U.S. patent application number 13/718838 was filed with the patent office on 2014-02-13 for method for manufacturing aluminum roof molding using porous oxide layer.
This patent application is currently assigned to HYUNDAI MOTOR COMPANY. The applicant listed for this patent is HYUNDAI MOTOR COMPANY. Invention is credited to Chul-Hong Bae, Chang-Yeol Yoo, Kwang-Min Yoon.
Application Number | 20140041196 13/718838 |
Document ID | / |
Family ID | 49638554 |
Filed Date | 2014-02-13 |
United States Patent
Application |
20140041196 |
Kind Code |
A1 |
Bae; Chul-Hong ; et
al. |
February 13, 2014 |
METHOD FOR MANUFACTURING ALUMINUM ROOF MOLDING USING POROUS OXIDE
LAYER
Abstract
Disclosed is a method of manufacturing an aluminum roof molding
using porous oxide layer comprising; forming a porous oxide layer
on a surface of the aluminum material by anodizing the aluminum
material; a slitting the aluminum material on which the porous
oxide layer is formed; roll forming the aluminum material to a
shape of the roof molding; heating the roll formed aluminum
material with a high frequency; and forming a PVC layer on the
heated aluminum material and simultaneously extruding the aluminum
material to bind the PVC layer to the aluminum material.
Inventors: |
Bae; Chul-Hong; (Hwaseong,
KR) ; Yoo; Chang-Yeol; (Suwon, KR) ; Yoon;
Kwang-Min; (Hwaseong, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HYUNDAI MOTOR COMPANY |
Seoul |
|
KR |
|
|
Assignee: |
HYUNDAI MOTOR COMPANY
Seoul
KR
|
Family ID: |
49638554 |
Appl. No.: |
13/718838 |
Filed: |
December 18, 2012 |
Current U.S.
Class: |
29/458 ;
72/46 |
Current CPC
Class: |
B21C 37/00 20130101;
B60R 13/04 20130101; Y10T 29/49885 20150115 |
Class at
Publication: |
29/458 ;
72/46 |
International
Class: |
B21C 37/00 20060101
B21C037/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 10, 2012 |
KR |
10-2012-0088031 |
Claims
1. A method for manufacturing an aluminum roof molding using a
porous oxide layer, comprising: forming the porous oxide layer on a
surface of an aluminum material by anodizing the aluminum material;
slitting the aluminum material on which the porous oxide layer is
formed; roll forming the aluminum material to a shape of the roof
molding; heating the roll formed aluminum material with a high
frequency; and forming a PVC layer on the heated aluminum material
and simultaneously extruding the aluminum material to bind the PVC
layer to the aluminum material.
2. The method for manufacturing an aluminum roof molding using
porous oxide layer of claim 1, further comprising: bending the
extruded aluminum material; and assembling an end piece and a clip
to the bent aluminum material.
3. The method for manufacturing an aluminum roof molding using
porous oxide layer of claim 1, further comprising: heating the roll
formed aluminum material with the high frequency at a temperature
range of about 100 to 150.degree. C. to facilitate the binding of
the aluminum material with the PVC layer.
4. The method for manufacturing an aluminum roof molding using
porous oxide layer of claim 1, wherein the extruding of the
aluminum material further comprises: applying about 50 to 100
kgf/cm.sup.2 of pressure.
5. The method for manufacturing an aluminum roof molding using
porous oxide layer of claim 1, wherein the anodizing further
comprises: degreasing the aluminum material; etching the degreased
aluminum material; activating the etched aluminum material; coating
the activated aluminum material; sealing the coated aluminum
material; and drying the sealed aluminum material.
6. The method for manufacturing an aluminum roof molding using
porous oxide layer of claim 5, wherein activating the etched
aluminum material further comprises: heating the etched aluminum
material with the high frequency.
7. The method for manufacturing an aluminum roof molding using
porous oxide layer of claim 6, wherein the high frequency heating
is performed using about 200 to 300 kHz of alternative current
frequency and about 100 to 200 V of voltage for about 1 to 3
minutes.
8. The method for manufacturing an aluminum roof molding using
porous oxide layer of claim 5, wherein the anodizing is performed
using about 100 to 300 V of voltage and about 100 to 200
mA/cm.sup.2 of current density.
