Method of manufacturing metal embossed plate

Abstract

First corrugated portions in a first direction are sequentially formed by die-pressing a raw metal plate. Second corrugated portions formed in a second direction intersecting the first direction are sequentially formed by die-pressing a primary formed plate having the first corrugated portions using elongate projections, so that each of the second corrugated portion has a half-height and a pitch larger than those of each of the first corrugated portion. Third corrugated portions formed approximately in the first direction are sequentially formed by die-pressing a secondary formed plate having the second corrugated portions using elongate projections, so that each of the third corrugated portions has a half-height and a pitch larger than those of the first corrugated portion.

What is claimed is: 
     
         1 . A method of manufacturing a metal embossed plate comprising:
 sequentially forming a plurality of first corrugated portions in a first direction by die-pressing a raw metal plate;   sequentially forming a plurality of second corrugated portions in a second direction intersecting the first direction by die-pressing a primary formed plate having the first corrugated portions, each of the plurality of second corrugated portions having a half-height and a pitch larger than a half-height and a pitch of each of the first corrugated portions, and the die-pressing being performed using an elongate projection provided on at least one of a pair of dies capable of approaching and separating from each other; and   sequentially forming a plurality of third corrugated portions approximately in the first direction by die-pressing a secondary formed plate having the second corrugated portions, each of the plurality of third corrugated portions having a half-height and a pitch larger than the half-height and the pitch of the first corrugated portion, the die-pressing being performed using an elongate projection provided on at least one of a pair of dies capable of approaching and separating from each other.   
     
     
         2 . The method of manufacturing a metal embossed plate according to  claim 1 , wherein the first direction and the second direction are approximately orthogonal. 
     
     
         3 . The method of manufacturing a metal embossed plate according to  claim 1 , wherein the half-height and the pitch of the second corrugated portion are set approximately same as the half-height and the pitch of the third corrugated portion, respectively. 
     
     
         4 . The method of manufacturing a metal embossed plate according to  claim 1 , wherein the half-height of the third corrugated portion is 2 to 4 times the half-height of the first corrugated portion, and the pitch of the third corrugated portion is 2.14 to 5.5 times the pitch of the first corrugated portion. 
     
     
         5 . The method of manufacturing a metal embossed plate according to  claim 1 , wherein a stainless steel plate is used as the raw metal plate. 
     
     
         6 . The method of manufacturing a metal embossed plate according to  claim 1 , wherein any one of the first corrugated portion, the second corrugated portion, and the third corrugated portion is die-pressed by a forming die having a surface that is treated with surface treatment by which dry lubricity of the surface increases. 
     
     
         7 . The method of manufacturing a metal embossed plate according to  claim 1 , wherein the first corrugated portions are sequentially formed by die-pressing with a pair of gear-shaped corrugating rolls. 
     
     
         8 . The method of manufacturing a metal embossed plate according to  claim 1 , wherein at least one of the second corrugated portion and the third corrugated portion is die-pressed multiple times to have depth that increases in a stepwise manner. 
     
     
         9 . The method of manufacturing a metal embossed plate according to  claim 1 , wherein only three types of corrugated portions which are the first corrugated portion, the second corrugated portion, and the third corrugated portion are sequentially formed on the raw metal plate.