Multi-Layer Metal Patterning via Segmented Concave Stacking
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Solution Overview
Problem
Existing methods for patterning metal objects, such as those used in ornaments, face challenges in achieving high machining accuracy and aesthetic quality, especially when forming complex patterns, as they require precise manipulation of metal parts or molten metals, which can be difficult to achieve without compromising the surface plane.
Innovation Solution
A method involving laminating multiple metal plates, joining them to form a multi-layer object, and then forming concaves in a predetermined pattern shape that reaches a lower metal layer, ensuring the surface height of both pattern and non-pattern parts are uniform, with the concave depth and width adjusted based on the hardness of the metal layers, allowing for precise and aesthetically superior pattern creation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal parts are inserted into concave pattern parts formed by stamping, then patterns can be formed on the metal surface using differences in colors and luster, but high machining accuracy is required and it is difficult to form patterns with high aesthetic
Solution Approach 1:
The metal object is divided into multiple layers with different materials arranged in a stepped manner. Each layer can be independently selected and positioned, allowing complex patterns to be formed by stacking simpler layers rather than requiring high-precision single-step machining.
Solution Approach 2:
The invention transitions from two-dimensional surface patterning to three-dimensional layered construction. By adding the vertical dimension with multiple stacked layers, the method achieves complex patterns that would be difficult to form with traditional single-layer stamping, reducing the required machining precision for each individual layer.
2Manufacturing precision
If molten metal is poured into concave pattern parts, then patterns can be formed on the metal surface, but it is difficult to form precise patterns when the patterns are complex because the metals are not able to be poured in the detail of the pattern shape concave
Solution Approach 1:
Complex patterns are segmented into multiple layers, each representing a portion of the final design. This segmentation allows each layer to be formed with standard precision techniques, and the cumulative effect of stacked layers achieves the desired complex pattern detail without requiring molten metal pouring into fine concaves.
Solution Approach 2:
The invention replaces the molten metal pouring process with a mechanical layering and pressing system. Solid metal layers are stacked and pressed together to form patterns, eliminating the limitations of molten metal flow and enabling precise formation of complex patterns that would be impossible to pour.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the formation of high aesthetic and precise patterns on metal objects without the need for high machining accuracy, allowing for complex designs with improved boundary gradation and material flexibility, reducing the risk of pattern detachment and enhancing the overall design quality.
Implementation Method 1
the jointing the plurality of metal plates in the junction step is performed by diffusion joining or solder junction of the metal plates
Implementation Method 2
the jointing the plurality of metal plates in the junction step is performed by diffusion joining or solder junction of the metal plates
Implementation Method 3
a forming plane step pressing the surface of a non-pattern part of the multi layer metal object and making the surface height of the concave and the surface height of the non-pattern part uniform
Data Source
AI summary
On the surface of the spread multi-layered metal object, as reaches from outside to inside of step-wise, the pattern shaped concave is formed by reaching the lower layer of metal layer of the metal layer. The concave is formed as step-wise, the innermost reaches inside of the metal layer from the surface, the outer reaches the top of the metal layer from the surface, and the outermost reaches the top of the metal layer. The metals removed to form the concave remains inside and effectively control on the pattern part obtained at the end. As a result, able to form desired pattern stably.