Method of manufacturing a metal component and metal sheet

Abstract

Provided is a manufacturing method of a metal member and a metal sheet. Provided is the following technology: regarding a process of forming a metal member in a metal plate, the metal member is formed so as to be easily separable from the metal plate while maintaining the layout of each metal member and the surrounding metal plate. A manufacturing method of a metal member includes the following steps: a first etching step of etching a first face of a metal plate to form a recess in the metal plate, forming a part of a metal member in the thickness direction of the metal plate; a step of attaching a protective layer to the first face; and a second etching step of etching a second face of the metal plate opposite the first face to which the protective layer is attached to form a recess in the metal plate, forming a remaining part of the metal member in the thickness direction of the metal plate.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a metal component and a metal sheet. Background Technology

[0002] The following technology exists: In the etching process, metal parts are separated from metal plates by etching (forming demolding) to form individual metal parts, and then decorative metal labels are manufactured by transferring adhesive to the back of the individual metal parts (see Patent Document 1).

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2018-134774 Summary of the Invention

[0006] The problem the invention aims to solve

[0007] However, in the technology described in Patent Document 1, color printing is performed on the metal parts after they have been molded and divided, which makes the process complicated. For example, positioning is required to avoid disrupting the processing position of the scattered metal parts. In addition, the following situation is not considered: instead of molding and dividing the metal parts, the metal parts are manufactured as thin sheets while maintaining the overall layout including the metal plates around the metal parts.

[0008] Therefore, the following technology is provided: regarding the process of forming metal parts on a metal plate, while maintaining the layout of each metal part with the surrounding metal plate, the metal parts are formed in a way that allows them to be easily separated from the metal plate.

[0009] Solution for solving the problem

[0010] This invention relates to a method for manufacturing metal parts, comprising the following steps:

[0011] In the first etching process, a first surface of a metal plate is etched to form a recess in the metal plate, thereby forming a part of a metal component in the thickness direction of the metal plate.

[0012] The process of applying a protective layer to the first surface; and

[0013] In the second etching process, a second side of the metal plate opposite to the first side to which the protective layer is attached is etched to form a recess in the metal plate, and the remaining portion of the metal component is formed in the thickness direction of the metal plate.

[0014] The effects of the invention

[0015] According to the present invention, a technique is provided that, in the process of forming metal parts on a metal plate, the metal parts are formed in a manner that allows them to be easily separated from the metal plate while maintaining the arrangement of each metal part with the surrounding metal plate. Attached Figure Description

[0016] Figure 1A This is a flowchart illustrating an example of a method for manufacturing a metal component corresponding to an embodiment.

[0017] Figure 1B This is a flowchart illustrating an example of the etching process corresponding to the embodiment.

[0018] Figure 2 This is a diagram illustrating the manufacturing method of the metal component corresponding to the embodiment.

[0019] Figure 3 This is a diagram showing a structural example of the metal component corresponding to the embodiment.

[0020] Figure 4 This is a diagram illustrating an example of the use of the metal component corresponding to the embodiment. Detailed Implementation

[0021] The embodiments are described in detail below with reference to the accompanying drawings. Furthermore, the following embodiments do not limit the invention as defined in the claims, and not all combinations of features described in the embodiments are essential to the invention. Two or more features from the plurality of features described in the embodiments may be arbitrarily combined. Additionally, the same or identical structures are labeled with the same reference numerals, and repeated descriptions are omitted. Furthermore, in the figures, the directions up, down, left, right, inside, and outside relative to the plane of the paper are used herein as the directions of the components (or assemblies) in this embodiment.

[0022] First, according to Figure 1A Flowcharts and Figure 2 To illustrate the manufacturing method of the metal component corresponding to the embodiments of the invention. Figure 1A This is a flowchart illustrating an example of a method for manufacturing a metal component corresponding to an embodiment. Figure 2 It shows according to Figure 1A The flowchart shows an example of a cross-section of a metal component manufactured.

[0023] exist Figure 1A In step S101, an etching process (corrosion process) is performed on the first surface of a metal sheet with a thickness of 0.1 mm to 0.15 mm, which is used as raw material, to form a part of a metal component in the thickness direction of the metal sheet. The metal sheet can be made of, for example, stainless steel, but can also be made of other metals, such as aluminum. Details of the etching process are as follows... Figure 1BAs shown below, details will be explained later.

