Patent Application
20110165378
The present invention relates to a method for manufacturing a wrinkled plate having a complicated wrinkled shape on a surface thereof and a wrinkled plate, and more particularly to a method for manufacturing a wrinkled plate and a wrinkled plate which can control a shape of wrinkles formed on a surface of the wrinkled plate.
The applicant of the present application disclosed a method for manufacturing a plate having a complicated wrinkled shape on a surface thereof in patent document 1.
According to this patent document 1, clay is placed on an upper surface of a rubber sheet in a stretched state, and an upper surface of the clay is covered with a surface layer which is removable by burning. Next, the rubber sheet is shrunken so as to form wrinkles on the upper surface of the clay and the surface layer and, thereafter, the clay is burnt and, at the same time, the surface layer is vanished by burning thus acquiring a wrinkled plate having a complicated wrinkled shape on a surface thereof.
Further, the applicant of the present application disclosed a method for manufacturing a wrinkled plate in patent document 2. In the method, clay is placed on a rubber sheet in a stretched state and, thereafter, the rubber sheet is shrunken halfway thus forming first wrinkles having relatively small waviness on an upper surface of the clay. Subsequently, the clay is dried slightly thus further shrinking the rubber sheet so as to form second wrinkles having relatively large waviness on an upper surface of the clay. Due to such a manufacturing method, the first wrinkles having relatively small waviness are formed on the surface of the second wrinkles having relatively large waviness and hence, it is possible to acquire a wrinkled plate having a more complicated wrinkled shape on a surface thereof.
However, in the invention disclosed in patent document 2, the first wrinkles having relatively small waviness are formed by shrinking the rubber sheet and hence, it is difficult to control a shape of the first wrinkles such as a distance between the wrinkles and the degree of waviness of the wrinkles.
Accordingly, it is an object of the present invention to provide a method for manufacturing a wrinkled plate and a wrinkled plate which can control a shape of wrinkles formed on a surface of the wrinkled plate.
The invention called for in claim 1 is directed to a method for manufacturing a wrinkled plate which includes the steps of: placing an unhardened support substrate having irregularities embossed on a surface thereof on an upper surface of a stretchable functional member in a stretched state in an overlapping manner; and forming wrinkles at least on a surface of the support substrate by shrinking the stretchable functional member; and hardening the support substrate.
Further, the invention called for in claim 2 is, in the method for manufacturing a wrinkled plate called for in claim 1, characterized in that embossing of the irregularities is performed by adhering a woven fabric to the upper surface of the unhardened support substrate.
Further, the invention called for in claim 3 is, in the method for manufacturing a wrinkled plate called for in claim 1, characterized in that embossing of the irregularities is performed by pressing an embossing plate on which irregularities are preliminarily formed to the upper surface of the unhardened support substrate.
Further, the invention called for in claim 4 is, in the method for manufacturing a wrinkled plate called for in any one of claims 1 to 3, characterized in that the step of forming the wrinkles at least on the surface of the support substrate by shrinking the stretchable functional member includes: a step of semi-hardening the unhardened support substrate; and a step of forming first wrinkles on the upper surface of the semi-hardened support substrate by shrinking the stretchable functional member halfway; and a step of forming second wrinkles larger than the first wrinkles on the surface of the support substrate by further shrinking the stretchable functional member.
Further, the invention called for in claim 5 is directed to a method for manufacturing a wrinkled plate which includes the steps of: placing an unhardened support substrate to which an irregular surface sheet having irregularities preliminarily formed thereon is adhered on an upper surface of a stretchable functional member in a stretched state in an overlapping manner; and forming wrinkles at least on a surface of the support substrate by shrinking the stretchable functional member; and hardening the support substrate.
Further, the invention called for in claim 6 is, in the method for manufacturing a wrinkled plate called for in any one of claims 1 to 5, characterized in that the support substrate is made of clay.
Further, the invention called for in claim 7 is directed to a method for manufacturing a wrinkled plate which includes the steps of: interposing an intermediate layer which is extensible and shrinkable, is removable by post treatment and has an irregular shape projecting toward the support substrate on a surface thereof between a stretchable sheet in a stretched state and an unhardened support substrate which is placed on an upper surface of the stretchable sheet in an overlapping manner; forming wrinkles at least on a surface of the support substrate by shrinking the stretchable sheet; and hardening the support substrate.
Further, the invention called for in claim 8 is, in the method for manufacturing a wrinkled plate called for in any one of claims 1 to 7, characterized in that the surface of the support substrate is covered with a coating material.
Further, the invention called for in claim 9 is directed to a method for manufacturing a wrinkled plate which includes the steps of: placing an intermediate layer which is extensible and shrinkable and is removable by post treatment on a stretchable functional member in a stretched state; adhering a sheet-shaped resilient member on an upper surface of the intermediate layer; forming wrinkles on the resilient member by shrinking the stretchable functional member; covering an upper surface of the resilient member with an unhardened lining material; and hardening the unhardened lining material.
