JP2001246717A - Method for manufacturing decorative molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a decorative molded article, reduced in the number of processes. SOLUTION: The method for manufacturing the decorative molded article consists of a first process for laminating a decorative sheet on a base material through a first adhesive, a second process for laminating a transparent film on the decorative sheet through a second adhesive and a third process for laminating a transparent protective layer on the transparent film.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative molded product particularly suitable for interior parts of automobiles.

[0002]

2. Description of the Related Art A decorative board using a veneer veneer is widely used as a decorative material for interior materials of automobiles and the like, because it can impart a preferable aesthetic appearance and luxury. I have. This decorative board is formed by integrating a base material and a decorative sheet serving as a decorative surface, and is conventionally manufactured by, for example, the following method.

Japanese Patent Application Laid-Open No. 3-97558 discloses that after the surface of a synthetic resin substrate is roughened by sandblasting,
A method of bonding a nameplate veneer with an adhesive is disclosed. However, in this manufacturing method, the surface roughening treatment is complicated, and when the substrate is thin, it adversely affects the strength of the substrate itself, or when the substrate has a curved surface, the adhesive strength of the precious wood veneer is partially insufficient. There is a possibility that.

Japanese Patent Application Laid-Open No. Hei 4-163030 discloses that a decorative material obtained by hot pressing a veneer veneer and a thermoplastic resin plate is placed in a mold, and a synthetic resin is placed on the back side of the decorative plate. After that, a method of forming and integrating is disclosed. This manufacturing method is suitable for mass production of the same shape, but when small quantities of different shapes are to be produced, it is necessary to make a mold for each shape. In the case of manufacturing using a plate, a mold must be produced each time, and the manufacturing cost is significantly increased.

[0005] In addition, for example, the interior of an automobile is subject to temperature changes depending on day and night and seasons. Therefore, the repetition of this temperature change may cause deformation such as warping or twisting of the interior parts. Is also important.

[0006] The present invention can reduce the number of man-hours, reduce the production cost by using an existing base material, and furthermore, is a cosmetic having excellent appearance characteristics such as durability, smoothness, depth and texture. It is an object of the present invention to provide a method for producing a cosmetic molded product from which a molded product can be obtained.

[0007]

According to the present invention, as a means for solving the above-mentioned problems, a first step of laminating a decorative sheet on a base material via a first adhesive and a second adhesive on a decorative sheet are provided. And a second step of laminating a transparent film through the method.

Further, the present invention provides, as another means for solving the above problems, a first step of laminating a decorative sheet on a base material via a first adhesive, and a transparent step on a decorative sheet via a second adhesive. Provided is a method for producing a decorative molded article, comprising a first step of laminating a film and a third step of laminating a transparent protective layer on a transparent film.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the method for producing a decorative molded article of the present invention will be described for each step, but the other steps are not particularly limited as long as the method of the present invention includes the following steps. Instead, before and after and between the following steps, ordinary processing steps performed by those skilled in the art can be appropriately added.

[0010] First, a process of a first step of laminating a decorative sheet on a base material via a first adhesive is performed. In the first step, after the first adhesive is applied on the base material, the decorative sheet is placed on the first adhesive, and is used at room temperature or under heating, at normal pressure or under pressure, preferably using a hot press. To obtain a laminate of the base material and the decorative sheet.

The shape, size and the like of the substrate used in the first step are not particularly limited and are appropriately determined depending on the application. For example, a flat or curved plate or a curved plate, or the like may be used.
Shallow bottom products such as plates and trays and deep drawn products such as cups may be used. Further, the base material can be newly prepared for a decorative molded product, or various existing molded products can be used as the base material.

Examples of the material used for the substrate include synthetic resins such as thermoplastic resins and thermosetting resins, wood, metals, ceramics, nonwoven fabrics, woven fabrics, papers and composites thereof. Among them, synthetic resins such as thermoplastic resins and thermosetting resins are preferred.

