Roll Forming Apparatus

1. Field of Invention

The present invention generally relates to a machine for producing frame members from a material sheet and a roll forming method of producing thereof wherein the ends of the material sheet is interlocking to each other without using attachment means to form a smooth surface joint and to enable other frame members to fit snugly into the groove to build up a frame.

2. Background of the Invention

Timber used to be the main source for construction of frames for doors, windows and the like. However, timbers are heavy in nature and secondly with our forest fast depleting, the quality of timber is not as consistent as it used to be. As a consequence, warping, shrinking or twisting may occur resulting in malfunctioning of the timber frames. After some years of use, timber trusses will deteriorate and eventually fail altogether. In light of the above metal frames of the present invention will be hailed as a more practical and efficient alternatives.

This prompted the creation and use of frames which are made of metal to overcome the problems associated with timber frames. However conventional methods of making metal frames for doors, windows or the like have been by the moulding method. This means that the metal has to be heated up to molten state before they are poured into relevant moulds for production of desired shape and configuration of frame members. Aluminium has been predominently used in the

manufacture of metal frame members as the melting point for aluminium is much lower as compared to most metals such as steel, copper, iron which melting points are way above that of aluminium. Higher the melting points will escalate cost of production as more energy is required to bring the metal to molten state for moulding purposes. Due to the above setback, aluminium being a metal having one of the lowest melting points is inevitably selected for a cost effective production of metal frame members.

While the shortcomings of timber frames have been solved, the aluminium frames are not as robust as those that would have been made of other metals such as steel. The present invention is relates to a machine for forming frames and a method of producing same from steel, copper, iron and the like besides aluminium by feeding a metallic sheet of steel, copper, iron or aluminium into a roll forming machine having a desired arrangement of rollers to roll form and transform the material sheet into frame members of desired configuration having a smooth surface joint with at least one groove formed thereon for fitting with other frame members to form a frame for window, door and the like.

The main feature lies with the rollers of the roll forming machine having a unique configuration at different forming stations to bend the material sheet to be roll formed with a seamless interacting joint.

3. Summary of the Invention

The present invention is an apparatus for metal sheet roll forming for producing frame members which are used to build frame structure comprising a sequential arrangement of forming stations having a plurality sets of upper and lower forming means that are rotated by a driving means, each secured to an apparatus frame and mounted spaced apart therealong for receiving the metal sheet passing along the forming stations for continuously enclosing the metal sheet into the frame member with an interacting joint where the edges of the metal sheet are progressively bend to a desired configuration by the forming stations and interacted to each other.

Preferably the forming stations includes at least one set of forming means with each upper forming means having one side formed with a ridge and the corresponding lower forming means with another ridge at the opposed side to form the lip bends at the edges of the metal sheet with one lip bend facing upwards and the other lip bend facing downwards to a pair of folded lip bends.

Preferably the forming stations includes at least one set of forming means with one of the forming means having extended portions at both sides to bend the edges of the metal sheet with angled bends.

Preferably the forming stations includes at least one set of forming means with one upper forming means having a fixed shaft attached with at least one roller to bend the metal sheet with vertical form bends for forming groove thereon.

Preferably the forming stations includes at least one set of forming means with an upper forming means having a roll mounted at substantially middle of a fixed shaft and a lower forming means formed with concave shaped roll for folding up the metal sheet to an enclosed frame member.

4. Brief Description of the Drawings

Other objects, features, and advantages of the invention will be apparent from the following description when read with reference to the accompanying drawings. In the drawings, wherein like reference numerals denote corresponding parts throughout the several views:

Figure Ia is an elevation view of the apparatus for metal sheet roll forming of the present invention.

Figure Ib is a top view of the apparatus for metal sheet roll forming of figure Ia.

Figure 2 shows a front view of the first forming station of the apparatus for the present invention.

Figure 3 shows a front view of the second forming station of the apparatus for the present invention.

Figure 4 shows a front view of the third forming station of the apparatus for the present invention.

Figure 5 shows a front view of the fourth forming station of the apparatus for the present invention.

Figure 6 shows a front view of the fifth forming station of the apparatus for the present invention.

Figure 7 shows a front view of the sixth forming station of the apparatus for the present invention.

Figure 8 shows a front view of the seventh forming station of the apparatus for the present invention.

Figure 9 shows a front view of the eighth forming station of the apparatus for the present invention.

Figure 10 shows a front view of the ninth forming station of the apparatus for the present invention.

Figure 11 shows a front view of the tenth forming station of the apparatus for the present invention.

Figure 12 shows a front view of the eleventh forming station of the apparatus for the present invention.

Figure 13 shows a front view of the twelfth forming station of the apparatus for the present invention.

Figure 14 shows a front view of the thirteenth forming station of the apparatus for the present invention.

Figure 15 shows a perspective view of the fourteenth forming station of the apparatus for the present invention.

Figure 16 depicts a diagram of the frame member profile with its edges interacted in locking position.

Figure 17 shows the frame member with additional groove formed thereon.

Figure 18 is a diagram of the frame member profile with other interacting positions.

5. Detailed Description of the Preferred Embodiments

Referring now to the drawings, and particularly to Figs. Ia and Ib thereof, there is shown a roll-forming machine (10) of the preferred embodiment of the invention comprising a main frame (11) which includes a base beam (Ha), a top beam (1 Ib) and a pair of lateral beams (lie, lid) which support the base and top beams (Ha, 11 b) and a series of rollers (12) located at spaced apart forming stations for a material to move through the roll forming machine (10) along a path and parallel to the base and top beams (Ha, l ib) for forming a closed loop frame. Each forming station comprises a pair of rollers (12) supported on a shaft in turn supported in a pair of bearings which is rotatably mounted onto the lateral beams (1 Ic, Hd) and driven by a chain drive (not shown).

A first forming station (12a) is used at the entry of the roll-forming machine (10) which includes an upper and lower roller (12a', 12a") mounted slightly offset from each other as shown in Fig. 2. The extended portion of each side of the rollers (12a', 12a") is formed with a inclined ridge (13) which inclined outwardly from the edge of the roller to an outer circular rim (14) attached thereto for forming a first lip bend (Bl) at each side of the material passing through the roll- forming machine (10), whereby the bends (Bl) are facing in opposing position to each other.

A second forming station (12b) is located spaced apart from the first forming station (12a) of the roll-forming machine (10). The second forming station (12b) includes an upper and lower rollers (12b', 12b") having the similar mounting configuration like the first pair of rollers (12a', 12a") as shown in Fig. 2 but the extended portion of each side of the rollers (12b', 12b") are formed differently.

Each extended portion of the rollers (12b', 12b") is formed with an outer circular rim (15) to further bend the first lip bend (Bl) of the material sheet to an upright lip bend (B2) as shown in Fig. 3. The outer circular rim (15) is slightly larger diameter than the diameter of the roller (12b).

A third forming station (12c) is spaced apart from the second forming station (12b) of the roll-forming machine (10). The third forming station (12c) includes an upper and lower rollers (12c' ₅ 12c") aligned together. The side edge of each roller which is opposed to the extended portion side of the roller at second forming station (12b) is formed with a ridge (16) with its outer part (16a) having the same diameter as the roller (12c) and tapered surface (16b) from substantially

middle of the ridge (16) towards the edge of the roller (12c) for bending the upright lip bend (B2) of the material sheet to a backward lip bend (B3) as shown in Fig. 4.

A fourth forming station (12d) is spaced apart from the third forming station (12c) of the roll-forming machine (10). The fourth forming station (12d) includes an upper and lower rollers (12d', 12d") having the similar mounting configuration like the third pair of rollers (12c', 12c") as shown in Fig. 4 but the ridge (17) of each side of the rollers (12d\ 12d") are formed differently. The ridges (17) of the pair of rollers (12d', 12d") are formed at the sides similar to the ridges (16) of the third pair of rollers (12c', 12c"). The ridge (17) of each roller (12d) includes an outer part (17a) having the same diameter as the roller (12d) and a step (17b) formed from the outer part (17a) towards the edge of the roller (12d) for bending the backward lip bend (B3) against the body of the material sheet to form a C- shaped bend (B4) as shown in Fig. 5.

A fifth forming station (12e) is spaced apart from the fourth forming station (12d) of the roll-forming machine (10). The fifth forming station (12e) includes an upper and lower rollers (12e', 12e") mounted aligned but the upper roller (12e') having its both sides formed with an extended portion which includes an outer circular rim (18) followed by an inclined recess (19) to a bulge part (20) which is attached at the edge of the roller (12e) as shown in Fig. 6 for bending both C- shaped bends (B4) downwards to C-shaped lip bends (B5).

A sixth forming station (12f) is spaced apart from the fifth forming station (12e) of the roll-forming machine (10). The sixth forming station (12f) includes an upper stationary holder (12f ) and a lower roller (12f ) which is similar to the lower roller (12e") of the fifth forming station. The upper stationary holder (12f ) has a shaft (21) which is fixed to the lateral beams (lie, l id) with fasteners (22). The shaft (21) of the upper stationary holder (12f ) is attached with a pair of side roller supports (23) and a roll (24) in between the side roller supports (23). At the bottom part of each side roller support (23), there is provided with a collar (25) projected over the bottom level of the roll (24) forming an area for receiving the lower roller (12f ). The left collar (25) of the side roller support (23) has a step (26) at the outer part of the collar for accommodating the C-shaped bend of the material sheet. The sixth forming station (12f) is used for bending the C-shaped lip bends (B5) to a pair of downward vertical bends (B6) as shown in Fig. 7.

A seventh forming station (12g) is spaced apart from the sixth forming station (12f) of the roll-forming machine (10). The seventh forming station (12g) includes an upper and lower rollers (12g', 12g") mounted aligned but the lower roller (12g") having its both sides formed with an extended portion which includes an outer circular rim (27) tapered towards the edge of the roller (12g) as shown in Fig. 8 for bending the pair of downward vertical bends (B6) slightly upwards to a pair of upside down V-shaped bends (B7).

A eighth forming station (12h) is spaced apart from the seventh forming station (12g) of the roll-forming machine (10). The eighth forming station (12h) includes an upper and lower rollers (12h\ 12h") mounted aligned but the lower roller

(12h") having its both sides formed with an extended portion which includes an inclined ridge (28) which inclines outwardly from the edge of the roller to an outer rim (29) whereby the outer rim (29) is formed with its diameter smaller than the edge of the inclined ridge (28) but slightly larger diameter than the roller (12h) for further bending up the pair of upside down V-shaped bends (B7) to a pair of bent upside down V-shaped bends (B8) as shown in Fig. 9.

A ninth forming station (12i) is spaced apart from the eighth forming station (12h) of the roll-forming machine (10). The ninth forming station (12i) includes an upper stationary holder (12i') and a lower roller (12i") which is similar to the lower roller (12e") of the fifth forming station. The upper stationary holder (12i') has a shaft (30) which is fixed to the lateral beams (lie, 1 Id) with fasteners (31). The shaft (30) of the upper stationary holder (12i') is attached with a pair of side roller supports (31) and a pair of angled rollers (32) spaced apart to each other in between the side roller supports (31). At the bottom part of each side roller support (31), there is provided with a collar (60) thereon. Each of the angled roller (32) includes a fixer arm (33) attached to a holder (34) in angled position which the edge of the fixer arm (33) engaging the collar (32) and the flat surface of the fixer arm (33) at a predetermined height of the collar (32) for fixing the pair of bent upside down V-shaped bends (B8) to a pair of upright bends (B9) as shown in Fig. 10.

A tenth forming station (12j) is spaced apart from the ninth forming station (12i) of the roll-forming machine (10). The tenth forming station (12j) includes an upper and lower rollers (12j', 12j") mounted aligned but the lower roller (12j")

having its both sides formed with an extended portion which includes an outer circular rim (35) tapered towards the edge of the roller (12j) as shown in Fig. 11 for pushing the upright bends (B9) upwards to a pair of fold upright bends (BlO).

An eleventh forming station (12k) is spaced apart from the tenth forming station (12j) of the roll-forming machine (10). The eleventh forming station (12k) includes an upper stationary holder (12k') and a lower roller (12k") which is similar to the lower roller (12g") of the seventh forming station (12g). The upper stationary holder (12k') has a shaft (35) which is fixed to the lateral beams (l ie, lid) with fasteners (36). The lower roller (12g") includes an outer circular rim (40) tapered towards the edge of the roller (12k). The shaft (35) of the upper stationary roller (12k ³ ) is attached with a pair of angled rollers (37) spaced apart to each other where each of the angled roller (37) includes a fixer arm (38) attached to a holder (39) in angled position which the edge of the fixer arm (38) engaging the bottom edge of the tapered our circular rim (40) for further bending the pair of fold upright bends (BlO) to a pair of angled Z-shaped bends (Bl 1) as shown in Fig. 12.

A twelfth forming station (12L) is spaced apart from the eleventh forming station (12k) of the roll-forming machine (10). The twelfth forming station (12L) includes an upper stationary holder (12L') and a lower roller (12L") which is similar to the lower roller (12e") of the fifth forming station (12e). The upper stationary holder (12L') has a shaft (41) which is fixed to the lateral beams (l ie, l id) with fasteners (42). The shaft (40) of the upper stationary holder (12L') is attached with a pair of side roller supports (43) and a pair of angled rollers (44)

spaced apart to each other in between the side roller supports (43). At the bottom part of each side roller support (43), there is provided with a collar (45) thereon. Each of the angled roller (44) includes a fixer arm (46) attached to a holder (47) in angled position which the edge of the fixer arm (46) engaging the collar (45) and the flat surface of the fixer arm (46) at a predetermined height of the collar (45) for bending the angled Z-shaped bends (Bl 1) to a pair of upright Z-shaped bends (B 12) as shown in Fig. 13.

A thirteenth forming station (12m) is spaced apart from the twelfth forming station (12L) of the roll-forming machine (10). The thirteenth forming station (12m) includes an upper holder (12m') and a lower roller (12m"). The upper holder (12m') has a shaft (48) which is fixed to the lateral beams (1 Ic, 1 Id) with fasteners (49). The shaft (48) of the upper holder (12m') is attached with a roll (50) located substantially center or the shaft (48). The lower roller (12m") is formed in a concave shaped roll which includes a flat surface portion at the middle of the roll (50) and the side portions which are inclined outwardly forming the concave shape. During the roll forming operation, the upper holder (12m') will press on the flat surface portion of the lower roller (12m") for forming curve bends (B 13) at both sides of the upright Z-shaped bends (B 12) as shown in Fig. 14.

A fourteenth forming station (12n) is spaced apart from the thirteenth forming station (12m) of the roll-forming machine (10). The fourteenth forming station (12m) includes an upper holder (12n') and a lower roller (12n") as shown in Fig. 15. The upper holder (12n') has a shaft (51) which is fixed to the lateral beams

(l ie, l id) with fasteners (52). The shaft (51) of the upper holder (12m') is attached with a roll (61) located substantially center or the shaft (51). The lower roller (12n") is formed in a concave shaped roll which includes a flat surface portion at the middle of the roll (52) and the side portions which are inclined outwardly forming the concave shape. The concave shape of this forming station has a deeper depth comparing to the concave shape of the thirteen forming station (12m) to further bend the curve bends (B 13).

Subsequent forming stations are similar in construction with the thirteenth and fourteenth forming stations with the lower roller having deeper concave shape to fold up the curve bends until the two ends of the material sheet interacted into a locking position to each other to form a frame member (53) having a groove (54) as shown in Fig. 16. For forming other shape for frame member having additional groove as shown in Fig. 17, additional forming stations are added in between to bend the material sheet with the groove. These frame members could be used for fitting to each other to construct the frame structure for windows, door or the like. Other desired configuration could be achieved with different sequential arrangement of the forming stations to form the edges of the metal sheet interacting in an overlapping or connecting position to each other as shown in Fig. 18. Additional bulge (55) could be added to the opposing edges of the metal sheet to form a lock fitting formation (56) when said metal sheet is bent to a desired profile with the edges in interaction position as shown in figure 19. This lock fitting formation (56) configuration could be achieved with different sequential

arrangement of the forming stations and/or with addition forming stations added to the forming process.

As will be readily apparent to those skilled in the art, the present invention may easily be produced in other specific forms without departing from its essential characteristics. The present embodiments is, therefore, to be considered as merely illustrative and not restrictive, the scope of the invention being indicated by the claims rather than the foregoing description, and all changes which come within therefore intended to be embraced therein.