JP7762077B2 - Materials - Google Patents

Description

The present invention relates to a component including a decorative surface.

Conventionally, many resin molded products with patterns such as embossing formed on their surfaces have been known as resin molded products used as interior components such as the upper housing of an automobile shift lever device, console boxes, and instrument panels. The embossing pattern is formed, for example, by transferring the pattern on the molding surface of a resin molding die (see, for example, Patent Document 1). The pattern on the molding surface of the die is formed, for example, by a embossing process using chemical etching.

Texturing by etching allows a pattern consisting of gently continuing, finely textured surfaces to be created on the molding surface of a mold. The pattern on the molding surface is transferred to the resin molded product produced by this mold, creating a gently textured surface. This type of textured pattern on a resin molded product disperses light that enters the textured surface in multiple directions, resulting in a matte finish.

Japanese Patent Application Laid-Open No. 2000-025046

However, the grain patterns on resin molded products that can be formed in this manner have little variation in surface properties, making it difficult to fully meet the needs for diverse designs.

The present invention was made in consideration of the above-mentioned problems with the conventional technology, and aims to provide components with improved design features for flat or curved design surfaces.

The present invention is a component including a design surface composed of at least one of a flat surface and a curved surface,
a first region of a predetermined shape is provided on the design surface, in which a plurality of combinations of two convex ridges or two concave grooves are formed in parallel with a gap of a certain width;
On the design surface, at least three first regions sharing a common vertex are arranged around the entire circumference in a circumferential direction centered on the vertex to form a second region, and a repeating pattern is formed on the design surface in which the second regions are arranged without gaps,
In the second region, two first regions adjacent to each other in the circumferential direction around the apex are a combination of regions in which the convex ridges or concave grooves are oriented in different directions, and are adjacent to each other without any gaps via a line of a predetermined shape that starts at the apex and extends toward the outer periphery ,
The component is characterized in that in the second region, first regions of the same shape are arranged without gaps around the entire circumference centered on the vertex, and lines of the specified shape extending from the vertex toward the outer periphery are formed at equal intervals in the circumferential direction .

The component of the present invention has a design surface provided with a first region of a predetermined shape, in which a plurality of combinations of two parallel convex ridges or concave grooves are formed with a gap of a certain width. This design surface has a second region formed with first regions of the same shape arranged without gaps all around the circumference, centered on a vertex. Two first regions adjacent in the circumferential direction in the second region are combinations of regions with convex ridges or concave grooves oriented in different directions .

In the second region, the direction of the convex ridges or concave grooves of the first region changes in the circumferential direction around the apex, and this change makes it possible to impart shading or light and shade to the design surface. The member according to the present invention has a design surface with shading or light and shade and exhibits high designability.

FIG. 2 is a perspective view of a resin molded product according to the first embodiment. FIG. 3 is an enlarged view of a portion of the upper surface of the resin molded product in Example 1. FIG. 2 is a perspective view of a molding die according to the first embodiment. FIG. 3 is a cross-sectional view of a molding surface in Example 1. FIG. 4 is an explanatory diagram of a pattern in the first embodiment. FIG. 4 is an explanatory diagram showing how the pattern reflects light in the first embodiment. 3 is a photograph (partially enlarged) of the upper surface of the resin molded article in Example 1. 3 is a photograph of a curved portion of the upper surface of the resin molded product in Example 1. FIG. 10 is an explanatory diagram of a first pattern in the second embodiment. FIG. 10 is an explanatory diagram of a second pattern in the second embodiment. FIG. 10 is an explanatory diagram of a third pattern in the second embodiment. FIG. 10 is an explanatory diagram of a fourth pattern in the second embodiment. FIG. 10 is an explanatory diagram of a pattern in Example 3.

The embodiments of the present invention will be specifically described using the following examples.
Example 1
This example relates to a resin molded product 1 which is an example of a member including a flat or curved design surface. The resin molded product 1 of this example will be described with reference to FIGS.

