JPH074864B2 - Method for manufacturing decorative product having uneven surface - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial field of application) The present invention is a decoration in which a pattern is formed on the entire surface of an article such as a plastic molded article having a three-dimensional three-dimensional shape and partially having openings. The present invention relates to a manufacturing method of a product, particularly, a molded product used for a cabinet of radio, television, video and audio, an instrument panel of an automobile, a console box, furniture interior parts, stationery, toys and the like.

(Prior Art) Conventionally, a method for forming a pattern on a three-dimensional article includes
Usually extruded by using 2-3 colored pellets for molding resin pellets, which is usually called the Suminagashi method. A method in which a molded plastic film with a pattern is called a hot stamp and the molded product is transferred under heat. After vacuum forming a film having a pattern close to the desired three-dimensional molded product, set the vacuum molded product in the mold of the three-dimensional molded product, and injection-mold the molded product and vacuum-formed film. How to be one. Or, by the same method, the vacuum forming film is made to have releasability, and only the pattern is transferred to the molded product. A method of transferring a design pattern by water pressure in water to a molded product of a film obtained by printing a design pattern on a film such as vinylon, which is called hydraulic transfer, has been performed.

(Problems to be Solved by the Invention) In the conventional method as described above, it is possible to form a pattern on the surface of a molded product having an uneven surface, but the uneven surface, for example, a conduit groove of wood grain Such a shape could not be imparted.

In addition, it is possible to form a concavo-convex pattern on the surface of the molded product by forming a concavo-convex pattern on the inner surface of the mold and injecting resin into it. Since it had to be engraved or the like, it was not possible to form a realistic concavo-convex pattern such as a conduit groove of wood grain.

(Means for Solving Problems) The present invention faithfully reproduces the realistic texture, texture, and texture of natural products, which cannot be obtained by the conventional methods as described above, and matches the pattern. , Three-dimensional decorative products that have a genuine feeling that is indistinguishable from natural products.

That is, an uneven pattern is formed on the surface of the thermoplastic resin sheet that can be laminated on the uneven surface of the laminate having the uneven surface,
The present invention relates to a technique of providing an unevenness protection layer so that the unevenness pattern is not deformed and then integrating it with a laminated body having an unevenness surface.

The present invention will be described in detail below with reference to the drawings.

First, as shown in FIG. 2, irregularities are formed on the surface of the thermoplastic resin sheet (1). The unevenness may be formed directly on the thermoplastic resin sheet, or a printed pattern layer may be formed on the surface of the thermoplastic resin sheet if necessary, and a resin layer capable of thermal softening may be formed thereon to form the resin. Roughness may be formed on the layer. Of course, a printed pattern layer may be formed on the surface of the thermoplastic resin sheet, and the unevenness may be formed thereon.

As a means for forming irregularities, an embossing plate or embossing roll in which irregularities are formed by engraving or etching on the surface of a metal plate or a metal roll, or a plate or roll wrapped with an embossed sheet that is raised and printed on the surface of a sheet Can be used, but if you use an embossing plate or embossing roll made based on an embossed sheet where the surface shape of a natural product such as wood is molded with a silicone resin, etc. Can be formed.

Next, the curable resin (2) is applied to the irregularity-formed surface of the thermoplastic resin sheet (1) to a thickness that does not impair the irregularity, and cured to prepare a laminating sheet (3).

Next, a large number of fine ventilation holes (5) are formed on the entire surface of the laminating sheet (3). The size of the vent holes is set to 20 to 80 μ in consideration of the degassing effect and the designability, and the density thereof is set to 1 to 9 pieces / cm ² . Next, as shown in FIG. 3, the object to be laminated (4)
The laminating sheet (3) is superposed on the above, and the periphery thereof is surrounded by a cushioning material (6) having a large air permeability, and then heated and pressed to laminate the laminating sheet (3) as shown in FIG. An integrated product with (4) is obtained.

As the thermoplastic resin sheet (1), polyvinyl chloride sheet, polyethylene sheet, polypropylene sheet, polyester sheet, nylon sheet, ABC resin sheet,
Polyimide sheet, acrylic sheet, polyvinyl acetate sheet, vinylidene chloride sheet, fluororesin sheet, polycarbonate sheet, synthetic paper or non-woven fabric using each of the above resins, and a sheet obtained by combining any of the above sheets in combination, etc. Can be used. Further, as described above, the printed pattern layer can be formed on the surface of the sheet, or a coloring material can be mixed into the sheet to form a colored sheet.