Further, the invention called for in claim 10 is directed to a wrinkled plate in which a large number of irregular wrinkles attributed to protuberance are continuously formed at least on a surface of the wrinkled plate, a large number of minute irregularities are formed on a surface of each wrinkle, and a distance between the neighboring wrinkles of the large number of wrinkles attributed to protuberance is set such that the distance at bottom portions of the wrinkles is larger than the distance at expanded portions of the wrinkles.
According to the invention called for in claim 1, the large number of complicated-shaped wrinkles attributed to shrinking of the stretchable functional member are formed on the surface of the hardened support substrate and, at the same time, minute wrinkles attributed to irregularities forming embossing are formed on the surface of each formed wrinkle. Accordingly, by applying irregularities forming embossing which has a preliminarily desired shape to the unhardened support substrate, it is possible to acquire the wrinkled plate having wrinkles of a desired shape.
According to the invention called for in claim 2, the irregular shape of the surface of the woven fabric is formed on the upper surface of the unhardened support substrate. Accordingly, by adhering the woven fabric having the desired surface shape to the upper surface of the unhardened support substrate, it is possible to acquire the wrinkled plate having wrinkles of a desired shape. Further, at the time of shrinking the unhardened support substrate, the woven fabric which is adhered to the upper surface of the unhardened support substrate is also shrunken in the same manner and hence, it is possible to form the large number of wrinkles on the surface of the support substrate while preventing the wrinkles from coming into contact with each other.
According to the invention called for in claim 3, embossing of the irregularities is performed by pressing the embossing plate on which irregularities are preliminarily formed to the upper surface of the unhardened support substrate. Accordingly, by embossing the upper surface of the unhardened support substrate using the embossing plate on which desired irregularities are formed, it is possible to acquire the wrinkled plate having wrinkles of a desired shape.
According to the invention called for in claim 4, it is possible to form the wrinkles of more complicated shapes on the surface of the plate while controlling a shape of the wrinkles formed on the surface of the plate.
According to the invention called for in claim 5, the irregular shape of the surface of the irregular surface sheet is formed on the upper surface of the unhardened support substrate and hence, by adhering the irregular surface sheet having a desired surface shape to the upper surface of the unhardened support substrate, it is possible to acquire the wrinkled plate having wrinkles of a desired shape. Further, at the time of shrinking the unhardened support substrate, the irregular surface sheet which is adhered to the upper surface of the unhardened support substrate is also shrunken in the same manner and hence, it is possible to form the large number of wrinkles on the surface of the support substrate while preventing the wrinkles from coming into contact with each other.
According to the invention called for in claim 6, by forming the support substrate using clay, it is possible to form the wrinkles on the surface of the clay by placing the support substrate on the upper surface of the stretchable functional member and by shrinking the stretchable functional member in an unhardened state and, at the same time, it is possible to harden the support substrate by drying or baking. Further, when the woven fabric is adhered to clay in an unhardened state, the woven fabric is vanished by baking and hence, the removal of the woven fabric becomes unnecessary leading to the more efficient manufacture of the wrinkled plate.
According to the invention called for in claim 7, the irregular shape of the surface of the intermediate layer is formed on the lower surface of the unhardened support substrate and hence, by interposing the intermediate layer having a desired surface shape between the stretchable sheet and the unhardened support substrate, it is possible to acquire the wrinkled plate having wrinkles of a desired shape. Further, at the time of shrinking the unhardened support substrate, the intermediate layer which is placed on the lower surface of the unhardened support substrate is also shrunken in the same manner and hence, it is possible to form the large number of wrinkles on the surface of the support substrate while preventing the wrinkles from coming into contact with each other. Still further, by adhering the surface layer which is shrinkable, is removable after post treatment, and has an irregular shape on the surface thereof to the upper surface of the unhardened support substrate, it is possible to acquire the wrinkled plate which forms wrinkles of a desired shape on both surfaces thereof.
According to the invention called for in claim 8, by covering the surface of the unhardened support substrate with a radio wave transmission material, for example, it is possible to form a shape of the surface of the wrinkled plate into a desired shape which is not influenced by the wrinkles formed on the plate while maintaining the radio wave absorbing performance. That is, for example, by forming the surface of the wrinkled plate into an approximately smooth surface by covering the surface of the wrinkled plate with the radio wave transmission material, it is possible to increase strength of the wrinkled plate and, at the same time, it is possible to prevent the adhesion of smears and hence, the wrinkled plate is effectively applicable to the a radio wave absorbing and insulating wall which prevents a medical device from being erroneously operated due to the influence of a radio wave exerted on the medical device or the like. Further, by covering the surface of the hardened support substrate with a foamed resin material such as foamed styrene or foamed urethane, it is possible to use the wrinkled plate as an acoustic insulation wall of a drawing room of an ordinary household or an audio room.
