METAL PLATE AND METAL COVER EMPLOYING SAME
20190009320 ยท 2019-01-10
Assignee
- NISSAN MOTOR CO., LTD. (Yokohama-shi, Kanagawa, JP)
- Nichias Corporation (Tokyo, JP)
- APJ CORPORATION (Yamato-shi, Kanagawa, JP)
Inventors
Cpc classification
F01N13/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/102
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/1811
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01N13/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Projection row (2) and recess row (3) are alternately and successively formed in a direction (Y-direction) perpendicular to a direction (X-direction) of their rows, thereby forming a corrugated cross-sectional shape of a cross-sectional wave shape. Between projection row (2) and recess row (3), there is provided inclined wall surface (4) having a wave shape in plan view. Each of projection row (2) and recess row (3) has a shape in a cross-section along X-direction that is formed into a corrugated cross-sectional shape of a wave shape. Pitch and height difference between valley portion (5) and crest portion (6) in the corrugated cross-sectional shape along this X-direction are smaller, as compared with a relationship between projection row (2) and recess row (3) in the corrugated cross-sectional shape along Y-direction. The corrugated metal plate of such shape has advantages that machining for making cross-sectional shapes in two directions of X and Y into wave shapes is easy and that the flexural rigidity difference between two direction of X and Y is extremely small.
Claims
1: A metal plate comprising an upper surface, a side wall surface, a lower surface and a side wall surface in this order in succession to form a row having a shape of a projection and a recess, wherein each side wall is provided such that a width between the two upper surfaces positioned to interpose the lower surface is wider than a width of the lower surface, wherein each side wall surface is formed into a wave shape in plan view, and wherein each of the upper surface and the lower surface is formed into a wave shape in a cross-section along a direction of a row thereof.
2: The metal plate as claimed in claim 1, wherein each side wall is an inclined surface.
3: The metal plate as claimed in claim 2, wherein each of the upper surface and the lower surface has a crest portion and a valley portion and has a wave shape in a cross-section along the direction of the row, the crest portion and the valley portion being alternately formed in succession in the direction of the row, having a pitch defined therebetween that is smaller than a pitch defined between the upper surface and the lower surface, and having a height difference therebetween that is smaller than a height difference between the upper surface and the lower surface.
4: The metal plate as claimed in claim 3, wherein, between the upper surface and the lower surface that are adjacent to each other with an interposal of the side wall surface, an edge line of the crest portion of the upper surface and an edge line of the crest portion of the lower surface are aligned with each other, and an edge line of the valley portion of the upper surface and an edge line of the valley portion of the lower surface are aligned with each other.
5: The metal plate as claimed in claim 4, wherein a shape in the cross-section of the row of the upper surface and a shape in the cross-section of the row of the lower surface are identical.
6: The metal plate as claimed in claim 5, wherein a shape in a cross-section passing through crest portions of the upper surface and the lower surface coincides with a shape prepared by inverting upside down a shape in a cross-section passing through valley portions of the upper surface and the lower surface.
7: The metal plate as claimed in claim 3, wherein, between the upper surface and the lower surface that are adjacent to each other with an interposal of the side wall surface, an edge line of the crest portion of the upper surface and an edge line of the crest portion of the lower surface are displaced from each other in a direction of the row, and an edge line of the valley portion of the upper surface and an edge line of the valley portion of the lower surface are displaced from each other in a direction of the row.
