with four or more corners, the contact area with the front plate 17 can be increased compared to a triangular plate-shaped fillet portion, thereby improving the rigidity of the metal processed products 10 and 10A on the front plate 17 side.

[0131] (Additional notes) Figures 14-21 are drawings for when a metal processed product according to the present invention is to be converted to a design registration. Figure 14 is a perspective view, Figure 15 is a front view, Figure 16 is a rear view, Figure 17 is a right side view, Figure 18 is a left side view, Figure 19 is a top view, Figure 20 is a bottom view, and Figure 21 is a reference perspective view showing the names of the parts used.

[0132] Furthermore, the article to which the design pertains in this case is a "roofing material" used as the roof of a building such as a house. Moreover, as shown in the "reference perspective view showing the names of the parts of use," the article to which the design pertains is roughly in the shape of a gutter, consisting of a base plate extending for a predetermined length, a pair of side plates erected from both sides in the longitudinal direction of the base plate, and a front plate erected from one end in the longitudinal direction of the base plate, between the pair of side plates. In addition, polygonal fillet sections are provided on both sides in the width direction of the front plate.

[0133] In each figure, the parts represented by solid lines are the parts for which design registration is sought as partial designs. Furthermore, the dashed lines shown in the "right side view" of Figure 17, the "left side view" of Figure 18, and the "bottom view" of Figure 15 indicate only the boundaries between the parts for which design registration is sought as partial designs and the other parts.

[0134] It should be noted that the present invention is not limited to the embodiments described above, and various modified embodiments are possible within the scope of the gist of the present invention, and such embodiments are also included in the scope of the present invention. [Explanation of symbols]

[0135] 1 cutting machine 3.5 Bending machine 10,10A Metal processing products 11 Bottom plate 13,15 Side panels 17 Front panel 23,25 Fillet part 30 Metal plate material 31,33 First fold line 35. Second fold line 37,39 Third fold line 41,43 First auxiliary fold line 45,47 Second auxiliary fold line 49,51 Outer edge 53,55 1st slope 57,59 2nd slope S1 Cutting process S2 Side plate bending process S3 Front panel bending process S4 Fillet part 1st bending process S5 Fillet section second bending process S6 Tip bending process

Claims

1. A metalwork product made of a metal plate, having a bottom plate, a pair of side plates erected from the bottom plate, and a front plate positioned between the pair of side plates, A metal product characterized in that the outer or inner surface of the front plate, on both sides adjacent to the pair of side plates, is formed by overlapping the metal plate material, and when the front plate is viewed from the outer or inner side, a polygonal shape with four or more corners is provided.

2. The metal product according to Claim 1, wherein the polygonal portion is a polygon with a different shape on both sides in the width direction of the front plate.

3. The metal product according to claim 1 or 2, wherein the polygonal portion is a polygon having a plurality of side edges that are inclined with respect to the bottom plate.

4. The metal product according to claim 3, wherein the plurality of side edges are inclined to be spaced apart from the side plate.

5. The metal product according to claim 1 or 2, wherein the metal product is used as a roofing material for a building.

6. The metal product according to claim 1 or 2, wherein the metal sheet material is made of a metal selected from aluminum-zinc alloy plated steel sheet, galvanized steel sheet, and copper sheet.

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