The resin molded product 1 is a component that forms the upper housing of a vehicle shift lever device (not shown). The resin molded product 1 has a substantially rectangular front shape and has a side wall 18 that surrounds its outer periphery. When the shift lever device is attached to the vehicle, the top surface 1S of the resin molded product 1 is exposed to the passenger compartment and is either flush with the surrounding area or recessed from the surrounding area. Therefore, the side wall 18 of the resin molded product 1 is not visible to vehicle occupants. The top surface 1S of the resin molded product 1 is a decorative surface that decorates the passenger compartment. Hereinafter, the top surface of the resin molded product 1 will be referred to as the decorative surface 1S.

In an assembled shift lever device (not shown), the shift lever operated by the vehicle driver is positioned through a lever through-hole 10 provided on the inner periphery of the resin molded product 1, which serves as the upper housing. The lever through-hole 10 is a rectangular opening that allows the shift lever to be operated in the shift direction along the fore-and-aft direction of the vehicle and in the select direction along the vehicle width direction. In the resin molded product 1, a long, narrow indicator window 101 is provided in a position adjacent to the lever through-hole 10 in the vehicle width direction. This indicator window 101 is an opening that allows visibility of an indicator panel (not shown) that displays the layout of the shift ranges, such as the parking range, drive range, neutral range, and reverse range.

The resin molded product 1 is a molded product made of a resin material such as ABS resin, polycarbonate resin, or ASA resin. The resin material in this example is a colored resin material kneaded with a colorant such as a black pigment. The resin molded product 1 in this example is made of this resin material and is black in color even when unpainted.

The pattern 100 shown in Figure 2 is formed over the entire design surface 1S of the surface of the resin molded product 1. This pattern 100 is formed by convex ridges 1R extending in various directions. Note that Figure 2 is an enlarged view of the area 19 indicated by the circular dashed line in Figure 1. The pattern 100 made of convex ridges 1R corresponds to the pattern on the molding surface 40 of the molding die 4 (see Figure 3) used to mold the resin molded product 1, and is formed during resin molding.

Now, we will explain the molding die 4 for the resin molded product 1. The molding die 4 (Figure 3) is a mold consisting of a combination of a metal upper die 42 and a lower die 41. The molding die 4 has holes (not shown) for pouring molten resin material into the interior when the upper die 42 and lower die 41 are clamped together. The resin molded product 1 can be molded by injecting resin material into the interior of the clamped molding die 4. The lower die 41 is the mold that molds the shape of the design surface 1S, which corresponds to the top surface of the resin molded product 1. The upper die 2 is the mold that molds the shape of the back side of the resin molded product 1. With the molding die 4 illustrated in Figure 3, the resin molded product 1 is molded upside down.

The molding surface 40 of the lower mold 41 is provided with a pattern corresponding to the pattern 100 (Figure 2) on the design surface 1S of the resin molded product 1. The pattern on the molding surface 40 of the lower mold 41 is a pattern made up of grooves 4T in various directions. The grooves 4T (Figure 4) on the molding surface 40 are wedge-shaped grooves 4T formed, for example, by laser processing. The convex ridges 1R that make up the pattern 100 (see Figure 2) on the design surface 1S of the resin molded product 1 are formed to correspond to the wedge-shaped grooves 4T in cross section and have a triangular cross section. The depth D of the grooves 4T on the molding surface 40 is approximately 10 μm. The width W of the grooves 4T is 50 μm.

The molding surface 40 of the lower mold 41 is machined, polished to a mirror finish, and then laser machined to form the grooves 4T. The decorative surface 1S of the resin molded product 1 molded using this molding surface 40 is a surface composed of convex ridges 1R and a glossy surface 118 (Figure 6).

The design surface 1S of the resin molded product 1 has a pattern 100 consisting of a pattern of ridges 1R, which creates a three-dimensional effect and enhances its aesthetic appeal. As shown in Figure 5, this pattern is a combination of multiple regions with ridges 1R arranged in different directions. The smallest unit of the pattern is a first region 11 (an example of a first region) in which ridges 1R are arranged side by side in a certain direction. A second region (an example of a second region) 12 is formed by combining multiple types of first regions 11 with ridges 1R arranged in different directions. The pattern on the design surface 1S of the resin molded product 1 is a repeating pattern in which second regions 12 of the same pattern are combined without gaps. In Figure 5, the shapes of two adjacent second regions 12 are shown at the top of the drawing.

The first region 11 (Figure 5) is a right-angled triangle containing a 30-degree angle. In the first region 11, a large number of ridges 1R are arranged in parallel, with two ridges 1R adjacent to each other with a gap of a fixed width, and the gap width is the same for all combinations of two adjacent ridges 1R. In the first region 11, linear ridges 1R are arranged at a fixed pitch (equally spaced) so that they are parallel to each other throughout the entire area. The height of the ridges 1R is 10 μm, corresponding to the depth D of the grooves 4T (see Figure 4) of approximately 10 μm on the molding surface 40. The formation width of the ridges 1R is 50 μm, corresponding to the formation width W of the grooves 4T of the molding surface 40 of 50 μm. The pitch of the parallel ridges 1R is approximately 200 μm. The groove 4T has a formation width W of 50 μm, so the gap between adjacent parallel ridges 1R is 150 μm.

The second region 12 (Figure 5) is a region in which 12 pieces of the first region 11, each sharing a vertex 13, are combined to form a regular hexagon (an example of a regular polygon) overall. In the second region 12, two first regions 11 with ridges 1R formed in different directions are arranged adjacent to each other via an imaginary straight line L, which is an example of a line of a predetermined shape starting from the vertex 13. As a result, in the second region 12, the first regions 11 are arranged without gaps around the entire circumference centered on the vertex 13.

Each of the 12 first regions 11 belonging to the second region 12 includes two pieces of the same type of first region 11, each with the same ridge 1R formation direction. In the second region 12, two circumferentially adjacent first regions 11 are of different types, and six types of 12 pieces of first regions 11 are arranged in line symmetry with respect to an imaginary line L originating from the center of the regular hexagon and the vertex 13 of the regular hexagon. Here, first regions 11 of the same type mean that the ridge 1R formation direction is the same. First regions 11 of different types mean that the ridge 1R formation direction is different. The second region 12 includes linear ridges 1R in six directions.

On the design surface 1S that forms the design surface of the resin molded product 1, the second regions 12 are arranged without any gaps, so that two second regions 12 are adjacent to each other across one side of a regular hexagon, forming a pattern 100. In this pattern 100, where two second regions 12 are adjacent, first regions 11 of the same type are adjacent across one side of the right triangle. Adjacent first regions 11 of the same type are integrated and appear to the naked eye to form a single region beyond the boundaries of the second regions 12.

Next, we will explain the visual effect of the pattern 100 formed on the design surface 1S of the resin molded product 1. As described above, the pattern on the design surface 1S of the resin molded product 1 is a pattern in which second regions 12 (Figure 5) are arranged without gaps, each consisting of a combination of six types of 12-piece first regions 11 with linear ridges 1R formed in different directions.

As shown in Figure 6, the design surface 1S of the resin molded product 1 on which this pattern 100 is formed is composed of convex ridges 1R and glossy surfaces 118 between the parallel ridges 1R. Here, the glossy surfaces 118 are highly smooth surfaces formed by the mirror-finished molding surface 40 of the molding die 4. When viewing the design surface 1S from viewpoint A in Figure 6, the direction in which light is reflected varies depending on the slopes on both sides of the ridges 1R and the glossy surfaces 118 between the ridges 1R.

On the design surface 1S, depending on the position of the viewpoint, either the slopes of the ridges 1R or the glossy surface 118 strongly reflect light. Furthermore, when the ridges 1R reflect light, the orientation of the slopes of the ridges 1R differs depending on the type of first region 11, so which of the ridges 1R in which first region 11 strongly reflects light changes depending on the position of the viewpoint. Also, when the glossy surface 118 strongly reflects light, whether or not the glossy surface 118 can be seen from the viewpoint may change depending on the direction of the ridges 1R, i.e., whether or not light reflected by the glossy surface 118 is incident on the viewpoint may change depending on the type of first region 11. In such cases, differences in brightness will occur depending on the type of first region 11.

In this way, on the design surface 1S of the resin molded product 1, differences in the intensity of reflected light occur for each type of first region 11. In other words, on the design surface 1S, a contrast in brightness occurs for each type of first region 11, resulting in shading or light and dark areas for each region, like a patchwork. This creates shading or light and dark areas between the regions (first regions 11) that belong to the second region 12, and can create a three-dimensional effect in the pattern 100, as shown in Figure 7.

