WO2012161430A2

WO2012161430A2 - Method of machining metal plate for manufacturing scaled model, method of manufacturing scaled model, and scaled model

Info

Publication number: WO2012161430A2
Application number: PCT/KR2012/003479
Authority: WO
Inventors: Il-weon KIM
Original assignee: Kim Il-Weon
Priority date: 2011-05-20
Filing date: 2012-05-03
Publication date: 2012-11-29
Also published as: DE112012002183T5; WO2012161430A3; CN103547708A; CN103547708B; WO2012161430A9; KR101068803B1

Abstract

Provided is a method of machining a metal plate for manufacturing a scaled model, which includes: a step (A) of preparing a metal plate; a step (B) of forming a first photosensitive resin layer on the surface of the metal plate; a step (C) of forming a second photosensitive resin layer; a step (D) of disposing and exposing a photomask for forming projection; a step (E) of removing the photosensitive resin on the surface; and a step (F) of forming projections on the surface of the metal plate, a scaled model including a metal plate machined by the machining method, a manufacturing method of a scaled model, and a scaled model manufactured by the manufacturing method. According to the method of machining a metal plate for manufacturing a scaled model, it is possible to easily form projections with different heights on the surface of a metal plate.

Description

[DESCRIPTION]

[Invention Ti le]

METHOD OF MACHINING METAL PLATE FOR MANUFACTURING SCALED MODEL, METHOD OF MANUFACTURING SCALED MODEL, AND SCALED MODEL

[Technical Field]

The present invention relates to a method of machining a metal plate for manufacturing a scaled model, a method of manufacturing a scaled model, and a scaled model, particularly, a method that makes it possible to easily form projections having different heights on the surface of a metal plate for manufacturing a scaled model by etching.

[Background Art]

<2> It is necessary to implement projections with different heights on the surface when manufacturing a scaled model. When manufacturing a scaled model of a freight car manufactured by joining metal plates, such as the freight car shown in Fig. 1, it is necessary to make the heights of the rivets 125 on the top 120 and the rivets 135 on the sides 130 different, even if they are the same rivets, and it is also necessary to make the heights of the top 120 and the sides 130 different. This configuration is for reflecting that the top looks protruding further than the sides in the actual object, in consideration of that consumers desire a scaled model having the same shape as the recognized actual object. Methods of attaching rivets manufactured by bonding to the surface of metal plate by welding, joining metal plates with different thicknesses, or the like has been used in the related art, as described above, in order to implement projections with different heights when manufacturing a scaled model, but the methods have a problem in that there is a limit in precise implementation and the work is not easy.

<3> It is required to develop a method of machining metal plates which overcomes the limit and makes it possible to easily form projections with different height on the surface of metal plates for manufacturing a scaled model in order to satisfy the customers' increasing expectation about precision of a scaled model.

[Disclosure] [Technical Problem]

<4> An embodiment of the present invention is directed to providing a method of machining a metal plate for manufacturing a scaled model which makes it possible to easily form projections, with different heights on the surface of the metal plate.

<5> Another embodiment of the present invention is directed to providing a scaled model including a metal plate machined by a method of machining a metal plate for manufacturing a scaled model which makes it possible to easily form projections with different heights on the surface of the metal plate.

<6> Another embodiment of the present invention is directed to providing a method of manufacturing a scaled model, using a metal plate for manufacturing a scaled model which makes it possible to easily form projections with different heights on the surface of the metal plate.

<7> Another embodiment of the present invention is directed to providing a scaled model manufactured by a method of manufacturing a model, using a metal plate for manufacturing a scaled model which makes it possible to easily form projections with different heights on the surface of the metal plate.

<8> The objects of the present invention are not limited to the objects described above, and the other objects not stated in the above will be clearly understood by those skilled in the art from the following description.

[Technical Solution]

<9> To achieve the object of the present invention, the present invention provides a method of machining a metal plate for manufacturing a scaled model, which includes: a step (A) of preparing a metal plate; a step (B) of forming a first photosensitive resin layer on the surface of the metal plate prepared in the step (A), by using a liquid-state photosensitive resin composite; a step (C) of forming a second photosensitive resin layer on the surface of the first photosensitive resin layer formed in the step (B) , by using a photosensitive resin film; a step (D) of disposing and exposing a photomask for forming projection, on the second photosensitive resin layer; a step (E) of removing the photosensitive resin on the surface to be corroded, by developing the metal plate exposed in the step (D); and a step (F) of forming projections on the surface of the metal plate by removing the photosensitive resin on a non-corroded surface after corroding the metal plate developed in the step (E) with an etching solution.

<io> The metal plate may be made of one selected from iron, copper, brass, phosphor bronze, cupronickel, beryllium copper, stainless steel, or nickel, or a an alloy of two or more of the elements. The projection may have a surface width of 0.1~5mm. The surface width is a meaning that includes a surface diameter. The shape of the surface of the projection is a circle or a line and the surface diameter of the circular projection is preferably 0.1~2mm and the surface width of the linear projection is preferably 0.3~5mm. The height of projection may be 0.01~5mm.

<ii> The liquid-state photosensitive resin composite of the step (B) may be a liquid-state composite containing a photoactive compound, and resin or a base material. The photoactive compound may be one or more selected from silver salt, dichromate, a diazo compound, an azide compound, or iron salt; the resin or the base material may be one or more selected from phenol resin (Nobolak resin), epoxy resin, acrylic resin, methacrylic resin, polyimide, polyurea, polyvinyl alcohol , gelatin, or glue. The composite may include, as a solvent, one or more selected from ammonia water, methylethyl ketone, or alcohol. The alcohol may be one or more selected from methanol or octyl alcohol .

<i2> The photosensitive resin film of the step (C) may include a support film and a photosensitive resin composite layer stacked on the support film.

<i3> The resin composite of the photosensitive resin composite layer may be the same as the resin composite in the liquid-state photosensitive resin composite.

