METAL PART MANUFACTURING METHOD AND METAL SHEET

Abstract

To provide a technology for separably forming a metal component easily from a metal plate while holding a layout of an individual metal component and its surrounding metal plate, in a treatment of forming the metal component on the metal plate.SOLUTION: A method for manufacturing a metal component comprises: a first etching step of etching a first surface of a metal plate to form a recess in the metal plate to form a portion of the metal component in a thickness direction of the metal plate; a step of affixing a protective layer to the first surface; and a second etching step for etching a second surface opposite to the first surface of the metal plate to which the protective layer is affixed to form a recess in the metal plate to form a remaining portion of the metal component in a direction of the thickness of the metal plate.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a metal part and a metal sheet. [Background technology]

[0002] There is a technology for manufacturing decorative metal stickers in which metal parts are cut out (punched) from a metal plate by etching in an etching process to form separate, independent metal parts, and then adhesive is transferred to the backside of the separate, independent metal parts (see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-134774 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the technology described in Patent Document 1 involves color printing on metal parts after they have been die-cut and divided, which makes the process complicated by the need to position the separate metal parts so that they are not misaligned when being processed, etc. Furthermore, it does not take into consideration the possibility of manufacturing metal parts as sheets while maintaining the overall layout including the surrounding metal plates, without die-cutting and dividing them.

[0005] Therefore, a technique is provided for forming metal parts on a metal plate in such a way that the layout of the individual metal parts and the surrounding metal plate is maintained while the metal parts are easily separated from the metal plate. [Means for solving the problem]

[0006] The present invention provides a method for manufacturing a metal part, comprising: a first etching step of etching a first surface of a metal plate to form a recess in the metal plate and form a part of a metal component in a thickness direction of the metal plate; applying a protective layer to the first surface; and a second etching step of etching a second surface of the metal plate opposite the first surface to which the protective layer is attached to form a recess in the metal plate and forming the remaining portion of the metal part in the thickness direction of the metal plate. The present invention also provides a metal sheet comprising a plurality of metal parts, the metal sheet comprising: the contour of the metal part is defined by a hole passing through the metal sheet; the entire first surface of the metal sheet is covered with an adhesive protective layer; a release layer that integrally covers the plurality of metal parts via an adhesive is attached to the metal parts on a second surface side of the metal sheet opposite to the first surface, The adhesive is formed at least on each of the plurality of metal components and spaced apart between the plurality of metal components. The present invention also provides a metal sheet comprising a plurality of metal parts, the metal sheet comprising: the contour of the metal part is defined by a hole passing through the metal sheet; the entire first surface of the metal sheet is covered with an adhesive protective layer; a release layer that integrally covers the plurality of metal parts via an adhesive is attached to the metal parts on a second surface side of the metal sheet opposite to the first surface, The adhesive is formed on each of the plurality of metal parts, spaced apart between the plurality of metal parts, and is formed so as not to be positioned on at least a portion of the metal sheet between the plurality of metal parts. The present invention also provides a metal sheet comprising a plurality of metal parts, the metal sheet comprising: the contour of the metal part is defined by a hole passing through the metal sheet; the entire first surface of the metal sheet is covered with an adhesive protective layer; a release layer that integrally covers the plurality of metal parts via an adhesive is attached to the metal parts on a second surface side of the metal sheet opposite to the first surface, The adhesive is formed only on each of the plurality of metal components and spaced apart between the plurality of metal components. The present invention also provides a metal sheet comprising a plurality of metal parts, the metal sheet comprising: the contour of the metal part is defined by a hole passing through the metal sheet; the entire first surface of the metal sheet is covered with an adhesive protective layer; a release layer that integrally covers the plurality of metal parts via an adhesive is attached to the metal parts on a second surface side of the metal sheet opposite to the first surface, The metal sheet has areas on the metal parts where multiple release layers are attached via the adhesive, and areas between the metal parts where the release layers are located without the adhesive. The present invention also provides a method for manufacturing a metal sheet comprising a plurality of metal parts, the method comprising: a first etching step of etching a first surface of a metal plate to form a recess in the metal plate and form a part of a metal component in a thickness direction of the metal plate; applying a protective layer to the first surface; a second etching step of etching a second surface of the metal plate opposite to the first surface to which the protective layer is attached to form a recess in the metal plate and form a remaining portion of the metal component in a thickness direction of the metal plate; forming an adhesive layer on the second surface of the metal parts, and attaching a release layer that integrally covers the plurality of metal parts via the adhesive layer; Including, the contour of the metal part is defined by a hole passing through the metal plate; The adhesive layer is formed on each of the plurality of metal parts, spaced apart between the plurality of metal parts, and is formed so as not to be positioned on at least a portion of the metal sheet between the plurality of metal parts. The present invention also provides a method for manufacturing a metal sheet comprising a plurality of metal parts, the method comprising: a first etching step of etching a first surface of a metal plate to form a recess in the metal plate and form a part of a metal component in a thickness direction of the metal plate; applying a protective layer to the first surface; a second etching step of etching a second surface of the metal plate opposite to the first surface to which the protective layer is attached to form a recess in the metal plate and form a remaining portion of the metal component in a thickness direction of the metal plate; forming an adhesive layer on the second surface of the metal parts, and attaching a release layer that integrally covers the plurality of metal parts via the adhesive layer; Including, the contour of the metal part is defined by a hole passing through the metal plate; The adhesive layer is formed only on each of the plurality of metal components and spaced apart between the plurality of metal components. The present invention also provides a method for manufacturing a metal sheet comprising a plurality of metal parts, the method comprising: a first etching step of etching a first surface of a metal plate to form a recess in the metal plate and form a part of a metal component in a thickness direction of the metal plate; applying a protective layer to the first surface; a second etching step of etching a second surface of the metal plate opposite to the first surface to which the protective layer is attached to form a recess in the metal plate and form a remaining portion of the metal component in a thickness direction of the metal plate; forming an adhesive layer on the second surface of the metal parts, and attaching a release layer that integrally covers the plurality of metal parts via the adhesive layer; Including, the contour of the metal part is defined by a hole passing through the metal plate; The metal sheet has areas on the metal parts where multiple release layers are attached via the adhesive layer, and areas between the metal parts where the release layers are located without the adhesive layer. [Effects of the Invention]

