Manufacturing method for metal plate with openwork pattern

Abstract

Provided is a manufacturing method for a metal plate with an openwork pattern that is innovative and has depth. The present invention is characterized by: embedding, between an upper side 1 and a lower mold 2 formed from a sand mold, a plate 3 that has a section with a thickness of 3 mm or less; separating the upper mold 1 and the lower mold 2 and removing the plate 3; and fitting together the upper mold 1 and the lower mold 2 and pouring a molten metal 19 into a gap formed by removing the plate 3.

Description

Manufacturing method for watermarked metal plate

[0001] The present invention relates to a method for producing an openwork metal sheet.

[0002] Metal plates with openwork patterns have existed for some time, but the openwork patterns on these metal plates have often been traditional, featuring motifs such as flowers and plants, and have been thick, static, and lacking novelty.

[0003] In view of the above-mentioned circumstances, the present invention has an object to provide a method for manufacturing a metal plate with a thin, lightweight, delicate, dynamic, original and deep watermark pattern.

[0004] In order to achieve the above object, the method for manufacturing a metal plate with an openwork pattern according to the invention described in claim 1 involves embedding a plate having a portion of 3 mm or less in thickness between upper and lower molds made of sand, separating the upper and lower molds to remove the plate, and then bringing the upper and lower molds together to remove the plate, and pouring molten metal into the gap created by removing the plate, thereby forming an irregular openwork pattern in the gap of 3 mm or less, and the plate is characterized in that it is made by combining clay plates of different thicknesses in a mosaic pattern.

[0005] The method for manufacturing a metal plate with an openwork pattern according to the invention described in claim 2 involves embedding a plate having a portion with a thickness of 3 mm or less between upper and lower molds made of sand, separating the upper and lower molds to remove the plate, and then bringing the upper and lower molds together to remove the plate, and pouring molten metal into the gap created by removing the plate, thereby forming an irregular openwork pattern in the gap of 3 mm or less.The plate is made of clay and is characterized by being partially scraped or built up.

[0006] The method for manufacturing a metal plate with an openwork pattern according to the invention described in claim 1 involves embedding a plate having a portion with a thickness of 3 mm or less between upper and lower molds made of sand, separating the upper and lower molds to remove the plate, and then bringing the upper and lower molds together and pouring molten metal into the gap created by removing the plate, thereby forming an irregular, lace-like openwork pattern that is sometimes unpredictable, making it possible to manufacture a lightweight metal plate with an openwork pattern that is innovative, profound, and full of delicacy and dynamism.

[0007] Furthermore, in the method for manufacturing a metal plate with an openwork pattern according to the invention described in claim 1, the plate is made by combining clay plates of different thicknesses in a mosaic pattern, which makes it possible to arrange a lace-like openwork pattern with different proportions of the area of ​​the translucent parts within a single metal plate, thereby making it possible to manufacture a metal plate with an openwork pattern that is even more innovative and profound.

[0008] In the method for manufacturing a metal plate with a watermark according to the invention described in claim 2, the plate is made of clay, and by partially scraping or building up the clay, opaque and transparent parts can be intentionally formed, enhancing the artistic quality.

[0009] Fig. 1 is an explanatory diagram showing the manufacturing process of the watermarked metal plate of the present invention. Fig. 2 is an explanatory diagram showing the manufacturing process of the watermarked metal plate of the present invention (continuation of Fig. 1-1). Fig. 3 is a photograph showing the state of the watermark for each size of gap. Fig. 4 is a photograph showing an example of the use state of the watermarked metal plate of the present invention. Fig. 5 is a plan view showing an example of a plate used when manufacturing the same metal plate.

[0010] An embodiment of the present invention will now be described with reference to the drawings. FIGS. 1-1 and 1-2 illustrate the manufacturing process for the openwork metal plate of the present invention. First, as shown in FIG. 1-1(a), multiple plates 4a, 4b, 4c, 4d, etc. of different thicknesses are made from clay. The thicknesses of the plates 4a, 4b, 4c, 4d, etc. are, for example, 4 mm, 3.5 mm, 3 mm, 2.5 mm, 2 mm, 1 mm, and 0.5 mm. Next, as shown in FIG. 1-1(b), clay plates 4a, 4b, 4c, 4d, etc. of different thicknesses are combined in a mosaic pattern to form a single plate 3, which is then placed on a lower mold 2 whose frame 5 is filled with sand 6. At this time, grooves 7 may be formed by carving the plate 3, or strings of clay 8 may be added to form a padding. Next, as shown in FIG. 1-1(c), the frame 5 of the upper mold 1 is placed on the frame 5 of the lower mold 2, and sand 6 is filled into the frame 5. Next, as shown in Figure 1-2(d), the upper mold 1 and the lower mold 2 are separated, and the embedded plate 3 is removed. Next, as shown in Figure 1-2(e), the upper mold 1 and the lower mold 2 are brought together, and molten metal 19, specifically copper or copper alloy at 1000 to 1200°C, is poured into the gap created by removing the plate 3. Thereafter, the upper mold 1 and the lower mold 2 are separated, and the metal plate is removed.