8: A metal cover that is formed and bent into a three-dimensional shape by using the metal plate as claimed in claim 1 as a base plate.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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[0033]
MODE FOR IMPLEMENTING THE INVENTION
[0034]
[0035] In
[0036] In case that one particular direction is defined as X-direction and that a direction perpendicular to this X-direction is defined as Y-direction, in the corrugated metal plate 1 shown in
[0037] That is, as shown in
[0038] As a plan view shape of projection row 2, as shown in
[0039] The plan view shape of this projection row 2 also appears even in recess row 3 adjacent to projection row 2. As shown in
[0040] When viewing the cross-sectional shape along the longitudinal direction (X-direction) of projection row 2, as shown in
[0041] The cross-sectional shape along the longitudinal direction (X-direction) of this projection row 2 also appears in recess row 3 adjacent to projection row 2. As shown in
[0042] Then, as clear from
[0043] Therefore, the corrugated metal plate 1 shown in
[0044] On the other hand, the corrugated metal plate 1 shown in
[0045] As is clear from above, in the metal plate 1 shown in
[0046] In other words, in case that the shape in the cross-section along Y-direction passing through edge lines 6a, 16a of crest portions 6, 16 in projection row 2 and recess row 3 is compared with a shape resulting from inverting the front and back of the shape in the cross-section along Y-direction passing through edge lines 15a, 5a of valley portions 15, 5 in recess row 3 and projection row 2, they coincide with each other in shape although projection row 2 or recess row 3 is displaced by one row in Y-direction.
[0047] Similarly, in case that the shape in the cross-section along X-direction of projection row 2 is compared with a shape resulting from inverting the shape along X-direction of recess row 3, they coincide with each other in shape although the crest portion 16, 6 or valley portion 15, 5 is displaced in X-direction by a half pitch. In other words, the corrugated metal plate 1 of the present embodiment has substantially the same projection-recess shape on the front side and the back side. Therefore, it is a so-called reversible metal plate that can be used and/or enables a product design without differentiating its front and back. Then, inclined wall surface 4 positioned between projection row 2 and recess row 3 extends in X-direction in a wave form in plan view as shown in
[0048] A wall surface interposed between projection row 2 and recess row 3 is turned into inclined wall surface 4. This is also effective for suppressing the occurrence of fracture (fissure or crack) of corrugated metal plate 1. One get the impression as if it appears to become advantageous in strength, for example, if one turns a wall surface interposed between projection row 2 and recess row 3 as a boundary wall shared thereby into a vertical wall and if one tries to decrease the pitch defined between those projection row 2 and recess row 3 to increase density of them. On the other hand, irrespective of being inclined wall surface 4 or being the vertical wall, fracture tends to occur by stress concentration at a raised portion of the wall surface if the wall surface is steeply raised. In view of this point, as mentioned above, the wall surface interposed between projection row 2 and recess row 3 is turned into inclined wall surface having a wave shape in plan view. Furthermore, provided that the pitch defined between projection row 2 and recess row 3 is constant, the adaptation of inclined wall surface 4 decreases the flat base plate's area and therefore becomes advantageous in terms of material cost, too, as compared with the adaptation of the vertical wall in place of inclined wall surface 4.
[0049] The corrugated metal plate 1 of such shape is formed by pressing with only a single machining, for example, by putting a flat base plate between upper and lower molds having irregularities of a predetermined pattern and then pressure clamping. Alternatively, it is formed by pressing with only a single machining similar to the above, by sending a flat base plate into a meshing section of gear-shape rotary molds formed with irregularities of a predetermined pattern.
[0050] The reason why it can be formed into a predetermined shape by a single pressing is based on that, as shown in
[0051] Therefore, such corrugated metal plate 1 can be prepared to have a predetermined shape by only a single pressing operation as mentioned above. Thus, the press molds can have a simple structure, and the workload becomes the minimum, thereby lowering the cost.
[0052] Furthermore, as shown in
[0053] This can be explained as follows. In the case of bending the corrugated metal plate 1 along X-direction, the edge lines of crest portions 6, 16 and valley portions 5, 15 in each of projection row 2 and recess row 3 are perpendicular to X-direction. Therefore, it can show a sufficient resistance against the bending force. Furthermore, in the case of bending the corrugated metal plate 1 along Y-direction, the edge lines of crest portions 6, 16 and valley portions 5, 15 in each of projection row 2 and recess row 3 are along Y-direction. Therefore, one gets the impression as if bending tends to occur from those edge lines as starting points. However, as is clear from
[0054] Moreover, the shape on the front side is substantially the same as that on the back side. Not only there is no need to differentiate the back side and the front side, but also flexural rigidity in X-direction and that in Y-direction are similar. Therefore, it is possible to minimize the difference between them. This means that, when using the corrugated metal plate 1 as a mechanical structure, not only there is no need to differentiate the front side and the back side, but also the directional property of X-direction and Y-direction does not matter. As a result, for example, in the case of conducting a product design of an automotive engine's heat insulation cover, etc. by using corrugated metal plate 1 as a base plate, its usability becomes extremely good.
