JP2004058599A - Molded article with surface decoration and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded article with surface decoration and a manufacturing method thereof which can provide inexpensively and simply a fine printed decoration on the surface of a three-dimensionally-shaped molded article having an indented or curved face and can respond also to a molded article which needs decoration for one article and in one mode for differentiation and individualization. <P>SOLUTION: The molded article with surface decoration has a three-dimensionally-shaped main body 2 of the molded article having the indented or curved face at least in a part of the surface and a decorating transfer layer 3 transferred onto a part of the surface of the main body 2 with heat and pressure. The decorating transfer layer 3 has a printed layer 5 whereon a character, a numeral, a mark, a pattern or other decoration is formed, a protective layer 7 which is in contact with the upper side of the printed layer 5 and protects this layer 5 and an adhesive layer 8 which is in contact with the lower side of the printed layer 5 and adheres to the surface of the main body 2 of the molded article. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a surface decoration molded product or a self-molded product in which a three-dimensional molded product having fine irregularities or curved surfaces such as a molded product of a humanoid robot's face is displayed with a realistic decoration. The present invention relates to a surface decoration molded product in which various decorations such as a realistic woodgrain tone are displayed. Furthermore, non-uniform and uniform decorations such as face photographs, holograms, identification symbols, barcodes or personal information for personal information devices such as mobile phones, electronic organizers, and IC cards are applied to the surface of molded products. It relates to the surface decoration molded product indicated.
[0002]
More specifically, characters, numbers, symbols, pictures, logos, graphic designs, and other detailed printing decorations are transferred to the surface of molded members such as three-dimensional shapes with irregularities or curved surfaces, realism, design, differentiation The present invention also relates to a surface decorative molded article which can have individuality and a method for producing the same.
[0003]
[Prior art]
In recent years, in order to differentiate molded products from design, ergonomic comfort, and inexpensive products, many industrial products have been designed to have a three-dimensional free surface shape or a shape incorporating fine irregularities. Furthermore, the surface shapes of the molded products are diversified, such as by changing the surface roughness of the molded products and adding a polished finish, and these are designed to enhance the design of these molded products and to differentiate and personalize them. It is often decorated with various and elaborate decorations that are not unique.
[0004]
In general, in decorating a molded article, a coating or a metal which forms a coating or a metal film on the surface of the molded article to protect the surface of the molded article by coating the surface of the molded article with a coating film to provide an anticorrosive, decorative effect, Direct printing or the like for printing a symbol or the like on the surface of a molded article is often used.
[0005]
However, coating and plating methods that cover the surface of such a molded product with a coating or film to protect the surface of the molded product require a large amount of simple decoration such as the same color or the same texture on the entire surface of the molded product. However, it is practically difficult to draw fine characters and symbols. In addition, although it is possible to print characters and symbols on the surface of a molded product close to a plate by using a direct printing method typified by a screen printing method or a pad printing method, a three-dimensional shape having severe unevenness or a curved surface is possible. It is difficult to decorate the surface of a molded article having a crack. Further, since only one color can be used in one printing, it is practically impossible to display a precise print decoration such as a picture, a graphic image, or a photograph requiring a plurality of colors on the surface of the molded article.
[0006]
Further, as another conventional technique, there is a method in which a print film or printing paper formed by printing is attached to the surface of a molded product.
[0007]
Further, as another conventional technique, a printed film on which characters, symbols, patterns, and the like are printed is sandwiched between injection molding dies to form a molded article by injection molding, and the surface of the molded article is applied with the printed film. There are decoration methods such as so-called in-mold injection and insert injection for decorating.
[0008]
Such in-mold injection or insert injection is suitable for decorating a predetermined single printed design on the surface of a molded product.
[0009]
[Problems to be solved by the invention]
However, in such a conventional decoration method of in-mold injection or insert injection, an expensive and special injection molding die is required, the injection molding conditions are difficult, and productivity is inferior. There is a disadvantage that the parts become expensive. In addition, since the injection molding of the molded product and the decoration with the print film are performed at the same time, it is suitable for molding a predetermined single print design in large quantities, but it has differentiation and individualization. However, it is not possible to cope with a case where it is desired to decorate a uniform molded product later, or a molded product formed by means other than injection molding. Further, the injection molding method injects a resin at a high temperature and a high pressure, so that the type and method of printing are limited. Furthermore, due to its manufacturing method, when decorating a molded article having a three-dimensional shape having irregularities or curved surfaces, the printed shape is deformed by the stretch of the molten film by the molten resin, or misalignment occurs, and it is unsightly. There was a drawback that it became something.