Furthermore, for example, if the viewpoint moves from A to B (see Figure 6), the degree of light reflection for each region changes, causing the shading or brightness of each region (first region 11) belonging to second region 12 to change. If the shading or brightness of each region changes, the visual effect of a corresponding change in the three-dimensionality of pattern 100 is created.

Furthermore, in the resin molded product 1 of this example, the design surface 1S is not flat, but has curved surfaces at the upper and lower edges. On the curved surface, the type of first region 1 that strongly reflects light changes depending on the position, and either the ridges 1R or the glossy surface 118 strongly reflects light. Therefore, as shown in the photographs of Figures 8(a) and (b), on the curved surface, the type that becomes the brightest or darkest among the multiple types of first region 11 changes depending on the position. Therefore, on the curved surface, more complex shadows or light and dark areas are created, producing a variety of visual effects.

In this way, the resin molded product 1 of this example has a highly varied and diverse visual effect due to the pattern 100 on the design surface 1S, resulting in an excellent aesthetic appearance. In particular, in this example, the combination of first regions 11 with different ridge directions 1R creates a three-dimensional effect in the pattern. This pattern is a repeating pattern in which second regions 12, each consisting of a combination of first regions 11, are arranged without gaps, giving the viewer a sense of the beauty of the orderly arrangement. This pattern 100 creates shading or light and shade in each region, creating a three-dimensional effect depending on this shading or light and shade. Furthermore, the shading or light and shade changes depending on the viewing direction of the pattern 100, which can change the three-dimensional effect. This pattern 100 can create a wide variety of visual effects depending on the viewing direction. Furthermore, on surfaces where the slope of the surface to which the pattern 100 is applied varies, such as curved surfaces, different visual effects can be produced at different positions.

In this way, the design surface 1S of the resin molded product 1 of this example can create a visual effect on the surface without requiring work processes such as painting or surface treatment. Therefore, this resin molded product 1 is an excellent product that exhibits high design quality while keeping production costs down. Because the resin molded product 1 of this example is molded from a black colored resin material, it does not require painting.

The fine ridges 1R on the design surface 1S have the effect of preventing fingerprints and scratches on the glossy surface 118 between the ridges 1R. Therefore, the design surface with ridges 1R can maintain its aesthetic appeal for a long time.

In this example, the resin molded product 1 is an upper housing for a shift lever device. However, it may also be a resin molded product used for decorative vehicle components, such as interior vehicle components such as console boxes and instrument panels, or exterior vehicle components such as grilles and wheel caps. In addition to decorative vehicle components, the resin molded product may also be used for decorative components for various items, such as home appliances, office automation equipment, and furniture. Colored resin materials other than black may also be used as the resin material. The surface shape of the design surface is not limited to a flat surface, but may be a convex or concave curved surface, or may include a convex or concave step. A pattern consisting of ridges 1R may be provided on only a portion of the design surface, rather than the entire surface. The cross-sectional shape of the ridges 1R may be a mountain shape, a semicircular shape, a trapezoidal shape, or other shape.

In this example, laser processing is used as an example of a processing method for forming grooves 4T on the molding surface 40 of the mold 4. Instead of laser processing, grooves 4T may be formed by engraving, cutting, or other processes. Furthermore, in addition to injection molding as used in this example, other molding methods such as blow molding and compression molding may also be used as a resin molding method for the resin molded product 1.

In this example, the visual effect is enhanced by providing convex ridges 1R on the surface of the resin molded product 1, but concave grooves may be provided instead of the convex ridges 1R. Concave grooves can also produce a visual effect similar to that of this example. However, in terms of the effect of preventing fingerprints from adhering to the design surface, the ridges 1R are expected to have a higher anti-fouling effect.
In this example, the ridges 1R formed by inclined surfaces that reflect light are used, but instead, ridges 1R or grooves that disperse light and have low light reflectance may be used.