[0013] The decorative sheet used in the first step is preferably a sheet made of natural wood. For example, a wood veneer having a wood grain pattern obtained by cutting wood very thinly can be used. Also, a cloth made of natural or synthetic fibers can be used. In addition, this decorative sheet can be reinforced by adhering a reinforcing material such as a nonwoven fabric, paper, or a metal foil such as an aluminum foil to one surface of the decorative sheet with an adhesive, if necessary.

In the decorative sheet, when a reinforcing agent is used, the water content including the reinforcing agent is preferably more than 0% by weight and 12% by weight or less, more preferably 2 to 8% by weight. When the water content is within the above range, it is possible to prevent the decorative sheet from becoming brittle and being damaged during production of the decorative molded article, and from forming irregularities and bubbles on the surface of the decorative sheet.

The thickness of the decorative sheet can be appropriately set according to the application.
It can be 8 mm.

The decorative sheet can be preliminarily subjected to a treatment for enhancing aesthetics, such as coloring with a dye or a pigment, and can be cut into the same shape as the base material.

The first adhesive may be transparent or opaque, and preferably has good heat resistance. An acrylic resin-based adhesive, a urethane resin-based adhesive or the like can be used, and a sheet-like adhesive may be used.

When applying the hot pressing method in the first step, the temperature is 60 to 130 ° C., the pressure is 0.4 to 2.0 MPa.
It is desirable to carry out for 4 to 8 minutes.

Next, a process of a second step of laminating a transparent film via a second adhesive is performed on the decorative sheet of the laminate of the base material and the decorative sheet obtained in the first step. In the second step, after applying the second adhesive on the decorative sheet,
Place the transparent film on the second adhesive, at room temperature or under heating,
A decorative molded article is obtained by integrating under normal pressure or under pressure, preferably by a hot press method using a hot press machine.

As the transparent film used in the second step,
Polycarbonate resins, (meth) acrylate resins such as polymethyl methacrylate, propylene resins, styrene resins, polyamide resins, polyester resins such as polyvinylidene fluoride, polyethylene terephthalate, silicone resins, and copolymers thereof Or a mixture, for example, a film made of polyvinylidene fluoride / polymethyl methacrylate, etc., may be used, and two or more of the above-mentioned films may be laminated and used.

The transparent film may contain additives of a kind and amount which do not impair the transparency, for example, agents such as ultraviolet absorbers, fillers, coloring agents, antibacterial agents and the like.

As the second adhesive, a transparent and heat-resistant adhesive is preferable, and an acrylic resin-based adhesive, a urethane resin-based adhesive or the like can be used, and a sheet-like adhesive may be used.

When the hot pressing method is applied in the second step, the temperature is 60 to 80 ° C., the pressure is 1.0 to 3.0 MPa,
It is desirable to carry out for 4 to 6 minutes.

According to the production method of the present invention, after the above-mentioned second step, a third protective layer is further laminated on a transparent film.
Step processing can be added. This protective layer is for imparting scratch resistance to the transparent film.

The protective layer can be formed by applying a liquid resin-based coating agent on the transparent film and curing the resin. However, the protective layer is cured at room temperature so that the smoothness of the transparent film surface is not impaired by heat. , For example, a known UV-curable coating agent is preferably used.

In the manufacturing method of the present invention, a step of trimming the decorative sheet and the transparent film or the transparent film may be provided between the second step and the third step. This step is for matching the planar shape of the used base material with the planar shape of the decorative sheet or the transparent film, and in the case where the planar shape of the base material and the decorative sheet are previously matched in the first step. In the case where the planar shapes of the base material, the decorative sheet and the transparent film are matched in advance in the second step, it becomes unnecessary. The trimming process in this step is performed using, for example, a punching die and an NC router.

Further, in the manufacturing method of the present invention, a sheet having a thermal expansion coefficient (volume expansion coefficient) equal to or close to that of the decorative sheet is attached to the surface of the substrate opposite to the decorative sheet laminated surface with an adhesive or the like. An attaching step can be provided. The processing in this step is for preventing the decorative molded product from being warped or twisted due to a change in the ambient temperature when there is a difference in the coefficient of thermal expansion between the substrate and the decorative sheet. Therefore, the process of this step may be performed together with any of the above-described steps, or may be performed before, after, or between any of the steps.

A sheet whose thermal expansion coefficient is equal to or similar to that of a decorative sheet (hereinafter referred to as a “backing sheet”) is, for example, when a veneer veneer is used as a decorative sheet, A plate, a plywood, or the like can be used.

The thickness of the backing sheet is not particularly limited, and is preferably, for example, about the same as the thickness of the decorative sheet. Also,
The shape of the backing sheet is not particularly limited, as long as it can prevent warping and twisting of the decorative molded product, for example, a sheet having the same shape as the decorative sheet and a size equal to or less than a strip can be used. A plurality of shapes, circles, triangles, polygons more than a quadrangle, irregular shapes, and the like can be used. Therefore, when a plurality of strip-shaped or circular backing sheets are used, the strip-shaped or circular backing sheet can be attached to the back surface of the substrate at an appropriate interval.

As described above, the production method of the present invention involves the integration of the base material and the decorative sheet and the integration of the decorative sheet (the laminate of the base material and the decorative sheet) and the transparent film in separate steps. It is. The reason for stacking and integrating in separate steps in this way is that by applying appropriate conditions for stacking and integrating in each step, the adhesion strength between each layer is increased, and processing when applying a decorative molded product to each application This is to enhance the durability at the time, the durability over a long period of time, and secure the beauty of the appearance. Therefore, when the base material, the decorative sheet and the transparent film are stacked via an adhesive and integrated at a time by a hot press or the like, depending on the conditions of the hot press, the adhesion strength between the layers becomes insufficient, There is a possibility that the surface may be uneven and the appearance may be impaired.

In the production method of the present invention, a preferred embodiment is a case where the production is carried out using a base material made of synthetic resin, a decorative sheet made of a veneer veneer, and a transparent film made of synthetic resin. In the case where the lamination and integration of the first step and the second step are performed at one time,
The adhesion strength between the layers is reduced, and the appearance of the transparent film is mainly deteriorated.

The production method of the present invention can be applied to both flat and three-dimensional decorative molded articles, and can also be applied to the production of three-dimensional articles such as deep drawn articles. Cosmetic molded products obtained by the production method of the present invention, as it is or appropriately processed, various vehicles, various ships, furniture, exterior panels of home appliances,
It can be used for daily necessities and building materials.

[0033]

EXAMPLES The present invention will be described in more detail with reference to the following Examples, but it should not be construed that the invention is limited thereto. Example 1 ABS / polycarbonate alloy base material (thickness 4.0
Acrylic adhesive (trade name: VERSILOK, manufactured by LORDFAREAST) is coated on one side of a single-sided veneer (wood type bird's eye maple, thickness of 0. mm, 170 mm long, 100 mm wide). 2mm, 180mm in height, 110mm in width) are overlapped and hot-pressed by a hot press (temperature 65 ° C, pressure 0.4MPa, time 6)
Min) and integrated.

Next, after the above-mentioned adhesive is coated on the decorative sheet, a transparent film (thickness 0.5 mm) larger than the base material is overlaid thereon, and hot-pressed at a temperature of 60 ° C. (Pressure: 2.0 MPa, time: 6 minutes).

Next, after trimming the portion of the transparent film protruding from the base material with an NC router, an ultraviolet-curable acrylic resin-based coating agent (trade name: Roskirac UV Coat 9830, manufactured by Washin Chemical Industry Co., Ltd.) is applied to the transparent film. After coating, a protective layer was formed by irradiating with ultraviolet light to form a protective layer, and a cosmetic molded product was obtained. The surface of this cosmetic molded product was smooth and the grain of the main veneer could be seen through the protective layer and the transparent film, so that the cosmetic product had a beautiful appearance with depth and texture.

Next, the adhesive strength between the base material and the decorative sheet and the adhesive strength between the laminate of the base material and the decorative sheet and the transparent film were measured by the following methods. Table 1 shows the results. [Test method] A test piece was prepared by cutting a laminate of a base material and a decorative sheet into a 25 mm width, and the jig was fixed with the decorative sheet facing down so that the base material was not bent (see FIG. 1). And 8
It was left in a 0 ° C. oven for the time shown in Table 1. Thereafter, the distance (mm) at which the decorative sheet was peeled when a weight of 300 g was attached to one end (unfixed side) of the decorative sheet (L in FIG. 1).
That is, the standing time is equivalent to 0 minutes).
The adhesion strength was evaluated based on the distance increased from. The smaller the increase distance from the distance L, the greater the adhesion strength. In addition, the adhesion strength between the decorative sheet (the laminate of the base material and the decorative sheet) and the transparent film was measured according to the above-mentioned measurement method except that the decorative molded article was used.

[0037]

[Table 1]

Example 2 In Example 1, after the cutting step, an acrylic adhesive was coated on the substrate on the side opposite to the laminated surface of the decorative sheet, and the same wood veneer (thickness) as the decorative sheet was formed thereon. 0.
2mm, 150mm in height, 75mm in width) are overlapped and hot-pressed with a hot press (temperature 65 ° C, pressure 0.4MPa,
A decorative molded article was obtained in the same manner except that the resultant was integrated after 6 minutes).

COMPARATIVE EXAMPLE 1 Using the same base material, decorative sheet, transparent film and adhesive as in Example 2, the base material, the adhesive, the decorative sheet, the adhesive and the transparent film were superposed in this order, and the temperature was 65 ° C., the pressure was 2 .0
It was hot-pressed at once under the conditions of MPa and time of 8 minutes to obtain a decorative molded product.

When the cosmetic molded product of Example 2 and the cosmetic molded product of Comparative Example 1 were allowed to stand at 50 ° C. for 30 minutes and then left at 5 ° C. for 30 minutes as one cycle, a total of 50 cycles were repeated. The appearance of the decorative molded article was observed. as a result,
Although the decorative molded product of Comparative Example 1 was warped, the decorative molded product of Example 2 did not show any change.

[0041]

According to the production method of the present invention, compared to the conventional method including a step of injecting a resin into a molding die and integrating the production steps in the production process,
Since man-hours can be reduced and an existing base material can be used, manufacturing costs can be reduced. Further, the obtained decorative molded article has high durability due to high adhesion strength between the layers, and when used in a form using a backing sheet, particularly has excellent long-term shape stability.

[Brief description of the drawings]

FIG. 1 is a diagram for explaining a method of measuring the adhesion strength between layers in a decorative molded article.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Hideo Inoki 7 Higashi-Mobara, Mobara-shi, Chiba Pref. Inside the Kosuga-Mobara factory (72) Inventor Michio Sato 7 Higashi-Mobara, Mobara-shi, Chiba pref. Reference) 4F100 AK01A AK25G AK45A AK74A AL05A AP01B AR00B AR00C AR00D AT00A BA02 BA03 BA04 BA07 BA10A BA10C BA10D BA21B BA21D CB00 EC182 EG001 EJ201 EJ301 EJ421 GB07 GB31 GB33 GB48 HB00J JA02BJA02J01N

Claims (7)

[Claims] 1. A makeup comprising: a first step of laminating a decorative sheet on a base material via a first adhesive; and a second step of laminating a transparent film on the decorative sheet via a second adhesive. Manufacturing method for molded products. 2. A first step of laminating a decorative sheet on a base material via a first adhesive, a second step of laminating a transparent film on the decorative sheet via a second adhesive, and transparent on the transparent film A method for producing a decorative molded article comprising a third step of laminating a protective layer. 3. The method of manufacturing a decorative molded product according to claim 1, wherein the first and second steps are laminated by a hot press method. 4. The method according to claim 1, further comprising a step of trimming the decorative sheet and the transparent film or the transparent film between the second step and the third step. 5. The decorative molding according to claim 1, further comprising a step of attaching a sheet having a thermal expansion coefficient equal to or close to that of the decorative sheet on a surface of the substrate opposite to the decorative sheet laminated surface. The method of manufacturing the product. 6. The method according to claim 1, wherein the base material is made of a synthetic resin, and the decorative sheet is made of natural wood. 7. The method for producing a decorative molded product according to claim 1, wherein at least the second adhesive is transparent.