[0010]
In addition, in the method of attaching a printing film or printing paper to the surface of a molded product, it is difficult to attach a printing film or the like to a molded product in which unevenness, a curved surface shape, a three-dimensional free surface shape, or the like is frequently used, Furthermore, when the outer periphery of the molded product is formed in a complicated shape or a shape such as a hole or a notch in the molded product, the cutting and finishing of the print film are performed manually, which makes automation and industrialization difficult. there were.
[0011]
Therefore, the present invention has been made in order to solve the conventional problems as described above, and is simple and inexpensive and easily forms a three-dimensional shape having irregularities or curved surfaces without using an expensive injection molding die. Provided is a surface decorative molded product that can be subjected to fine print decoration on the surface of the product, and can easily cope with a molded product that requires uniform decoration in order to provide differentiation and individualization, and a method of manufacturing the same. Is an issue.
[0012]
Another object of the present invention is to provide a surface decorative molded article which does not require cutting and finishing the end face of the printing decoration, and a method of manufacturing the same.
[0013]
[Means for Solving the Problems]
In order to achieve this object, an invention according to claim 1 is a method of transferring a molded article body having a three-dimensional shape having irregularities or a curved surface at least on a part of the surface by heating and pressing to a part of the surface of the molded article body. And a decorative transfer layer, the decorative transfer layer protects the print layer by contacting the upper surface of the print layer and the print layer on which decorations such as letters, numbers, symbols, and patterns are formed. It is characterized by having a protective layer and an adhesive layer which is in contact with the lower surface of the printing layer and adheres to the surface of the molded article main body.
[0014]
The invention of the manufacturing method according to claim 2 is a method of manufacturing a surface decorative molded product in which a decorative transfer layer is transferred to a surface of a molded product body having a three-dimensional shape having irregularities or curved surfaces at least in part of the surface, A molding step in which the decorative transfer layer is formed on one surface of a resin film, and is formed into a shape that matches the external shape of the molded article body with the decorative transfer layer side of the resin film with the decorative transfer layer facing inside; And transferring the decorative transfer layer to the molded article main body by heating and pressing the decorative transfer layer while covering the resin film formed in the molding step on the molded article main body.
[0015]
The invention of the manufacturing method according to claim 3 is a method of manufacturing a surface decorative molded product in which a decorative transfer layer is transferred to a surface of a molded product body having a three-dimensional shape having irregularities or a curved surface at least in part of the surface, The decorative transfer layer is formed on one surface of the resin film, and the decorative transfer layer side of the resin film with the decorative transfer layer is set to the inside, and the external shape of the molded product body is adjusted using the molded product body. A molding step of molding and bringing into close contact with the molded article body by the molding step, and a transfer step of transferring the decorative transfer layer adhered to the molded article body to the molded article body by heating and pressing. I have.
[0016]
According to a fourth aspect of the present invention, in addition to the configuration of the second or third aspect, the heating and pressurizing in the transferring step heats the resin film, and a predetermined range of the heated resin film is applied. Only the decorative transfer layer corresponding to the pressurized predetermined range is transferred to the molded article main body.
[0017]
According to a fifth aspect of the present invention, in addition to the configuration described in any of the second to fourth aspects, the heating and pressurizing in the transfer step is performed using a heating and pressurizing body having a fluid substance. .
[0018]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0019]
[First Embodiment of the Invention]
1 to 9 show a first embodiment of the present invention.
[0020]
First, the structure will be described. In FIG. 1, reference numeral 1 denotes a surface decoration molded product. The surface decoration molded product 1 is a molded product main body 2 having a three-dimensional shape having an unevenness or a curved surface on a part of its surface. And a decorative transfer layer 3 transferred along the outer shape of the main body 2.
[0021]
The decorative transfer layer 3 transferred to the molded article body 2 is a thin film layer, and as shown in FIG. 2, an adhesive layer 8 for firmly bonding the molded article body 2 and the decorative transfer layer 3 to the innermost surface. A print layer 5 in contact with the upper surface of the adhesive layer 8 and printed with decorations such as characters, symbols, and patterns by an electronic printing device; and an ink component of the print layer 5 in contact with the upper surface of the print layer 5. The receiving layer 6 includes a receiving layer 6 and a protective layer 7 which is in contact with the upper surface of the receiving layer 6 and serves as the outermost surface of the decorative transfer layer 3 to protect the surface of the printing layer 5.
[0022]
In addition, before the decorative transfer layer 3 is transferred to the molded article main body 2, that is, when the decorative transfer layer 3 is formed on the surface of the resin film 4, the resin film 4 and the decorative transfer layer A release layer 9 from which the resin film 4 and the decorative transfer layer 3 can be easily separated between the protective layer 7 and the protective layer 7 is formed.
