JP6476149B2 - Manufacturing method of cover material with embossed pattern - Google Patents

Description

The present invention relates to the production how the upholstery embossed pattern is formed on the surface. The cover material is used, for example, for a cover such as a pencil case, a notebook, a small box that houses a clock or a ring.

  Regarding the outer covering material of the present invention, the present applicant has previously proposed the method for forming a surface of a thermoplastic resin sheet of Patent Document 1. There, a material sheet is heated and pressed against a pressing mold in which a dent pattern is formed to form a cover material having an embossed pattern. The material sheet is made of artificial leather made by impregnating polyurethane resin (thermoplastic resin) into a nonwoven fabric made of ultra-fine fibers, for example. Is transcribed. The stamping die is composed of, for example, an elastic layer formed of a porous polyester resin and a woven fabric fixed to the stamping surface. An embossed pattern of an arbitrary shape is formed on the stamping surface by a laser process. Or as a dent.

Japanese Patent No. 5462401 (paragraph 0040, FIG. 1)

  According to the method for forming a cover material of Patent Document 1, a convex embossed pattern can be clearly formed on the surface of a material sheet. In addition, since the stamping die can be easily formed by applying laser processing to the mold material, it is suitable for a large variety of small-quantity production, and various types of surface materials having an embossed pattern can be manufactured at low cost. However, since the base material layer of the pressing mold is formed of a porous polyester resin that can be elastically deformed, the dent pattern may be distorted when the material sheet is pressed against the pressing mold. For this reason, the embossed pattern that can be shaped on the cover material is limited to simple patterns such as geometric patterns and heart marks, and it has been difficult to form complex embossed patterns.

An object of the present invention, the embossed pattern with high definition and shall rich impression on appearance interest, can exhibit a higher degree of design effect is to provide a manufacturing how the upholstery which has an embossed pattern .

  The manufacturing method of the facing material provided with the embossed pattern M according to the present invention pressurizes the material sheet 1 while heating it to the forming die 2 provided with the forming concave portion 4 so that the material sheet 1 has a protruding shape on the shaping surface. Form an embossed pattern. In the mold 2 for forming the embossed pattern, the mold material 3 is subjected to laser processing based on the engraving data obtained by adjusting the original image 5 into the computer to form a molding recess 4 corresponding to the original image 5. It is. When manufacturing the outer packaging material, the mold 2 and the preparation step of placing the material sheet 1 formed of a thermoplastic resin on the fixed electrode table 11 and placing the heated movable electrode table 12 on the material sheet 1 The facing material is formed including a pressing step of pressing the material sheet 1 against the mold 2 while pressing and supplying a high-frequency current between the fixed electrode table 11 and the movable electrode table 12. In the pressing step, the sheet surface of the material sheet 1 that is not directly opposed to the molding recess 4 is compressed to the maximum depth dimension D or more of the molding recess 4, and the material sheet 1 is brought into close contact with the inner surface of the molding recess 4. A protruding embossed pattern M is exposed on the sheet 1.

  In the pressurizing step, the heated movable electrode table 12 is pressed against the material sheet 1 and primary pressure is applied to the mold 2 while pressing the material sheet 1 while supplying a high-frequency current between the fixed electrode table 11 and the movable electrode table 12. And a secondary pressurizing step of pressurizing the heated movable electrode table 12 in a state where the supply of the high-frequency current to both the electrode tables 11 and 12 is stopped.

  The engraving data is adjusted in four or more stages according to the density difference of the gradation processed image. The molding recessed part 4 is formed in a multistage shape with four or more kinds of concave surfaces 7 having different depths.

  The mold material 3 is formed of either one of a phenol resin or a methacryl resin.