[0024] Here, refer to Figure 2 , Figure 2 (A) shows a metal plate 200 used as raw material. The thickness of the metal plate 200 is shown magnified for illustrative purposes, but the actual thickness is 0.1 mm to 0.15 mm. When the upper surface of the metal plate 200 is used as the first surface for etching, as shown... Figure 2 As in (B), approximately half of the surface of the metal plate 200 is etched along its thickness direction to form a recess 201. Furthermore, the width of the recess 201 is not uniform and can be set to various widths. Additionally, the depth of the recess 201 may also be non-uniform. A pattern is formed on the surface of the metal plate 200 through this recess 201. The recess 201 includes a portion forming the pattern of the metal part and a portion forming the outline of the metal part. Additionally, the first surface is the surface for attaching a label.

[0025] Back Figure 1A The description continues, stating that in the next step S102, an adhesive film is adhered to the first surface as a protective layer. This adhesive film is a protective layer used to prevent the first surface from being eroded during the etching of the second surface, and an acid-resistant film that will not be corroded by the etching process can be used. The acid-resistant film, for example, has a thickness of 0.4 mm and is formed by the adhesive layer and a PET substrate. The first surface is bonded to the PET substrate through the adhesive layer, thereby protecting the first surface from damage caused by the subsequent etching process. Figure 2 (C) shows the case where the metal plate 200 is flipped over to bond the adhesive film 202 to the first surface.

[0026] Back Figure 1A As explained in step S103, the second side of the metal plate, opposite to the first side (the back side of the first side), is etched to form the remaining portion of the metal part in the thickness direction of the metal plate. Thus, as... Figure 2 As shown in (D), a through hole 203 is formed by penetrating a portion of the recess corresponding to the outline of the metal part through a recess formed in connection with a portion of the recess 201 formed in S101, thus completing the metal part and performing an etching process as described above. The area surrounded by the through hole 203 constitutes the metal part 204. The recesses 201 other than the portion connected to the recess formed in S103 form patterns on the first surface of the metal part 204. Through the etching process on the second surface, each metal part 204 is cut from the metal plate 200, but since an adhesive film 202 is attached to the first surface beforehand, each metal part 204 does not separate or detach from the metal plate 200 but remains as a single unit.

[0027] Back Figure 1AAs explained in step S104, an adhesive is applied to the second side of the metal plate. The adhesive can be a known material, but it must have a higher adhesive strength than the adhesive layer of the adhesive film 202, which serves as a protective layer for the first side. This is to prevent the metal parts from adhering to the adhesive film 202 side when the PET substrate of the adhesive film 202 is peeled off. Figure 2 (E) shows the case where adhesive 205 is applied to each metal part 204.

[0028] Back Figure 1A As explained in the following S105, a release film is adhered to the adhesive on the second side of the metal plate as a release layer. Figure 2 (F) shows the case where the adhesive 205 is adhered to the release film 206. Since the adhesive force of the adhesive 205 is stronger than that of the adhesive layer of the adhesive film 202, when the adhesive film 202 is peeled off, the metal part 204 remains on the side of the release film 206, and the rest of the metal plate separates from the metal part 204 along with the adhesive film 202. Therefore, by peeling off the adhesive film 202, only the metal part 204 is separated to the side of the release film 206, and by peeling the metal part 204 separately from the release film 206, it can be used as a metal label.

[0029] In addition, although Figure 1A The description is omitted, but the first surface can also be colored after S101 and before the processing in S102. In this case, in S102, the adhesive film is applied to the colored first surface. Additionally, in... Figure 1A The diagram shows a case where the formation of a release layer on the second side of a metal plate is performed in two steps, S104 and S105. However, it can also be performed as a single step by using a release film with adhesive.

[0030] Next refer to Figure 1B To explain Figure 1ADetails of the etching processes in S101 and S103 are as follows: First, in S111, the surface of the metal plate serving as the substrate is cleaned. Next, in S112, a photoresist is laminated onto the back side of the metal plate. Next, in S113, a photomask corresponding to the outline and pattern of the metal part to be formed is applied to the metal plate, and then ultraviolet light is irradiated. This exposes the photoresist in the areas not covered by the photomask, transferring the photomask pattern. Next, in S114, a development process is performed to remove the photoresist in the unexposed areas of S113 using a chemical reagent. This leaves the desired areas in a masked state. Next, in S115, a chemical reagent (etchant) for dissolving metal is applied to the result of the development process in S114 to dissolve the unmasked areas, thereby forming the outline or pattern of the metal part. Next, in S116, the photoresist is peeled off and the plate is cleaned, then dried.

[0031] Next refer to Figure 3 To show by Figure 1A An example of the structure of a metal part manufactured by this method. Figure 3 (A) shows a structural example of a sheet 300 comprising three metal components on its first side. The sheet 300 includes metal components 301, 302, and 303. The outlines of each metal component are defined by… Figure 2 The through hole 203 is specified. Furthermore, the patterns 304 to 306 formed on each metal component are... Figure 2 The recess 201 is formed. A [material / structure] is adhered to the first surface of the sheet 300. Figure 2 The adhesive film 202. The adhesive film 202 is made of a PET substrate and is therefore transparent. Figure 3 It is shown in the middle as a semi-transparent diagonal area.

[0032] Figure 3 (B) shows a structural example of the second side of a sheet 300 including three metal components. Adhesive 205 is attached to the metal components 301, 302, and 303 of the sheet 300, and a release film 206 is attached thereto. Furthermore, similar to the first side, the outline of each metal component is determined by… Figure 2 The through-hole 203 is specified. Additionally, an identification number for identifying each metal component is formed on the second surface. This identification number can also be formed by the through-hole 203 through the etching processes of S101 and S103. For example, in... Figure 3In the case of the circled number in (B), the central number may be formed by the recess 201 obtained through S101, and the outer circular outline may be formed by the through hole 203 obtained through S101 and S103. In this case, the identification number may be adhered to the release film 206 side when the adhesive film 202 is peeled off, as the adhesive 205 is attached to the identification number. In this case, the identification number of each metal part remains even when the adhesive film 202 is peeled off, making it easy to identify the metal part. Alternatively, the identification number may be formed only in the etching process of the second side of S103. In this case, the identification number remains on the sheet 300 side when the adhesive film 202 is peeled off, separating from the corresponding metal part.

[0033] exist Figure 3 Example of an identification number is shown in (B) with reference numerals 307 to 309, but the method of assigning the identification number is not limited to the circled number shown here, and can be any form. This allows the metal part to be used as a component in the manufacture of model toys. Furthermore, the identification number can be assigned near the metal part associated with that identification number, or it can be on the second side of the metal part. In this case, the identification number is assigned to the adhesive side of the metal part, so the number is not visible on the surface and therefore does not affect the appearance of the metal part. In this case, the depth of the recess forming the identification number can be shallower than the depth formed by recess 201.

[0034] Figure 3 (C) shows the state after metal parts 301 to 303 have been removed from the adhesive film 202 and the release film 206, respectively. Metal parts 301 to 303 removed from the release film 206, etc., are called metal stickers, decorative stickers, etched stickers, etc., and can be used as parts for model toys such as plastic models. These stickers have adhesive on their backs, so they do not need to be glued to the surface of the model toy using instant adhesives as in the past.

[0035] Figure 4 Examples of use of metal parts 301 to 303 are shown. Figure 4 (A) shows an example of the use of metal component 301, and similarly, Figure 4 (B) shows an example of the use of metal component 302. Figure 4 (C) shows an example of the use of metal part 303. In this way, it can be adhered to various components of model toys such as plastic models to represent vents, etc. However, the use of metal parts manufactured by the method corresponding to this embodiment is not limited to this; they can also be used to decorate the surface of model toys such as plastic models, and can also be used as markers or signs for car models or vehicle models. Furthermore, the appearance of the metal part is not limited to... Figure 3 and Figure 4As shown, it can have an appearance that represents any pattern, graphic, number, character, animal, plant, etc.

[0036] According to the manufacturing method of the metal component in this embodiment described above, the conventional method of connecting the metal component to the sheet, known as a gate, is unnecessary. Gates are provided to prevent the metal component from becoming scattered, but separating the metal component from the sheet requires cutting off each gate individually, which is cumbersome. Furthermore, cutting off the gate requires skill; therefore, a correspondingly skilled technique is needed to cut it cleanly. The metal component obtained by the manufacturing method of this embodiment is not connected to the sheet via a gate, but can be used directly by peeling off the adhesive film and release film, thus allowing for simple and clean use of the metal component.