[0023]
In the first embodiment, the decorative transfer layer 3 is transferred to the upper surface of the molded article main body 2, but the present invention is not limited to this, and the decorative transfer layer 3 may be transferred to the entire surface of the molded article main body 2. Is also possible.
[0024]
Next, a method for manufacturing the surface decorative molded product 1 according to Embodiment 1 of the present invention will be described.
[0025]
First, the constituent members of the surface decoration molded product 1 will be described.
[0026]
The material of the resin film 4 on which the decorative transfer layer 3 to be transferred to the surface of the molded article main body 2 is formed may be basically any thermoplastic resin film. In consideration of the moldability of No. 4, polyester resins, acrylic resins, styrene resins, olefin resins, polycarbonate resins, ABS resins, polypropylene resins, polyarylate resins, vinyl chloride resins, and modified polymers thereof And a thermoplastic resin film such as an alloy compound.
[0027]
Specifically, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polypropylene, polyacrylate, polystyrene, polyvinyl chloride, and the like are exemplified, and a thermoplastic film that can be pressure-formed and / or vacuum-formed is used. The thickness of the resin film 4 is about 10 μm to 200 μm.
[0028]
Then, a release layer 9 made of a silicone release agent is coated on one side of the resin film 4 with a thickness of 1 μm or less. As described above, since the resin film 4 and the decorative transfer layer 3 are easily peeled off by coating the release layer 9 on one surface of the resin film 4, the decorative transfer layer 3 is transferred to the surface of the molded article body 2 described later. After that, the resin film 4 and the decorative transfer layer 3 can be surely peeled off.
[0029]
Further, the decorative transfer layer 3 having the protective layer 7, the print layer 5, and the adhesive layer 8 is formed on the resin film 4 with the release layer 9 interposed therebetween. The printed layer 5 of the decorative transfer layer 3 is formed by printing decorations such as characters, symbols, and pictures by an electronic printing apparatus. Then, the protective layer 7 is coated on one surface of the printing layer 5 using a method such as coating so that the printing layer 5 is not directly exposed to the surface when the decorative transfer layer 3 described later is transferred to the molded article body. It is formed on the other surface by using a method such as coating, painting, and transfer so that the decorative transfer layer 3 is reliably transferred to the surface of the molded article body 2 when the decorative transfer layer 3 is transferred to the molded article body 2. The adhesive layer 8 is formed to a thickness of about several μm.
[0030]
The protective layer 7 is basically a colorless transparent or colored transparent or translucent resin, for example, a urethane-based resin, a polyester-based resin, an acryl-based resin, a silicone-based resin, and the like. Characteristics such as abrasion resistance, high strength for a polyester resin, high hardness and scratch resistance for an acrylic resin, and antifouling properties for a silicone resin are obtained. Further, if necessary, a heat-resistant additive, an ultraviolet absorber, an anti-wear agent and the like can be incorporated in the material.
[0031]
As the printing layer 5, in order to easily perform complicated and richly designed printing, a thermal transfer printing method, a fusion transfer printing method, a sublimation transfer printing method, a toner transfer printing method, a heating color printing method, and an ink jet printing method are used. Using a printer which is at least one kind of electronic printing device of at least one of a printing method and a water developing type printing method, for example, from a color, a pattern, a symbol, etc. with a plurality of fine dots of three colors such as cyan, magenta, and yellow. The graphic print layer having the print layer 5 is transferred and formed on the surface of the molded article main body 2. Further, inks of three or more colors can be used to increase the color tone and gradation, and those expressing pseudo colors by software can also be used.
[0032]
Furthermore, it is also possible to add special inks such as aluminum, indium, gold, silver, chromium, carbon, fluorescent light, luminous, luminescent, pearl, and conductive.
[0033]
In addition, these printings can be combined with a metal deposition film, a sputtering thin film, a transfer foil and the like to be laminated, and decorative processing such as leather processing can be performed.
[0034]
Furthermore, if necessary, appropriate processing is performed on the print layer 5 in order to enhance the printability of these prints. For example, depending on the appropriate printing method, a receiving layer 6 of the printing ink, for example, in the case of sublimation type thermal transfer printing, a vinyl chloride-based, vinyl acetate-based or polyester-based coating layer may be formed, and in the case of inkjet printing, In order to fix the water-soluble or solvent-based ink, a water-absorbing layer of a polymer that easily absorbs the liquid may be formed.
[0035]
The adhesive layer 8 is selected in consideration of the adhesiveness and workability between the molded article main body 2 and the decorating transfer layer 3. For example, a vinyl chloride resin adhesive, a vinyl acetate alcohol resin adhesive, Examples thereof include a butadiene resin adhesive, an acrylic resin adhesive, a polyester resin adhesive, an ABS resin adhesive, a polyurethane resin adhesive, and a polyvinyl alcohol resin adhesive. Further, examples of the adhesive include a hot melt type, a solvent volatile type, a moisture curable type, a two-part curable type, a photocurable type, an electron beam curable type, and the like. In consideration of bonding, it is preferable to use a hot melt type.