According to the invention called for in claim 9, by applying the lining material to the resilient member after forming the wrinkles on the sheet-shaped resilient member, it is possible to hold a shape of the wrinkles formed on the resilient member and, at the same time, it is possible to acquire the wrinkled plate having a desired thickness at a manufacturing stage so that it is unnecessary to perform an operation to remove an undesired portion as the post treatment whereby the Manufacturing efficiency can be enhanced and, at the same time, a manufacturing cost can be suppressed. Further, it is sufficient that the resilient member is a sheet-shaped member having resiliency and hence, the degree of freedom is high in the selection of material whereby it is possible to manufacture the wrinkled plate which conforms to various applications. Further, the intermediate layer can be recycled and hence, the wrinkled plate can be manufactured at a lower cost.
According to the invention called for in claim 10, it is possible to provide the wrinkled plate which exhibits the excellent radio wave absorbing performance, and can absorb an electromagnetic wave of desired frequency by controlling a shape of a large number of minute irregularities formed on the surface of each wrinkle.
Hereinafter, a method for manufacturing a wrinkled plate according to this embodiment is specifically explained in conjunction with
In manufacturing the wrinkled plate according to this embodiment, firstly, as shown in
The clay 5 is hardened by drying so that the clay 5 is in an unhardened state at a stage shown in
Further, the clay 5 contains organic compound powder such as starch or wheat flour and an iron compound such as iron oxide (Fe2O3) which constitutes inorganic compound powder. These organic compound powder compound and inorganic compound powder are turned into carbon (C) and iron (Fe) respectively by reduction baking. That is, a pottery plate which contains carbon and iron is formed by such baking.
Here, carbon and iron function as a radio wave absorbing material and hence, a radio wave which is incident on an upper surface of the wrinkled plate which contains these components is absorbed by the wrinkled plate when the radio wave propagates in the inside of the wrinkled plate. Accordingly, the radio wave absorbing performance of the wrinkled plate can be enhanced. Here, any material can be used as the radio wave absorbing material provided that the material has the radio wave absorbing performance and, for example, ferrite powder, titanium oxide or the like may be used in place of carbon or iron.
In placing the unhardened clay 5 on an upper surface of the rubber sheet 4, the rubber sheet 4 is held in a stretched state. Whether the stretching direction of the rubber sheet 4 is to be set to the one dimensional direction (rectilinear direction) or two dimensional directions (planar direction) is suitably selected based on a kind of wrinkles formed on a surface of a product. When the rubber sheet 4 is stretched in the one dimensional direction, wrinkles having an approximately corrugated shape can be formed on the surface of the product. On the other hand, when the rubber sheet 4 is stretched in the two dimensional direction, complicate-shaped wrinkles constituted of a large number of protruding portions each of which bulges in an opening-squeezed pouch shape can be formed on the surface of the product. Further, even when the rubber sheet 4 is stretched in the two dimensional direction, it is not always necessary to set a stretching amount of the rubber sheet 4 in the predetermined direction and a stretching amount of the rubber sheet 4 in the direction orthogonal to the predetermined direction equal to each other. By making the stretching amounts of the rubber sheet 4 in both directions different from each other, it is possible to make a shape of the wrinkles formed on the surface of an obtained product different corresponding to the difference in the stretching amounts of the rubber sheet 4.
The clay 5 is placed on the upper surface of the rubber sheet 4 having the above-mentioned constitution, and a thickness size of the clay 5 and the distribution of the thickness size are appropriately set corresponding to a shape of a product to be obtained. In this case, the thickness size of the clay 5 may be set smaller than a thickness size of a product to be obtained. Although the distribution of the thickness size may be set arbitrarily, the distribution of the thickness size is set uniform in general. In such a state, a lower surface of the clay 5 and the upper surface of the rubber sheet 4 are brought into close contact with each other.
Here, embossing of irregularities is applied to the upper surface of the clay 5 placed on the upper surface of the rubber sheet 4. In this embodiment, this embossing of irregularities is performed by adhering a woven fabric 6 having a mesh-like meshes to the upper surface of the clay 5 as shown in
By adhering such a woven fabric 6 to the upper surface of the clay 5, minute irregularities formed by such fibrous bodies 7 are embossed to the upper surface of the clay 5. That is, the clay 5 intrudes into irregularities or minute spaces in the woven fabric 6 which are formed by the entanglement of the fibrous bodies 7 of the woven fabric 6.
In this manner, a shape, a size, a depth and the like of the irregularities formed on the surface of the clay 5 can be made changed depending on weaving of the woven fabric 6 or a diameter or twisting of the fibrous bodies 7 and hence, it is possible to control the minute irregularities by selecting the woven fabric 6.
When the clay 5 is adhered to the upper surface of the stretched rubber sheet 4 and the woven fabric 6 is adhered to the upper surface of the clay 5 as described above, the rubber sheet 4 is shrunken thereafter.