  In the method for manufacturing a facing material according to the present invention, an embossed pattern is formed on the sheet surface of the material sheet 1 by using the molding die 2 having a high-definition molding recess 4 corresponding to the original image 5. Further, in the pressurizing step, the sheet surface of the material sheet 1 that does not face the molding recess 4 is compressed to the maximum depth D or more of the molding recess 4 so that the material sheet 1 is in close contact with the inner surface of the molding recess 4. The protruding embossed pattern M is exposed on the material sheet 1. Therefore, according to the manufacturing method of the facing material of the present invention, the embossed pattern is made high-definition and the appearance impression is richer than the conventional facing material. In addition, since the sheet surface of the material sheet 1 is compressed to be equal to or larger than the maximum depth dimension D of the molding recess 4 and the material sheet 1 is brought into close contact with the inner surface of the molding recess 4, the original image is formed on the protruding surface of the embossed pattern M. A corresponding three-dimensional pattern can be formed, and as a whole, a cover material that can exhibit a higher degree of design effect can be manufactured.

  The embossed pattern M is formed on the sheet surface of the material sheet 1 by sequentially performing the primary pressing process and the secondary pressing process. In the primary pressurizing step, the material sheet 1 is heated from the inside by the heat of the heater 14 while being heated from the inside by the high frequency induction heating action, so that the material sheet 1 is quickly brought to the molding temperature. By heating, the projecting embossed pattern M can be accurately formed on the material sheet 1. Further, in the secondary pressurization step, the supply of the high-frequency current is stopped, and the material sheet 1 is heated only by the heat of the heater 14, so the material sheet 1 that has already been heated to the molding temperature in the primary pressurization step. The material sheet 1 can be kept at an appropriate temperature by preventing the temperature of the material sheet 1 from lowering than the molding temperature. Therefore, the embossed pattern M formed in the primary pressurization process can be further clarified by further accurately shaping the material sheet 1.

  The engraving data is adjusted in a plurality of stages according to the difference in density of the gradation-processed image after the original image 5 is taken into the computer. However, if the adjusted engraving data has three or less levels, the contour of the pattern can be formed, but the sense of depth becomes poor, so that the embossed pattern M rich in stereoscopic effect cannot be formed. In order to form the embossed pattern M rich in three-dimensionality while forming the outline of the pattern, in the present invention, based on the engraving data adjusted in four or more stages according to the density difference of the gradation processed image, The molding recessed part 4 was formed in a multistage shape with four or more kinds of concave surfaces 7 having different depths so that an embossed pattern M rich in three-dimensional effect could be formed.

  When the mold material 3 is made of phenol resin or methacrylic resin, which is harder than other plastic materials, a high-definition pattern that faithfully reproduces the original image 5 when the molding recess 4 is formed by the laser processing machine 6. Can be reproduced. Further, in the primary pressurizing step and the secondary pressurizing step, even if a pressing force is applied to the molding concave portion 4, the pixel portion constituting the pattern does not bend. The pattern M can be formed accurately.

According to the cover material obtained by the manufacturing method according to the present invention, the embossed pattern M that is more complicated and faithful to the original image 5 can be formed on the cover material compared to the conventional cover material, and the embossed pattern M is highly refined. The impression on the exterior can be interesting. In addition, since a high-definition protruding embossed pattern that faithfully reproduces the original image 5 can be formed on the surface side of the cover material, the embossed pattern is limited to simple patterns such as geometric patterns and heart marks. Compared to the outer cover material, it is possible to provide a cover material that can exhibit a high degree of design effect. Moreover, the original image 5 can be freely selected from patterns such as animals, plants, vehicles, buildings, landscapes, etc., so the degree of freedom of design is high, and the embossed pattern formed on the cover material is diversified to meet the diverse needs of users. Can respond accurately.

It is principle explanatory drawing which shows the manufacturing method of the surface covering material which concerns on this invention. A printed view of the original image is formed on the formed shape type. FIG. 4 is a print diagram of an image obtained by converting an original image into monochrome and performing gradation processing. It is a perspective view which shows the process of forming a shaping | molding die. It is a front view of the high frequency welder which shape | molds a surface material. It is an exploded top view which shows the relationship between a raw material sheet | seat, a shaping | molding die, and a positioning frame. It is a top view of the surface covering material provided with the embossed pattern.