9. A method for manufacturing an aluminum roof molding using a
porous oxide layer, comprising: forming the porous oxide layer on a
surface of an aluminum material by anodizing the aluminum material;
in response to forming the porous oxide layer, slitting the
aluminum material on which the porous oxide layer is formed; in
response to slitting the aluminum material, roll forming the
aluminum material to a shape of the roof molding; in response to
roll forming the aluminum material, heating the roll formed
aluminum material with a high frequency; and in response to heating
the roll formed aluminum material, forming a PVC layer on the
heated aluminum material and simultaneously extruding the aluminum
material to bind the PVC layer to the aluminum material.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. .sctn.119
to Korean Patent Application No. 10-2012-0088031, filed on Aug. 10,
2012, in the Korean Intellectual Property Office, the disclosure of
which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] (a)Technical Field
[0003] The present invention relates to a method of manufacturing
an aluminum roof molding using a porous oxide layer, and more
particularly, to a method of manufacturing aluminum roof molding
using a porous oxide layer, including forming a porous oxide layer
on a surface of an aluminum material by anodizing the aluminum
material and binding a Poly Vinyl Chloride (hereinafter, called as
PVC) layer on the porous oxide layer without using chemicals such
as adhesives.
[0004] (b)Background Art
[0005] FIG. 1 is an exemplary view showing an aluminum roof molding
applicable to vehicles and FIG. 2 is an exemplary view illustrating
a cross section of an aluminum roof molding wherein as shown in the
drawings, an aluminum roof molding 100 is formed by combining an
aluminum material 200 and a PVC layer 210 and covering a soldering
portion of a roof panel and a side panel to enhance the appearance
of the roof.
[0006] FIG. 3 is an exemplary sectional view illustrating an
aluminum roof molding formed using adhesives according to a related
art wherein the aluminum roof molding is manufactured by roll
forming an aluminum material (e.g., A 5052) having the composition
shown in Table 1 below, forming a PVC layer 210 on the applied
adhesives 220 and extrusion molding the aluminum material.
TABLE-US-00001 TABLE 1 Cr Cu Fe Mg Mn Si Ti Zn Description (wt %)
(wt %) (wt %) (wt %) (wt %) (wt %) (wt %) (wt %) Rem. A5052
0.15-0.35 o.1 or less 0.4 or less 2.2-2.8 0.1 or less 0.25 or less
0.015 or less 0.1 or less --
[0007] According to the related art, adhesives are required to
manufacture an aluminum roof molding which may increase
manufacturing costs. Further, durability of the aluminum roof
molding is determined depending on the performance of the adhesive,
making it difficult to predict the quality of the final product. In
addition, the solidification time of the liquid type adhesives
increases the process time, increasing entire process time.
[0008] Moreover, the adhesives generally have inferior water
resistance and heat resistance, and thus the PVC layer bound to the
aluminum material is easily separated from the aluminum
material.
[0009] The description provided above as a related art of the
present invention is just for helping understanding the background
of the present invention and should not be construed as being
included in the related art known by those skilled in the art.
SUMMARY OF THE DISCLOSURE
[0010] The present invention provides a method for manufacturing an
aluminum roof molding using a porous oxide layer, and the method
includes: forming a porous oxide layer on a surface of the aluminum
material by anodizing the aluminum material; slitting the aluminum
material on which the porous oxide layer is formed and roll forming
the aluminum material to a shape of the roof molding; heating the
roll formed aluminum material with a high frequency; and forming a
PVC layer on the heated aluminum material and simultaneously
extruding the aluminum material to bind the PVC layer to the
aluminum material.
[0011] Further, the method for manufacturing an aluminum roof
molding using a porous oxide layer according to an exemplary
embodiment of the present invention further includes: bending the
extruded aluminum material; and assembling an end piece and a clip
to the bent aluminum material.
[0012] Additionally, the heating of the roll formed aluminum
material may be performed at a temperature range of about 100 to
150.degree. C. to facilitate the combination of the aluminum
material with a PVC layer. Further, the forming of the PVC layer is
performed by extrusion, applying about 50 to 100 kgf/cm.sup.2 of
pressure.
[0013] Meanwhile, the anodizing treatment includes: degreasing the
aluminum material; etching the degreased aluminum material;
activating the etched aluminum material; coating the activated
aluminum material ; sealing the coated aluminum material; and
drying the sealed aluminum material.