Since the upper surface of the rubber sheet 4 and the lower surface of the clay 5 are adhered to each other by an adhesive force of the clay 5, when the rubber sheet 4 is shrunken, a force in the shrinking direction is applied to the lower surface of the clay 5 which is placed on the upper surface of the rubber sheet 4. Accordingly, a force in the compressive direction is applied to the clay 5 in the planar direction. Even in such a state, the lower surface of the clay 5 is brought into the upper surface of the rubber sheet 4 and is held in an adhered state in a close contact state and hence, a planar shape of the clay 5 is decreased along with the shrinkage of the rubber sheet 4 whereby the clay 5 is plastically deformed in the direction where the thickness of the clay 5 is increased. During this plastic deformation, a stress in the buckling direction is applied to the upper surface of the clay 5 and the woven fabric 6 which are not supported at all different from the lower surface of the clay 5 which is supported by the rubber sheet 4. Then, based on this stress, as shown in
In this case, since the woven fabric 6 is adhered to the upper surface of the clay 5, there is no possibility that portions of the clay 5 are brought into direct contact with each other at peak portions of the large number of protruding portions. That is, as shown in
Next, by inserting a thin plate between the lower surface of the clay 5 and the upper surface of the rubber sheet 4 or the like, the clay 5 is taken out from the upper surface of the rubber sheet 4 together with the woven fabric 6 and is transferred to an upper surface of a receiving plate provided separately and having sufficient heat resistance (although not shown in the drawing, a planar plate made of carborundum or iron in general or a wooden planar plate when a transfer operation is performed before baking). Then, the clay 5 and the woven fabric 6 are put into a furnace and are heated together with the receiving plate (after sufficiently performing drying treatment when necessary) thus baking the clay 5. A heating temperature of such heating is determined arbitrarily corresponding to a kind of the clay 5 or the like in the same manner as a temperature at the time of baking a clay tile or a porcelain in general, and is set to approximately 1000° C., for example. The heating temperature may be suitably determined based on a using material, a required strength or the like. For example, the temperature of 600° C. or more may be used at the time of baking clay, and the temperature of approximately 1700° C. may be used at the time of baking fine ceramics.
Due to such baking, as shown in
Further, during baking the clay 5, the woven fabric 6 placed on the upper surface of the clay 5 is vanished by burning. Accordingly, in a state where the wrinkled plate 1a is completed, as shown in
Further, in this embodiment, the clay 5 is used as the material of the support substrate and hence, in an unhardened state, the mounting of the clay 5 on the upper surface of the rubber sheet 4 and the formation of the wrinkles on the surface of the clay 5 due to the shrinkage of the rubber sheet 4 can be easily performed. Further, the clay 5 has the property that the clay 5 is hardened when the clay 5 is dried or baked and hence, in the step of baking the clay 5, the clay 5 can be hardened and, at the same time, the woven fabric 6 adhered to the upper surface of the clay 5 is vanished by baking whereby the removal of the woven fabric 6 becomes unnecessary leading to the more efficient manufacture of the wrinkled plate.
By changing the thickness of the woven fabric 6, it is possible to control a distance between the peak portions of the protruding portions 3, 3 to be formed on the upper surface of the product to be obtained. To be more specific, the thickness of the woven fabric 6 is increased to increase the distance between the peak portions of the protruding portions 3, 3. When the wrinkles are formed on the upper surface of the clay 5, the woven fabric 6 is collapsed more or less by pushing between the peak portions of the neighboring protruding portions 3, 3. Accordingly, the thickness of the woven fabric 6 is set to a value slightly larger than ½ of the distance between the peak portions of the neighboring protruding portions 3, 3.
Further, the support substrate which becomes the material for constituting the wrinkled plate 1a may be formed by suitably using mortar (concrete), fine ceramic, glass powder, metal powder, wood powder (saw chips), rubber, biomaterial or the like depending on usage. Among these materials, with respect to fine ceramic, glass powder, metal powder and wood powder, the material is mixed with a suitable binder (adhesive agent) thus forming a gel-like (glue-like) substance, wrinkles are formed on a surface of the substance, and the substance is hardened. As a means for hardening the substance, sintering, baking, drying, curing or the like is selected corresponding to a kind of the above-mentioned material or a kind of the binder. The metal powder maybe formed into sintered metal by sintering the metal powder with a suitable binder. Further, wood powder may be mixed with a suitable synthetic resin, wrinkles are formed on wood powder and, thereafter, solidified. A solidified material may be used as a wall plate having the excellent acoustic absorbing performance. Further, by using electrically conductive rubber which contains electrically conductive material powder made of carbon or the like as the rubber, it is possible to acquire an ornamental material which has the excellent electromagnetic wave absorbing performance. Further, the above-mentioned biomaterial can contribute to the realization of an artificial internal organ such as an artificial kidney or an artificial lung by making use of a large surface area.
Further, the support substrate may be formed using a synthetic resin which is hardened by post treatment such as a thermosetting resin, an ultraviolet-ray setting resin or an infrared-ray setting resin.
In forming the support substrate using the synthetic resin, the support substrate can be manufactured by steps similar to the steps for forming the support substrate using the clay 5. That is, firstly, the unhardened synthetic resin is placed on an upper surface of a rubber sheet 4 in an overlapping manner with the rubber sheet 4 held in a stretched state, and a woven fabric is adhered to an upper surface of the synthetic resin. Next, wrinkles are formed on the upper surface of the synthetic resin and the woven fabric by shrinking the rubber sheet 4 and, thereafter, the synthetic resin is hardened.