EXAMPLES 1 to 7 show an embodiment of a manufacturing how the face material with the embossed pattern according to the present invention. The surface material is pressed while heating the material sheet 1 against the mold 2 using a high frequency welder to form a protruding embossed pattern M. In FIG. 1, a material sheet 1 is formed by laminating a shaping layer 1a and a base layer 1b, the shaping layer 1a is a thermoplastic resin, and the base layer 1b has a heat resistant temperature higher than that of the shaping layer 1a and melts. It is made of non-woven fabric that is difficult to do. In this embodiment, Clarino (registered trademark), which is an artificial leather of Kuraray Co., Ltd., is used as the material sheet 1, and the material sheet 1 in this case is a non-woven fabric formed of superfine fibers of polyamide resin or polyester resin. (Base layer 1b) is impregnated with polyurethane resin (shaped layer 1a), and the total thickness is 0.6 to 0.8 mm.

  The mold 2 is formed by applying laser processing to a mold material 3 made of a bakelite plate (phenolic resin) or an acrylic plate (methacrylic resin) having a thickness of 0.5 mm. (See FIG. 1). In order to display the embossed pattern M in high definition and realistically, the original image 5 is taken into a computer, the engraving data is adjusted, and the mold material is subjected to laser processing based on the engraving data to form the molding recess 4.

  As shown in FIG. 2, in this embodiment, the mold 2 in the case where the original image 5 is a photograph of the whole body of the cat will be described. First, the original image 5 is taken into a computer and converted into monochrome by adjusting the color tone and color balance, and then converted into 7 levels of engraving data with different engraving depths according to the density difference of the gradation processed image. Convert. The monochrome image 5a is actually a sepia-colored image, and as shown in FIG. 3, the portion with the larger engraving depth is expressed as black or gray near black, and the portion with the smaller engraving depth is shown. It is expressed as white gray, and the part other than the cat image is white.

  By outputting the engraving data to the laser processing machine 6 and applying laser processing to the mold material 3 as shown in FIG. 4, the molding recess 4 has seven types of concave surfaces 7 having different depths (see FIG. 1). It is formed in a multistage shape. Since each concave surface 7 corresponds to the difference in the density of the previous sepia image, the molding concave portion 4 faithfully reproducing the original image 5 can be formed with high definition. The laser beam machine has a machining area corresponding to the A2 size, and the maximum linear density of the laser beam is 2000 dpi. By adjusting the output of the laser beam, the engraving depth of the engraving portion formed on the mold material 3 can be adjusted.

  In FIG. 5, the high-frequency welder has a fixed electrode base 11 and a movable electrode base 12 facing each other up and down on the front surface of the frame 10, and an operation mechanism 13 that moves the movable electrode base 12 up and down in the upper frame. A heater 14 is provided on the upper surface of the movable electrode base 12. A rectangular frame-shaped positioning frame 15 is disposed around the upper surface of the fixed electrode table 11, and the molding die 2 and the material sheet 1 placed on the placement surface 16 of the fixed electrode table 11 are positioned by the positioning frame 15. To do. The positioning frame 15 is guided by four guide shafts 18 (see FIG. 1) fixed to the lower base 17 so as to be vertically slidable, and is urged upward by a compression coil spring 19 toward the movable electrode base 12. . Reference numeral 20 denotes a stopper for receiving the positioning frame 15 at the rising limit position.

  The movable electrode table 12 is supported by the upper base 23, and the movable electrode table 12 can be pressed against the fixed electrode table 11 or separated from the fixed electrode table 11 by moving the upper base 23 up and down with the operation mechanism 13. The operation mechanism 13 includes an operation cylinder 24 and a slide shaft 25 fixed to the upper base 23. The slide shaft 25 is guided and supported by the upper frame so as to be movable up and down. Electrical conductors 26 are provided on the left and right sides of the lower surface of the upper base 23. A high frequency power supply unit 27 (see FIG. 1) for supplying a high frequency current to both electrode bases 11 and 12 is provided inside the frame 10.