[0055] Furthermore, it does not have an extremely bent region where blanks are stacked. Therefore, for example, even if it receives a repeated vibration force, there is no risk of the occurrence of cracks and/or fracture caused by stress concentration.
[0056] Furthermore, as mentioned above, projection row 2 and its adjacent recess row 3 share inclined wall surface 4 therebetween. Therefore, even if corrugated metal plate 1 is used in any direction, a region functioning as a liquid pool is not generated. As a result, it is possible to prevent the occurrence of secondary defects caused by accumulation of oil, rain water, etc. In particular, it also becomes a preferable one, even in the case of using it particularly as a heat insulation cover that is arranged close to an exhaust manifold as an automobile's heat generating section.
[0057]
[0058] Corrugated metal plate 1 used as this heat insulation cover was prepared as mentioned above by using a flat aluminum plate having a thickness of 0.6 mm as a base plate and conducting an embossing corrugation machining thereon. The pitch defined between projection row 2 and recess row 3 shown in
[0059] This heat insulation cover 7 was subjected to a high-temperature vibration test, a high-temperature tensile test, a heat insulation performance test, a sound vibration performance test, an electrolytic corrosion test, etc. As a result, it was confirmed to meet all of necessary performances needed in practical use.
[0060] Herein, corrugated metal plate 1 of the present embodiment is not limited to the use as a heat insulation cover for the above-exemplified exhaust manifold and other automobile's heat generating sections. For example, it can be widely used as a structural member in various industrial fields, such as architecture, home electric appliances and sports goods, as well as transport equipment such as automobiles, railways, watercrafts and aircrafts. As to its use, it can also be used as a heat exchanging material, a reinforcing material, etc. as well as various heat insulation materials, sound insulation materials, sound absorbing materials, wind insulation materials, light insulation materials, etc.
[0061] In this case, depending on use, thickness and material of a flat base plate for producing corrugated metal plate 1 are suitably selected. As material of the base plate, it is possible to use aluminum (for example, A1050), nonferrous metal plates other than aluminum one, metal plates represented by steel plate, and a composite material (cladding material) having two or three layers of a steel plate, a metal plate other than that, and a nonferrous metal. As corrugated metal plate 1 used for a vehicle-mounted, heat insulation cover, etc., aluminum or an aluminum-based material is desirable from the viewpoint of weight reduction. As to its thickness too, for example, one having a range of about 0.15-1.0 mm is desirable.
[0062] Thus, corrugated metal plate 1 of the present embodiment has a shape that can be prepared by conducting a necessary bending machining with a substantially single step. Therefore, it is possible to reduce the cost by decreasing the number of the press machinings. Furthermore, the recess portion and/or valley portion does not function as a liquid pool. Thus, it is possible to prevent the occurrence of secondary defects based on a part functioning as a liquid pool as before.
[0063]
[0064] In this second embodiment, an embossed pattern similar to that of
[0065] According to this second embodiment, it will exhibit functions similar to those of the above first embodiment. It is possible to expect a further improvement of surface rigidity. In particular, there is an advantage that it is possible to further decrease the difference between flexural rigidity in X-direction and flexural rigidity in Y-direction (a good X-Y rigidity ratio).
[0066]
[0067] In this third embodiment, an embossed pattern similar to that of
[0068] This third embodiment also makes it possible to obtain advantageous effects similar to those of the first embodiment.
[0069]
[0070] In the fourth embodiment shown in
[0071] In the sixth embodiment shown in
[0072] In the fourth to seventh embodiments shown in
[0073] Therefore, the fourth to seventh embodiments shown in