JP2699189B2 - Method of reproducing or adding contrast of squeezed pattern - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for reproducing or giving a contrast of a drawn pattern in a drawn (grain) forming means, and more particularly, to
In the drawing forming means such as an electroforming mold or a drawing roll for forming a resin skin material having a drawn pattern suitably used for interior materials such as automobiles, exterior materials of home appliances, and other interior materials for building materials, the drawing method is used. The surface roughness of the ridges and valleys of the squeezed pattern is made uniform as the blast removal of burnt debris and leaching substances adhered to the molding surface of the molding means. And a method of post-applying the contrast when the surface roughness of the peaks and valleys of the drawn pattern transferred to the drawing forming means is substantially uniform and the contrast of the real tone cannot be obtained. Things.

2. Description of the Related Art There is an increasing tendency to use a synthetic resin skin material with a squeezed pattern of a real skin tone as an interior surface material such as a pad or a door trim in an instrument panel of a passenger car or the like. This squeezed pattern is a surface pattern in which wrinkle-like undulations are irregularly continuous, and as described later, by making the surface roughness of the crests and valleys significantly different, a remarkable contrast is obtained. It comes closer to the feel of real leather. The following method is generally used as a means for applying such a drawn pattern to the surface of the synthetic resin skin material.

A calendering method, in which a sheet is rolled by passing a synthetic resin such as PVC (polyvinyl chloride) or ABS (acrylonitrile butadiene styrene) through a rolling mill having a large number of heating rolls, a T-die or a coat hanger A method of extruding a sheet having a required thickness from a die and forming the sheet by pressing an squeezing roll on which the squeezed pattern is transfer-molded to the sheet by using an extrusion molding method.

Using a mold having a cavity of a required shape and a drawing pattern transferred to the molding surface, performing known slush molding or injection molding with this mold, at the same time as molding a skin material having a required shape, A method of transferring a drawn pattern to the surface of the skin material.

However, in order to use this as various interior materials such as automobiles, the sheet of PVC or the like to which the squeezed pattern is transferred by the above method is further subjected to processing such as vacuum forming to form a desired three-dimensional shape. There is a need. However, when these processes are performed as a post-process, a large stretching force in various directions is applied to the sheet at that time, so that the initial drawn pattern suitably applied at the time of forming the sheet collapses, In many cases, the height difference between the mountain and the valley is lost. Therefore, in recent years, in order to obtain a skin material for an interior of a vehicle or the like, a method of simultaneously providing a desired shape and a drawn pattern by the above-described slash molding or the like has been preferred.

Regardless of which of the above methods and methods is adopted, a squeezing roll or a mold in which a squeezed pattern is preliminarily transferred to a molding surface is used in order to apply a squeezed pattern with a real tone to a sheet or a skin material for an interior material. Is done. In order to transfer the squeezed pattern to these squeezing rolls or dies, a genuine leather having a predetermined squeezed pattern or a skin material to which a squeezed pattern is artificially attached is pasted on a wooden mold or the like, and the squeezed roll or metal mold is used. A method in which the drawing pattern is applied to the forming surface of a drawing roll or a mold by inversion at the time of forming the mold is preferably used frequently. As a means for inverting the squeezed pattern in the real skin material or the artificial skin material when a squeezed roll or a mold is prepared, a method of transferring the squeezed pattern using a silicone resin or the like (Japanese Patent Laid-Open No.
-29529) and a method of transferring by electroforming (Japanese Patent Laid-Open No.
No. 01910, JP-A-62-292409) are generally known. In this specification, a mold or a squeezing roll on which a squeezed pattern is transferred to a molding surface will be generically referred to as "squeezing means".

Of the above-mentioned squeezed patterns, those exhibiting the appearance, luster, and feel of this leather tone are particularly suitable for use as interior materials for passenger cars, as they can give a luxurious impression as well as a three-dimensional feel. . The feature of the squeezed pattern exhibiting the real skin tone is that the peaks in the squeezing are glossy and the valleys are matted. That is, when the drawing pattern is observed in an enlarged manner, as shown in FIG.
12 is composed of irregularly continuous undulations, and the height difference d
Is usually about 150 to 250 μm. When the roughness of the peak 10 is small (glossy state) and the roughness of the valley 12 is relatively large (matte state), the contrast between the two is conspicuous. Appearance, gloss, and feel.

For example, an electroforming mold is used for slush molding, and by relatively changing the surface roughness (gloss) of the peaks and valleys of the drawn pattern on the molding surface of the electroforming mold,
The drawn pattern transferred to the molded product also has a glossy contrast, and a three-dimensional feeling and feel of the real skin can be obtained. In order to obtain such a squeezed pattern of the real skin on the molding surface of the electroforming mold, in the electroforming process of the mold, paste a material having a high gloss contrast such as the real leather on the surface of the model, This is reproduced by faithfully transferring it to an electroforming mold. Note that this is equally applicable to the case where a squeezed pattern is transferred to the forming surface of a squeezing roll used for calendering.
It is necessary to paste a material having a drawn pattern with a large gloss contrast on the surface of the model.

PROBLEM TO BE SOLVED BY THE INVENTION As described above, draw forming means such as an electroforming mold and a draw roll,
When a squeezed pattern exhibiting the contrast of the real skin tone is transferred, if the squeezed pattern is frequently transferred to the sheet by the squeezing means, the burning surface of the PVC resin or the like is formed on the molding surface of the squeezing means. Debris and elutes accumulate over time, producing so-called mold stains. In such a case, in order to remove these burning debris and leachables from the forming surface of the squeezing means, a grit sprayed with coarse particles (grit) of metal, vegetable non-fibrous material, other minerals, etc. together with high-pressure air. Blast is commonly used. However, due to the polishing effect associated with the grit sweeping, the peaks and valleys of the drawn pattern transferred to the drawing means are adjusted to have a uniform surface roughness, and the original skin tone obtained at an early stage is obtained. Contrast has the serious disadvantage that it is subsequently lost.

Also, in order to transfer the squeezed pattern of the real skin to the squeezing means,
As described above, in the process of manufacturing the drawing forming means such as the electroforming mold, the leather is stuck on the surface of the model, and this is faithfully reproduced. However, the leather is generally expensive and cannot be used if the gloss contrast of the leather material is uneven. Also, there is a drawback in that the squeezing means having a large molding surface on which the squeezed pattern is to be transferred cannot easily obtain such wide genuine leather. Therefore, in such a case, in order to reduce the cost and obtain a drawn pattern of an arbitrary size, generally available artificial leather is used. However, a striking pattern transferred to the stretching means by artificial leather does not have a remarkable gloss contrast as seen in the real leather material, and is monotonous and poor in three-dimensional appearance. Therefore, even if a sheet or an interior material is formed using this drawing method, the obtained drawn pattern is monotonous and lacks a three-dimensional effect without contrast, and is far from the luxurious feeling of the real skin tone. There are disadvantages that can be significant.

SUMMARY OF THE INVENTION In view of the above-mentioned problems, the present invention has been proposed to solve the problem suitably, and it has been proposed that a resin sheet having a squeezed pattern or a squeezing roll such as a mold or a squeezing roll be used to form a skin material. In the forming means, when blast removal of burnt debris and leached matter adhered to the squeezing means, it is possible to satisfactorily reproduce the contrast of the real tone which is lost by this, and transfer the squeezed pattern to the squeezing means. It is an object of the present invention to provide a method for providing the contrast after the fact that the contrast of the real tone cannot be obtained due to artificial leather or the like.

Means for Solving the Problems In order to overcome the problems and appropriately achieve the intended purpose, the method for reproducing the contrast of the drawn pattern according to the present invention has a drawn pattern on a molding surface such as an electroformed mold or a drawn roll. In the squeezing means, which is transferred and burned or eluted material of the molding material adheres to the molding surface with use and the molding accuracy of the squeezed pattern is reduced, by applying grit blast to the entire squeezed pattern, After removing burning debris and leachables of the molding material and adjusting the whole drawn pattern to a certain surface roughness, applying a curable and solvent-soluble sol to the drawn pattern, then curing the sol and drawing the sol. A hard coating is applied to the entire pattern, and the coating on the crests in the drawn pattern is removed with a solvent, thereby exposing the crests, which is larger than the grit used for the previously applied grit blast. The roughness of the exposed ridges on the surface is reduced by blasting a grit of fineness or small particle size over the entire striated pattern so that the coating applied to the valleys is not removed. By removing or improving the coating applied to the valleys with a solvent, the surface roughness of the ridges and the valleys in the squeezed pattern is made different from each other. Characterized by reproducing a high contrast.

Also, a method for imparting contrast of a drawn pattern according to another invention of the present application is that in a drawn forming means such as an electroforming die or a drawn roll in which the drawn pattern is transferred to a molding surface, grit blast is applied to the entire drawn pattern. After adjusting the whole drawn pattern to a certain surface roughness by applying a curable and solvent-soluble sol to the drawn pattern, hardening the sol to apply a hard coating to the whole drawn pattern, By removing the coating on the crests of the pattern with a solvent, the crests are exposed, and grit of a larger or smaller size than the grit used in the previously applied grit blast is applied to the valleys. By blasting the entire squeezed pattern to the extent that the remaining coating is not removed, the roughness of the exposed ridges of the surface is improved relative to the roughness of the valleys. By raising or lowering, and then removing the coating applied to the valley portion with a solvent, the surface roughness of the ridge portion and the valley portion in the drawn pattern is made different to give a remarkable contrast. It is characterized by the following.

EXAMPLES Next, a method for reproducing or providing a contrast of a drawn pattern in the drawing means according to the present invention will be described with reference to preferred examples.

(1) A method of reproducing the contrast of the drawn pattern in the drawing means.

In the draw forming means according to the present embodiment, it is assumed that a draw pattern of a real skin tone having a large gloss contrast is previously transferred to a forming surface thereof. In such a draw forming means, by using the means in the above-described calendering or slash forming, the drawn pattern of the skin tone is transferred to the surface of the sheet or the skin material to be formed. is there. However, if the squeezing means is used frequently, burning scraps and elutions such as PVC resin and ABS resin adhere to the molding surface and the transfer accuracy of the squeezed pattern is reduced.

Therefore, first, as shown in FIG.
Grit blasting is applied to the entire squeezed pattern (including the peaks 10 and the valleys 12) in 14 to remove the burnt debris and the leached matter 16 such as the PVC resin. For this grit blast, for example, as grit, glass beads having a particle size of 100 to 1000 mesh and ceramic beads having a particle size of 100 to 600 mesh were mixed and used at an arbitrary ratio. The air pressure is
It was used to adjust the range of ^{0.5kg / cm 2 ~5kg / cm 2} . By this grit blast, the burning debris and the eluate 16 such as the PVC resin are completely removed from the drawing means 14, and the surface roughness of the crests 10 and the valleys 12 of the drawn pattern is made uniform and the whole And becomes uniform. In other words, a large gloss contrast was initially obtained in the drawn pattern transferred to the drawing means 14, but the gloss contrast was lost by this grit blast. Therefore, even if a sheet or a skin material is formed by using the drawing forming means 14 thereafter, the three-dimensional feeling and touch of the real skin cannot be obtained from the drawn pattern transferred to the molded product.

Next, for example, a brush containing a PVC sol which can be cured by heat and is soluble in a solvent is contained in the brush, and the entire brush pattern (the peaks 10 and the valleys) is drawn by the drawing means 14 as shown in FIG. 2 (b). On 12), apply so that the thickness becomes about 50-200μ. Then, by baking and drying the film at 100 to 200 ° C., a hard film coating 18 is formed on the entire drawn pattern. At this time, the ridges 10 and valleys 12
As described above, since the height difference is 150 to 250 μ as described above, the sol to be applied is applied so as to substantially fill the valley 12 of the drawn pattern. Then, by dry baking, the valley
The sol in 12 undergoes volume shrinkage, forming a coating 18 with its surface slightly dented. In this application, it is, of course, preferable that the thickness of the coating 18 applied on the crests 10 be substantially uniform. The PVC sol has a composition of a PVC resin (21%), a plasticizer such as DOP (dioctyl phthalate), DBP (dibutyl phthalate) and a stabilizer (7%), and a solvent (72%) such as a thinner. A peelable enamel paint diluted about 1.5 to 3 times with a solvent such as ethyl acetate is preferably used.

Next, an aliphatic solvent such as ethyl acetate or acetone, or an aromatic solvent is contained in a sweeper such as a brush or a cloth, and the coating 18 that masks the peak 10 is swept with the sweeper. As shown in FIG. 2 (c), the coating 18 is eluted and removed to expose only the crest portion 10 of the drawn pattern. The portion of the valley portion 12 of the drawn pattern is still masked by the coating 18.

Then, as shown in FIG. 2 (d), if the second grit blast is applied to the drawn pattern of the drawn forming means 14, the grit that has been sprayed will have the coating 16 removed and the drawn gutter will be exposed. It collides with the peak portion 10 of the pattern, and the surface roughness at this portion is adjusted. Therefore, by making the grit used in the second grit blast different from the grit used in the first grit blast, the surface roughness (gloss) of the peaks 10 and the valleys 12 can be reduced. With a difference, it is possible to provide different gloss contrasts.

Here, ceramic beads with a particle size slightly larger than the grit used for the first grit blast (particle size 10
(0-600 mesh) was used for the grit, and the air pressure at the time of the blast was adjusted to such an extent that the coating 18 masking the valley 12 was not removed or removed. As a result, the surface roughness of the exposed peak portion 10 becomes larger than the surface roughness of the valley portion 12 (where the coating 18 is applied), and a so-called matte state is obtained.

Finally, as shown in FIG. 2 (e), the coating 18 masking the valleys 12 is completely removed by sweeping with the above-mentioned solvent, so that the peaks in the drawing pattern of the drawing forming means 14 are removed. A state where the surface roughness of the portion 10 is larger than the surface roughness of the valley 12 is obtained. That is, the peaks 10 in the drawn pattern of the drawing means 14 are in a matte state and the valleys 12 are in a glossy state, so that a remarkable contrast is obtained.
Therefore, if slash molding is performed using a drawing means after this processing, for example, an electroforming mold, the surface roughness (gloss) in the drawing pattern is directly transferred to the surface of the formed skin material. The Rukoto. In other words, the squeezed pattern reverse-transferred to the surface of a sheet or an interior skin material has a valley portion in a matte state and a ridge portion in a glossy state, and a gloss contrast and feel very similar to the real skin can be obtained.

In connection with FIG. 2 (d), the particle size of the grit used in the second grit blasting is changed to the first one, contrary to the above.
If a grit having a smaller particle size than the grit used for the grit blasting is used, the surface roughness of the exposed peak portion 10 becomes smaller than the surface roughness of the valley portion 12, so that a so-called glossy state is obtained. Accordingly, it is possible to easily obtain a remarkable contrast in a state opposite to that of the embodiment, if necessary.

(2) Concerning a method of providing a contrast of a drawn pattern in a drawing method.

In the draw forming means according to the present embodiment, although the drawn pattern is transferred to the forming surface, as described above, for example, since artificial leather is used for the transfer, the outstanding gloss contrast as seen in the real leather material is not obtained. It is assumed that it is not obtained and is monotonous and poor in three-dimensional appearance. In such a draw forming means, even when used in the above-described calendering or slush molding of the means, the surface of a sheet or a skin material that can be formed,
The leather pattern is not reproduced.

Therefore, in the section of the contrast reproducing method, the same process as that described with reference to FIGS. 2A to 2E is performed. That is, the entire drawn pattern is adjusted to a constant surface roughness by applying grit blast to the whole drawn pattern in the drawing means.

After applying a sol that is curable and soluble in a solvent to the drawn pattern, the sol is cured to apply a hard coating to the entire drawn pattern.

By removing the coating on the ridge portion of the drawn pattern with a solvent, the ridge portion is exposed.

Grit of a larger or smaller size than the grit used in the previously applied grit blast is blasted over the entire squeezing pattern such that the coating applied to the valleys is not removed. Thereby, the roughness of the exposed peak portion of the surface is improved or reduced as compared with the roughness of the valley portion.

Next, the coating applied to the valleys is removed with a solvent.

By performing such a process, even in the case of the drawing pattern of the drawing forming means having no contrast at first, the surface roughness of the crest portion and the valley portion in the drawing pattern is made different from each other, so that it is outstanding. High contrast can be provided.

In addition, in any of the above-described methods of reproducing or giving contrast, the “curable and solvent-soluble sol” applied to the drawn pattern in the drawing means.
As the above, in addition to the above-mentioned PVC sol, the following can be suitably used.

(1) Rubber latex.

This is obtained by diluting various rubbers with a rubber volatile (a mixed organic solvent such as gasoline), and a rubber film is formed by volatilizing and baking the organic solvent.

(2) Styrene-based resins such as ABS resin and impact-resistant styrene resin (a rubber component such as butadiene mixed or graft-polymerized with styrene resin).

It can be dissolved in thinner, methyl ethyl ketone, acetone, toluene, ethyl acetate and the like.

(3) In addition, any plastic that can be used with an organic solvent can be used.

Effect of the Invention As described above, according to the method of the present invention, the surface roughness (gloss) of the peaks and the valleys in the drawing pattern of the drawing forming means can be easily made different from each other. The surface roughness of the ridges and valleys of the squeezed pattern is made uniform as the blast removal of burnt debris and leaching substances adhered to the molding surface of the molding means. Or when the surface roughness of the peaks and valleys of the drawn pattern transferred to the drawing forming means is substantially uniform and the contrast of the real skin tone cannot be obtained, the contrast can be added afterwards. it can. Therefore, it is possible to reuse expensive drawing means, and it is not necessary to use expensive and dimensionally limited leather as a means for transferring the drawing pattern to the forming surface of the drawing means. It works.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view in which a drawn pattern in a drawing means is observed in an enlarged manner, and FIGS. 2 (a) to 2 (e) show a method of reproducing or applying a drawn pattern contrast according to the present invention. FIG. 4 is an explanatory view schematically showing the procedure of FIG. 10 ... peaks, 12 ... valleys 14 ... drawing forming means, 16 ... burnt debris, leachables 18 ... coating

Claims (2)

(57) [Claims] An squeezed pattern is transferred to a molding surface such as an electroforming mold or a squeezing roll, and as a result of the use, burning debris or leaching of the molding material adheres to the molding surface, and the squeezed pattern molding accuracy is reduced. In the drawing forming means, by applying grit blasting to the entire drawing pattern, the burning pattern and the leached material of the molding material are removed, and the whole drawing pattern is adjusted to a constant surface roughness. And after applying a sol that is soluble in a solvent, the sol is cured and a hard coating is applied to the entire drawn pattern, and the coating of the crest portion in the drawn pattern is removed with a solvent, thereby removing the crest portion. Exposing and applying grit of a larger or smaller size than the grit used for the previously applied grit blast over the entire squeezed pattern so that the coating applied to the valleys is not removed By blasting, the roughness of the exposed peak portion of the surface is improved or reduced compared to the roughness of the valley portion, and then the coating applied to the valley portion is removed with a solvent. A method of reproducing the contrast of the drawn pattern in the drawing forming means, wherein the surface roughness of the crest portion and the valley portion in the drawn pattern are made different to reproduce a distinctive contrast. 2. A draw forming means such as an electroforming die or a draw roll having a drawn pattern transferred onto a forming surface, wherein the whole drawn pattern is adjusted to a constant surface roughness by applying grit blast to the whole drawn pattern. After applying a curable and solvent-soluble sol to the drawn pattern, the sol is cured to apply a hard coating to the entire drawn pattern, and the coating of the crests in the drawn pattern is removed with a solvent. By exposing the crest portion, the grit having a larger or smaller particle size than the grit used in the grit blast applied earlier is applied to the entire squeezed pattern so that the coating applied to the valley portion is not removed. Blasting the surface to increase or decrease the roughness of the exposed crests as compared to the roughness of the valleys, and then apply to the valleys By applying a solvent to remove the coating that has been applied, thereby making the surface roughness of the ridges and valleys of the squeezed pattern different to provide outstanding contrast. Method.