Here, hardening of the synthetic resin is performed by heating when the thermosetting resin is used as the synthetic resin, and is performed by the radiation of ultraviolet rays when the ultraviolet-ray setting resin is used as the synthetic resin, for example. By hardening the synthetic resin in this manner, it is possible to form the synthetic-resin-made wrinkled plate.
Further, in such a case, there arises a state where the woven fabric remains on a surface of the wrinkled plate thus providing the wrinkled plate having highly aesthetic appearance where the resin and fibers are integrally formed with each other. Here, as the synthetic resin, to be more specific, an acrylic resin, a silicon resin, a phenol resin, an epoxy resin, an urethane resin or the like can be used.
The woven fabric may be removed from the surface of the wrinkled plate without leaving the woven fabric on the surface of the wrinkled plate as described above. As a method for removing the woven fabric, it is possible to use a method which decomposes the woven fabric using enzyme after wrinkles are formed on the upper surface of the synthetic resin and the woven fabric, a method which physically removes the woven fabric by a human hand before the synthetic resin is completely hardened (semi-hardened), a method which removes the woven fabric by hardening the synthetic resin and, thereafter, washing away the woven fabric using water, a solvent, acid, alkali or the like. By using these methods, it is possible to remove the woven fabric without collapsing a shape of wrinkles formed on the upper surface of the synthetic resin.
On the surface (incident surface on which a radio waver or a sonic wave is incident) of the wrinkled plate manufactured by the above-mentioned manufacturing method, as shown in
Due to such a constitution, it is possible to provide the wrinkled plate which exhibits the excellent radio wave absorbing performance and the excellent sound absorbing performance, and can absorb an electromagnetic wave or a sound wave of desired frequency by controlling an average distance between the respective wrinkles 2 or a shape of minute irregularities 9 formed on the surface of each wrinkle 2.
The wrinkled plate 1a which is formed in the above-mentioned manner exhibits the particularly excellent radio wave absorbing performance and is useful as a so-called radio wave absorber. Hereinafter, the radio wave absorbing performance of the wrinkled plate 1a according to this embodiment is explained in conjunction with
This measurement uses a network analyzer E8362B made by Agilent Technologies Inc. A radio wave of 6 to 18 GHz is vertically incident on the wrinkled plate 1a and the attenuation characteristic of a reflection wave is measured by detecting the reflection wave reflected on the wrinkled plate 1a. In this measurement, the measurement is applied not only to a front surface (surface on which the wrinkles are formed) of the wrinkled plate 1a but also to a back surface (plane on which wrinkles are not formed) in the same manner.
Further, the attenuation characteristic of the reflection wave is taken on an axis of coordinates of a graph shown in
10 log{reflection from wrinkled plate/reflection from aluminum plate having the same size as wrinkled plate} (dB)
Here, attenuation characteristic of −10 dB implies that energy of the reflection radio wave from the wrinkled plate 1a takes a value expressed by a following formula compared with the reflection radio wave from the aluminum plate.
{reflection from wrinkled plate/reflection from aluminum plate}=10−1= 1/10
Attenuation characteristic of −20 dB implies that energy of the reflection radio wave from the wrinkled plate 1a takes a value expressed by a following formula compared with the reflection radio wave from the aluminum plate.
{reflection from wrinkled plate/reflection from aluminum plate}=10−2= 1/100
As shown in
Further, in this measurement, the favorable attenuation characteristic is also recognized with respect to a radio wave having a wavelength corresponding to an average distance between wrinkles formed on the front surface. Accordingly, by controlling the shape of the wrinkles formed on the front surface as in the case of this manufacturing method of this embodiment, it is possible to manufacture the wrinkled plate 1a which can absorb the radio wave of desired frequency.
Here, currently, the radio wave absorber is used by selecting a suitable material corresponding to frequency of a radio wave to be attenuated in general. For example, as a wall surface panel for preventing a ghost in surface wave television broadcasting, a panel having favorable radio wave absorbing performance suitable for a frequency band of 93 to 220 MHz is selectively used. Here, to take facts that the wrinkled plate according to this embodiment exhibits the favorable radio wave absorbing performance of 20 dB or more in the frequency band of 13 GHz or more, a material of the wrinkled plate is porcelain so that the wrinkled plate is brittle and the like into consideration, the use of the wrinkled plate in fixed facilities such as building is considered most promising.
In the above-mentioned embodiment, the embossing of irregularities on the upper surface of the unhardened clay 5 is performed by adhering the woven fabric 6 to the upper surface of the clay 5. However, in place of such a method, the irregularities may be formed on the upper surface of the unhardened clay 5 by pressing an embossing plate on which irregularities are preliminarily formed.