[0036]
Thereby, the decorative transfer layer 3 to be transferred to the molded article body 2 having a three-dimensional shape having a curved surface can be formed on the surface of the resin film 4.
[0037]
The material of the molded article main body 2 is not particularly limited, but if it is a resin, a polyester resin, an acrylic resin, a styrene resin, an olefin resin, a polycarbonate resin, an ABS resin, a polypropylene resin, Examples include polyarylate resins, vinyl chloride resins, polyurethane resins, polystyrene resins, and composites, derivatives, modified products, and elastomer resins thereof. Further, among the resins, as long as the resin is a cured resin material, a polyurethane resin, a polyester resin, a melamine resin, an epoxy resin, an acrylic resin, a methacrylic resin, a silicone resin and the like are exemplified. In addition, as a production method, molding is performed using a method such as injection molding, transfer molding, compression molding, blow molding, vacuum molding, extrusion molding, calendar molding, casting molding, casting molding, cutting processing and the like. Furthermore, if it is a metal-based material, iron, aluminum, stainless steel, copper, brass and the like can be mentioned, and as a manufacturing method, it is formed using a method such as cutting, casting, or forging.
[0038]
In the first embodiment, the shape of the molded article main body 2 is simply formed into a three-dimensional shape having a curved surface. However, the present invention is not limited to this, and the surface of the molded article main body 2 may have fine irregularities or surface roughness. It is also possible to change the polished finish.
[0039]
Next, a molding step of molding the resin film 4 according to the present invention into a shape conforming to the outer shape of the molded article main body 2 will be described in detail with reference to examples in accordance with the order of the steps in FIGS.
[0040]
As a molding method for molding the resin film 4 on which the decorative transfer layer 3 is formed into a curved surface shape according to the outer shape of the molded article main body 2, air pressure vacuum molding or the like is used.
[0041]
When the resin film 4 on which the decorative transfer layer 3 is formed is formed into a curved shape conforming to the outer shape of the molded article main body 2, a far-infrared heater or the like is used before setting the resin film 4 in a mold. Preheat.
[0042]
The temperature at which the resin film 4 is preheated is determined by the material of the resin film 4, but is generally in the range of about 100 to 250 ° C., more preferably in the range of 120 to 200 ° C., at a temperature at which the thermoplastic resin softens. It is good to set. For example, in the case of an ABS-based thermoplastic resin film having a thickness of 150 μm, preheating may be performed until the thermoplastic resin film reaches about 120 ° C. The preheating time at this time is about several seconds.
[0043]
The preheated and softened resin film 4 is introduced into a mold 10 for pressurized vacuum forming as shown in FIG. 3 in the case of pressurized vacuum forming.
[0044]
The molding die 10 is composed of two upper and lower dies, an upper die 11 and a lower die 12, and has a predetermined lower temperature than the preheated die so that the softened resin film 4 can be cooled and solidified. Kept at temperature. Then, as shown in FIG. 4, the resin film 4 is inserted into the molding die 10 with the decorative transfer layer 3 formed on the resin film 4 facing the lower die 12, and the upper die 11 and the lower metal The upper mold 11 is connected to an air pump 14 through an air hole 13, and compressed air for molding is applied from the upper mold 11.
[0045]
The pressure of the air is adjusted according to the moldability of the resin film 4, but is generally set to a pressure of about 0.1 to 1 MPa. The lower mold 12 is provided with a three-dimensional projection 15 having a curved surface for extending the resin film 4 into the same curved shape as the surface of the molded article main body 2. Is connected to a vacuum pump 17 via a vacuum exhaust hole 16.
[0046]
The preheated resin film 4 is deformed by a compressed air force from above and a vacuum force from below while being sandwiched between the forming molds 10 of the upper mold 11 and the lower mold 12, as shown in FIG. As shown, the resin film 4 is deformed along the protrusion 15 of the lower mold 12 to form a curved shape. The resin film 4 in contact with the lower mold 12 is cooled by the lower mold 12 and solidified to complete the formation of a curved surface on the resin film 4 with the decorative transfer layer 3.
[0047]
When the resin film 4 is formed, the decorative transfer layer 3 is in close contact with the lower mold 12 of the molding die 10, so that the decorative transfer layer 3 does not adhere to the lower mold 12. It is desirable that a release coating or plating of silicone or Teflon (registered trademark) or the like be provided on the surface of the substrate.
[0048]
As described above, the pressurized air vacuum forming requires only a heater for heating the resin film 4 and a simple forming die 10 having a concave portion, so that molding can be performed with very inexpensive facilities, and the productivity is low. Also, productivity several times higher than that of injection molding can be obtained.
[0049]
When it is difficult to sufficiently deform the resin film 4 only by the compressed air or the vacuum force when the resin film 4 is formed into a shape conforming to the outer shape of the molded article main body 2, for example, a molding die The projection 15 and the bottom surface of the lower mold 12 of the 10 are formed to be vertically movable. Then, the protrusions 15 and the bottom surface which are formed to be movable up and down when the air-pressure vacuum molding is performed are moved toward the resin film 4, and the resin film 4 is pressed from below to form the resin film along the shape of the protrusions 15. 4 can also be sufficiently deformed.
[0050]
Also, the resin film 4 is not limited to the case of the compressed air vacuum forming, but is formed by using one forming method selected from vacuum forming, pressure forming, and compression forming. It can also be formed into a shape.
[0051]
For example, in the case of vacuum forming, by removing air from the vacuum holes provided in the concave portion of the mold and making the concave portion vacuum, the heated and softened resin film 4 is deformed to form the concave portion and the molded product. What is necessary is just to make a curved shape by closely contacting the protrusion formed in the same outer shape as the main body 2. On the other hand, in the case of pressure molding, the resin film 4 is deformed from the side of the resin film 4 by using the pressure of air to form the concave portion of the mold and the protrusion formed in the same outer shape as the molded article main body 2. Adhere.
[0052]
At this time, since the molding die is cooled, the softened resin film 4 is brought into close contact with the recesses and projections of the molding die and is cooled and solidified at the same time, and a desired shape is formed on the resin film 4. Further, in the compression molding method, after the resin film 4 is heated to a temperature at which the resin film 4 is softened, the resin film 4 is sandwiched between two cooled molding dies having predetermined concave portions and convex portions, and a pressure for closing the molding dies. Is a method of forming the resin film 4 into the surface shape of the molded article main body 2 by using the method shown in FIG.
[0053]
As described above, in the compression molding, since a pair of concave and convex molds can be used, molding can be performed with very inexpensive equipment, and the productivity can be several times higher than that of injection molding.
[0054]
Next, after the resin film 4 molded into the outer shape of the molded article body 2 was taken out from the molding die 10, the resin film 4 was molded inside the curved surface shape molded into the resin film 4 by the above-described manufacturing method in advance. A transfer in which the molded article main body 2 is disposed, the decorative transfer layer 3 is heated and pressed, and the decorative transfer layer 3 is brought into close contact with the surface of the molded article main body 2 to transfer the decorative transfer layer 3 to the surface of the molded article main body 2. The steps will be described in detail with reference to an example according to the order of the steps in FIGS.
[0055]
As shown in FIG. 6, first, the molded article main body 2 is disposed on a positioning jig 18 for disposing the molded article main body 2 and the resin film 4 at predetermined positions, and then molded so as to cover the molded article main body 2. The resin film 4 formed into the outer shape of the molded article main body 2 by the process is arranged on the positioning jig 18, and the resin film 4 and the molded article main body 2 are overlapped and adhered at a predetermined position. Then, as shown in FIG. 7, the decorative transfer layer 3 is transferred onto the surface of the molded article main body 2 by heating and pressing the resin film 4 arranged on the positioning jig 18 and in close contact with the molded article main body 2.
[0056]
As the heating and pressurizing, the surface of the resin film 4 arranged on the positioning jig 18 and in close contact with the molded article main body 2 is heated using an infrared heater or the like (not shown). Thereby, the decorative transfer layer 3 formed on the resin film 4 is also heated.
[0057]
The temperature at which the resin film 4 is heated is determined by the material of the resin film 4, but may be heated until the surface of the resin film 4 reaches about 100 ° C. The heating time at this time is about several seconds.
[0058]
Then, the surface of the heated resin film 4 is uniformly evacuated by air pressure from an air pump or the like (not shown) to bring the decorative transfer layer 3 into close contact with the surface of the molded article main body 2 and sufficiently evacuate. Thereby, the adhesive layer 8 of the decorative transfer layer 3 formed on the resin film 4 is adhered to the surface of the molded article main body 2, and the transfer of the decorative transfer layer 3 to the surface of the molded article main body 2 is completed.
[0059]
The pressure of the air is adjusted depending on the transferability of the decorative transfer layer 3, and is preferably set to a pressure of about 0.1 to 1 MPa.
[0060]
In the heating and pressurizing, even if the resin film 4 is heated above the range of the decorative transfer layer 3 to be transferred to the molded article main body 2, the pressurizing range is set within a predetermined range, so that the decoration within the predetermined range is performed. Only the transfer layer 3 can be transferred to the molded article main body 2.
[0061]
The heating and pressurization of the resin film 4 causes the heated resin film 4 to come into close contact with the molded article body 2 by pressurization, so that the decorative transfer layer 3 is transferred. That is, when the entire resin film 4 is heated and pressurized, the entire decorative transfer layer 3 is transferred to the molded article main body 2, and when only a predetermined range of the heated resin film 4 is pressurized, the pressurized predetermined range is reduced. Only the corresponding decorative transfer layer 3 is transferred to the molded article main body 2, and the decorative transfer layer 3 corresponding to the range where no pressure is applied is held by the resin film 4. In addition, the decorative transfer layer 3 in a portion that is heated and pressed but is not in close contact with the molded article main body 2 is not transferred to the molded article main body 2 but is held by the resin film 4.
[0062]
Then, after transferring the decorative transfer layer 3 formed on the resin film 4 to the surface of the molded article body 2 by heating and pressing, the resin film 4 adhered to the molded article body 2 is peeled off from the molded article body 2. Then, since the decorative transfer layer 3 is a thin film layer, the decorative transfer layer 3 is pressed and transferred to the molded article main body 2, and the decorative transfer layer 3 is held in the resin transfer film 4 without being pressed with the decorative transfer layer 3. The decorative transfer layer 3 is cut off at the boundary with the layer 3, one of which is in a state of being transferred to the molded article main body 2, and the other is in a state of being held by the resin film 4 and is removed at the same time as the resin film 4. The surface decoration molded product 1 is obtained.
[0063]
For example, as shown in FIG. 8, a molded article main body 2 having a curved surface shape on a part of the upper surface 2 c and a through hole 2 a formed in the curved surface shape 2 c, and a decorative transfer layer 3 over the entire resin film 4. When the decorative transfer layer 3 is transferred only to the upper surface 2c of the molded article main body 2 by using the resin film 4 formed into the outer shape of the molded article main body 2 by the molding method described above, After the molded article main body 2 and the resin film 4 are arranged on the positioning jig 18 and overlapped with each other, the decorative transfer layer 3 is heated, and only the curved area A of the resin film 4 is pressed. Then, the decorative transfer layer 3 is transferred only to the upper surface 2c of the molded product main body 2, and the decorative transfer layer 3 is not transferred to the side surface 2b of the molded product main body 2 which is not pressurized, and is held by the resin film 4. State. Although the resin film 4 on the upper surface of the through hole 2a is heated and pressurized, the decorative transfer layer 3 on the upper surface of the through hole 2a is made of resin because the molded article main body 2 is not in close contact with the resin film 4. The state is held by the film 4. Further, after transferring the decorative transfer layer 3 to the surface of the molded article main body 2 by heating and pressing, as shown in FIG. 9, when the resin film 4 adhered to the molded article main body 2 is peeled off from the molded article main body 2, Since the decorative transfer layer 3 is a thin film layer, the decorative transfer layer 3 is pressed at the boundary between the decorative transfer layer 3 transferred to the molded article body 2 and the decorative layer 3 held by the resin film 4 without being pressed. The decorative transfer layer 3 is cut, and the decorative transfer layer 3 that is not pressed is removed while being held by the resin film 4. In addition, the decorative transfer layer of the portion which is not heated and pressed or the portion which is not heated and pressurized but is not in close contact with the molded article main body 2, such as the decorative transfer layer 3 formed on the upper surface of the through hole 2a. 3 is also removed while being held by the resin film 4.
[0064]
The surface decorative molded product 1 configured as described above is formed on a surface of a molded product main body 2 having a shape such as irregularities or a curved three-dimensional shape by a molding method so as to conform to the outer shape of the molded product main body 2, The molded article main body 2 is disposed inside the resin film 4 on which the decorative transfer layer 3 on which numbers, symbols, pictures, etc. are printed is formed, and the resin film 4 is heated and pressed to decorate the molded article main body 2. The transfer of the layer 3 makes it possible to manufacture a simple and inexpensive product without the need for a large-scale apparatus or an expensive molding die, and to easily and precisely print the molded product body 2 having a shape such as irregularities or a three-dimensional curved surface. Decoration can be formed.
[0065]
Further, instead of simultaneously performing the decorating performed on the surface of the molded article main body 2 and the molded article main body 2 having a shape such as unevenness or a three-dimensional curved surface as in the prior art injection molding method, a molded article molded in advance is used. Since the decoration is transferred to the main body 2, it is possible to easily cope with a case where a uniform decoration is required later in order to impart differentiation and individuality to the molded article main body 2.
[0066]
Further, the decorative transfer layer 3 includes a print layer 5 formed by an electronic printing device, a protective layer 7 formed so that the print layer 5 is not directly exposed to the outside, the molded article body 2 and the decorative transfer layer. Since the decorative transfer layer 3 has an adhesive layer 8 for adhering the decorative transfer layer 3 to the decorative transfer layer 3, the decorative transfer layer 3 is rich in design, is excellent in abrasion resistance and abrasion resistance. Transfer to the molded article main body 2 can be ensured.
[0067]
In addition, since the transfer performed by heating the resin film 4 and pressing a predetermined location is performed by transferring the molded product main body 2 to the molded product main body 2 according to the state of close contact between the molded product main body 2 and the resin film 4 at the pressurized location, it is necessary. Since the decorative transfer layer 3 can be formed only in the place to be formed, any decoration can be performed at an arbitrary position on the molded article body 2 having a three-dimensional shape such as a curved surface shape, a complicated hole, and a notch. Can be.
[0068]
[Embodiment 2]
FIG. 10 shows a second embodiment of the present invention, and is a view showing another manufacturing step of the first embodiment.
[0069]
In the second embodiment, as shown in FIG. 10, a molded article main body 2 for transferring a decorative transfer layer 3 formed on a resin film 4 to a lower mold 12 of a molding mold 10 is arranged at a predetermined position. Then, the preheated and softened resin film 4 is introduced into a molding die 10 for compressed air vacuum molding.
[0070]
The resin film 4 is sandwiched between the molding dies 10 of the upper mold 11 and the lower mold 12, and is formed into an outer shape of the molded article main body 2 by a compressed air force from above and a vacuum force from below. The resin film 4 is deformed along and adheres to the molded article main body 2 to form a curved shape on the resin film 4. The resin film 4 in contact with the lower mold 12 and the molded article main body 2 is cooled by the lower mold 12 and the molded article main body 2, solidified, and adheres to the molded article main body 2 on the resin film 4 with the decorative transfer layer 3. The molding of the curved surface is completed.
[0071]
Next, in a molding step, the resin film 4 formed in close contact with the surface of the molded article main body 2 and the molded article main body 2 are mounted on the positioning jig 18 in a state of being in close contact with each other. The decorative transfer layer 3 is transferred to the surface of the molded article main body 2 by heating and pressing in the same manner as described above.
[0072]
As described above, by molding the resin film 4 using the molded article main body 2 on the molding die 10, the molding die 10 for compressed air and vacuum can be formed in a simpler shape, so that molding can be performed with less expensive equipment. It becomes. Further, since the resin film 4 is deformed into a curved shape conforming to the outer shape of the molded product main body 2 and is in close contact with the molded product main body 2 at a predetermined position, the resin film 4 has an inner side of the curved shape of the resin film 4 in a transfer step described later. It is possible to reduce the work of arranging the molded article main body 2 in the apparatus.
[0073]
Other configurations and operations are the same as those of the first embodiment of the present invention, and a duplicate description will be omitted.
[0074]
Third Embodiment of the Invention
FIG. 11 shows a third embodiment of the present invention, and is a view showing another transfer step of the first embodiment.
[0075]
In the third embodiment, the heating and pressurizing of the surface of the resin film 4 in the transfer step is performed using a heating and pressing body, and the decorative transfer layer 3 formed on the resin film 4 is transferred to the surface of the molded article main body 2. Things.
[0076]
The heating and pressurizing body includes a balloon body 20 for heating and pressurizing the resin film 4 and a balloon pressurizing body 21 for pressing the balloon body 20.
[0077]
The balloon body 20 is a balloon made of silicone rubber which is rich in heat resistance and fluidity, and the thickness of the balloon body 20 is about 1 mm. The balloon pressurizing body 21 is a heat-resistant metal body or the like, and has a shape capable of sufficiently pressing the balloon body 20.
[0078]
Then, when the decorative transfer layer 3 formed on the resin film 4 is transferred to the surface of the molded article main body 2, the inside of the balloon body 20 is filled with air. The amount of air to be charged is inflated to about 30 to 70% of the state when the balloon body 20 is in the maximum inflated state.
[0079]
Further, the expanded balloon body 20 is placed between a pair of heated hot plates (not shown), and the balloon body 20 is sandwiched and heated. The temperature at which the surface of the balloon 20 is heated is preferably set to a temperature in the range of 100 to 150 ° C. depending on the material of the balloon 20.
[0080]
Furthermore, the balloon pressurizing body 21 that presses the balloon body 20 is heated. The temperature at which the balloon pressurizing body 21 is heated is determined by the material of the balloon pressurizing body 21, but is preferably set to a temperature in the range of 100 to 150 ° C. By heating the balloon pressurizing body 21 in this manner, when the balloon pressurizing body 21 described below is brought into close contact with the balloon body 20 and pressed, the temperature of the balloon body 20 is not reduced, and thus the heated balloon The body 20 can sufficiently heat the surface of the resin film 4.
[0081]
Then, similarly to the first embodiment, the heated balloon body 20 is arranged on the upper surface of the resin film 4 arranged so as to cover the surface of the molded article main body 2 arranged on the positioning jig 18. Further, a balloon pressurizing body 21 is arranged above the heated balloon body 20, and the balloon pressurizing body 21 is moved toward the resin film 4 to sufficiently press the balloon body 20.
[0082]
The balloon body 20 pressed by the balloon pressurizing body 21 uniformly adheres along the entire surface of the resin film 4, and heats and presses the resin film 4 to apply the heat formed on the resin film 4 to the surface of the molded article body 2. The decoration transfer layer 3 is transferred.
[0083]
In the second embodiment, the inside of the balloon 20 is filled with air and expanded, but the present invention is not limited to this, and a liquid may be filled instead of air. For example, when hot water is used as the liquid, the balloon 20 may be filled at a temperature set in the range of 80 to 100 ° C. When oil or the like is used as the liquid material, it is preferable to set the temperature in the range of 100 to 150 ° C. and fill the balloon 20. The liquid such as oil is hard to cool and is filled inside the balloon 20. It is preferable as a filler.
[0084]
As described above, since the resin film 4 is heated and pressed using the fluid balloon body 20 as the heating and pressing body, the resin film 4 can be uniformly heated and pressed along the curved surface of the resin film 4. And stable transfer can be performed.
[0085]
Other configurations and operations are the same as those of the first embodiment of the present invention, and a duplicate description will be omitted.
[0086]
[Embodiment 4]
FIG. 12 shows a fourth embodiment of the present invention, and is a view showing another transfer step of the first embodiment.
[0087]
In the fourth embodiment, the heating and pressurizing of the surface of the resin film 4 in the transfer step is performed using a heating and pressing body, and the decorative transfer layer 3 formed on the resin film 4 is transferred to the surface of the molded article main body 2. Things.
[0088]
The heating and pressurizing body includes an outer balloon body 22 for heating and pressurizing the resin film 4, a plurality of inner balloon bodies 23 disposed inside the outer balloon body 22 for heating and pressurizing the resin film 4, an outer balloon body 22 and the inner balloon. And a balloon pressurizing body 21 for pressing the body 23.
[0089]
The outer balloon body 22 and the inner balloon body 23 are balloons made of silicone having high heat resistance and fluidity and have a thickness of about 1 mm, and at least the inner balloon body 23 has a size that can be arranged inside the outer balloon body 22. And The balloon pressurizing body 21 is a heat-resistant metal body or the like, and has a shape capable of sufficiently pressing the outer balloon body 22 and the inner balloon body 23.
[0090]
Further, the outer balloon 22 has an inlet 24 for injecting heated air into the outer balloon 22, and an outlet for discharging the air injected from the inlet 24 to the outside of the outer balloon 22. 25 are formed.
[0091]
Then, when the decorative transfer layer 3 formed on the resin film 4 is transferred to the surface of the molded article main body 2, the inside of the inner balloon 23 is filled with air. The amount of air to be filled is inflated to about 30 to 70% of the state when the inner balloon 23 is in the maximum inflated state.
[0092]
Further, the inflated inner balloon body 23 is placed between a pair of heated hot plates (not shown), and the inner balloon body 23 is sandwiched and heated. The temperature at which the surface of the inner balloon 23 is heated is determined by the material of the inner balloon 23, but is preferably set to a temperature in the range of 100 to 150C.
[0093]
Furthermore, the balloon pressurizing body 21 that presses the outer balloon body 22 and the inner balloon body 23 is heated in the same manner as in the second embodiment.
[0094]
The heated plurality of inner balloons 23 are arranged inside the outer balloon 22 and arranged so as to cover the surface of the molded article body 2 arranged on the positioning jig 18 as in the first embodiment. The outer balloon body 22 in which the inner balloon body 23 is disposed on the upper surface of the resin film 4 thus arranged. Further, the inside of the outer balloon body 22 is filled with heated air from an inlet 24 formed in the outer balloon body 22. The temperature of the heated air is preferably set to a temperature in the range of 100 to 150 ° C. Further, by discharging the air filled in the outer balloon body 22 from the discharge port 25 formed in the outer balloon body 22, the air filled in the outer balloon body 22 is circulated, and the temperature inside the outer balloon body 22 is reduced. