Metal foil manufacturing method, and metal foil

Abstract

To provide a metal foil with various expressions.SOLUTION: A metal foil manufacturing method has: an arrangement process in which a plurality of metal sheets are arranged at positions close to each other; and a foil beating process in which the plurality of arranged metal sheets are beaten and stretched to form one metal sheet. Preferably, the manufacturing method further has a cutting process in which one beaten metal sheet is cut into a plurality of metal sheets. In the arrangement process, the plurality of metal sheets cut in the cutting process are arranged so that outer sides of the beaten metal sheets contact each other. Preferably, in the arrangement process, the plurality of metal sheets are arranged so that ends thereof overlap each other.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for producing a metal foil and a metal foil. [Background technology]

[0002] For example, Patent Document 1 discloses a method for producing metal foil, which comprises rolling a polymerized metal material formed by stacking and pressing two or more sheets of metal material of a predetermined shape together multiple times to achieve a total rolling reduction of 70% or more, thereby thinning the polymerized metal material and generating metal crystals at the interface between the layers to produce a single sheet of metal foil.

[0003] Patent Document 2 discloses a precious metal alloy foil in which a thin film of a precious metal and a precious metal alloy are clad together, characterized in that the precious metal and the precious metal alloy are formed into a thin film material of 1 to 3 μm, and the precious metal foil and the precious metal alloy thin film body are clad together, resulting in a precious metal alloy foil in which pinholes of 2 to 60 μm do not overlap each other. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 1-180706 [Patent Document 2] Japanese Patent Application Laid-Open No. 2000-334882 Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention aims to provide metal foils with a variety of expressions. [Means for solving the problem]

[0006] The metal foil manufacturing method of the present invention includes an arrangement step of arranging multiple metal sheets in a position close to each other, and a foil beating step of beating and stretching the arranged multiple metal sheets to form a single piece of metal foil.

[0007] Preferably, the method further includes a cutting step of cutting a single metal sheet that has been hammered and stretched into multiple metal sheets, and in the arranging step, the multiple metal sheets cut in the cutting step are arranged so that the outer sides of the hammered and stretched metal sheets are in contact with each other.

[0008] Preferably, in the arranging step, the metal sheets are arranged so that the ends of the metal sheets overlap each other.

[0009] The metal foil according to the present invention has different layer structures depending on the region.

[0010] Preferably, the peripheral region is a single layer and a portion of the central region is a multi-layer. [Effects of the Invention]

[0011] According to the present invention, metal foils with a variety of expressions can be provided. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a flowchart illustrating a method (S10) for producing a metal foil 1 in this embodiment. [Figure 2] 1A to 1C are diagrams illustrating the state of a metal sheet 10 in each step until a metal foil 1 is manufactured. [Figure 3] 1 is a diagram illustrating a metal foil 1 in Example 1 and an AA′ cross section of the metal foil 1. FIG. [Figure 4] 2 is a diagram illustrating a metal foil 1 in Example 2, and a BB' cross section and a CC' cross section of the metal foil 1. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0013] The background to the invention will be explained. Metal foils generally tend to be valued for their highly uniform surface. Specifically, metal foils that are smooth, have a uniform luster, and are consistent in color are considered beautiful. Therefore, when adding variety to decorations using metal foil, it has been necessary to prepare different metal foils. Furthermore, fluctuations in the prices of precious metals such as gold used in metal foils affect the production of metal foils, so more efficient use of precious metals is required. In view of the above problems, the present invention provides a metal foil that is made up of multiple metal sheets having irregular shapes, each of which has a different color, pattern, and gloss.

[0014] Hereinafter, embodiments of the present invention will be described with reference to the drawings, but the scope of the present invention is not limited to the illustrated examples. First, a general method for manufacturing gold foil will be described, taking the case where the metal of the metal foil is gold as an example. The manufacturing process of gold leaf consists of the rolling, skimming, and beating processes. In the rolling process, gold alloy bullion is made. The bullion is rolled into a thin strip and then further rolled to a thickness of about 3 to 5 mm. In the skimming process, the metal is further beaten to a thickness of less than one-tenth of its original size. Specifically, it is beaten through four processes - Kohyo, Arakane, Koju, and Oju - in order to become thinner in succession, until it is about one-thousandth of a millimeter thick. Finally, it is subjected to a matte skimming process and cut into 20cm square pieces. The metal that has completed the skimming process is called "suki." In the gold leaf beating process, the top layer is cut into 9 to 16 pieces, which are then sandwiched between komagami (gold beating paper) and fixed in place so that the gold leaf beating paper and the top layer do not shift. The gold leaf is then beaten out with a gold leaf beating machine until it is about 10cm square. The top layer of the rolled out mixture is called "koma," and this koma is transferred to foil-beating paper called "mamagami," where it is stretched to approximately 1 / 10,000 of a millimeter using a foil-beating machine. The rolled out pieces are then cut to the required size to complete the gold leaf.

[0015] 1 is a flowchart illustrating a method (S10) for producing a metal foil 1 in this embodiment. The method (S10) for producing a metal foil 1 in this embodiment describes a method for producing a metal foil 1 in accordance with the manufacturing process of a gold foil, and the metal sheet 10 is assumed to have undergone a supernatant process. In step 100 (S100), a worker cuts the metal sheet 10, which has been through the skimming process and is approximately 1 / 1000 mm thick, into 9 to 16 pieces, and sandwiches the cut skimmed pieces between small sheets (gold-beating paper). The worker then beats and stretches the skimmed pieces sandwiched between the small sheets using a foil-beating machine until they are approximately 10 cm square. As shown in FIG. 2(a), the corners of the square metal sheet 10 are stretched and rounded. In step 105 (S105), the worker cuts the metal sheet 10 that has been hammered and stretched in S100 into a plurality of metal sheets (cutting step). Specifically, in S100, the hammered and stretched metal sheet 10 is cut into two pieces approximately in the center. In step 110 (S110), the worker arranges the cut metal sheets 10 in positions close to each other (arrangement process). Specifically, the worker arranges the cut metal sheets 10 so that the outer edges of the hammered and stretched metal sheets 10 are in contact with each other. More specifically, the worker arranges the cut metal sheets 10 so that the irregularly shaped outer edges of the metal sheets 10 overlap each other. As illustrated in FIG. 2(b), there are gaps between the metal sheets 10 when they are arranged.

[0016] In step 115 (S115), the worker beats and stretches the arranged multiple metal sheets 10 to form a single metal foil (foil beating process). Specifically, the worker beats and stretches the arranged multiple metal sheets 10 until the thickness is about 5 / 10,000 mm to about 1 / 10,000 mm. As shown in FIG. 2(c), the gaps become smaller as the sheets are beaten and stretched. If there are gaps in the metal sheet 10 that has been hammered out in step 120 (120), i.e., if it is not possible to cut out the metal sheet 10 of the specified shape without any gaps (S120: Yes), proceed to S130, and if there are no gaps in the stretched metal sheet 10, i.e., if it is possible to cut out the metal sheet 10 of the specified shape without any gaps (S120: No), proceed to S125. In step 125 (S125), the worker cuts the metal sheet 10 that has been beaten, stretched, and joined into a product shape, for example, a square of a predetermined size, and one sheet of metal foil 1 is completed.

[0017] In step 130 (S130), the worker uses another metal sheet piece 12 to patch the gap in the metal sheet 10 that was beaten out in step 115. Specifically, the worker cuts out the metal sheet piece 12 from the other metal sheet 10 in a shape and size that corresponds to the gap. In step 135 (S135), the worker arranges the cut metal sheet pieces 12 so that the ends of the metal sheet pieces 12 overlap the metal sheet 10, so that the cut metal sheet pieces 12 fill the gaps in the metal sheet 10 that has been beaten and stretched. In step 140 (S140), the metal sheet 10 that has been joined with the metal sheet pieces 12 and the gaps filled is cut into a product shape, for example, a square of a predetermined size, and one sheet of metal foil 1 is completed. In S140, if necessary, the overlapping portion of the metal sheet piece 12 and the metal sheet 10 may be joined by hammering and stretching, and then cut into a product shape, for example, a square of a predetermined size, to produce one sheet of metal foil 1. Although the metal foil 1 in this embodiment is square, it is not limited to this shape as long as it has a shape suitable for the product.

[0018] FIG. 2 is a diagram illustrating the state of the metal sheet 10 in each step until the metal foil 1 is manufactured. 2(a) is a diagram illustrating a metal sheet 10 in a state where the skim has been beaten and flattened. The beaten and flattened metal sheet 10 changes from a square shape to a shape with rounded corners and irregularly uneven outer edges. That is, the beaten and flattened metal sheet 10 is thinner and has a wavy outer edge rather than a straight edge. FIG. 2(b) shows an example of the arrangement of the cut metal sheet 10. The metal sheet 10 is arranged so that the outer edges of the metal sheets 10a and 10b, which are cut into two pieces approximately in the center, overlap. Specifically, the cut positions are arranged so that the cut positions are on the outside and so that the gaps that occur due to the arrangement are small. Furthermore, the ends of the central metal sheets 10a and 10b are arranged so that they slightly overlap. This arrangement prevents the formation of a gap in the center when the sheet is hammered and stretched, and eliminates the need for a splice to close the gap. In this example, the left and right sides of the metal sheets 10a and 10b are swapped. The metal sheets 10 may be arranged, for example, by arranging metal sheets 10a and 10b cut from a single metal sheet 10, or by arranging metal sheets 10 made of the same metal but with different metal purities, for example, a metal sheet made of pure gold No. 2 and a metal sheet made of pure gold No. 3, to form the metal foil 1, or by combining metal sheets made of different metals, for example, a metal sheet made of gold and a metal sheet made of silver, to form the metal foil 1.

[0019] 2(c) shows an example of the finished metal foil 1 after the arranged metal sheets 10a and 10b are hammered out and cut into a predetermined shape, for example, a square. The metal foil 1 has a pattern or design that appears where the metal sheets 10a and 10b overlap. 2(d) is a diagram illustrating an example of a metal sheet 10 with gaps patched up. If gaps occur in the metal sheet 10 after it has been laid out and hammered out, metal sheet pieces 12 corresponding to the shape and size of the gaps are cut out from another metal sheet to patch up the gaps. The overlapping areas of the metal sheet pieces 12 also appear as a pattern or design.

[0020] Example 1 FIG. 3(a) is a diagram illustrating the metal foil 1 in Example 1. As shown in FIG. The metal foil 1 is a metal foil that is completed by cutting a metal sheet that has been through a skimming process into two pieces, bringing the outer edges of the cut metal sheets 10 close to each other, and then hammering and stretching them out. No joining using metal sheet pieces 12 is performed. The metal foil 1 has cut metal sheets 10a and 10b. The metal foil 1 has a predetermined shape, for example, a square, and the areas where the cut metal sheets 10a and 10b overlap appear as a pattern, design, or line, and have a different color tone from the other areas. As shown in the AA' cross-sectional view of the metal foil 1 in Figure 3(b), the metal foil 1 has a different layer structure depending on the region. Specifically, the peripheral region of the metal foil 1 is single-layered, and part of the central region of the metal foil 1 is multi-layered. More specifically, the metal foil 1 has a single-layer region made of the metal sheet 10a or the metal sheet 10b, and a multi-layer region made of the metal sheet 10a and the metal sheet 10b. In other words, the multi-layer region is a region where multiple metal sheets 10 overlap each other. Furthermore, different layer structures refer to different thicknesses and different delamination properties. Furthermore, in a multilayer region, delamination properties differ depending on the number of layers. Furthermore, in a multilayer region, delamination properties differ depending on the combination of overlapping metal sheets 10. The multilayer region of the metal foil 1 is in a state where metal sheets 10 are stacked, and has a different thickness from the single-layer region. Specifically, the multilayer region is thicker than the single-layer region. In other words, the difference in thickness between the multilayer region and the single-layer region causes unevenness in the thickness of the metal foil 1, resulting in a pattern on the metal foil 1. The thickness of the metal foil 1 is approximately 1 / 10,000 mm to approximately 5 / 10,000 mm. The metal sheet 10 is a metal foil that constitutes the metal foil 1. The metal used for the metal sheet 10 is a single metal such as gold, silver, copper, platinum, tin, or aluminum, or an alloy of these metals. When gold is used for the metal sheet 10, it is the thinnest of all metal foils, and therefore patterns and designs are easily developed.

[0021] Example 2 FIG. 4(a) is a diagram illustrating a metal foil 1 in which a gap is patched. The metal foil 1 in Example 1 is prepared by arranging cut metal sheets 10 and hammering and stretching them to cut out metal foil 1 of a predetermined size, whereas the metal foil 1 in Example 2 is prepared by further patching gaps that arise during hammering and stretching using metal sheet pieces 12, as illustrated in Figure 4(a). The metal foil 1 includes a cut metal sheet 10a, a cut metal sheet 10b, and a metal sheet piece 12 for joining. The metal foil 1 has an area where the metal sheet 10 and the metal sheet piece 12 overlap, as illustrated in the BB' cross-sectional view of the metal foil 1 in Fig. 4(b). Specifically, the metal foil 1 has an area where the metal sheet 10a and the metal sheet piece 12 overlap, and an area where the metal sheet 10b and the metal sheet piece 12 overlap. In addition, depending on the area, the metal foil 1 has an area where the metal sheet 10a, the metal sheet 10b, and the metal sheet piece 12 overlap, as illustrated in the CC' cross-sectional view of the metal foil 1 in Fig. 4(c). The metal sheet piece 12 may be the same as the metal sheet 10a or 10b to be joined, or may be made of the same metal but different purities, or may be made of different metals. Furthermore, the metal sheet piece 12 may be made of the remaining metal sheet 10 cut from the metal sheet 10a or 10b.

[0022] As explained above, metal foil 1 is produced by manufacturing a single metal foil from metal sheets 10 having multiple irregular shapes, and therefore the joining areas of the metal sheets 10, i.e., the areas where multiple metal sheets 10 overlap, appear as patterns, designs, and color variations, giving the metal foil a richer and more tasteful appearance than metal foils that have a uniform luster and color. Furthermore, by joining metal sheets 10 with different metal types or metal purities together, significant variations occur within a single metal foil, making it possible to produce metal foils 1 with a variety of colors, patterns, and lusters. Therefore, each metal foil 1 has a different appearance depending on the type of metal sheet 10 used, the shape of the cut metal sheet 10, and the method of arranging the metal sheets 10. Furthermore, when restoring traditional cultural properties, using the expressive metal foil 1 has the advantage that the restored part blends in more easily without standing out compared to using a more uniform metal foil. Furthermore, since the metal foil 1 is manufactured from a plurality of metal sheets 10, for example, if the metal foil 1 is manufactured using a plurality of different metal sheets 10, the amount of one metal sheet 10 required will be less than if the metal foil 1 is manufactured from one type of metal sheet 10, and the metal foil 1 can be manufactured efficiently.

[0023] (Variation) In Examples 1 and 2, one metal sheet is cut into two pieces, arranged, and hammered and stretched, but this is not limited to this. For example, one metal sheet 10 may be cut into three or more pieces, arranged with the irregularly shaped outer edges close to each other, and hammered and stretched to produce metal foil 1. As a result, the joining area of ​​the metal sheet 10 becomes more diverse than when the metal sheet 10 is cut into two pieces, and the pattern, color, and luster that appears on the metal foil 1 become more complex.

[0024] Furthermore, in the above embodiment, in S120 of the manufacturing method (S10) of the metal foil 1, if a gap occurs, the gap is patched with metal sheet pieces 12 and then cut to a predetermined size, but this is not limited to this. For example, the metal foil 1 may be manufactured by cutting to a predetermined size (S140), preparing metal sheet pieces 12 (S130), and arranging the metal sheet pieces 12 (S135). [Explanation of symbols]

[0025] 1...Metal foil 10...Metal sheet 12...Metal sheet piece

Claims

1. an arrangement step of arranging a plurality of metal sheets in positions adjacent to each other; a foiling process in which the arranged plurality of metal sheets are hammered and stretched to form a single metal foil; A method for manufacturing a metal foil comprising the steps of:

2. A cutting process in which a single hammered and stretched metal sheet is cut into multiple metal sheets. and In the arranging step, the plurality of metal sheets cut in the cutting step are arranged so that the outer sides of the hammered and stretched metal sheets are in contact with each other. The method for producing metal foil according to claim 1 .

3. In the arranging step, the metal sheets are arranged so that the ends of the metal sheets overlap each other. The method for producing metal foil according to claim 2 .

4. A metal foil with different layer structures in different areas.

5. The peripheral region is single layer, and part of the central region is multilayer The metal foil according to claim 4.

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