As shown in
In manufacturing the wrinkled plate according to this embodiment, the embossing plate 10 is brought into pressure contact with the upper surface of the unhardened clay 5 placed on a rubber sheet 4 thus forming the mesh-like irregularities on the upper surface of the clay 5. Then, after removing the embossing plate 10 from the upper surface of the clay 5, in the same manner as the above-mentioned embodiment, the rubber sheet 4 is shrunken thus forming wrinkles on the surface of the clay 5, and the clay 5 is hardened by baking thus completing the wrinkled plate. Further, in the same manner as the above-mentioned embodiment, the complicated-shaped wrinkles are formed on the surface of the hardened clay 5 due to shrinkage of the rubber sheet 4 and, at the same time, a large number of minute irregularities are formed on a surface of each formed wrinkle due to recessed portions 11 of the embossing plate 10.
Here, as the embossing plate 10, besides the embossing plate which forms the mesh-like recessed portions 11 thereon as shown in
In this manner, by embossing the upper surface of the unhardened clay 5 using the embossing plate having the desired irregularities, it is possible to acquire the wrinkled plate having wrinkles of the desired shape. As a result, it is possible to manufacture the wrinkled plate which absorbs a radio wave having a desired wavelength band or to manufacture the wrinkled plate to which a desired pattern is applied to the surface thereof thus having high aesthetic appearance.
In the above-mentioned embodiment 2, the embossing of irregularities on the surface of the support substrate is performed by embossing the upper surface of the unhardened support substrate (clay 5) by the embossing plate 10. However, in place of such an embossing operation, it may be possible to perform an embossing operation by adhering an irregular surface sheet on which irregularities are preliminarily formed on the upper surface of the unhardened support substrate.
In such a case, firstly, the irregular surface sheet is adhered to the upper surface of the unhardened clay which is placed on a rubber sheet. The irregular surface sheet is formed using a material which is vanished when the clay is baked, and recessed portions having a mesh shape, an emboss shape, a straight-line shape or a corrugated shape are formed on a surface of the irregular surface sheet. Further, a thickness of the irregular surface sheet is set small to an extent that wrinkles are formed on the irregular surface sheet together with the clay due to the shrinkage of the rubber sheet.
Then, in the same manner as the above-mentioned embodiment, wrinkles are formed on the surface of the clay and the irregular surface sheet by shrinking the rubber sheet, and the clay is hardened by baking thus completing the wrinkled plate. Here, in the same manner as the above-mentioned embodiment, a large number of minute wrinkles are formed due to shrinkage of the rubber sheet on the surface of the hardened clay, and a large number of minute irregularities are formed on a surface of each formed wrinkle due to recessed portions of the irregular surface sheet.
The irregular surface sheet is not always formed using a material which is vanished by baking. When an irregular surface sheet which is not vanished by baking is used, although the irregular surface sheet may be physically removed using a human hand or the like after the clay is hardened to some extent, it may be also possible to leave the irregular surface sheet on the upper surface of the clay. In such a case, the acquired wrinkled plate assumes a state where the irregular surface sheet partially or totally remains on the surface of the wrinkled plate and hence, the aesthetic appearance of the wrinkled plate can be enhanced.
The methods for manufacturing a wrinkled plate which have been explained in conjunction with the respective embodiments are particularly effective manufacturing methods when the clay 5 is used as the support substrate, wherein embossing of irregularities on the unhardened support substrate is applied to the upper surface of the unhardened support substrate using the woven fabric 6, the embossing plate 10 or the irregular surface sheet. However, when the support substrate is made of a synthetic resin, it is possible to manufacture a wrinkled plate more efficiently by performing embossing of irregularities by interposing an intermediate layer which is shrinkable, is removable by post treatment and has irregularities on a surface thereof between the rubber sheet 4 and the unhardened support substrate.
That is, firstly, as shown in
As described above, when the intermediate layer 20, the synthetic resin 21 and the surface layer 22 are placed on the upper surface of the rubber sheet 4 which is in a stretched state, the rubber sheet 4 is shrunken before the synthetic resin 21 is hardened (in a semi-hardened state). As a result, as shown in
In this manner, after the synthetic resin 21 is hardened in a state a large number of wrinkles are formed on both upper and lower surfaces thereof, as shown in
Due to such a constitution, the irregularities 24 attributed to the intermediate layer 20 or the surface layer 22 are formed on both surfaces of the synthetic resin 21 and hence, by interposing the intermediate layer 20 having the desired surface shape between the rubber sheet 4 and the synthetic resin 21, it is possible to acquire the wrinkled plate having wrinkles of a desired shape. Further, by adhering the surface layer 22 to the upper surface of the synthetic resin 21, it is also possible to acquire the wrinkled plate which forms wrinkles of a desired shape on both surfaces thereof. By covering, for example, an inner wall surface of a drawing room of an ordinary household or an audio room with such a wrinkled plate 1e, it is possible to enhance the acoustic characteristic while taking the aesthetic appearance of an inner surface of the room into consideration.
A wrinkled plate made of a synthetic resin which simply has a large number of wrinkles on a surface thereof may be manufactured by injection molding. In this case, however, it is necessary to configure the wrinkled plate such that a width (diameter) of an opening portion is set equal to or larger than a width (diameter) of a deep portion with respect to a cross-sectional shape of the recessed portions having a large number of wrinkles. In other words, it is impossible to form the wrinkled plate made of a synthetic resin of this embodiment which has a large number of wrinkles where a cross-sectional shape of the recessed portion has an opening-squeezed pouch shape. According to the method for manufacturing a wrinkled plate of this embodiment, it is possible to acquire the wrinkled plate having the shape not obtainable by injection molding which is a common manufacturing method of a synthetic resin product.
The explanation has been made with respect to the method which manufactures the wrinkled plate using the support substrate in the above-mentioned respective embodiments. However, the method has drawbacks with respect to manufacturing efficiency and a manufacturing cost. That is, in the method which manufactures the wrinkled plate using the support substrate, it is necessary to remove the hardened support substrate from the stretchable functional member after the support substrate is hardened. However, the support substrate and the stretchable functional member are brought into a closely adhered state due to the hardening of the support substrate and hence, the operation of removing the support base from the stretchable functional member is difficult. Further, it is necessary for the support substrate to ensure a certain amount of thickness and hence, to obtain a thin wrinkled plate, it is necessary to remove a bottom portion of the wrinkled plate acquired by the above-mentioned manufacturing method in the post treatment. Further, it is not also possible to reuse the removed portion in the manufacture of wrinkled plate.
Accordingly, in this embodiment, to manufacture the wrinkled plate more efficiently and at a low cost, in place of the method for manufacturing a wrinkled plate according to the above-mentioned respective embodiments, there is provided the method for manufacturing a wrinkled plate which includes the steps of: placing an intermediate layer which is extensible and shrinkable and is removable by post treatment on a stretchable functional member in a stretched state; adhering a sheet-shaped resilient member on an upper surface of the intermediate layer; forming wrinkles on the resilient member by shrinking the stretchable functional member; covering an upper surface of the resilient member with an unhardened lining material; and hardening the unhardened lining material.
In this case, firstly, as shown in
Here, to be more specific, the sheet-shaped resilient member may be formed using a synthetic resin film, a metal foil, paper or the like.
The intermediate layer 40 and the resilient member 41 are placed on an upper surface of the rubber sheet 4 with the rubber sheet 4 held in a stretched state as described previously, and the rubber sheet 4 is shrunken. As a result, as shown in
Next, after forming the wrinkles on the resilient member 41, as shown in
The lining material 42 may be formed using a material which gradually increases viscosity thereof in the course of hardening such as a thermosetting resin, an ultraviolet-ray setting resin, an infrared-ray setting resin or clay.
The lining material 42 is hardened in a state where the large number of wrinkles are still formed on the resilient member 41 and, thereafter, the intermediate layer 40 is removed as shown in
In this manner, according to the method for manufacturing a wrinkled plate of this embodiment, by applying the lining material 42 to the resilient member 41 after forming the wrinkles on the sheet-shaped resilient member 41, the wrinkled plate having a desired thickness can be acquired at a manufacturing stage so that it is unnecessary to perform an operation to remove undesired portions as the post treatment whereby manufacturing efficiency can be enhanced and, at the same time, a manufacturing cost can be suppressed. Further, it is sufficient that the resilient member 41 is a sheet-shaped member having resiliency and hence, the degree of freedom is high in the selection of the material of the resilient member 41 whereby it is possible to manufacture the wrinkled plates which conform to various applications. Further, the intermediate layer 40 can be recycled and hence, the wrinkled plate can be manufactured at a lower cost.
In the wrinkled plate 1h acquired by such a manufacturing method, a large number of irregular or untidy wrinkles attributed to protuberance are continuously formed on a surface of the wrinkled plate 1h, and a distance between neighboring wrinkles attributed to protuberance is set such that the distance at bottom portions of the wrinkles is larger than the distance at expanded portions of the wrinkles. Due to such structure, it is possible to provide the wrinkled plate which exhibits the excellent radio wave absorbing performance and the excellent sound wave absorbing performance.
The sheet-shaped resilient member 41 may have an irregular shape on a surface thereof. In this case, the sheet-shaped resilient member may be formed using a fabric which is formed by weaving carbon, metal or glass fibers or the like besides a synthetic resin film, a metal foil and paper. Here, with respect to a material which originally has no irregular shape on a surface thereof such as the synthetic resin film, the metal foil or paper, a predetermined irregular shape is formed on a surface of the resilient member 41 by pressing a feed roller or the like on which the predetermined irregular shape is formed.
In this manner, with the use of the sheet-shaped resilient member having the irregular shape on the surface thereof, it is possible to acquire the wrinkled plate where the wrinkles attributed to the shrinkage of the rubber sheet 4 are formed on the wrinkled plate 1h, and a large number of irregular shapes attributed to the irregularities preliminarily formed on the support substrate are formed on the surface of each wrinkle. Accordingly, with the use of the resilient member to which the irregularities of a desired shape are preliminarily applied, it is possible to acquire the wrinkled plate having irregularities of a desired shape. Further, at the time of shrinking the resilient member, the intermediate layer which is placed on the lower surface of the resilient member is also shrunken in the same manner and hence, it is possible to form the large number of wrinkles on the surface of the resilient member such that the wrinkles do not come into contact with each other thus forming the wrinkled plate into a shape useful as a radio wave absorber.
In the above-mentioned embodiments 1 to 3 or in the above-mentioned embodiments 5 and 6, the rubber sheet 4 is shrunken in one step and hence, the wrinkles having a relatively large waviness and the minute wrinkles attributed to the woven fabric 6 or the embossing plate 10 which are formed on the surface of each wrinkle are formed on the upper surface of the clay 5. However, in place of such shrinking of the rubber sheet 4, the rubber sheet 4 may be shrunken in multiple stages so as to further increase the number of wrinkles formed on the surface of the clay 5.
That is, in this embodiment, firstly, as shown in
Next, as shown in
When the first wrinkles 18 having such small waviness are formed on the upper surface of the clay 5 in this manner, the rubber sheet 4 is left in such a state (the state where the rubber sheet 4 is shrunken halfway) for some time thus slightly drying the clay 5 so as to slightly harden the clay 5 (so as to increase viscosity of the clay 5). When the clay 5 is slightly hardened, as shown in
With respect to the surface of the wrinkled sheet 1d acquired in the above-mentioned manner, the first wrinkles 18 smaller than the second wrinkles 19 are formed on the surfaces of the second wrinkles 19 having the large waviness and, further, the wrinkles attributed to the irregularities of the woven fabric 6 are formed on the surfaces of the first wrinkles 18. That is, due to such a constitution, it is possible to form the more complicate-shaped wrinkles on the surface of the plate while controlling the shapes of the wrinkles formed on the surface of the plate.
In the above-mentioned respective embodiments, the surface of the support substrate or the resilient member may be covered with various kinds of coating materials after being hardened.
That is, after forming the wrinkled plate 1f by the manufacturing method according to any one of the above-mentioned embodiments, as shown in
Here, as the radio wave permeable material, an FRP (Fiber Reinforced Plastic) resin, a GFRP (Glass Fiber Reinforced Plastic) resin or the like may preferably be used as a material.
Further, by covering the upper surface of the wrinkled plate 1f with a foamed resin material such as foamed styrene or foamed urethane as a covering material, it is possible to effectively use the wrinkled plate 1f as an acoustic insulation wall of a drawing room of an ordinary household or an audio room.
Further, in the above-mentioned respective embodiments, wrinkles may be formed on the surface of the support substrate such that minute particles are adhered to the surface of the unhardened support substrate and, thereafter, the stretchable functional member is shrunken so as to form the wrinkles.
That is, for example, the unhardened clay 5 is placed on the rubber sheet 4 in a stretched state, and the woven fabric 6 is adhered to an upper surface of the unhardened clay 5 and minute particles are also adhered to the upper surface of the unhardened clay 5. Here, the minute particles are resin-made or metal-made minute particles, and it is desirable to use a material which is not vanished by baking. Then, wrinkles are formed on the upper surface of the clay 5 and the woven fabric 6 by shrinking the rubber sheet 4 and, thereafter, the composite is baked thus forming a wrinkled plate 1g shown in
Due to such a constitution, a surface shape of the wrinkled plate becomes further complicated and hence, a radio wave which is incident on the wrinkled plate is reflected at random whereby it is possible to acquire the wrinkled plate having the further improved radio wave absorbing performance.
Here, instead of adhering the minute particles to the surface of the unhardened support substrate as described above, the minute particles may be mixed into the unhardened support substrate preliminarily. Due to such a constitution, the wrinkled plate can acquire not only advantageous effects substantially equal to the above-mentioned advantageous effects but also an advantageous effect that time and efforts necessary for adhering the minute particles to the upper surface of the unhardened support substrate can be saved thus enhancing the production efficiency. Further, by mixing particles having a relatively large particle size and particles having a relatively small particle size in the unhardened support substrate, it is possible to form the more minute irregularities due to these particles on the upper surface of the support substrate after the support substrate is hardened so that the radio wave absorbing performance of the wrinkled plate can be further enhanced.
Although some of the embodiments of the present invention have been explained in detail in conjunction with the drawings, these are provided only as examples, and can be carried out in other modes which adopt various modifications and improvements based on knowledge of those who are skilled in the art.
For example, in the above-mentioned respective embodiments, the rubber sheet is used as the stretchable functional member. However, it is sufficient for the stretchable functional member to have a stretchable function and hence, for example, a thermo shrinkable film, a shape memory alloy, a shape memory resin or the like can be used as the stretchable functional member.
Further, the stretchable functional member may be formed of, besides the above-mentioned stretchable functional member which is stretched or shrunken attributed to physical property which the material possesses, a member which is mechanically shrunken and stretched such as a stop device of a camera which performs a shrinking operation by sliding a plurality of throttle blades arranged along a periphery of a substrate formed in an approximately circular shape toward the center of the substrate. When the member which is mechanically shrunken and stretched is used as the stretchable functional member, it is possible to enhance the production efficiency and, at the same time, it is possible to manufacture wrinkled plates which exhibit small individual differences.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2008-013552 | Jan 2008 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2009/050960 | 1/22/2009 | WO | 00 | 10/29/2010 |