<i4> The exposing in the step (D) is performed with the amount of exposure

2

of 10~500mW/cm for 1-500 seconds, by using one or more selected from ultraviolet rays or sunlight, or light emitted from a mercury lamp. Preferably, it may be possible to use a mercury lamp having lamp power of 8kW, lamp voltage of 1200V, and lamp current of 7.5A.

The developing in the step (E) may be performed with an alkali solution. The alkali solution may be sodium carbonate solution of 3-10 volume% (also called a solution of soda ash).

The etching solution in the step (F) may be a ferric chloride solution and the process using the etching solution performed with a ferric chloride solution of 20-60 volume% for 1-120 minutes.

<i7> The metal plate of the step (A) may include the projection formed on the surface.

The projection formed on the surface of the metal plate of the step (A) may be higher than the projection formed in the step (F).

<i9> The projection formed in the step (F) may be formed by the projection formed on the surface of the metal plate in step (A), thereon. The shape of the surface of the projection may be a circle or a line and the surface diameter of the circular projection may be preferably 0.1~2mm and the surface width of the linear projection may be preferably 0.3~5mm. The height of projection may be 0.01~5mm.

<20> The projection formed on the surface of the metal plate in the step (A) may be formed by a method of forming a projection including^', a step (Al) of forming a photosensitive resin layer on the surface of a metal plate, by using one or more selected from a photosensitive resin film or a liquid-state photosensitive resin composite; a step (A2) of disposing and exposing a photomask for forming a projection on the photosensitive resin layer of the step (Al); a step (A3) of removing the photosensitive resin on the surface to be corroded, by developing the metal plate exposed in the step (A2); and a step (A4) of forming a projection on the surface of the metal plate by removing the photosensitive resin on a non-corroded surface after corroding the metal plate developed in the step (A3) with an etching solution.

<2 i > The method may further include: a step (G) of forming a first photosensitive resin layer on the surface of the metal plate with the projection formed in the step (F), by using a liquid-state photosensitive resin composite; a step (H) of forming a second photosensitive resin layer on the surface of the photosensitive resin layer formed in the step (G), by using a photosensitive resin film; a step (I) of disposing and exposing a photomask for forming a projection lower than the projection formed in the step (F), on the second photosensitive resin layer of the step (H); a step (J) of removing the photosensitive resin on a surface to be corroded, by developing the metal plate exposed in the step (I); and a step (K) of further forming a projection lower than the projection formed in the step (F), on the surface of the metal plate, by removing the photosensitive resin on a non- corroded surface after corroding the developed metal plate with an etching solution.

<22> The method may further include a step of forming an opening through the metal plate after forming the last projection. The opening may be formed by a method including: a step (L) of forming a first photosensitive resin layer on the surface of the metal plate that has undergone the last step, by using a liquid-state photosensitive resin composite; a step (M) of forming a second photosensitive resin layer on the surface of the first photosensitive resin layer formed in the step (L), by using a photosensitive resin film; a step (N) of disposing and exposing a photomask for forming an opening, on the second photosensitive resin layer; a step (0) of removing the photosensitive resin on the surface to be corroded, by developing the metal plate exposed in the step (N); and a step (P) of forming an opening through the metal plate by removing the photosensitive resin on a non-corroded surface after corroding the metal plate developed in the step (0) with an etching solution

<23> Further, the present invention provides a scaled model comprising a metal plate machined by the machining method of the present invention.

<24> Further, the present invention provides a method of manufacturing a scaled model which includes: a step of bending a metal plate machined by the method of machining a metal plate for manufacturing a scaled model of the present invention; and a step of assembling the metal plate bent in the step.

<25> Further, the present invention provides a scaled model manufactured by the method of manufacturing a scaled model of the present invention.

[Advantageous Effects] <26> According to the method of machining a metal plate for manufacturing a scaled model, it is possible to easily form projections with different heights on the surface of a metal plate and to easily manufacture a scaled model having projections with various heights.

[Description of Drawings]

<27> Fig. 1 is a view showing a scaled model of a freight car that is an embodiment of the present invention.

<28> Fig. 2 is a view showing an example of metal plate for manufacturing the scaled model of a freight car shown in Fig. 1.

<29> Fig. 3 is an enlarged view of the AA' cross-section of the portion indicated by an ellipse in Fig. 2.

<30> Fig. 4 is a view showing an example of preparing a metal plate in a method of machining a metal plate for manufacturing a scaled model which is an embodiment of the present invention.

<3 i > Fig. 5 is a view showing an example of a process of forming projections on a surface by machining a metal plate prepared through the process shown in

Fig. 4.

<32> Fig. 6 is a view showing an example of a process of additionally forming projections by machining again the metal plate that has undergone the process shown in Fig. 5.

<33> Fig. 7 is a view showing an example of a process of forming an opening by machining again the metal plate that has undergone the process shown in

Fig. 6.

<34> Fig. 8 is a view showing an example of the shape of a metal plate for manufacturing a scaled model of a cap roof included in a steam locomotive. <35> Fig. 9 is a view showing a photomask for forming an example of projections of a metal plate for manufacturing a scaled model of a cap roof included in a steam locomotive.

<36> Fig. 10 is a view showing a photomask for forming another example of projections of a metal plate for manufacturing a scaled model of a cap roof included in a steam locomotive.

<37> Fig. 11 is a view showing a photomask for forming an opening of a metal plate for manufacturing a scaled model of a cap roof included in a steam locomotive.

<38> Fig. 12 is a view showing an embodiment of a machined metal plate for manufacturing a scaled model of a cap roof included in a steam locomotive.

<39> Fig. 13 is a view showing a comparative example of a machined metal plate for manufacturing a scaled model of a cap roof included in a steam locomotive.

<40> Fig. 14 is an enlarged view of the BB' cross-section of the portion indicated by an ellipse in Fig. 13.

<4i> Fig. 15 is a view showing another comparative example of a machined metal plate for manufacturing a scaled model of a cap roof included in a steam locomotive.