[0007] According to the present invention, in a process for forming metal parts on a metal plate, a technology can be provided that forms metal parts in a manner that allows them to be easily separated from the metal plate while maintaining the layout of the individual metal parts and the surrounding metal plate. [Brief explanation of the drawings]

[0008] [Figure 1A] 4 is a flowchart showing an example of a method for manufacturing a metal part according to an embodiment. [Figure 1B] 1 is a flowchart showing an example of an etching process according to an embodiment. [Figure 2] 5A to 5C are diagrams for explaining a method for manufacturing a metal part according to an embodiment. [Figure 3] 1A and 1B are diagrams showing an example of the configuration of a metal part according to an embodiment. [Figure 4] 10A to 10C are diagrams showing examples of use of metal parts according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] The following embodiments will be described in detail with reference to the accompanying drawings. The following embodiments do not limit the scope of the claimed invention, and not all combinations of features described in the embodiments are necessarily essential to the invention. Two or more of the features described in the embodiments may be combined arbitrarily. Identical or similar components are designated by the same reference numerals, and redundant descriptions will be omitted. In each figure, the up, down, left, right, front, and back directions relative to the paper surface will be used in the description of the present embodiment as the up, down, left, right, front, and back directions of components (or parts) in the present embodiment.

[0010] First, a method for manufacturing a metal part according to an embodiment of the present invention will be described with reference to the flowchart of Fig. 1A and Fig. 2. Fig. 1A is a flowchart showing an example of a method for manufacturing a metal part according to an embodiment. Fig. 2 is a diagram showing an example of a cross section of a metal part manufactured according to the flowchart of Fig. 1A.

[0011] In FIG. 1A, in S101, an etching process (corrosion process) is performed on a first surface of a metal plate having a thickness of 0.1 mm to 0.15 mm, which is used as a raw material, so as to form a part of a metal part in the thickness direction of the metal plate. The metal plate may be made of stainless steel, for example, but may also be made of other metals, such as aluminum. Details of the etching process are as shown in FIG. 1B and will be described in detail later.

[0012] Referring now to FIG. 2, FIG. 2(A) shows a raw metal plate 200. The thickness of the metal plate 200 is enlarged for illustrative purposes, but the actual thickness is 0.1 to 0.15 mm. When etching is performed with the upper surface as the first surface, the surface of the metal plate 200 is etched approximately halfway in the thickness direction, forming recesses 201, as shown in FIG. 2(B). Note that the width of the recesses 201 is not uniform and can vary. Furthermore, the depth of the recesses 201 does not have to be uniform. These recesses 201 form a pattern on the surface of the metal plate 200. The recesses 201 include those that form the pattern of the metal part and those that form the outline of the metal part. Furthermore, the first surface becomes the surface of the seal.

[0013] Returning to the explanation of FIG. 1A, in step S102, an adhesive film is attached to the first surface as a protective layer. This adhesive film is a protective layer to prevent the first surface from being eroded when the second surface is etched, and an acid-resistant film that is not eroded by the etching process can be used. The acid-resistant film has a thickness of, for example, 0.4 mm and is formed of an adhesive layer and a PET substrate. The adhesive layer bonds the first surface to the PET substrate, protecting the first surface from the subsequent etching process. Here, FIG. 2(B) shows the state in which the metal plate 200 is turned over and the adhesive film 202 is bonded to the first surface.

[0014] Returning to the explanation of FIG. 1A, in the subsequent step S103, an etching process is performed on the second surface (back surface) opposite the first surface of the metal plate to form the remaining portion of the metal component in the thickness direction of the metal plate. As a result, as shown in FIG. 2(C), recesses formed to connect with portions of the recesses 201 formed in S101 penetrate the portion corresponding to the outline of the metal component, forming through-holes 203, completing the etching process. The area surrounded by the through-holes 203 constitutes the metal component 204. The recesses 201 other than the portion connected with the recesses formed in S103 form a pattern or the like on the first surface of the metal component 204. By etching the second surface, each metal component 204 will be separated from the metal plate 200, but because the adhesive film 202 was previously attached to the first surface, each metal component 204 is held together without separating or detaching from the metal plate 200.

[0015] Returning to the explanation of FIG. 1A, in the next step S104, an adhesive is attached to the second surface of the metal plate. The adhesive may be a known material, but it is necessary to use an adhesive with stronger adhesive strength than the adhesive layer of the adhesive film 202 attached as a protective layer to the first surface. This is to prevent the metal parts from sticking to the adhesive film 202 when the PET substrate of the adhesive film 202 is peeled off. FIG. 2(E) shows the state in which adhesive 205 has been attached to each metal part 204.

[0016] Returning to the explanation of FIG. 1A, in the subsequent S105, a release film is attached as a release layer to the adhesive on the second surface of the metal plate. FIG. 2(F) shows the state in which release film 206 has been attached to adhesive 205. Because the adhesive strength of adhesive 205 is stronger than that of the adhesive layer of adhesive film 202, when adhesive film 202 is peeled off, metal component 204 remains on the release film 206 side, and the rest of the metal plate is separated from metal component 204 together with adhesive film 202. Therefore, by peeling off adhesive film 202, only metal component 204 is separated onto the release film 206 side, and by peeling each metal component 204 from release film 206, it can be used as a metal seal.

[0017] Although not shown in Fig. 1A, the first surface may be colored after S101 and before the process of S102. In this case, an adhesive film is attached to the colored first surface in S102. Also, Fig. 1A shows a case where the formation of a release layer on the second surface of the metal plate is carried out in two separate steps, S104 and S105, but this may be a single step by using a release film with an adhesive attached thereto.

[0018] Next, with reference to FIG. 1B, the etching processes in S101 and S103 in FIG. 1A will be described in detail. First, in S111, the surface of the metal plate, which is the base material, is cleaned. Next, in S112, photoresist is laminated on both sides of the metal plate. Next, in S113, a photomask corresponding to the outline and pattern of the metal part to be formed is placed over the metal plate and ultraviolet light is irradiated. This exposes the photoresist in the areas not shielded by the photomask, transferring the pattern of the photomask. Next, in S114, a development process is performed by removing the photoresist in the areas not exposed in S113 with chemicals. This leaves the necessary areas masked. Next, in S115, a chemical (etchant) that dissolves metal is applied to the result of the development process in S114 to dissolve the unmasked areas, thereby forming the outline and pattern of the metal part. Next, in S116, the resist is peeled off and washed, and then dried.

[0019] Next, referring to Figure 3, an example of the configuration of a metal part manufactured by the manufacturing method of Figure 1A is shown. Figure 3(A) shows an example of the configuration of the first surface side of sheet 300 including three metal parts. Sheet 300 includes metal parts 301, 302, and 303. The outline of each is defined by through-hole 203 of Figure 2. Furthermore, patterns 304 to 306 formed on each metal part are formed by recessed part 201 of Figure 2. Adhesive film 202 of Figure 2 is attached to the first surface of sheet 300. Since adhesive film 202 is made of a PET base material, it is transparent and is shown by a semi-transparent shaded area in Figure 3.

[0020] FIG. 3(B) shows an example of the configuration of the second surface of a sheet 300 including three metal components. Adhesive 205 is attached to each of metal components 301, 302, and 303 of the sheet 300, and a release film 206 is further attached thereto. The outlines of each are defined by the through-holes 203 shown in FIG. 2, as in the case of the first surface. An identification number for identifying each metal component is formed on the second surface. The identification number may be formed by the through-holes 203 during the etching processes S101 and S103. For example, in the case of circled numbers as shown in FIG. 3(B), the inner number may be formed by the recess 201 formed by S101, and the outline of the outer circle may be formed by the through-holes 203 formed by S101 and S103. In this case, adhesive 205 may be attached to the identification number so that it adheres to the release film 206 when the adhesive film 202 is peeled off. In this case, the metal parts can be easily identified because the identification numbers of the individual metal parts remain even when adhesive film 202 is peeled off. The identification numbers may also be formed only by etching the second surface in S103, in which case they remain on sheet 300 when adhesive film 202 is peeled off, and are separated from the corresponding metal parts.

[0021] Examples of identification numbers are shown in FIG. 3(B) as reference numerals 307 to 309, but the identification numbers may be assigned in any format, not just the circled numbers shown here. This allows the metal parts to be used as components for creating toy models. The identification numbers may be assigned near the metal part associated with the identification numbers or on the second surface of the metal part. In this case, the identification numbers are assigned to the adhesive surface of the metal part, so they are not visible on the outside and do not affect the appearance of the metal part. In this case, the depth of the recesses forming the identification numbers may be shallower than that formed by recess 201.

[0022] 3(C) shows the state in which metal parts 301 to 303 have been removed from adhesive film 202 and release film 206, respectively. Metal parts 301 to 303 removed from release film 206 in this way are called metal stickers, decorative stickers, etching stickers, etc., and can be used as parts for model toys such as plastic models. These stickers have an adhesive on the backside, so there is no need to attach them to the surface of model toys with instant adhesive or the like, as in the past.

[0023] FIG. 4 shows examples of use of metal parts 301 to 303. FIG. 4(A) shows an example of use of metal part 301, and similarly, FIG. 4(B) shows an example of use of metal part 302, and FIG. 4(C) shows an example of use of metal part 303. In this way, the metal parts can be attached to various parts of model toys such as plastic models to represent ventilation holes, etc. However, the use of metal parts manufactured by a method corresponding to this embodiment is not limited to this. They may also be used to decorate the surface of model toys such as plastic models, or as marks or emblems for model cars or vehicle models. Furthermore, the appearance of the metal parts is not limited to those shown in FIGS. 3 and 4 , and they may have any pattern, figure, number, character, animal, plant, or other appearance.

[0024] According to the manufacturing method of a metal part corresponding to the present embodiment described above, the conventionally required connection portion called a gate that connects the metal part to the sheet is no longer necessary. Gates are provided to prevent the metal part from coming apart, but separating the metal part from the sheet requires the gate to be separated one by one, which is cumbersome. Furthermore, separating the gate requires skill, so a certain level of proficiency is required to separate the metal part cleanly. The metal part manufactured by the manufacturing method of this embodiment is not connected to the sheet via a gate, and can be used immediately by peeling it off the adhesive film and release film, allowing the metal part to be used simply and in a clean state.

[0025] In addition, the adhesive film used to prevent corrosion during the manufacturing process continues to protect the surface of metal parts even after the product is completed, allowing each metal part to remain in a brand new, undamaged condition until just before use.

[0026] The invention is not limited to the above-described embodiment, and various modifications and variations are possible within the scope of the gist of the invention.

Claims

1. A metal sheet including a plurality of metal parts, the contour of the metal part is defined by a hole passing through the metal sheet; the entire first surface of the metal sheet is covered with an adhesive protective layer; a release layer that integrally covers the plurality of metal parts via an adhesive is attached to the metal parts on a second surface side of the metal sheet opposite to the first surface, The adhesive is formed on each of the plurality of metal components, spaced apart between the plurality of metal components, and is formed so as not to be disposed on at least a portion of the metal sheet between the plurality of metal components. Metal sheet.

2. A metal sheet including a plurality of metal parts, the contour of the metal part is defined by a hole passing through the metal sheet; the entire first surface of the metal sheet is covered with an adhesive protective layer; a release layer that integrally covers the plurality of metal parts via an adhesive is attached to the metal parts on a second surface side of the metal sheet opposite to the first surface, The adhesive is formed only on each of the plurality of metal components and spaced apart between the plurality of metal components. Metal sheet.

3. A metal sheet including a plurality of metal parts, the contour of the metal part is defined by a hole passing through the metal sheet; the entire first surface of the metal sheet is covered with an adhesive protective layer; a release layer that integrally covers the plurality of metal parts via an adhesive is attached to the metal parts on a second surface side of the metal sheet opposite to the first surface, The metal sheet has regions on the metal components where the release layers are attached via the adhesive, and regions between the metal components where the release layers are located without the adhesive. Metal sheet.

4. 4. The metal sheet according to claim 1, wherein when the protective layer is peeled off from the metal sheet, the plurality of metal components remain on the release layer side, and the portions of the metal sheet other than the plurality of metal components are separated from the metal components together with the protective layer.

5. The metal sheet according to claim 1 , wherein the adhesive strength of the adhesive protective layer to the first surface is weaker than the adhesive strength of the adhesive.

6. The metal sheet according to claim 1 , wherein a portion of the metal sheet other than the plurality of metal components is integrally formed.

7. 1. A method for manufacturing a metal sheet including a plurality of metal parts, comprising: a first etching step of etching a first surface of a metal plate to form a recess in the metal plate and form a part of a metal component in a thickness direction of the metal plate; applying a protective layer to the first surface; a second etching step of etching a second surface of the metal plate opposite to the first surface to which the protective layer is attached to form a recess in the metal plate and form a remaining portion of the metal component in a thickness direction of the metal plate; forming an adhesive layer on the second surface of the metal parts, and attaching a release layer that integrally covers the plurality of metal parts via the adhesive layer; Including, the contour of the metal part is defined by a hole passing through the metal plate; A method for manufacturing a metal sheet, wherein the adhesive layer is formed on each of the plurality of metal parts, spaced apart between the plurality of metal parts, and is formed so as not to be positioned on at least a portion of the metal sheet between each of the plurality of metal parts.

8. 1. A method for manufacturing a metal sheet including a plurality of metal parts, comprising: a first etching step of etching a first surface of a metal plate to form a recess in the metal plate and form a part of a metal component in a thickness direction of the metal plate; applying a protective layer to the first surface; a second etching step of etching a second surface of the metal plate opposite to the first surface to which the protective layer is attached to form a recess in the metal plate and form a remaining portion of the metal component in a thickness direction of the metal plate; forming an adhesive layer on the second surface of the metal parts, and attaching a release layer that integrally covers the plurality of metal parts via the adhesive layer; Including, the contour of the metal part is defined by a hole passing through the metal plate; A method for manufacturing a metal sheet, wherein the adhesive layer is formed only on each of the plurality of metal parts, spaced apart between the plurality of metal parts.

9. 1. A method for manufacturing a metal sheet including a plurality of metal parts, comprising: a first etching step of etching a first surface of a metal plate to form a recess in the metal plate and form a part of a metal component in a thickness direction of the metal plate; applying a protective layer to the first surface; a second etching step of etching a second surface of the metal plate opposite to the first surface to which the protective layer is attached to form a recess in the metal plate and form a remaining portion of the metal component in a thickness direction of the metal plate; forming an adhesive layer on the second surface of the metal parts, and attaching a release layer that integrally covers the plurality of metal parts via the adhesive layer; Including, the contour of the metal part is defined by a hole passing through the metal plate; A method for manufacturing a metal sheet, wherein the metal sheet has areas on the metal parts where multiple release layers are attached via the adhesive layer, and areas between the metal parts where the release layers are located without the adhesive layer.

Images