Patterned Composite Metal Plate Forming Without Twisting Limits
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Solution Overview
Problem
Existing methods for producing damascene patterned metal objects are limited to small sizes due to the need for size reduction and distortion of elongated structures, restricting their application to small objects like knives and jewelry.
Innovation Solution
A method involving the use of at least two different metal powders filled in a container with non-parallel or non-straight layers, subjected to hot isostatic pressing and hot deformation to form a patterned composite metal plate without the need for twisting, allowing for larger sizes by hot rolling in two perpendicular directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If traditional lamination techniques with twisting and flat rolling are used, then damascene pattern is formed, but the product size is limited to small objects
Solution Approach 1:
The patent applies preliminary action by pre-forming non-parallel and non-straight layers of metal powders within a container before consolidation. This preliminary arrangement of layers eliminates the need for subsequent twisting operations, allowing direct production of large-sized patterned composite metal plates while maintaining the damascene pattern formation during normal hot deformation
Solution Approach 2:
The patent introduces dimensional change by creating three-dimensional non-solid bodies with non-parallel and non-straight layer configurations. This spatial arrangement of powder layers in multiple dimensions enables pattern formation during conventional hot rolling without requiring additional twisting steps, thereby overcoming size limitations
2Length of stationary object
If powder filling with non-parallel layers is used, then large size plates can be produced, but filling complexity increases
Solution Approach 1:
The patent uses a container as an intermediary tool to facilitate the filling of metal powders in non-parallel and non-straight layers. The container provides a structured environment for arranging powder layers before consolidation, simplifying the overall process by enabling large-sized plate production without requiring complex post-consolidation twisting operations
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
Enables the production of large-sized patterned composite metal plates with high cleanliness and controlled particle sizes, suitable for creating decorative patterns in larger objects beyond the limitations of previous techniques.
Implementation Method 1
subjecting the container to hot isostatic pressing in order to form a consolidated body comprising non parallel and/or non straight metal and/or metal alloy layers
Implementation Method 2
subjecting the consolidated body to hot deformation in order to form an intermediate body
Implementation Method 3
hot rolling the consolidated or the intermediate body in two perpendicular directions in order to form a plate
Data Source
Figure 1
AI summary
The invention relates to a method of producing a patterned composite metal plate by the steps of a) providing at least two different metal and/or metal alloy powders b) filling a container, b1) with the powders in different individual layers, wherein the individual power layers include at least two non parallel layers and/or non straight layers, or b2) making a three dimensional non-solid body of one of the powders, which comprises least two non parallel parts or layers and/or non straight parts or layers, inserting said body in the container and filling the cavities in and around the said body completely with the other powder, c) sealing and evacuating the container, d) subjecting the container to hot isostatic pressing in order to form a consolidated body comprising non parallel and/or non straight metal and/or metal alloy layers, e) optionally subjecting the consolidated body to hot deformation in order to form an intermediate body having a thickness of 50 to 200 mm, f) hot rolling the consolidated or the intermediate body in two perpendicular directions in order to form a plate, optionally one or more of the steps of g) cold rolling the hot rolled plate in order to form a cold rolled plate h) slitting the plate in two or more parts and i) etching the plate in order to reveal or enhance the pattern.