<42> Fig. 16 is an enlarged view of the CC cross-section of the portion indicated by an ellipse in Fig. 15.

[Mode for Invention]

<43> Advantages and features of the present invention and methods to achieve them will be clear from exemplary embodiments described below in detail with reference to the accompanying drawings. However, the present invention is not limited to exemplary embodiment disclosed herein but will be implemented in various forms. The exemplary embodiments are provided by way of example only so that a person of ordinary skill in the art can fully understand the disclosures of the present invention and the scope of the present invention. Therefore, the present invention will be defined only by the scope of the appended claims.

<44> Like reference numerals designate like components throughout the specification. The term "and/or" means including each and all of one or more of combinations of the stated components.

<45> Terms used herein are to explain exemplary embodiments rather than limiting the present invention. In the specification, a singular type may also be used as a plural type unless stated specifically, "comprises" and/or "comprising" used herein does not exclude the existence or addition of one or more other components, steps, operations and/or elements. <46> Fig. 1 is a view showing an example of a scaled model of a freight car.

<47> Fig. 2 is a view showing an example of a metal plate machined to manufacture the scaled model of a freight car shown in Fig. 1. It is possible to manufacture the freight car shown in Fig. 1 by bending the metal plate shown in Fig. 2. As shown in Figs. 1 and 2, a scaled model 100 of a freight car includes projections that need to be implemented with different heights, such as top rivets 125, a top 120, sides 130, side rivets 135, a side-horizontal line 137, edges 123, metal plate joints 127, a front 140, front rivets 145, and front-horizontal lines 147 and 149, and an opening, such as an entrance 150.

<48> Fig. 3 is an enlarged view of the AA' cross-section of the portion indicated by an ellipse in Fig. 2.

<49> As shown in Fig. 3, the top rivets 125 are the highest projections, the next higher projection (second stage) is the top 120, the next higher projections (third stage) are the edge 123, the side rivets 135, and the side-horizontal line 137, and it is necessary to form an entrance 150 that is the opening. It is necessary to dispose the top rivets 125 to protrude from the surface of the top 120.

<50> A detailed example of a method of machining a metal plate for manufacturing a scaled model of a freight car is shown in Figs. 4 to 7, by means of the cross-section of Fig. 3.

<5i> Fig. 4 is a view showing an example of preparing (A) a metal plate,

Fig. 5 is a view showing a process of forming a projection on a surface by machining the metal plate prepared by the process shown in Fig. 4, Fig. 6 is a view showing a process of additionally forming a projection by machining again the metal plate that has undergone the processes shown in Fig. 5, and Fig. 7 is a view showing a process of forming an opening by machining again the metal plate that has undergone the processes shown in Fig. 6.

<52> As shown in Fig. 4, a metal plate 10 made of one selected from iron, copper, brass, phosphor bronze, cupronickel, beryllium copper, stainless steel, or nickel, or an alloy of two or more of them is prepared (Ala).

<53> If necessary, grease removing and/or surface machining may be performed on the metal plate.

<54> Grease removing is for removing stains and foreign substances on the surface of the metal plate, in which it is preferable that the color and the luster of the surface do not change. Grease removing can be performed with a degreasing agent, such as sodium hydroxide (NaOH), and it is preferable to perform neutralization with acid when using a strong alkali decreasing agent. The degreasing agent may be a degreasing agent (Super Ti) that is on the market .

<55> Surface machining is a process that makes the surface of the metal plate even to perform precise etching, in which it is possible to make the surface of the metal plate even by removing scratches on the surface by polishing the surface of the metal plate with, for example, sandpaper, a brush, or calcium carbonate. The surface machining may be performed by a brush machine equipped with a brush.

<56> It is possible to form a photosensitive resin layer on the surface of the metal plate, using a photosensitive resin film or one or more selected from liquid-state photosensitive resin composites (Alb). Fig. 4 (Alb) shows a photosensitive resin layer formed by a method (lamination) that presses a photosensitive resin film 20 on the surface of a metal plate, but the present invention is not limited thereto. The photosensitive resin layer may be formed by a method that dries a liquid-state photosensitive resin composite after applying the composite by using coating with a spin coater, spray coating, or deep coating, a method that presses a photosensitive resin film after applying a liquid-state photosensitive resin composite by using coating with a spin coater, spray coating, or deep coating, and then drying the composite, or a method that applies a liquid-state photosensitive resin composite by using coating with a spin coater, spray coating, or deep coating, and then drying the composite, after pressing a photosensitive resin film. The liquid-state photosensitive resin composite may be dried preferably at 5-40^°C for 5~60 minutes after being applied.

<57> In the present invention, the 'Photosensitive resin composite' means a resin composite having photosensitivity, may contain a photoactive compound and, resin or a base material, and may contain a liquid-state solvent. The photosensitive resin may be largely divided into positive photosensitive resin and negative photosensitive resin. For the positive photosensitive resin, an exposed portion is dissolved in a developer, whereas for the negative photosensitive resin, an exposed portion is not dissolved but a non- exposed portion is dissolved. The solvent facilitates applying by maintaining the photoactive compound in a liquid state, the resin or the base material is a macromolecular substance and determines mechanical properties of a film, and the photoactive compound makes a photochemical reaction with light. In the positive photosensitive resin, the photoactive compound functions as a dissolution inhibitor that prevents a macromolecule from being dissolved in a solvent, but the structure is broken and the dissolution inhibition function is not kept when it is exposed to light (for example, ultraviolet rays, near ultraviolet rays, or sunlight), so that the portion irradiated with light is selectively melt. This mechanism is called dissolution inhibition.

<58> For example, there is NQD/Novolak resin as a binary photosensitive composite, and NQD (Naphthoquinonediazide) , which is a photoactive compound (PAC) that is insoluble in an alkali aqueous solution, functions as a dissolution inhibitor, but creates indene ketene when being exposed to ultraviolet rays, and the created indene ketene changes into alkali-soluble 3-indene carbonic acid by reacting with water and functions as a solutizer that is dissolved well in an alkali aqueous solution that is a developer. That is, solubility of the exposed region increases and a positive phase remains by exposing a Novolak resin film contained Naphthoquinonediazide (NQD) of 15~25w%.