[0014] Further, the activation of the etched aluminum material is
performed by heating the etched aluminum material with a high
frequency. In addition, the high frequency heating is performed at
about 200 to 300 kHz of alternative current frequency and about 100
to 200 V of voltage for about 1 to 3 minutes. Additionally, the
anodizing is performed at about 100 to 300 V of voltage and about
100 to 200 mA/cm.sup.2 of current density.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above and other features and advantages of the present
invention will now be described in detail with reference to
exemplary embodiments thereof illustrated the accompanying drawings
which are given hereinbelow by way of illustration only, and thus
are not limitative of the present invention, and wherein:
[0016] FIG. 1 is an exemplary view showing an aluminum roof molding
applicable to vehicles, according to the related art;
[0017] FIG. 2 is an exemplary sectional view illustrating an
aluminum roof molding, according to the related art;
[0018] FIG. 3 is an exemplary sectional view illustrating an
aluminum roof molding using adhesives according to the related
art;
[0019] FIG. 4 is an exemplary flow chart of the aluminum roof
molding processes according to an exemplary embodiment of the
present invention;
[0020] FIG. 5 is an exemplary diagram showing a process for
combining a PVC layer to the aluminum material according to an
exemplary embodiment of the present invention;
[0021] FIG. 6 is an exemplary enlarged photo showing the composite
layer 240 according to an exemplary embodiment of the present
invention;
[0022] FIG. 7 is an exemplary flow chart of an anodizing treatment
according to=an exemplary embodiment of the present invention;
[0023] FIG. 8 is an exemplary enlarged photo showing an oxide layer
produced by an anodizing treatment according to the related
art;
[0024] FIG. 9 is an exemplary enlarged photo showing a porous oxide
layer produced by anodizing treatment according to an exemplary
embodiment of the present invention; and
[0025] FIG. 10 is an exemplary photo showing a comparison of
accelerated weatherproof test results between an aluminum roof
molding using adhesives(upper side) according to the related art
and an aluminum roof molding produced according to an exemplary
embodiment of the present invention(lower side).
[0026] It should be understood that the accompanying drawings are
not necessarily to scale, presenting a somewhat simplified
representation of various exemplary features illustrative of the
basic principles of the invention. The specific design features of
the present invention as disclosed herein, including, for example,
specific dimensions, orientations, locations, and shapes will be
determined in part by the particular intended application and use
environment.
[0027] In the figures, reference numbers refer to the same or
equivalent parts of the present invention throughout the several
figures of the drawing.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT
[0028] It is understood that the term "vehicle" or "vehicular" or
other similar term as used herein is inclusive of motor vehicles in
general such as passenger automobiles including sports utility
vehicles (SUV), buses, trucks, various commercial vehicles,
watercraft including a variety of boats and ships, aircraft, and
the like, and includes hybrid vehicles, electric vehicles,
combustion, plug-in hybrid electric vehicles, hydrogen-powered
vehicles and other alternative fuel vehicles (e.g. fuels derived
from resources other than petroleum).
[0029] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. As
used herein, the term "and/or" includes any and all combinations of
one or more of the associated listed items.
[0030] Unless specifically stated or obvious from context, as used
herein, the term "about" is understood as within a range of normal
tolerance in the art, for example within 2 standard deviations of
the mean. "About" can be understood as within 10%, 9%, 8%, 7%, 6%,
5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated
value. Unless otherwise clear from the context, all numerical
values provided herein are modified by the term "about."
[0031] Hereinafter, the present invention now will be described in
detail with reference to the accompanying drawings.
[0032] FIG. 4 is an exemplary flow chart of the aluminum roof
molding according to an exemplary embodiment of the present
invention. As shown in FIG. 4, an aluminum material (e.g., A5052
material quality) may be cut and the cut aluminum material may be
anodized to form a porous oxide layer on a surface of the aluminum
material (S100). The anodizing process is a surface treatment
performed in solutions such as sulfuric acid, boric acid, etc. by
applying direct or alternative current, or both with the metal to
be plated as a positive electrode to form an anodizing layer (e.g.,
Al203) on a surface of the metal to be plated. Generally, the
aluminum material used for vehicles is cut into a plate with a
thickness of about 0.5 to 0.8 mm and a length of about 500 to 1250
mm
[0033] Further, the aluminum material on which the porous oxide
layer is formed may be slit and the slit aluminum material may be
roll formed to a shape of a roof molding (S110). The roll formed
aluminum material may be heated to a temperature range of about
100-150.degree. C. with a high frequency to facilitate a
combination with a PVC layer (S120).
[0034] Upon heating the roll formed aluminum material with high
frequency, the PVC layer may be formed on a surface of the heated
aluminum material, and may be extruded simultaneously by passing
the material through an extrusion mold to bind the PVC layer to the
aluminum material, wherein for sufficient bonding, a pressure of
about 50.about.100 kgf/cm2 may be applied, and as a result,
heterogeneous materials may be combined through the PVC being
filled between gaps of the porous oxide layer formed in the step
S100 (S130).
[0035] FIG. 5 is an exemplary schematic diagram showing a process
for binding a PVC layer to the aluminum material. As shown in FIG.
5, the aluminum material 200 on which porous oxide layer 230 is
formed on a surface by step S100 may be heated with high frequency
in step S120.
[0036] Further, the PVC layer 210 may be formed on the porous oxide
layer 230 and may be simultaneously extruded using an extrusion
mold wherein the PVC is filled into the empty space of the porous
oxide layer (e.g., gap of the rugged part) to form a composite
layer 240, and as a result the combination is completed.
[0037] FIG. 6 is an exemplary enlarged photo showing the composite
layer 240 and the PVC filled into the gap of the aluminum oxide
layer 231.
[0038] In addition, the extruded aluminum material may be bent into
a shape for the roof applicable to vehicle (S140), and the aluminum
roof molding may be manufactured completely by assembling other
contingent parts such as an end piece, a clip, etc., (S150).
[0039] As described-above, according to the present invention, a
method for combining heterogeneous material of aluminum and PVC
through compression using the extrusion mold without using
adhesives is provided wherein a porous layer may be formed by
anodizing.
[0040] In other words, an object of the conventional anodizing is
to create a smooth surface by anodizing under a proper condition;
the object of the anodizing of the present invention is to produce
a porous oxide layer having fine spaces to be filled with the PVC
by maximizing anodizing reaction.
TABLE-US-00002 TABLE 2 process Composition (solution) Condition
Degreasing Na.sub.3Po.sub.4 30 g/L Cathode Degreasing for 0.5~3
minutes, at current density of 1~4 A/dm, 4~6 V Etching CrO.sub.3
180 g/L Immersion for 3 minutes at 20~30.degree. C. Activation --
High Frequency Heating: Frequency 200~300 kHz, Voltage 100~200 V,
Immersion for 1~3 minutes Coating Na.sub.2SiO.sub.3_9H20 10~15 g/L
Temperature: 30~40.degree. C. KF_2H.sub.2O 3~5 g/L Voltage: 100~300
V KOH 2~4 g/L Current Density: 100~200 mA/cm.sup.2 Current
Duration: 1~2 minutes Sealing Ethylene Immersion for 1 minute at
20~30.degree. C. Drying -- Maintaining for 10~20 minutes at 90 .+-.
10.degree. C.
[0041] The above Table 2 shows detailed conditions to form a porous
oxide layer on the surface of the aluminum material in anodizing
treatment, and FIG. 7 is an exemplary flow chart showing the
anodizing according to an exemplary embodiment of the present
invention.
[0042] As shown in FIG. 7, the aluminum material may be degreased
by removing fatty contamination on the surface thereof (S200), and
the surface of the degreased aluminum material may be etched to
improve close adhesiveness with the oxide layer to be formed
(S210). Furthermore, the etched aluminum material may be activated,
which is a pre-treatment process to destroy passivation of the
surface, to facilitate the generation of the oxide layer on the
surface (S220).
[0043] In a conventional anodizing treatment, the activation is
performed by immersing the aluminum material into 2"4 g/L of
potassium hydroxide (KOH) of an alkaline solution at
20.about.30.degree. C. to prevent excessive anodizing reaction
through adjusting the anodizing reaction properly. Unlike the
conventional method, the present invention provides a method,
wherein the activation of the aluminum material may be performed by
embedding the materials in two plates through which alternative
current of high frequency may flow to maximize the anodizing
reaction and by heating the material with high frequency (e.g.,
using electromagnetic induction phenomenon).
[0044] Specifically, as a pre-treatment process for porosity of the
oxide layer, the high frequency heating according to the present
invention may be executed by heating the embedded aluminum material
for about 1.about.3 minutes at about 200.about.300 kHz of
alternative current frequency and about 100.about.200 V of voltage
wherein the surface temperature of the aluminum material may be
maintained within a temperature range of about
100.about.200.degree. C.
[0045] After the activation, the coating may be performed to
produce a porous oxide layer (S230). The electrolyte used in the
coating step (S230) may comprise one or more of Sodium Silicate
(Na.sub.2SiO.sub.3), Potassium Fluoride (KF) and Potassium
Hydroxide (KOH). Alternatively, the electrolyte may comprise all of
Sodium Silicate 9 Hydrates (Na.sub.2SiO.sub.3--9H2O), Potassium
Fluoride 2 Hydrates (KF.sub.--2H.sub.2O) and Potassium Hydroxide
(KOH).
[0046] The electrolyte may accelerate ionization of the water, and
more specifically, a coating layer of anodizing aluminum oxide
(Al.sub.2O.sub.3) may be formed by following chemical reactions (1)
and (2);
2H.sub.2O->2OH.sup.-+H.sub.2: (1)
2Al+3OH->Al.sub.2O.sub.3+3H.sub.2: (2)
[0047] Moreover, the anodizing reaction may be performed at a high
current density and a high voltage, wherein the anodizing reaction
may be performed at about 100.about.300 V of voltage and about
100.about.200 mA/cm.sup.2 of current density to form a porous layer
of a desired level.
[0048] FIG. 8 is an exemplary enlarged photo showing an oxide layer
produced by an anodizing treatment according to a prior art, and
FIG. 9 is an exemplary enlarged photo showing a porous oxide layer
produced by anodizing treatment according to an exemplary
embodiment of the present invention. As shown in the photos, the
oxide layer produced by the method of the present invention is a
porous layer.
[0049] Furthermore, a sealing treatment may be performed by filling
the vesicles of the coated aluminum material. The sealing treatment
may be performed to improve corrosion resistance of the aluminum
material and stabilize the produced porous oxide layer due to the
activity in the anodizing oxide layer in an initial stage of
formation which may become inactive and placed in a contaminated
state due to the absorption of gases in the air, etc., (S240).
[0050] In addition, the sealed aluminum material may be dried to
firmly combine the produced porous layer and to evaporate the
solution, thereby completing the formation of the porous layer.
[0051] FIG. 10 is an exemplary photo showing a comparison of
accelerated weatherproof test results between an aluminum roof
molding using adhesives (upper side) according to a prior art and
an aluminum roof molding produced according to an exemplary
embodiment of the present invention (lower side).
[0052] As shown in the photo, a contaminated part 500 is generated
in the aluminum roof molding when adhesives are used according to
the related art, however, the aluminum roof molding according to
the present invention shows no abnormality in appearance such as
discoloration.
[0053] As described above, an aluminum metal and a PVC layer may be
combined with adhesives according to a prior art, but according to
the present invention, a porous oxide layer may be formed on a
surface of the aluminum and a PVC may be bound with the aluminum
material using the oxide layer without the adhesive thereby
improving adhesiveness.
[0054] The method of manufacturing an aluminum roof molding of the
present invention may be performed by mechanically compressing the
PVC on the aluminum material using porosity of the aluminum oxide
layer formed by anodizing to omit the process of using adhesives.
In addition, the method of the present invention may improve heat
resistance, water resistance, durability, etc., by binding the PVC
layer on the surface of the aluminum material without using
adhesives vulnerable to heat or moisture. Moreover, the gap of a
porous oxide layer on the surface of the aluminum material formed
by the method of the present invention may be filled with the PVC
so the adhesiveness of the heterogeneous material may be
improved.
[0055] The invention has been described in detail with reference to
exemplary embodiments thereof. However, it will be appreciated by
those skilled in the art that changes or modifications may be made
in these embodiments without departing from the principles and
spirit of the invention, the scope of which is defined in the
accompanying claims and their equivalents.
* * * * *