JP4425388B2 - Decorative member and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a decorative member for forming a colored pattern on a base material made of an inorganic material, such as a metal decorative panel used for an elevator landing door, a car door, a car room wall, and the like, and a method for manufacturing the decorative member. is there.
[0002]
[Prior art]
Conventionally, for example, when manufacturing metal decorative panels such as elevator landing doors, car doors, and car room walls, a pattern sheet is pasted with an adhesive on a metal substrate with a base coating on the surface. There is a way. The pattern sheet used in this method is manufactured by forming an ink receiving layer on a transparent polyester film and printing a colored pattern with pigment ink on the ink receiving layer.
[0003]
[Problems to be solved by the invention]
In the conventional method for manufacturing a metal decorative panel as described above, the pattern sheet and the base coating layer are bonded with an adhesive, but sufficient adhesion cannot be obtained simply by bonding, and a large area is also required. It is difficult to evenly bond the pattern sheet to the whole, and it is necessary to bond the pattern sheet and the base coating layer more firmly and evenly. Further, simply pasting a thin pattern sheet does not give depth to the colored pattern, and the texture is limited.
[0004]
The present invention has been made to solve the above-described problems, and allows the pattern sheet to be firmly and evenly bonded onto the base material, and also has a change in texture, resulting in a deeper depth. It aims at obtaining the decoration member which can express a certain coloring pattern, and its manufacturing method.
[0005]
[Means for Solving the Problems]
According to a first aspect of the present invention, there is provided a method for manufacturing a decorative member, comprising: forming a diffusely reflecting layer on a thermoplastic resin sheet to diffusely reflect light; adhering an ink receiving layer to the diffusely reflecting layer via an adhesive layer; A process of manufacturing a pattern sheet by printing a colored pattern on the receiving layer, a process of forming a coating layer with a resin coating on a substrate made of an inorganic material, a process of roughening the surface of the coating layer, a thermoplastic resin The method includes a step of stacking the pattern sheet on the substrate so that the sheet is bonded to the coating layer, and a step of welding the thermoplastic resin sheet to the coating layer by heating the pattern sheet.
[0006]
According to a second aspect of the present invention, there is provided a method for producing a decorative member, comprising: forming a diffusely reflecting layer on a thermoplastic resin sheet to diffusely reflect light; adhering an ink receiving layer to the diffusely reflecting layer via an adhesive layer; A process for producing a pattern sheet by printing a colored pattern on the receiving layer, a process for roughening the surface of a substrate made of an inorganic material, a process for forming a coating layer containing organosilane on the substrate, thermoplasticity The method includes a step of stacking the pattern sheet on the base material so that the resin sheet is bonded to the coating layer, and a step of welding the thermoplastic resin sheet to the coating layer by heating the pattern sheet.
[0007]
The method for producing a decorative member according to the invention of claim 3 includes a step of applying an ink receiving layer on the surface of a separator having a large number of minute irregularities, a step of forming an irregular reflection layer for irregularly reflecting light on a thermoplastic resin sheet, The process of adhering the ink receiving layer on the irregular reflection layer via an adhesive, peeling the separator to form a large number of minute irregularities on the surface of the ink receiving layer, and coloring patterns on the exposed surface of the ink receiving layer Printing a pattern sheet, forming a coating layer with a resin paint on a base material made of inorganic material, stacking the pattern sheet on the base material so that the thermoplastic resin sheet is bonded to the coating layer, And a step of welding the thermoplastic resin sheet to the coating layer by heating the pattern sheet.
[0008]
According to a fourth aspect of the present invention, there is provided a decorative member manufacturing method using a diffusely reflecting layer having a transparent resin and a plurality of reflecting pieces mixed in the transparent resin and irregularly reflecting light.
[0009]
In the method for manufacturing a decorative member according to the fifth aspect of the present invention, the irregular reflection layer is formed by vapor-depositing a metal on the thermoplastic resin sheet.
[0010]
According to a sixth aspect of the present invention, there is provided a method for manufacturing a decorative member, comprising: placing a base material on which a pattern sheet is stacked on a vacuum exhaust stand having an exhaust passage, and a sheet-like elastic body having air permeability. A process of covering the pattern sheet with a sheet-like cover, and exhausting the space between the vacuum evacuation table and the cover via the exhaust passage, thereby pressing the pattern sheet against the substrate via the elastic body and the cover, and the thermoplastic resin The step of bringing the sheet into close contact with the substrate side is included before the step of heating the pattern sheet.
[0011]
The manufacturing method of the decorative member according to the invention of claim 7 is a step of covering the pattern sheet with a cover, and interposing a long fiber sheet composed of long fibers and having air permeability between the pattern sheet and the cover. is there.
[0012]
The method for manufacturing a decorative member according to the invention of claim 8 uses an elastic body composed of long fibers.
[0013]
A decorative member according to the invention of claim 9 is a substrate made of an inorganic material, a coating layer formed on the substrate and having a roughened surface, and a thermoplastic resin layer welded on the coating layer. An ink receptive layer formed on the thermoplastic resin layer to diffusely reflect light, an ink receptive layer formed on the diffusely reflective layer through an adhesive layer to form a colored pattern, and the ink receptive layer. A transparent protective film layer formed on the layer is provided.
[0014]
A decorative member according to a tenth aspect of the present invention is a base material made of an inorganic material and having a roughened surface, a coating layer formed on the surface of the base material and containing organosilane, and welded onto the coating layer Formed on the thermoplastic resin layer, an irregular reflection layer that irregularly reflects light, and an ink that is adhered on the irregular reflection layer via an adhesive layer to form a colored pattern by a coloring material A receiving layer and a transparent protective film layer formed on the ink receiving layer are provided.
[0015]
The decorative member according to an eleventh aspect of the invention uses a diffuse reflection layer having a transparent resin and a large number of reflection pieces mixed in the transparent resin and irregularly reflecting light.
[0016]
The decorative member according to the invention of claim 12 uses a reflective piece in which a small piece of resin is coated with a metal.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
Embodiment 1 FIG.
FIG. 1 is a sectional view of a decorative member manufactured by the manufacturing method according to Embodiment 1 of the present invention. Here, an example of a decorative panel for an elevator is shown. In the figure, a coating layer 12 is formed on the surface of a substrate 11 bent into a panel shape. The base material 11 consists of metals, such as a steel plate or an aluminum alloy, for example. The coating layer 12 is made of, for example, melamine, acrylic, urethane, or epoxy resin paint. Further, the surface of the coating layer 12 is roughened by forming a large number of minute irregularities.
[0018]
An opaque thermoplastic resin layer 13 is formed on the coating layer 12. On the thermoplastic resin layer 13, an irregular reflection layer 51 is formed. The irregular reflection layer 51 is configured by mixing a large number of reflecting pieces that irregularly reflect light with a transparent resin. As the transparent resin, for example, a paint or resin such as polyurethane resin, acrylic resin, styrene resin, ABS resin, AS resin, epoxy resin, polyester resin, or polyethylene resin is used.
[0019]
Further, as the reflecting piece, a metal such as aluminum or stainless steel, or a pearl mica piece is used. Further, as the pearl mica pieces, mica, scale pieces, or a resin or glass piece having a metal film deposited thereon are used. For example, a pearl mica piece can be obtained by vapor-depositing a metal such as nickel, titanium oxide, or indium tin oxide on a small piece of resin or glass.
[0020]
On the irregular reflection layer 51, a transparent ink receiving layer 15 is bonded via an adhesive layer. The ink receiving layer 15 is formed with a colored pattern 16 of pigment ink as a coloring material. A transparent protective film layer 17 is formed on the ink receiving layer 15.
[0021]
The protective film layer 17 is made of paint or resin such as polyurethane resin, acrylic resin, styrene resin, ABS resin, AS resin, epoxy resin, polyester resin, or polyethylene resin.
[0022]
Next, FIG. 2 is a cross-sectional view of an essential part of the pattern sheet 18 used for manufacturing the decorative member of FIG. In the figure, an irregular reflection layer 51 is formed on the thermoplastic resin sheet 13A. On the irregular reflection layer 51, the ink receiving layer 15 is bonded via the adhesive layer 14. A colored pattern 16 is printed on the ink receiving layer 15.
[0023]
Next, the manufacturing method of the pattern sheet 18 of FIG. 2 will be described. First, as shown in FIG. 3, a resin as a material for the ink receiving layer 15 is applied to the surface of the polyester film 19 as a separator. By drying the resin, the ink receiving layer 15 is formed. Moreover, as shown in FIG. 4, the surface of the polyester film 19 used here is in a state where minute irregularities are formed on one surface, that is, a so-called mat state.
[0024]
On the other hand, the irregular reflection layer 51 is formed on one surface of the thermoplastic resin sheet 13A by a technique such as printing, spraying, roll coating, or blade coating. In the case of forming the irregular reflection layer 51, it is possible to apply a mixture of a transparent resin and a reflection piece in advance, or to coat the reflection piece from above after coating the transparent resin.
[0025]
Thereafter, as shown in FIG. 5, an adhesive layer 14 is applied on the ink receiving layer 15, and further, a thermoplastic resin sheet 13A is bonded thereon as shown in FIG. That is, the irregular reflection layer 51 formed on the thermoplastic resin sheet 13 </ b> A is bonded to the ink receiving layer 15 through the adhesive layer 14. After this adhesion, the sheet laminate 20 is wound up through a drying process.
[0026]
Thereafter, as shown in FIG. 7, the polyester film 19 is peeled off from the wound sheet laminate 20, and the colored pattern 16 is printed on the exposed ink receiving layer 15 before curing. The illustrated pattern sheet 18 is manufactured. At this time, the colored pattern 16 is printed by the inkjet printer 22 connected to the computer 21. Further, the matte surface state of the polyester film 19 is copied on the surface of the ink receiving layer 15 exposed by the peeling of the polyester film 19, as shown in FIG.
[0027]
Next, a method for manufacturing a decorative member using the pattern sheet 18 will be described. First, the coating layer 12 is formed on the substrate 11. Next, the surface of the coating layer 12 is roughened. This roughening step is performed by a method of spraying a large number of glass beads (not shown) onto the coating layer 12 from a shot blast nozzle (not shown), that is, shot blasting.
[0028]
Further, the roughening step of the coating layer 12 may be performed by a knurling process in which a knurl (not shown) having minute irregularities formed on the outer peripheral surface is rolled against the coating layer 12 while rolling. Furthermore, the roughening step of the coating layer 12 may be performed by hairline processing, non-directional sanding processing, vertical and horizontal sanding processing, or processing combining these.
[0029]
After the surface of the coating layer 12 is roughened to a predetermined surface roughness, the pattern sheet 18 is overlaid at a predetermined position on the coating layer 12. At this time, the thermoplastic resin sheet 13 </ b> A of the pattern sheet 18 is bonded to the coating layer 12. And between the thermoplastic resin sheet 13A and the coating layer 12 is vacuum-pressurized, and further the thermoplastic resin sheet 13A is heated and melted.
[0030]
The molten thermoplastic resin sheet 13 </ b> A is cured again by being returned to room temperature, and becomes a thermoplastic resin layer 13, and is welded to the coating layer 12 by an anchor effect. As a result, the ink receiving layer 15 on which the colored pattern 16 is formed is also firmly fixed to the surface of the coating layer 12 through the adhesive layer 14, the irregular reflection layer 51, and the thermoplastic resin layer 13. Further, the ink receiving layer 15 is cured by heating, whereby the colored pattern is fixed.
[0031]
Next, a protective film layer 17 is formed by applying a thermosetting clear coating onto the ink receiving layer 15 and curing by heating. The clear coating material of the protective film layer 17 is selected so that the heat curing temperature is lower than the melting temperature of the thermoplastic resin layer 13. Finally, the surface of the protective film layer 17 is polished to increase the flatness, and the decorative member having the cross section shown in FIG. 1 is completed.
[0032]
Next, the process of vacuum-bonding the pattern sheet 18 to the substrate 11 will be specifically described. First, FIG. 9 is a perspective view showing an evacuation table used for manufacturing the decorative member of FIG. In the figure, a flat vacuum evacuation table 31 includes a planar portion 31a on which the substrate 11 is placed, a plurality of concave portions 31b provided in the planar portion 31a, and a plurality of portions for exhausting the concave portions 31b. And an exhaust passage 31c. A packing 32 for keeping the air tightness of the flat surface portion 31a is continuously provided on the peripheral edge portion of the flat surface portion 31a over the entire circumference.
[0033]
FIG. 10 is an exploded perspective view showing a main part of a decorative member manufacturing apparatus having the vacuum exhaust table 31 of FIG. 9, that is, a vacuum pressure bonding apparatus. A plurality of exhaust pipes 33 for connecting the exhaust passage 31 c to an exhaust pump (not shown) are connected to the side surface portion of the vacuum exhaust stand 31. On the flat surface portion 31a, a panel body 34 in which the pattern sheet 18 is superimposed on the base material 11 is placed. In this panel body 34, the thermoplastic resin sheet 13A of the pattern sheet 18 is joined to the coating layer 12 roughened to a predetermined surface roughness.
[0034]
The panel body 34 is covered with a sheet-like elastic body 35 having air permeability. Examples of the material of the elastic body 35 include silicon rubber sponge, Teflon sponge, polyamide sponge, silicon fiber sheet, Teflon fiber sheet, polyamide fiber sheet, glass fiber sheet, glass fiber cotton, stainless steel wool, titanium wool, or aluminum wool. For example, a resin, glass, metal or the like having heat resistance and flexibility is used.
[0035]
On the elastic body 35, a sheet-like cover 36 that covers the packing 32 over the entire circumference and keeps airtight between the flat surface portion 31 a is covered. As the cover 36, for example, a rubber sheet, a polyethylene sheet, or a silicon sheet is used. The peripheral edge of the cover 36 is sandwiched between the pressing frame 37 and the packing 32. As the material of the presser frame 37, a material having sufficient rigidity and heat resistance such as metal, FRP, polyamide resin, or cement is used.
[0036]
FIG. 11 is a perspective view showing an assembled state of the vacuum pressure bonding apparatus of FIG. A plurality of pressers 38 for pressing the presser frame 37 against the packing 32 are mounted on the side of the assembly of the vacuum exhaust table 31 and the presser frame 37. Each presser bar 38 is provided with a pressure adjusting mechanism 39 such as a spring.
[0037]
For example, as shown in FIG. 12, one side of the pressing frame 37 and one side of the vacuum evacuation table 31 may be connected by a hinge mechanism, and the positioning of the pressing frame 37 with respect to the vacuum evacuation table 31 is facilitated, and workability is improved. Will improve. Further, the holding frame 37 and the vacuum evacuation table 31 may be connected by a pantograph mechanism (not shown) or the like.
[0038]
Next, FIG. 13 is a cross-sectional view showing an assembled state of the vacuum pressure bonding apparatus of FIG. 10, and evacuation has not yet started in this state. From this state, the exhaust pump is driven to evacuate the recess 31b through the exhaust passage 31c. Thereby, the air between the cover 36 and the vacuum evacuation table 31 is discharged, and as shown in FIG. 14, the cover 36 is pressed against the panel body 34 at atmospheric pressure, and the elastic body 35 is compressed. Further, the pattern sheet 18 and the coating layer 12 are also deaerated, and the adhesion is improved.
[0039]
Thereafter, the vacuum pressure bonding apparatus is placed in a drying furnace (not shown) while being evacuated, and the panel body 34 is heated together with the vacuum pressure bonding apparatus. By such heating, the flexibility of the cover 36 is increased, and the cover 36 is pressed against the panel body 34 at atmospheric pressure to a finer portion. Thereby, the pattern sheet 18 is pressed against the surface of the base material 11 through the elastic body 35 with an equal pressure. Therefore, the pattern sheet 18 is pressure-bonded onto the substrate 11 with sufficient and uniform strength.
[0040]
According to such a method for manufacturing a decorative member, the surface of the coating layer 12 is roughened before the pattern sheet 18 is joined to the coating layer 12, and therefore, the thermoplastic resin layer 13 of the coating layer 12. As a result, the pattern sheet 18 can be firmly bonded to the substrate. Furthermore, it can be easily applied not only to a plane but also to a quadric surface and a three-dimensional shape.
[0041]
Further, since the panel body 34 is placed on the vacuum evacuation table 31, and the cover 36 is covered with the elastic body 35 and the cover 36, the inside of the cover 36 is evacuated. Crimping can be performed, and workability and quality can be improved.
[0042]
In addition, although the irregular reflection layer 51 is provided on the base of the ink receiving layer 15, the reflection pieces included in the irregular reflection layer 51 diffusely reflect incident light rays according to the size and surface state thereof, and thus the thin pattern sheet 18. Despite the use of, the appearance is deep.
[0043]
Furthermore, the texture can be changed by selecting the size, surface state, density, etc. of the reflecting piece. Furthermore, when a reflecting piece in which a metal is deposited on a resin piece is used, the degree of irregular reflection can be easily adjusted. Further, it is possible to partially change the density in one panel or to draw a pattern by distributing reflectors.
[0044]
In Embodiment 1, since the surface of the ink receiving layer 15 located on the surface of the pattern sheet 18 is in a matte state, the friction coefficient is high, and the side slip of the elastic body 35 and the cover 36 is prevented. The applied pressure is transmitted well to the pattern sheet 18, and the pattern sheet 18 can be evenly pressed against the substrate 11 by suppressing the elongation of the pattern sheet 18 and the generation of wrinkles.
[0045]
Further, since the surface of the ink receiving layer 15 is matted, the surface area of the ink receiving layer 15 is increased, and a solvent such as moisture excluding coloring components such as pigments is absorbed, dispersed and dried several times faster than before. The As a result, the recording density can be increased, and a beautiful image with a fineness and sharpness can be provided.
[0046]
Furthermore, since the matte surface state of the polyester film 19 is copied to the ink receiving layer 15, it is easy to make the surface of the ink receiving layer 15 matte.
[0047]
Embodiment 2. FIG.
Next, FIG. 15 is a sectional view showing a method for manufacturing a decorative member according to Embodiment 2 of the present invention. In this example, when the pattern sheet 18 is vacuum-bonded onto the base material 11, a breathable long fiber sheet 41 is interposed between the elastic body 35 and the ink receiving layer 15 of the pattern sheet 18. The long fiber sheet 41 is a sheet composed of long fibers. Other manufacturing methods are the same as those in the first embodiment.
[0048]
By interposing such a long fiber sheet 41, it is possible to prevent the elastic body 35 from adhering to the ink receiving layer 15 during vacuum pressure bonding. In order to prevent such adhesion, a method of applying a chemical having a peeling effect on the ink receiving layer 15 is generally used. However, a protective film layer 17 is formed on the ink receiving layer 15 in a later step. Since it is applied, the method of applying a drug having a peeling effect adversely affects the adhesion of the protective film layer 17. On the other hand, according to the method using the long fiber sheet 41, there is no influence on the adhesion of the protective film layer 17.
[0049]
Although the long fiber sheet 41 is provided separately from the elastic body 35 in the second embodiment, the elastic body 35 may be formed of long fibers. Alternatively, a sheet in which the long fiber sheet 41 is bonded and integrated on one surface of the elastic body 35 may be used.
[0050]
Embodiment 3 FIG.
FIG. 16 is a cross-sectional view of a decorative member according to Embodiment 3 of the present invention. Here, an example of a decorative panel for an elevator is shown. In the figure, a transparent coating layer 42 containing organosilane is formed on the surface of the substrate 11 bent into a panel shape. The base material 11 consists of metals, such as stainless steel or an aluminum alloy, for example.
[0051]
Moreover, the surface of the base material 11 is roughened by forming a lot of minute irregularities. Furthermore, the film thickness of the coating layer 42 is sufficiently thin with respect to the irregularities on the surface of the substrate 11.
[0052]
Examples of the organosilane used as the material of the coating layer 42 include vinyltrimethoxysilane, vinyltriethoxysilane, vinyltris (βmethoxyethoxy) silane, β- (3,4 epoxycyclohexyl) ethyltrimethoxysilane, and γ-glycidoxy. Propyltrimethoxysilane, γ-glycidoxypropylmethyldiethoxysilane, γ-glycidoxypropyltriethoxysilane, γ-glycidoxypropylmethyldimethoxysilane, γ-methacryloxypropyltrimethoxysilane, γ-methacryloxypropyl Triethoxysilane, γ-methacryloxypropylmethyldiethoxysilane, N-β (aminoethyl) γ-aminopropylmethyldiethoxysilane, N-β (aminoethyl) γ-aminopropyltriethoxysilane, N-β (A Minoethyl) γ-aminopropyltrimethoxysilane, γ-aminopropyltrimethoxysilane, γ-aminopropyltriethoxysilane, γ-mercaptopropyltrimethoxysilane, or the like is used.
[0053]
An opaque thermoplastic resin layer 13 is formed on the coating layer 42. Other configurations are the same as those in the first embodiment. Therefore, between the thermoplastic resin layer 13 and the adhesive layer 14, an irregular reflection layer 51 is formed in which a large number of reflection pieces that irregularly reflect light are mixed with a transparent resin.
[0054]
Next, a method for manufacturing a decorative member according to Embodiment 3 will be described. First, the surface of the base material 11 is roughened by, for example, sand shot processing, hairline processing, non-directional sanding processing, vertical and horizontal sanding processing, or a combination thereof.
[0055]
Thereafter, the base material 11 is degreased by being immersed for about several minutes to several tens of minutes in a liquid such as acetone, a surfactant, or alcohol which is set to a temperature from room temperature to about the boiling point and placed in a liquid tank. Subsequently, the substrate 11 is washed with tap water at about room temperature using a method such as spraying or dipping, and further washed with pure water in the same manner, and dried for several minutes to several tens of minutes.
[0056]
Next, the coating layer 42 is formed on the substrate 11. Specifically, an organosilane solution in which organosilane is diluted to about 1 to 10% with a low boiling point solvent such as alcohol or ether is used. That is, the organosilane solution is sprayed on the surface of the substrate 11 by spraying, or the substrate 11 is immersed in the organosilane solution, and after any of the operations, the temperature is 50 to 100 ° C. in a drying chamber. Dry from minutes to several tens of minutes. As a result, the organosilane reacts with the substrate 11 and the coating layer 42 is bonded to the substrate 11.
[0057]
After the coating layer 42 is formed, the pattern sheet 18 similar to that of the first embodiment is overlaid at a predetermined position on the coating layer 42. At this time, the thermoplastic resin sheet 13 </ b> A of the pattern sheet 18 is bonded to the coating layer 42. And between the thermoplastic resin sheet 13A and the coating layer 42 is vacuum-compressed, and further, the thermoplastic resin sheet 13A is heated and melted. The method of vacuum pressure bonding is the same as in Embodiment 1 or 2.
[0058]
The melted thermoplastic resin sheet 13 </ b> A is returned to room temperature and cured, whereby the thermoplastic resin layer 13 is formed. This thermoplastic resin layer 13 is welded to the coating layer 42 by an anchor effect. As a result, the ink receiving layer 15 on which the colored pattern 16 is formed is also bonded onto the substrate 11 via the adhesive layer 14, the irregular reflection layer 51, and the thermoplastic resin layer 13. Further, the ink receiving layer 15 is cured by heating, whereby the colored pattern is fixed.
[0059]
Next, a protective film layer 17 is formed by applying a thermosetting clear coating onto the ink receiving layer 15 and curing by heating. The clear coating material of the protective film layer 17 is selected so that the heat curing temperature is lower than the melting temperature of the thermoplastic resin layer 13. Finally, the surface of the protective film layer 17 is polished to increase the flatness, and the decorative member having the cross section shown in FIG. 16 is completed.
[0060]
Here, FIG. 17 is an explanatory diagram for explaining the action of the organosilane contained in the coating layer 42 of FIG. Organosilane has a structure having an inorganic silyl group and an organic functional group. The organic functional group is, for example, an amino group, an epoxy group, a methacryloxy group, or a vinyl group.
[0061]
When a steel plate is used as the substrate 11, for example, the molecular arrangement on the substrate 11 side is such that Fe and O are alternately arranged (iron oxide) and hydroxyl groups are bonded to the surface. Furthermore, for example, a carboxyl group or an ester carbonyl group exists on the end surface on the thermoplastic resin layer 13 side.
[0062]
18 is an explanatory view showing a state in which the base material 11, the coating layer 42, and the thermoplastic resin layer 13 of FIG. 17 are combined. The organic functional group of the organosilane reacts with a carboxyl group or an ester carbonyl group of the thermoplastic resin layer 13 to discharge alcohol or water to form a chemical bond, for example, to form an amide. The inorganic silyl group reacts with a hydroxyl group on the surface of the substrate 11 to discharge alcohol and form a chemical bond, for example, in the form of oxygen sharing.
[0063]
By these chemical bonds, the organic thermoplastic resin layer 13 is firmly bonded to the inorganic base material 11 via the coating layer 42. In addition, unlike a general adhesive or a coating film, organosilane works effectively to the extent that a monomolecular layer covers the surface of the substrate 11, so that the physical shape of the surface of the substrate 11 is substantially reduced. It is hard to influence.
[0064]
However, for example, organosilane having chlorine, such as vinyltrichlorosilane, is preferably not used depending on the type of the substrate 11 because hydrochloric acid is discharged instead of alcohol during the reaction.
[0065]
In such a method for producing a decorative member, since the coating layer 42 containing organosilane is used, the pattern sheet 18 can be firmly and evenly bonded onto the inorganic base material 11. Moreover, since the surface of the base material 11 was roughened, the surface area of the base material 11 can be enlarged and the pattern sheet 18 can be combined more firmly.
[0066]
In addition, although the irregular reflection layer 51 is provided on the base of the ink receiving layer 15, the reflection pieces included in the irregular reflection layer 51 diffusely reflect incident light rays according to the size and surface state thereof, and thus the thin pattern sheet 18. Despite the use of, the appearance is deep.
[0067]
Furthermore, the texture can be changed by selecting the size, surface state, density, etc. of the reflecting piece. Furthermore, when a reflecting piece in which a metal is deposited on a resin piece is used, the degree of irregular reflection can be easily adjusted. Further, it is possible to partially change the density in one panel or to draw a pattern by distributing reflectors.
[0068]
In the method of manufacturing the decorative member according to the third embodiment, when the pattern sheet 18 is vacuum-bonded onto the base material 11, the elastic body 35 and the ink receiving layer 15 of the pattern sheet 18 are formed as in the second embodiment. Between them, a long fiber sheet 41 having air permeability may be interposed. Further, the elastic body 35 may be composed of long fibers, or a sheet in which the long fiber sheet 41 is joined and integrated on one surface of the elastic body 35 may be used.
[0069]
Moreover, although the panel-shaped decoration member was shown in Embodiment 1-3, the shape of a decoration member is not limited to this.
Furthermore, the material of the base material may be another metal such as copper or titanium, or an inorganic material other than a metal such as glass.
[0070]
In the first to third embodiments, the irregular reflection layer 51 in which the reflective piece is mixed with the transparent resin is shown. However, a metal such as nickel, titanium oxide, or indium tin oxide is directly deposited on the surface of the thermoplastic resin sheet 13A. Thus, it is possible to form a diffuse reflection layer.
[0071]
【The invention's effect】
As described above, in the method for manufacturing a decorative member according to the first aspect of the present invention, since the surface of the coating layer is roughened, the adhesion of the coating layer to the thermoplastic resin sheet is improved, and thus the pattern is formed. The sheet can be firmly bonded to the substrate. Furthermore, since the irregular reflection layer is provided on the base of the ink receiving layer, the texture can be changed and a deep colored pattern can be expressed.
[0072]
In the method for producing a decorative member according to the second aspect of the present invention, the pattern sheet is bonded onto the base material made of an inorganic material through the coating layer containing organosilane. Can be combined evenly. Moreover, since the surface of the base material is roughened, the surface area of the base material can be increased to bond the pattern sheet more firmly. Furthermore, since the irregular reflection layer is provided on the base of the ink receiving layer, the texture can be changed and a deep colored pattern can be expressed.