[0011] In the metal plate manufactured by the above process, molten metal flows into gaps of 3 mm or less, forming an irregular lace-like openwork pattern 12 in which the proportion of the area of ​​the translucent portions (transparent portions) varies depending on the size of the gap, as shown in Figures 2(a) to 2(d). As is clear from these photographs, the larger the gap, the easier it is for molten metal 19 to flow into the gap, so the proportion of the area of ​​the translucent portions decreases (see Figure 2(a)), and the smaller the gap, the more difficult it is for molten metal 19 to flow into the gap, so the proportion of the area of ​​the translucent portions increases (see Figure 2(d)). As a result of experiments conducted by the applicant, it was found that when the gap size was 0.5 to 1 mm, a lacy openwork pattern 12 with a translucent area ratio of 65 to 45% was obtained, when the gap size was 1.0 to 2.5 mm, a lacy openwork pattern 12 with a translucent area ratio of 40 to 20%, and when the gap size was 2.5 to 3.5 mm, a lacy openwork pattern 12 with a translucent area ratio of 20 to 10% was obtained. Also, by partially scraping the clay plate 3 to be embedded in the mold, the molten metal 19 will not flow into that portion, and conversely, by adding padding to the clay plate 3, the molten metal 19 will flow into that portion, so that transparent and opaque portions can be intentionally formed to enhance artistic quality.

[0012] 3 shows an example of how the openwork metal plate 9 of the present invention is used, in which the metal plate 9 is attached in front of a mirror 10. The openwork metal plate 9 has a rectangular outer shape with a large, approximately circular hole 11 formed in the center, around which an irregular lace-like openwork pattern 12 is formed.

[0013] Figure 4 shows an example of a plate 3 used in manufacturing this openwork metal plate 9. As shown in the figure, this plate 3 is composed of five different clay plates 4a, 4b, 4c, 4d, and 4e with thicknesses of 4 mm, 3 mm, 2.5 mm, 2 mm, and 1 mm. A 4 mm thick clay plate 4a is used for the surrounding rectangular frame-shaped portion 13, a 3 mm thick clay plate 4b is used for the portion between the frame-shaped portion 13 and the outer circle 14, a 2.5 mm thick clay plate 4c is used for the portion between the outer circle 14 and the inner rectangle 15, a 2 mm thick clay plate 4d is used for the portion between the inner rectangle 15 and the inner circle 16, and a 1 mm thick clay plate 4e is used inside the inner circle 16. Runners 17 are formed on both the left and right sides of this plate 3, and multiple weirs 18 are provided spanning from the runners 17 to the surrounding rectangular frame-shaped portion 13. The molten metal 19 is poured into the mold, which is made up of the upper and lower halves 1 and 2, in a vertical position, from a sprue 20 provided at the upper end of the runner 17.

[0014] The surrounding frame-shaped portion 13 is made of a 4 mm thick clay plate 4a, so the molten metal 19 flows into this portion as a whole. Between the surrounding frame-shaped portion 13 and the central circle 16, clay plates 4b, 4c, and 4d of different thicknesses are combined and used, forming an irregular and complex lace-like openwork pattern 12 between the surrounding frame-shaped portion 13 and the central circle 16 (see Figure 3).

[0015] As described above, in the method for manufacturing an openwork metal plate according to the present invention, a plate 3 having a portion 3 mm or less in thickness is embedded between an upper mold 1 and a lower mold 2 made of sand, the upper mold 1 and the lower mold 2 are separated to remove the plate 3, the upper mold 1 and the lower mold 2 are brought together, and molten metal 19 is poured into the gap created when the plate 3 is removed, thereby forming an irregular, sometimes unpredictable lace-like openwork pattern 12, thereby making it possible to manufacture a lightweight, delicate, dynamic, and novel openwork metal plate 9 with depth. In the method for manufacturing an openwork metal plate according to the present invention, the plate 3 is formed by combining clay plates 4a, 4b, 4c, 4d, ... of different thicknesses in a mosaic pattern, making it possible to arrange a lace-like openwork pattern 12 with a different proportion of the area of ​​the translucent portions within a single metal plate 9, making it possible to manufacture a metal plate 9 with an even more novel and profound openwork pattern. In addition, in the method for manufacturing a metal plate with a watermark according to the present invention, the plate 3 is made of clay, and by partially scraping or building up the clay, opaque and transparent parts can be intentionally formed, thereby enhancing the artistic quality.

[0016] The present invention is not limited to the above-described embodiments. The plate embedded between the upper and lower molds may be made of any material or have any shape, as long as it has at least a portion with a thickness of 3 mm or less. The method (plan) for pouring molten metal into the gap formed between the upper and lower molds may be any method. The metal is not limited to copper or copper alloys, but may also be iron, aluminum, or the like. The uses of the openwork metal plate according to the present invention are not particularly limited, and it may be used, for example, to decorate mirrors, picture frames, doors, partitions, etc., or simply for decorative purposes.

[0017] 1 Upper mold 2 Lower mold 3 Plates 4a, 4b, 4c, 4d, 4e Clay plates

Claims

1. A method for manufacturing a metal plate with an openwork pattern, in which a plate having a thickness of 3 mm or less is embedded between an upper and lower mold made of sand, the upper and lower molds are separated to remove the plate, and the upper and lower molds are brought together to remove the plate, and molten metal is poured into the gap created by the removal, thereby forming an irregular openwork pattern in the gap of 3 mm or less, the plate being made by combining clay plates of different thicknesses in a mosaic pattern.

2. A method for manufacturing a metal plate with an openwork pattern, comprising embedding a plate having a thickness of 3 mm or less between an upper and lower mold consisting of a sand mold, separating the upper and lower molds to remove the plate, and then bringing the upper and lower molds together to remove the plate and pouring molten metal into the gap created by the removal, thereby forming an irregular openwork pattern in the gap of 3 mm or less; the plate is made of clay and is partially scraped or built up.

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