At the time of embossing, a cover material is formed through a preparation process, a pressurization process, and a mold release process.
In the preparation step, the mold 2 and the material sheet 1 are placed on the placement surface 16 of the fixed electrode base 11 as shown in FIG. At this time, the mold 2 and the material sheet 1 are positioned front and rear, and left and right by the positioning frame 15.
In the pressurizing step, the primary pressurization and the secondary pressurization are sequentially performed to form the embossed pattern M on the material sheet 1. In the primary pressurizing step, the movable electrode table 12 is heated to 60 to 90 ° C. by the heat of the heater 14, and the heated movable electrode table 12 is moved down by the operation mechanism 13. Press. In parallel, a high-frequency current (40.2 to 40.7 MHz) is supplied from the high-frequency power supply unit 27 to both electrode bases 11 and 12, and the material sheet 1 is pressurized for 6 to 7 seconds while being heated. In this state, as shown in FIG. 1, since the positioning frame 15 is pushed down against the urging force of the spring 19, the molding die 2 and the material sheet 1 are strongly pressed by the fixed electrode base 11 and the movable electrode base 12. .

  In the secondary pressurization step, the movable electrode table 12 is pressed against the fixed electrode table 11 while the heater 14 is driven in a state where the supply of the high-frequency current to both the electrode tables 11 and 12 is stopped. Pressurize for seconds. The applied pressure of the movable electrode base 12 in the secondary pressurizing process is slightly larger than the applied pressure of the movable electrode base 12 in the primary pressurizing process, and the latter applied pressure is 15.2 N per square centimeter. At that time, the pressure applied to the former was set to 16.8N. In the secondary pressurizing step, the sheet surface that is not directly opposed to the molding recess 4 is compressed to be equal to or greater than the maximum depth dimension D of the molding recess 4, and the material sheet 1 is brought into close contact with the inner surface of the molding recess 4. 1 shows a protruding embossed pattern M. The heating of the heater 14 is stopped simultaneously with the end of the secondary pressurizing step. The maximum depth D of the molding recess 4 in this example is 0.6 to 0.8 mm, and FIG. 1 shows a state in the middle of secondary pressurization.

  As described above, in the pressurizing step, the embossed pattern M is formed by sequentially performing the primary pressurization and the secondary pressurization. In the primary pressurizing step, the material sheet 1 is heated from the inside by the heat of the heater 14 while being heated from the inside by the high frequency induction heating action, so that the material sheet 1 is quickly brought to the molding temperature. By heating, the projecting embossed pattern M can be accurately formed on the material sheet 1. Further, in the secondary pressurization step, the supply of the high-frequency current is stopped, and the material sheet 1 is heated only by the heat of the heater 14, so the material sheet 1 that has already been heated to the molding temperature in the primary pressurization step. The material sheet 1 can be kept at an appropriate temperature by preventing the temperature of the material sheet 1 from lowering than the molding temperature. Therefore, the embossed pattern M formed in the primary pressurization process can be further clarified by further accurately shaping the material sheet 1. Further, in the secondary pressurizing step, the sheet surface of the material sheet 1 is compressed to be equal to or larger than the maximum depth dimension D of the molding recess 4 and the material sheet 1 is brought into close contact with the inner surface of the molding recess 4. Since a three-dimensional pattern corresponding to the original image can be formed on the projecting surface, the embossed pattern can be made high-definition and the appearance impression can be rich, and a cover material that can exhibit a higher degree of design effect can be manufactured.

  In the mold release step, the movable electrode table 12 is lifted by the operation mechanism 13 to be separated from the fixed electrode table 11, and the cover material on which the embossed pattern M is formed is removed from the mold 2. Thereafter, by repeatedly performing the preparatory process, the pressurizing process, and the mold releasing process, it is possible to easily form the cover material on which the embossed pattern M having the same pattern is formed. As shown in FIG. 7, since the embossed pattern M having the same high definition as that of the original image 5 is formed on the obtained cover material, it is possible to make the impression on the appearance of the cover material rich. Therefore, a cover material that is more realistic and can exhibit a higher degree of design effect than the conventional cover material of this type can be obtained.

  As described above, when the mold material 3 is formed of a bakelite plate or an acrylic plate having a higher hardness than other plastic materials, the original image 5 is faithfully reproduced when the molding recess 4 is formed by the laser processing machine 6. Can reproduce the high-definition pattern. Further, in the primary pressurizing step and the secondary pressurizing step, even if a pressing force is applied to the molding concave portion 4, the pixel portion constituting the pattern does not bend. The pattern M can be formed accurately. Incidentally, among the pressurizing forces acting on the material sheet 1, the largest pressurizing force acts on the white portion other than the cat image in FIG. 3, and the pressurizing force decreases as the engraving depth increases. However, the embossed pattern M can be formed with high definition by bringing the material sheet 1 into close contact with the molding recess 4 even at the deepest engraving depth.

  In the above embodiment, the engraving data is adjusted in seven steps according to the density difference of the gradation processed image, but this is not necessary. If the engraving data is adjusted to at least four levels according to the difference in density of the gradation processed image, the embossed pattern M rich in stereoscopic effect can be formed. If the adjusted engraving data has three or less levels, the contour of the pattern can be formed, but the sense of depth becomes poor, so that the embossed pattern M rich in three-dimensionality cannot be formed. The mold material 3 is preferably formed of a bakelite plate or an acrylic plate that requires less cost, but an aluminum alloy plate or a copper alloy plate may be applied if necessary. In the pressurizing step of the above-described embodiment, primary pressurization and secondary pressurization are performed, but it is not necessary. For example, the heated movable electrode table 12 is pressed against the material sheet 1, and the embossed pattern M is formed by pressing the material sheet 1 against the mold 2 while supplying a high-frequency current between the fixed electrode table 11 and the movable electrode table 12. May be. The original image 5 can be selected from an arbitrary pattern such as an animal, a plant, a vehicle, a building, a landscape, a painting, a sculpture, an image of a television or a movie. In addition, the maximum depth dimension D of the molding recessed part 4 may be smaller than the full thickness dimension of the raw material sheet 1.

The cover material obtained by the manufacturing method according to the present invention can be used as a cover material such as a pencil box, a notebook, a small box for storing a watch or a ring, but a handprint or a footprint is formed as an embossed pattern M to commemorate the birth. It can be used as childcare memorial goods and wedding commemorative goods. If necessary, the cover material may be used as a school bag forming material.

DESCRIPTION OF SYMBOLS 1 Material sheet 2 Mold 3 Mold material 4 Molding recessed part 5 Original image 11 Fixed electrode stand 12 Movable electrode stand 14 Heater 15 Positioning frame 27 High frequency power supply part M Embossed pattern D The maximum depth dimension of a molding recessed part

Claims (4)

Manufacture of a covering material for forming a protruding embossed pattern on the shaping surface of the material sheet (1) by applying pressure while heating the material sheet (1) to a forming die (2) having a forming recess (4). A method,
The molding die (2) is subjected to laser processing on the mold material (3) based on the engraving data obtained by adjusting the original image (5) into the computer, and the molding recess (4) corresponding to the original image (5). Is formed,
A forming step (2), a preparation step of placing a material sheet (1) formed of a thermoplastic resin on the fixed electrode table (11) and placing the heated movable electrode table (12) on the material sheet (1) And forming a cover material including a pressing step of pressing the material sheet (1) against the mold (2) while supplying a high-frequency current between the fixed electrode table (11) and the movable electrode table (12). And
In the pressurizing step, the sheet surface of the material sheet (1) not facing the forming recess (4) is compressed to the maximum depth dimension (D) of the forming recess (4), and the material sheet (1) is compressed. A method for producing a cover material having an embossed pattern, characterized in that the projecting embossed pattern (M) is exposed on the material sheet (1) by being in close contact with the inner surface of the molding recess (4). In the pressing process, the heated movable electrode table (12) is pressed against the material sheet (1), and the high-frequency current is supplied between the fixed electrode table (11) and the movable electrode table (12). A primary pressurizing step of pressurizing the mold (2);
2. The embossed pattern according to claim 1, comprising a secondary pressurizing step of pressurizing the heated movable electrode stand (12) in a state where the supply of high-frequency current to both electrode stands (11, 12) is stopped. A manufacturing method of the cover material. The engraving data has been adjusted to 4 or more levels according to the density difference of the gradation processed image,
The manufacturing method of the surface covering material provided with the embossed pattern of Claim 1 or 2 with which the shaping | molding recessed part (4) is formed in multiple steps by four or more types of concave surfaces (7) from which depth differs. The manufacturing method of the surface covering material provided with the embossed pattern as described in any one of Claim 1 to 3 with which the type | mold raw material (3) is formed with either one of a phenol resin or a methacryl resin .