[0073]
According to a third aspect of the present invention, there is provided a method for producing a decorative member, wherein an ink receiving layer is applied to the surface of the separator, and then the separator is peeled to form a large number of minute irregularities on the surface of the ink receiving layer. Therefore, it is easy to form minute irregularities on the surface of the ink receiving layer. Furthermore, since the irregular reflection layer is provided on the base of the ink receiving layer, the texture can be changed and a deep colored pattern can be expressed.
[0074]
In the method for manufacturing a decorative member according to the fourth aspect of the invention, since the irregular reflection layer in which the reflective piece is mixed with the transparent resin is used, the texture is easily changed by selecting the size, surface state, density, etc. of the reflective piece. be able to.
[0075]
Since the irregular reflection layer is formed by vapor-depositing a metal on the thermoplastic resin sheet, the decorative member manufacturing method of the invention of claim 5 easily changes the texture by changing the vapor deposition material and vapor deposition conditions. Can be made.
[0076]
According to a sixth aspect of the present invention, there is provided a decorative member manufacturing method comprising: placing a base material on which a pattern sheet is stacked on a vacuum evacuation table having an exhaust passage; and providing a pattern via a sheet-like elastic body having air permeability. Since a sheet-like cover is put on the sheet and then the space between the vacuum evacuation table and the cover is exhausted through the exhaust passage, the pattern sheet can be firmly and evenly bonded to the base material and welded. Workability and quality can be improved.
[0077]
In the method of manufacturing the decorative member according to the seventh aspect of the invention, in the step of covering the pattern sheet with the cover, a long fiber sheet made of long fibers and having air permeability is interposed between the pattern sheet and the cover. Therefore, the elastic body is prevented from adhering to the ink receiving layer at the time of vacuum pressure bonding.
[0078]
In the method for manufacturing a decorative member according to the eighth aspect of the invention, since the elastic body is made of long fibers, the elastic body is prevented from adhering to the ink receiving layer during vacuum pressure bonding.
[0079]
In the decorative member of the invention of claim 9, since the surface of the coating layer is roughened, the adhesion of the coating layer to the thermoplastic resin sheet is improved, thereby firmly bonding the pattern sheet to the substrate. be able to. Furthermore, since the irregular reflection layer is provided on the base of the ink receiving layer, the texture can be changed and a deep colored pattern can be expressed.
[0080]
In the decorative member of the invention of claim 10, the pattern sheet is bonded to the base material made of an inorganic material through the coating layer containing organosilane, so that the pattern sheet is firmly and evenly bonded to the base material. Can be made. Moreover, since the surface of the base material is roughened, the surface area of the base material can be increased to bond the pattern sheet more firmly. Furthermore, since the irregular reflection layer is provided on the base of the ink receiving layer, the texture can be changed and a deep colored pattern can be expressed.
[0081]
Since the decorative member of the invention of claim 11 uses a diffuse reflection layer in which a reflective piece is mixed with a transparent resin, the texture can be easily changed by selecting the size, surface state, density, etc. of the reflective piece. .
[0082]
The decorative member according to the twelfth aspect of the present invention uses a reflecting piece obtained by vapor-depositing a metal on a small piece of resin, so that the degree of irregular reflection can be easily adjusted.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a decorative member manufactured by a manufacturing method according to Embodiment 1 of the present invention.
2 is a cross-sectional view of an essential part of a pattern sheet used for manufacturing the decorative member of FIG. 1;
3 is a perspective view showing a state in the middle of manufacturing the pattern sheet of FIG. 2. FIG.
4 is a cross-sectional view of the polyester film and ink receiving layer of FIG. 3;
5 is a perspective view showing a step of applying an adhesive layer on the ink receiving layer of FIG. 3. FIG.
6 is a perspective view showing a process of bonding a thermoplastic resin sheet on the adhesive layer of FIG. 5. FIG.
7 is a perspective view showing a step of printing a colored pattern on the ink receiving layer after the step of FIG. 6. FIG.
8 is an enlarged cross-sectional view showing a state where a polyester film is peeled from the sheet laminate of FIG.
FIG. 9 is a perspective view showing an evacuation table used for manufacturing the decorative member of FIG. 1;
10 is an exploded perspective view showing a main part of a vacuum pressure bonding apparatus having the vacuum evacuation table of FIG. 9;
11 is a perspective view showing an assembled state of the vacuum pressure bonding apparatus of FIG.
12 is a perspective view showing another example of the assembled state of the vacuum pressure bonding apparatus of FIG.
13 is a cross-sectional view showing an assembled state of the vacuum pressure bonding apparatus of FIG.
14 is a cross-sectional view showing a state where the vacuum pressure bonding apparatus of FIG. 13 is evacuated. FIG.
FIG. 15 is a sectional view showing a method for manufacturing a decorative member according to Embodiment 2 of the present invention.
FIG. 16 is a cross-sectional view of a decorative member according to Embodiment 3 of the present invention.
FIG. 17 is an explanatory diagram for explaining the action of organosilane contained in the coating layer of FIG. 16;
18 is an explanatory view showing a state where the base material, the coating layer, and the thermoplastic resin layer in FIG. 17 are bonded together.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 11 Base material, 12 Coating layer, 13 Thermoplastic resin layer, 13A Thermoplastic resin sheet, 14 Adhesive layer, 15 Ink receiving layer, 16 Colored pattern, 18 Pattern sheet, 19 Polyester film (separator), 42 Coating layer, 51 Diffuse reflection layer.

Claims (12)

Forming an irregular reflection layer for irregularly reflecting light on a thermoplastic resin sheet;
A step of producing a pattern sheet by adhering an ink receiving layer on the irregular reflection layer via an adhesive layer and printing a colored pattern on the ink receiving layer;
Forming a paint layer with a resin paint on a substrate made of an inorganic material;
A step of roughening the surface of the coating layer,
Including a step of superimposing the pattern sheet on the substrate so that the thermoplastic resin sheet is bonded to the coating layer, and a step of welding the thermoplastic resin sheet to the coating layer by heating the pattern sheet. The manufacturing method of the decorative member characterized by the above-mentioned. Forming an irregular reflection layer for irregularly reflecting light on a thermoplastic resin sheet;
A step of producing a pattern sheet by adhering an ink receiving layer on the irregular reflection layer via an adhesive layer and printing a colored pattern on the ink receiving layer;
A step of roughening the surface of a substrate made of an inorganic material;
Forming a coating layer containing organosilane on the substrate;
A step of superimposing the pattern sheet on the substrate so that the thermoplastic resin sheet is bonded to the coating layer, and a step of welding the thermoplastic resin sheet to the coating layer by heating the pattern sheet. The manufacturing method of the decorative member characterized by the above-mentioned. Applying an ink receiving layer to the surface of a separator having a large number of minute irregularities;
Forming an irregular reflection layer for irregularly reflecting light on a thermoplastic resin sheet;
Adhering the ink receiving layer to the irregular reflection layer via an adhesive;
Forming a large number of minute irregularities on the surface of the ink receiving layer by peeling the separator, and printing a colored pattern on the exposed surface of the ink receiving layer to form a pattern sheet;
Forming a paint layer with a resin paint on a substrate made of an inorganic material;
Including a step of superimposing the pattern sheet on the substrate so that the thermoplastic resin sheet is bonded to the coating layer, and a step of welding the thermoplastic resin sheet to the coating layer by heating the pattern sheet. The manufacturing method of the decorative member characterized by the above-mentioned. 4. The decorative member according to claim 1, wherein the irregular reflection layer includes a transparent resin and a plurality of reflection pieces mixed in the transparent resin and irregularly reflecting light. Production method. The method for producing a decorative member according to any one of claims 1 to 3, wherein the irregular reflection layer is formed by depositing a metal on a thermoplastic resin sheet. Placing the base material on which the pattern sheets are stacked on a vacuum evacuation table having an exhaust passage, and covering the pattern sheet with the sheet-like cover through a sheet-like elastic body having air permeability; and The pattern sheet is pressed against the base material through the elastic body and the cover by exhausting between the vacuum exhaust stand and the cover through the exhaust passage, and the thermoplastic resin sheet is attached to the base material. The process of adhering to the side,
The method for producing a decorative member according to any one of claims 1 to 5, further comprising a step of heating the pattern sheet. 7. The decorative member manufacturing method according to claim 6, wherein in the step of covering the pattern sheet with a cover, a long fiber sheet composed of long fibers and having air permeability is interposed between the pattern sheet and the cover. Method. The method for manufacturing a decorative member according to claim 6, wherein the elastic body is composed of long fibers. A substrate made of an inorganic material,
A coating layer formed on this substrate and having a roughened surface,
A thermoplastic resin layer welded onto this paint layer,
An irregular reflection layer formed on this thermoplastic resin layer and irregularly reflecting light,
It is provided with an ink receiving layer that is bonded to the irregular reflection layer via an adhesive layer and has a colored pattern formed by a coloring material, and a transparent protective film layer formed on the ink receiving layer. A decorative member. A base material made of an inorganic material and having a roughened surface,
A coating layer formed on the surface of the substrate and containing an organosilane;
A thermoplastic resin layer deposited on the coating layer;
An irregular reflection layer formed on this thermoplastic resin layer and irregularly reflecting light,
It is provided with an ink receiving layer that is bonded to the irregular reflection layer via an adhesive layer and has a colored pattern formed by a coloring material, and a transparent protective film layer formed on the ink receiving layer. A decorative member. The decorative member according to claim 9 or 10, wherein the irregular reflection layer includes a transparent resin and a plurality of reflection pieces mixed in the transparent resin and irregularly reflecting light. The decorative member according to claim 11, wherein the reflecting piece is formed by coating a small piece of resin with metal.

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