In this example, the formation width of the ridges 1R is 50 μm. The formation width of the ridges 1R is preferably a width that is difficult to see when viewed from the extension direction of the ridges 1R, and is preferably 10 to 200 μm. If it is less than 10 μm, the reflection of light on the inclined surface of the ridges 1R may be difficult to see. If it exceeds 200 μm, the ridges 1R may be easily seen as lines, and the difference in appearance from conventional line patterns may be reduced. Preferably, the formation width of the ridges 1R is 50 μm ± 20 μm. If the formation width of the ridges 1R is 50 μm ± 20 μm, the ridges 1R will be difficult to see as lines when viewed from the extension direction of the ridges 1R, and the areas of ridges 1R lined up in the same direction will be seen as if they were a single surface.

In this example, the width of the gap between the parallel ridges 1R is 150 μm. The gap width should be between 20 and 800 μm. If it is less than 20 μm, the width of the flat surface between adjacent ridges 1R will be reduced, reducing the glossy surface that reflects light, which may reduce the contrast between light and dark and make it difficult to visually perceive the three-dimensional effect. If it exceeds 800 μm, the width of the flat surface will increase, resulting in excessive glossy surface that reflects light, which may be perceived as a simple glossy design. The maximum value of the range of the width of the gap between ridges 1R is preferably 150 μm. If the gap width is 150 μm or less, the width of the flat surface can ensure a glossy surface that reflects light appropriately, resulting in a well-balanced contrast between light and dark and an easier-to-visual three-dimensional effect.

In this example, the height of the ridges 1R is 10 μm. The height of the ridges 1R is preferably 2 μm to 30 μm. If the height is less than 2 μm, the reflective surface of the ridges 1R becomes smaller, reducing the difference in reflection between the flat portion and the inclined surface, which may make it difficult to visually recognize the three-dimensional effect. If the height exceeds 30 μm, it may have a negative effect on the releasability of the resin molding. Preferably, the height of the ridges 1R is 5 μm to 25 μm. If the height of the ridges 1R is 5 μm to 25 μm, the angle of the uneven slope becomes appropriate and the difference in reflection between the flat portion and the inclined surface can be ensured, making the three-dimensional effect more easily visible and achieving the effect of improving the releasability of the resin molding.
In this example, a metal mold 4 is used as an example, but a resin mold may also be used.

Example 2
This example is an example in which the pattern of the design 100 is changed based on Example 1. This will be described with reference to FIGS.
9 shows an example of a pattern 100 made up of regular hexagonal second regions 12 formed by combining six equilateral triangular first regions 11. In this pattern 100, the six first regions 11 share a vertex 13, and the first regions 11 are arranged without gaps around the entire circumference of the vertex.

Furthermore, in the first region 11 shown in the figure, the width of the gap between the parallel ridges 1R is not constant, but is narrower the closer to the apex 13 and wider the farther from the apex 13. Setting the gap between the ridges 1R in this way creates a visual effect of concentrating on the apex 13. The gap width is 70 μm at its narrowest point and 240 μm at its widest point.

Figure 10 shows an example in which the setting of the gap between ridges 1R in the first region 11 has been changed based on Figure 9. In each first region 11 in the figure, as in Figure 9, the width of the gap between parallel ridges 1R is not constant. The width of the gap between ridges 1R in the first region 11 is wider the closer to the vertex 13 and narrower the farther from the vertex 13. Figure 10 creates a visual effect of surrounding the center where the vertex 13 is located. The gap width is 70 μm at its narrowest point and 240 μm at its widest point.

Figure 11 shows an example of a pattern 100 consisting of square-shaped (rectangular) second regions 12 formed by combining four first regions 11 each shaped like a right-angled isosceles triangle. In this pattern 100, the four first regions 11 share a vertex 13, and the first regions 11 are arranged without gaps around the entire circumference centered on the vertex. As with the pattern 100 in Figure 9, the width of the gaps between the ridges 1R in the first regions 11 is not constant; the closer to the vertex 13, the narrower this width is, and the farther from the vertex 13, the wider this width is. The gap width is 70 μm at its narrowest point and 200 μm at its widest point.

Figure 12 shows an example in which the setting of the gap between ridges 1R in the first region 11 has been changed based on Figure 11. In this pattern, similar to pattern 100 in Figure 10, the width of the gap between ridges 1R in the first region 11 is not constant; the width is wider closer to the vertex 13 and narrower the farther away from the vertex 13. The gap width is 70 μm at its narrowest point and 200 μm at its widest point.

The shape of the second region 12 may be any polygonal shape, such as a triangular shape or a pentagonal shape.
The other configurations and effects are the same as those of the first embodiment.

Example 3
This example is based on the first embodiment and is an example of the configuration of the pattern 100 in which the line (adjacent line) dividing the two first regions 11 in the second region 12 is curved.
13 , in the pattern 100 of this example, the second region 12 has a square shape. In the second region 12, four first regions 11 are arranged without any gaps around the entire circumference, centered on a vertex 13. In the second region 12, a virtual curve L (an example of a line with a predetermined shape) that separates adjacent first regions 11 is a curve like a waveform for a quarter cycle from the zero crossing point where the positive and negative signs of a sine wave are inverted to the positive or negative extreme point.

This pattern 100 uses curved ridges 1R. The ridges 1R are arc-shaped with the vertex 15 of the square-shaped second region 12 as the center. Where two second regions 12 adjoin, two first regions 11 of the same type belong to different second regions 12, but are adjacent. Here, in this example, the same type of first region 11 means that the centers (vertices 15) of the arc-shaped ridges 1R are the same, and different types of first regions 11 means that the centers (vertices 15) of the arc-shaped ridges 1R are different.

The shape of the ridge 1R may be various curved shapes instead of the arc shape of this example.
The other configurations and effects are the same as those of the first embodiment.

Although specific examples of the present invention have been described in detail above as examples, these specific examples merely disclose examples of the technology encompassed by the claims. Needless to say, the scope of the claims should not be interpreted as being limited by the configurations, numerical values, etc. of the specific examples. The claims encompass technologies that incorporate various modifications, alterations, or appropriate combinations of the specific examples, utilizing publicly known technology and the knowledge of those skilled in the art.

1. Resin molded products (components)
1R ridge 1S design surface (top surface)
11 First region (first region)
118 Glossy surface 12 Second region (second region)
13 Vertex 15 Vertex 100 Pattern 4 Forming mold 4T Groove 40 Forming surface 41 Lower mold 42 Upper mold L Straight line, curved line (line of predetermined shape)

Claims (6)

A component including a design surface composed of at least one of a flat surface and a curved surface,
a first region of a predetermined shape is provided on the design surface, in which a plurality of combinations of two convex ridges or two concave grooves are formed in parallel with a gap of a certain width;
On the design surface, at least three first regions sharing a common vertex are arranged around the entire circumference in a circumferential direction centered on the vertex to form a second region, and a repeating pattern is formed on the design surface in which the second regions are arranged without gaps,
In the second region, two first regions adjacent to each other in the circumferential direction around the apex are a combination of regions in which the convex ridges or concave grooves are oriented in different directions, and are adjacent to each other without any gaps via a line of a predetermined shape that starts at the apex and extends toward the outer periphery ,
A component characterized in that in the second region, first regions of the same shape are arranged without gaps around the entire circumference centered on the vertex, and lines of the predetermined shape extending from the vertex toward the outer periphery are formed at equal intervals in the circumferential direction . According to claim 1, each of the first regions forming the second region is a region in which the convex ridges or concave grooves are provided along a certain direction ,
the predetermined shape of the line in the second region is a straight line or a curved line , and the second region is a regular polygon;
In the design surface, two adjacent second regions are adjacent to each other in a state where they share one side of the regular polygonal shape, so that the plurality of second regions are arranged without any gaps;
A component characterized in that a first region that forms one of two adjacent second regions and a first region that forms the other of the two second regions are combined, and that the directions of the convex ridges or concave grooves in the two first regions that are adjacent via one side are the same. According to claim 2 , the first region has a triangular shape that shares one side of the regular polygonal shape of the second region, and the convex ridge or concave groove is provided in parallel to the one side,
A component characterized in that the width of the gaps between the parallel convex ridges or concave grooves in the first region gradually increases or decreases with increasing distance from the apex. 4. The member according to claim 1, wherein the gaps between the convex ridges or the concave grooves on the surface of the first region are formed by a glossy surface. A component according to any one of claims 1 to 4, characterized in that the first region has convex ridges formed therein. A component according to any one of claims 1 to 5, characterized in that it is an interior component for a vehicle.