As the curable resin (2), a photocurable resin such as an acrylic resin or a polyester resin, an acrylic urethane resin,
Thermosetting resins such as urethane-based, polyester-based, epoxy-based, melamine-based, etc. can be used, and the thickness that does not impair the uneven shape thereof is preferably about 2 to 30 μm.

As the layered body (4), a resin molded product molded by injection molding, extrusion molding, or the like can be used, but of course, a wood-like material formed into an uneven shape by cutting or the like can also be used.

The unevenness formed on the surface of the thermoplastic resin sheet (1) includes
It is also possible to embed a coloring material by the wiping method,
Further, a resin having releasability may be applied after the surface protective layer is formed on it.

As the cushion material (6) having a large breathability, soft urethane foam, soft polystyrene foam, or the like can be used.

An adhesive such as a pressure sensitive adhesive or a heat sensitive adhesive is applied to the adhesive surface of the laminating sheet.

(Function) The thermoplastic resin sheet is softened and easily deformed by the heat of heating and softening when it is attached to the laminated body, but the concave portion of the surface of the thermoplastic resin sheet is completely covered by the curable resin applied to the surface. Since it is kept in shape, it does not deform,
The real concavo-convex shape given during embossing is reproduced as it is on the surface of the decorative product.

(Effect of the invention) Since the sheets having the realistic unevenness pattern formed on the surface are laminated, a decorative product having a high design property can be obtained.

Since unevenness is formed in advance on the sheets before lamination, it is possible to use an electroforming plate with high reproducibility and use of a high-frequency molding method that is low in cost, and it is possible to inexpensively manufacture a product that more closely resembles a natural product. .

(Example) A colored ABS resin sheet having a thickness of 0.4 mm was provided with an oak grain pattern by a gravure printing method, and an uneven pattern was formed on the surface thereof by using an embossing roll. The embossing roll used was an electroformed roll made from natural wood having an oak grain pattern.

Then, a coloring material is embedded in the concave and convex portions by a wiping method, and an acrylic photocurable resin is applied to the entire surface of the sheet by a gravure printing method to a thickness of 5 μm.
The resin was cured by irradiation with an 80 W / cm photopolymerization lamp for 6 seconds, and then a hot-melt type adhesive was applied to the back surface to obtain a laminating sheet.

Next, a ventilation hole was formed on the entire surface of the laminating sheet by using a roll in which a large number of needle-shaped objects having a thickness of 60 μm were embedded.

Next, stack the laminating sheet on the ABS resin control box molded product of the automobile, surround it with soft urethane foam, sandwich the top and bottom with a lid to prevent deformation of urethane, and further heat A decorative product was obtained by sandwiching the laminate sheet on the surface of the molded product by heating and pressurizing it under the conditions of 120 ° C. and 2.5 Kg / cm ² .

[Brief description of drawings]

The drawings are for explaining the method of the present invention. FIG. 2 is a constitution of a laminating sheet, FIG. 3 is a step of laminating a laminating sheet on the surface of a laminated body, and FIG. 1 is a molded product and laminating. It is sectional drawing which respectively shows the state which integrated the sheet. (1) ... thermoplastic resin sheet (2) ... curable resin (3) ... laminating sheet (4) ... laminated body (5) ... vent hole, (6) ... cushion material (7) ) …… Hot plate, (8) …… Lid

Claims (1)

[Claims] 1. A first step of forming irregularities on a surface of a thermoplastic resin sheet. A second step in which a curable resin is applied to the irregularity-formed surface to a thickness that does not impair the irregularity and cured to produce a laminating sheet. A third step of forming a large number of fine ventilation holes on the entire surface of the laminating sheet. A fourth step of stacking the laminating sheet on the layered body, surrounding the layered sheet with a highly breathable cushioning material, and applying heat and pressure to integrate the layered sheet with the layering sheet. A method for manufacturing a decorative product having an uneven surface, comprising the above steps.