<59> The photoactive compound may be an azide compound such as

Naphthoquinonediazide, dichromate such as ammonium dichromate, a diazo compound, an azide compound, silver salt, or iron salt. The resin may be synthetic resin or natural resin, and preferably, may be phenol resin (Nobolak resin), epoxy resin, acrylic resin, methacrylic resin, polyimide, polyurea, polyvinylalcohol , gelatin, and/or glue. The solvent may be ammonia water, methylethyl ketone, and/or alcohol. The alcohol may be methanol or octyl alcohol.

<6o> The liquid-state photosensitive resin composite may be made by, for example, dissolving PVA (poly vinyl alcohol) of 70ml in water and heating it for 20-30 minutes, mixing ammonia water of 2ml with octyl alcohol of 3ml, and then putting ammonium dichromate of 6ml into the mixture and mixing it well with a hera right before applying a liquid photosensitive resin composite. Further, liquid-state photosensitive resin composite may be made by using gelatin. Water of 4000ml is put into refined gelatin of 500ml and heated for five- hours and it is mixed with a composite obtained by putting water of 1000ml into refined glue of 80ml and heating it. Ammonia water of 10ml is added to the mixture, octyl alcohol of 3ml and a formalin solution of 2ml is added and stirred and the mixture is kept warm, and then mixture can be used by combining an appropriate amount of ammonium dichromate, with a ratio of 15ml per photosensitive resin composite of 1000ml. The liquid-state photosensitive composite may be made in person, or products that are on the market (for example, products made by K0L0NG, Inc. (liquid-state etching resist, NR series, Korea) and products made by SHINHWA FC, Inc. (photoresist, Korea) .

<6i> The 'Photosensitive resin film' which is a film containing photosensitive resin, is also called a dry film and may be made in person or products that are on the market may be used. The photosensitive resin film may include a support film and a photosensitive resin composite layer stacked on the support film, and preferably, the support film, the photosensitive resin composite layer, and a protective film may be sequentially stacked. The support film may be made of polyester. The protective film may be made of polyolefin resin and the polyolefin may be preferably polyethylene. The photosensitive resin film may be made, in detail, by coating and drying a liquid-state photosensitive resin composite on a polyester film and covering it with a polyethylene film.

<62> The photosensitive resin film may be products that are on the market

(for example, products made by K0L0NG, Inc. (film photoresist, Korea). <63> A photosensitive resin layer may be formed by pressing a photosensitive film with a roller. The roller may have been heated. It is possible to remove the protective film, with the photosensitive resin composite attached to the support film, when forming the photosensitive resin layer. The protective film may be removed after forming a resin layer and exposing.

<64> In the present invention, the resin in the photosensitive resin composite or the photosensitive resin film includes both positive photosensitive resin and negative photosensitive resin. Fig. 4 which is described below exemplifies a negative photosensitive resin, but positive photosensitive resin is not excluded. The positive photosensitive resin is opposite, in the light shield of a photomask, to the negative photosensitive resin, but can be manufactured by the same method.

<65> It is possible to cure photosensitive resin 25 corresponding to the portions except for the surface to be corroded in the photosensitive resin, without curing photosensitive resin 27 on the surface to be corroded (A2b), by disposing a photomask 30 for forming projections (A2a) and exposing the photomask with light 50, such as ultraviolet rays, after forming a photosensitive resin layer on the surface of a metal plate.

<66> The photomask 30 for forming projections is a mask including a portion that blocks light and a portion that transmits light in exposing and may be made by printing a light shield 37 on a transparent support portion 33, such as a film, with a laser printer or a film maker. The support portion is not limited as long as it can transmit light and a light shield can be formed on the surface thereof, but for example, it may be a polyester film, an 0PP film, or a PET (Polyethylene terephthalate) film. The 0PP film may be a film made by monoaxially or biaxial ly orienting PP (poly propylene). The light shield may be formed by toner powder, which includes black-carbon black and can block light, on a support portion, such as a film, using a laser printer, or may be formed by a film maker (for example, Lux Setter 5600, Fuji Film).

<67> The light that can be used for exposing is ultraviolet ray or sunlight, and may be light emitted from a mercury lamp, and the amount of light may be

2

4-16KW. The amount of exposure may be 10~500mW/cm and the time of exposure may be 1-500 seconds.

<68> It is possible to perform film hardening with a hardener in order to harden the film formed on the metal plate. For processing the hardener, there are a method of hardening a film by putting a hardener onto a sponge or an absorbent cotton in a wet state, uniformly applying the hardener throughout a surface, and removing the hardener with water and drying it after 30 seconds passes and a method of hardening a film by exposing a metal plate, which has been cleaned and dried after being exposed, with the sunlight for 5-10 minutes or by exposing the metal plate with an exposure for 20-30 minutes, instead of the sunlight.

<69> It is possible to remove the photosensitive resin 27 on the surface to be corroded by performing development with a developer after exposing (A3). The developer is an alkali solution, which may be sodium carbonate solution of 3-10 volume% (also called a solution of soda ash). The development may be performed by immersing the exposed metal plate into a developer at 10-40 ^°C or spraying the developer to the exposed metal plate, in which the processing time may be 10-3600 seconds, and preferably, 10-300 seconds.

<70> It is possible to form the top rivets 125 that are the projections on the surface of the metal plate (A4b) by removing the photosensitive resin remaining on the non-corroded surface, after corroding the developed metal plate with an etching solution (A4a) . The etching solution may be selected from etching solutions known in the art, such as ferric chloride (Fe₂Cls).