[0037] In addition, the adhesive film used to prevent corrosion during the manufacturing process protects the surface of the metal parts even after the product is finished, so that each metal part can be maintained in the same flawless state as a new product until it is used.

[0038] The invention is not limited to the embodiments described above, and various modifications and alterations can be made within the scope of the spirit of the invention.

Claims

1. A method for manufacturing a metal part, comprising the following steps: In the first etching process, a first surface of a metal plate is etched to form a first recess that does not penetrate the metal plate, and a portion of each of a plurality of metal parts is formed in the thickness direction of the metal plate. The process of applying a protective layer to the entire first surface; as well as In the second etching step, a second side of the metal plate opposite to the first side where the protective layer is attached is etched to form a second recess in the metal plate that connects with a portion of the first recess formed in the first etching step. The remaining portion of the metal component is formed in the thickness direction of the metal plate, thereby forming a through hole. Following the second etching process, the process further includes a step of attaching a release layer to the second surface of the metal components, which integrally covers the plurality of metal components. The process of applying the release liner includes the following steps: On the second surface, an adhesive layer is formed on the metal component; and On the second side, the release layer is adhered to the metal component through the adhesive layer. The through hole forms the outline of the metal component. The recesses formed in the first etching process, except for the portion of the recesses, do not penetrate the metal plate and form a pattern on the surface of the metal component that is inside the outline of the metal component. The metal component is configured to be separable from the metal plate through the through hole. The metal component has an appearance representing a pattern, number, graphic, character, animal, or plant. The plurality of metal components are cut from the metal plate through the second etching process, and the plurality of metal components are held together with the metal plate by the protective layer. The adhesive layer is formed on each of the plurality of metal components in a manner that separates them from each of the plurality of metal components, and is formed such that at least a portion of the metal plate between each of the plurality of metal components does not have the adhesive layer disposed thereon. When the protective layer is peeled off, only the metal component remains on the peeling layer side, and the portion of the metal plate other than the metal component separates from the metal component together with the protective layer.

2. The manufacturing method according to claim 1, characterized in that, In the second etching process, only the second recess for forming the through hole is formed.

3. The manufacturing method according to claim 1, characterized in that, In the second etching process, identification information for identifying the metal component is also formed.

4. The manufacturing method according to claim 1 or 2, characterized in that, The process includes coloring the first surface after the first etching process and before the process of attaching the protective layer.

5. The manufacturing method according to claim 1, characterized in that, The adhesive force of the protective layer to the first surface is weaker than the adhesive force of the adhesive layer to the second surface.

6. A metal sheet, wherein, The metal sheet comprises multiple metal components. The metal component has a first recess on the first side of the metal sheet that does not penetrate the metal sheet, and a portion of the first recess has a pattern formed inside the outline of the metal component. The outline of the metal component is formed by a through hole penetrating the metal sheet. The through hole is formed by forming a second recess that connects to other recesses in the first recess formed on the first side of the metal sheet, excluding the aforementioned portion of the recesses. The metal component is configured to be separable from the metal sheet through the through hole. The entire first surface of the metal sheet and the metal component is covered by a protective layer. On the second side of the metal component, on the side opposite to the first side of the metal sheet, a release layer is bonded with adhesive to integrally cover the plurality of metal components. The metal component has an appearance representing a pattern, number, graphic, character, animal, or plant. The plurality of metal components are cut from the metal sheet, and the plurality of metal components are held together with the metal sheet by the protective layer. The adhesive is formed on each of the plurality of metal components in a manner that separates them from each of the plurality of metal components, and is formed such that at least a portion of the metal sheet, between each of the plurality of metal components, is not provided with the adhesive. The metal sheet has an area above the metal component to which multiple release layers are bonded with the adhesive, and an area between the metal components where the release layers are not bonded with the adhesive. When the protective layer is peeled off, only the metal component remains on the peeling layer side, and the portion of the metal sheet other than the metal component separates from the metal component together with the protective layer.

7. The metal sheet according to claim 6, characterized in that, The metal component and the metal sheet are on the same plane.

8. The metal sheet according to claim 6 or 7, characterized in that, The metal component is made of the same material as the metal sheet.

9. The metal sheet according to claim 6 or 7, characterized in that, The adhesive force of the protective layer to the first surface is weaker than that of the adhesive.

Images