The temperature of the etching solution is 30~50^°C, where when the temperature is above 50^°C, the etched surface is rough, and when the temperature under 30 °C, the etching time may be long. The process using the etching solution performed with a ferric chloride solution of 20-60 volume% at 30-60 ^°C for 1-120 minutes. The etching should be performed for an appropriate etching time, and since the corrosion function of the etching solution is reduced, it is necessary to frequently check the concentration of the etching solution during etching. The metal surface, except for the portion protected by the photosensitive resin, is corroded by the process using the etching solution, the top rivets 125 that are the projections are formed. The remaining resin is removed by immerging the resin into a sodium hydroxide (NaOH) solution at 20~80^°C, preferably, 3-10 volume% for 10-30 minutes or by spraying the solution to the resin, or by rubbing the remaining resin with a sandpaper or a brush machine equipped with a brush. It is possible to make the metal plate glossy by rubbing it with calcium carbonate after removing the remaining resin and cleaning with water.

<7i> As a result, it is possible to prepare a metal plate with top rivets

125 that are the projections shown in Fig. 4b.

<72> Thereafter, as shown in Fig. 5, it is possible to form a first photosensitive resin layer by spraying the liquid-state photosensitive resin composite 40 onto the surface of the metal plate and then drying it (B), after preparing the metal plate 10 having the shape shown in Fig. 4b.

<73> It is possible to form a second photosensitive resin layer by pressing the photosensitive resin film 20 on the surface of the first photosensitive resin layer, for example, with a roller (C).

<74> As described above, it is possible to form a photosensitive resin layer throughout the surface of the metal plate in a desired thickness by additionally forming the second photosensitive resin layer from a photosensitive resin film, after forming the first photosensitive resin layer from a liquid-state resin composite and filling the surface of the metal plate, preferably even the joint of the projections and the surface with a fluid liquid.

<75> In the present invention, the photosensitive resin composite that can be contained in the photosensitive resin film, which forms the second photosensitive resin layer, may preferably include a photosensitive material, which is the same as the photosensitive resin composite contained in the liquid-state photosensitive resin composite forming the first photosensitive resin layer, and resin or a base material. It is possible to easily form desired projections, when the photosensitive material, and the resin or the base material, which are contained in both layers, are made the same, because it is possible to process them in the same way in the following processes, such as exposing and etching. That is, since the components of the layers are the same, the refractive indexes in exposing are the same, the layers can be processed in the same way, even though they are different layers.

<76> Further, the resin contained in the liquid-state photosensitive resin composite and the photosensitive resin film, preferably the resin contained in the surface of the film are the same, which may be preferably acrylic resin. As the same kind of resin is contained, it is possible to form a uniform photosensitive resin layer due to affinity of the resin. As a uniform photosensitive resin layer is formed, the refractive indexes are the same in the following processes, such as exposing, so that it is possible to achieve an expectable effect.

<77> Thereafter, it is possible to cure photosensitive resin 25 on the non- corroded surface of the photosensitive resin, without curing photosensitive resin 27 on the surface to be corroded (D2), by disposing a photomask 30 for forming projections (Dl) on the second photo sensitive resin layer and exposing the photomask with light 50, for example, ultraviolet rays.

<78> It is possible to remove the photosensitive resin 27 on the surface to be corroded by performing development with a developer after exposing (E).

<79> It is possible to form the top 120 that is the projection on the surface of the metal plate (F2) by removing the photosensitive resin on the non-corroded surface, after corroding the developed metal plate with an etching solution (Fl). It is possible to form the top rivets 125 that are higher projections on the surface of the top 120 in this method.

<80> As a result, it is possible to prepare the metal plate with projections having different heights on the surface in the shape shown in (F2) of Fig. 5.

<8i> If not specifically state, those described in connection with Fig. 4 are applied in the same way to the liquid-state photosensitive resin composite, photosensitive resin film, photomask for forming projections, exposing, developing, etching solution, and corroding that are described in connection with Fig. 5.

<82> Thereafter, as shown in Fig. 6, it is possible to form a first photosensitive resin layer by spraying the liquid-state photosensitive resin composite 40 onto the surface and then drying it (G), after preparing the metal plate 10 having the shape shown in (F2) of Fig. 5 (F).

<83> It is possible to form a second photosensitive resin layer by pressing the photosensitive resin film 20 on the surface of the first photosensitive resin layer, for example, with a roller (H) .

<84> Thereafter, it is possible to cure photosensitive resin 25 on the non- corroded surface of the photosensitive resin, without curing photosensitive resin 27 on the surface to be corroded (12), by disposing a photomask 30 for forming projections (II) on the second photo sensitive resin layer and exposing the photomask with light 50.

<85> It is possible to remove the photosensiti e resin 27 on the surface to be corroded by performing development with a developer after exposing (J). It is possible to form the edge 123, the side rivets 135, and the side- horizontal line 137 that are the projections on the surface of the metal plate (K2) by removing the photosensitive resin on the non-corroded surface, after corroding the developed metal plate with an etching solution (Kl).

<86> . As a result, it is possible to prepare a metal plate with the projections on the surface in the shape shown in K2 of Fig. 6.

<87> If not specifically state, those described in connection with Fig. 5 are applied in the same way to the liquid-state photosensitive resin composite, photosensitive resin film, photomask for forming projections, exposing, developing, etching solution, and corroding that are described in connection with Fig. 6.

<88> Thereafter, as shown in Fig. 7, it is possible to form a first photosensitive resin layer by spraying the liquid-state photosensitive resin composite 40 onto the surface and then drying it (L), after preparing the metal plate 10 having the shape shown in (K2) of Fig. 6 (K2).

<89> Thereafter, it is possible to form a second photosensitive resin layer by pressing the photosensitive resin film 20 on the surface of the first photosensitive resin layer (M).

<90> Thereafter, it is possible to cure photosensitive resin 25 on the non- corroded surface, without curing photosensitive resin 27 on the surface to be corroded (N2), by disposing a photomask 30 for forming projections (Nl) on the second photo sensitive resin layer and exposing the photomask with light 50.

<9i > It is possible to remove the photosensitive resin 27 on the surface to be corroded by performing development with a developer after exposing (0). It is possible to form an entrance 150 that is the opening formed through the metal plate (P2) by removing the photosensitive resin on the non-corroded surface, after corroding the developed metal plate with an etching solution (PI).

<92> As a result, it is possible to prepare a metal plate with the opening formed in the shape shown in P2 of Fig. 7. It is possible to form the projections and the opening with single equipment, using the method described above .

<93> Fig. 7 shows a method of corroding a surface, but the steps L to P2 may be simultaneously applied in the same way to the other surface. It is possible to replace the steps L and M with the same step as Alb of Fig. 4, in the steps L to P2 when applying the steps to the other side. Preferably, it is possible to form a photosensitive resin layer from one or more selected from a photosensitive resin film or a liquid-state photosensitive resin composite, on the other side of the metal plate, and more preferably, it is possible to form a photosensitive resin layer from a photosensitive resin film on the other side of the metal plate.

<94> It is possible to effectively form the opening within a short time, by making it possible to corrode both surfaces of the metal plate.

<95> If not specifically state, those described in connection with Fig. 4 are applied in the same way to the liquid-state photosensitive resin composite, photosensitive resin film, photomask for forming projections, exposing, developing, etching solution, and corroding that are described in connection with Figs. 5, 6, and 7. However, the corroding time when forming the opening is preferably 15-45 minutes and more preferably 30 minutes, and the corroding time when forming the projections is preferably 1~10 minutes and more preferably 2 minutes. It becomes easy to form the opening by making the corroding time longer when forming the opening than when forming the projections.

<96> As a result, it is possible to manufacture the metal plate with the projection shown in Fig. 3. The metal joint 127 of the metal plate shown in Fig. 2 can be simultaneously formed in the same way when forming the sides 130.

<97> As a result, it is possible to machine metal plates for manufacturing the roof and the sides of the scaled model of a freight car which is shown in Fig. 2.

<98> Further, it is possible to respectively form the front 140 and the rear

(having the same shape as the front and not shown in Fig. 1) of a freight car which is shown in Fig. 1, by forming projections, such as the front rivets 145 and the front-horizontal lines 147 and 149 in the same way as the method described in connected with Fig. 4. The metal plate (not shown) for the floor can be prepared in a rectangular shape by cutting a metal plate such that the length is the same as the width of the front 140 of a freight car and the width is the same as the width of the side 130. Further, it is possible to prepare a wheel assembly composed wheels 160 and a shaft 165 connected with each other, and a body fixing member 167, which are manufactured by molding.

<99> It is possible to bend the metal plates for the roof and the sides of a freight car shown in Fig. 2 in the shape shown in Fig. 1, assemble the metal plates to the front, the rear, and the floor plate, using welding, and then fix the wheel assembly and the body fixing member to the floor plate by welding. As a result, it is possible to manufacture a scaled model of a freight car shown in Fig. 1.

<ioo> Hereinafter, machining a metal plate for manufacturing a scaled model of a steam locomotive is described in detail with reference to embodiments and comparative examples.

<ioi> Embodiment 1> Machining of Metal Plate for Manufacturing Scaled Model of Steam Locomotive

<i02> A metal plate for manufacturing a scaled model of the cap roof of a steam locomotive was machined by the following method. The cap roof is a roof of the place for supplying coal in a steam locomotive and a metal plate for manufacturing the cap roof has the shape shown in Fig. 8. The metal plate shown in Fig. 8 is a metal plate 10 having rivets 170, bands 173, and a groove-forming protrusion 175 that are formed on the surface, openings, such as through-grooves 180, through-holes 185, and cutoff portions 190, and connecting portions 195. The cutoff portions 190 and the connecting portion 195 can be separated in use from the metal plate for the convenience of work when manufacturing an actual model. Preferably, it is possible to easily separate individual metal plates for use by cutting the connection portions when forming a plurality of metal plates for manufacturing a scaled model from one metal plate.

<i03> A metal plate made of height or yellow brass A, which is a kind of brass, was prepared, a photosensitive resin film (acrylic resin layer- including film, K0L0N Inc. (Korea), DRY FILM) was pressed by a film-pressing roller (110^°C), and then a film type of photomask for forming projections (rivets) shown in Fig. 9 was disposed on the film. The photomask was printed on a polyester film by a film maker (Lux Setter 5600, Fuji Film, Japan), with a counter-rivet portion 70 transparent and the other potions black. Thereafter, the photomask was exposed by a UV lamp, at the amount of light of

2

80mW/cm , for 20 seconds.

<i04> A sodium carbonate solution (3 volume%) at 25^°C was sprayed to the exposed metal plate for 5 minutes and the photosensitive resin on the surface to be corroded (portions except for the rivet portions) was removed by cleaning the metal plate with water and the drying it.

<i05> Thereafter, a ferric chloride solution (38 volume ) at 50^°C was sprayed for 1.2 minutes and the metal plate was corroded after being cleaned with water. Thereafter, the photosensitive resin remaining on the non-corroded surface (surfaces of the rivets) were removed by processing a sodium hydroxide solution (3 volume%) at 60°C for 20 munutes. As a result, projections (rivets) were formed on the surface of the metal plate.

<i06> A liquid-state photosensitive resin composite (acrylic resin composition, SHINHWA FC, Korea) was applied to the surface of the metal plate with the projections (rivets) and dried at 20"C for 30 minutes, thereby forming a first photosensitive resin layer.

<i07> A second photosensitive resin layer was formed by pressing a photosensitive resin film (acrylic resin-containing film, KS-4840, K0L0N Inc., Korea) on the surface of the dried first photosensitive resin layer with a film press (YH-6300DL, by OTS, Korea), and then a film type of photomask for forming projections (bands and groove-forming protrusions) shown in Fig. 10 was disposed on the film. The photomask was printed on a polyester film by a film maker (Lux Setter 5600, Fuji Film, Japan), with counter-band portions 73 and counter-groove-forming protrusions 75 transparent and the other portions black. Thereafter, the photomask was

2

exposed by a UV lamp, at the amount of light of 80mW/cm , for 20 seconds.

<io8> A sodium carbonate solution (3 volume%) at 25^°C was sprayed to the

2

exposed metal plate for 5 minutes at a pressure of 2kg/cm from a developer and the photosensitive resin on the surface to be corroded (portions except for the portions where the bands and the openings are disposed) was removed by cleaning the metal plate with water and drying it.

<i09> Thereafter, a ferric chloride solution (38 volume ) at 50 ^°C was sprayed

2

for 2 minutes at a pressure of 3kg/cm and the metal plate was corroded after being cleaned with water. And the cleaned plate was dried. Thereafter, the photo sensitive resin remaining on the non-corroded surface (surfaces of the bands and the groove-forming protrusions) was removed by immersing the metal plate in a sodium hydroxide solution (3 volume%) at 60°C for 20 minutes, thereby forming the bands and the groove-forming protrusions on the surface of the metal plate.

<iio> A liquid-state photosensitive resin composite (acrylic resin-containing photoresist, SHINHWA FC, Korea) was applied to the surface of the metal plate with the bands and the groove-forming protrusions and dried at 20^°C for 30 minutes, thereby forming a first photosensitive resin layer.

<in> A second photosensitive resin layer was formed on the surface of the first photosensitive resin layer by pressing a photosensitive resin film (acrylic resin-containing film, dry file resist, KOLON Inc.) on the surface of the dried first photosensitive resin layer and the other side of the metal plate where a resin layer was not formed, using a film press (YH-6300DL, by OTS, Korea), thereby forming a photosensitive resin layer with a film pressed on the metal plate. Thereafter, a photomask for forming an opening shown in Fig. 11 is disposed on the second photosensitive resin layer and the same photomask was aligned on the photosensitive resin layer on the other side of the metal plate to form a desired opening. Thereafter, both sides were

2

exposed by a UV lamp, at the amount of light of 80mW/cm , for 20 seconds.

<π2> The photosensiti e resin remaining on the surface of the object to be corroded (through-groove, through-hole, and cutoff portion) was removed by spraying a sodium hydroxide solution (3 volume%) at 25^°C with a pressure of

2

2kg/cm for 5 minutes.

<ii3> Thereafter, a ferric chloride solution (38 volume%) at 50 ^°C was sprayed

2

to both sides for 30 minutes at a pressure of 3kg/cm and the metal plate was corroded after being cleaned with water. And the cleaned plate was dried. Thereafter, the photosensitive resin remaining on the non-corroded surface (surfaces of the portions where the bands and the openings are formed) by being immerged in a sodium hydroxide solution (3 volume%) at 60^°C for 20minutes, thereby forming openings (through-groove, through-hole, and cutoff portion) through the metal plate. The result is shown in Fig. 12.

<ii4> As shown in Fig. 12, the metal plate shown in Fig. 8 was machined, in which it can be seen that rivets (diameter of 0.7mm), bands (width of 1.3mm), and grooves (width of 0.1mm) were clearly formed.

<Π5> Comparative Example 1> Machining of Metal Plate for Manufacturing

Scaled Model of Cap Roof of Steam Locomotive, Using Liquid-State Photosensitive Resin Composite

<ii6> The machining was performed in the same way as Embodiment 1, except for omitting the process of forming the second photosensitive resin layer by pressing a photosensitive resin film (acrylic resin-containing film, dry file resist, KOLON Inc.) on the surface of a photosensitive resin layer dried when forming projections (bands and groove-forming protrusions) and openings.

The result is shown in Figs. 13 and 14. Fig. 13 is a picture of a portion of a machined metal plate and Fig. 14 is a view showing the BB' cross-section indicated by an ellipse in Fig. 13. As shown in Figs. 13 and 14, it can be seen that the rivet that is the highest projection was removed and a recessed groove 177 was formed.

<U8> In the method of using a liquid-state photosensitive resin for etching, it is not easy to form the highest projection when forming projections of which the difference in height is 2 or more. It is difficult to form projections with various heights because the highest projection on the surface of the metal plate is frequently removed in repeated etching.

<ii9> Comparative Example 2> Machining of Metal Plate for Manufacturing

Scaled Model of Cap Roof of Steam Locomotive, Using Photosensitive Resin Film

<i20> The machining was performed in the same way as Embodiment 1, except for forming a photosensitive resin layer by directly pressing a photosensitive resin film on the surface of the metal plate with a film press, instead of forming a second photosensitive resin layer by pressing a photosensitive resin film on the surface of a dried photosensitive resin layer, after forming a first photosensitive resin layer by drying after applying a liquid- state photosensitive resin composite on the surface of the metal plate when forming projections (bands and groove-forming protrusions) and openings.

<i2i> The result is shown in Fig. 15. Fig. 15 is a picture of a portion of a machined metal plate and Fig. 16 is a view showing the CC cross-section indicated by an ellipse in Fig. 15. As shown in Figs. 15 and 16, it can be seen that it is difficult to implement a band in a desired shape, because the sides of the band portion that is lower in the projections are dug deep and grooves 197 are formed.

;i22> In the method of using a photosensitive resin film for etching, it is not easy to form the lowest projection when forming projections of which the difference in height is 2 or more.

:i23> It can be . seen from the results that it is possible to implement projections with various heights on the surface of a metal plate by using the machining method of the present invention.

<i24> While the present invention has been described with respect to the specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims. [Industrial Applicability!

< i25> The present invention has an industrial applicability because it provides a method of machining a metal plate for manufacturing a scaled model that allows projections with various heights to be formed on the surface of the metal plate, a scaled model including a metal plate manufactured by the method, a manufacturing method of a scaled model, and a scaled model manufactured by the manufacturing method.

Claims

[CLAIMS]

[Claim 1]

<i27> A method of machining a metal plate for manufacturing a scaled model, comprising:

<i28> a step (A) of preparing a metal plate;

<i29> a step (B) of forming a first photosensitive resin layer on the surface of the metal plate prepared in the step (A), by using a liquid-state photosensitive resin composite;

<i30> a step (C) of forming a second photosensitive resin layer on the

surface of the first photosensitive resin layer formed in the step (B), by using a photosensitive resin film;

<i3i> a step (D) of disposing and exposing a photomask for forming a

projection, on the second photosensitive resin layer;

<i32> a step (E) of removing the photosensitive resin on the surface to be corroded, by developing the metal plate exposed in the step (D); and <i33> a step (F) of forming a projection on the surface of the metal plate by removing the photosensitive resin on a non-corroded surface after corroding the metal plate developed in the step (E) with an etching solution.

[Claim 2]

<i34> The method according to claim 1, wherein the metal plate is made of one selected from iron, copper, brass, phosphor bronze, cupronickel, beryllium copper, stainless steel, or nickel, or a an alloy of two or more of the elements.

[Claim 3]

<i35> The method according to claim 1, wherein the projection has a surface width of 0.1~5mm.

[Claim 4]

<i36> The method according to claim 1, wherein the liquid-state photosensitive resin composite of the step (B) is a liquid-state composite containing a photoactive compound and resin or a base material.

[Claim 5]

:i37> The method according to claim 4, wherein the photoactive compound is one or more selected from silver salt, dichromate, a diazo compound, an azide compound, or iron salt.

[Claim 6]

<138> The method according to claim 4, wherein the resin or the base material is one or more selected from phenol resin (Nobolak resin), epoxy resin, acrylic resin, methacrylic resin, polyimide, polyurea, polyvinylalcohol , gelatin, or glue.

[Claim 7]

<i39> The method according to claim 4, wherein the composite includes, as a solvent, one or more selected from ammonia water, methylethyl ketone, or alcohol .

[Claim 8]

<i40> The method according to claim 1, wherein the photosensitive resin film of the step (C) includes a support film and a photosensitive resin composite layer stacked on the support film.

[Claim 9]

<i4i> The method according to claim 8, wherein the resin composite of the photosensitive resin composite layer is the same as the resin composite in the liquid-state photosensitive resin composite.

[Claim 10]

<i42> The method according to claim 1, wherein the exposing in the step (D)

2

is performed with the amount of exposure of 10~500mW/cm for 1-500 seconds, by using one or more selected from ultraviolet rays or sunlight.

[Claim 11]

<i43> The method according to claim 1, wherein the developing in the step (E) is performed with an alkali solution.

[Claim 12]

<i44> The method according to claim 1, wherein the etching solution in the step (F) is a ferric chloride solution.

[Claim 13]

<i45> The method according to claim 1, wherein the metal plate of the step

(A) includes the projection formed on the surface.

[Claim 14]

<i46> The method according to claim 13, wherein the projection formed on the surface of the metal plate of the step (A) is higher than the projection formed in the step (F).

[Claim 15]

<i47> The method according to claim 14, wherein the projection formed in the step (F) is formed by the projection formed on the surface of the metal plate in step (A), thereon.

[Claim 16]

<i48> The method according to claim 13, wherein the projection has a surface width of 0.1~5mm.

[Claim 17]

<i49> The method according to claim 13, wherein the projection formed on the surface of the metal plate in the step (A) is formed by a method of forming a projection including:

<i50> a step (Al) of forming a photosensitive resin layer on the surface of a metal plate, by using one or more selected from a photosensitive resin film or a liquid-state photosensitive resin composite;

<i5i> a step (A2) of disposing and exposing a photomask for forming a projection on the photosensiti e resin layer of the step (Al);

<i52> a step (A3) of removing the photosensitive resin on the surface to be corroded, by developing the metal plate exposed in the step (A2); and <i53> a step (A4) of forming a projection on the surface of the metal plate by removing the photosensitive resin on a non-corroded surface after corroding the metal plate developed in the step (A3) with an etching solution.

[Claim 18]

<i54> The method according to claim 1, further comprising:

<i55> a step (G) of forming a first photosensitive resin layer on the surface of the metal plate with the projection formed in the step (F), by using a liquid-state photosensitive resin composite;

<i56> a step (H) of forming a second photosensitive resin layer on the surface of the photosensitive resin layer formed in the step (G), by using a photosensitive resin film;

<i57> a step (I) of disposing and exposing a photomask for forming a projection lower than the projection formed in the step (F) , on the second photosensitive resin layer of the step (H);

<i58> a step (J) of removing the photosensitive resin on a surface to be corroded by developing the metal plate exposed in the step (I); and

<i59> a step (K) of further forming a projection lower than the projection formed in the step (F), on the surface of the metal plate, by removing the photosensitive resin on a non-corroded surface after corroding the developed metal plate with an etching solution.

[Claim 19]

<i60> The method according to claim 18, further comprising a step of forming an opening through the metal plate after forming the last projection.

[Claim 20]

<i6i> The method according to claim 19, in order to form the opening, the method further comprising:

<i62> a step (L) of forming a first photosensitive resin layer on the surface of the metal plate that has undergone the last step, by using a liquid-state photosensitive resin composite;

<i63> a step (M) of forming a second photosensitive resin layer on the surface of the first photosensitive resin layer formed in the step (L), by using a photosensitive resin film;

<i64> a step (N) of disposing and exposing a photomask for forming an opening, on the second photosensitive resin layer;

<i65> a step (0) of removing the photosensitive resin on the surface to be corroded, by developing the metal plate exposed in the step (N); and <i66> a step (P) of forming an opening through the metal plate by removing the photosensitive resin on a non-corroded surface after corroding the metal plate developed in the step (0) with an etching solution.

[Claim 21]

<i67> A scaled model comprising a metal plate machined by the method according to any one of claims 1 to 20.

[Claim 22]

A method of manufacturing a scaled model comprising-^'

, a step of bending a metal plate machined by the method according to any one of claims 1 to 20; and

<i70> a step of assembling the bent metal plate.

[Claim 23]

<i7i> A scaled model manufactured by the method according to claim 22.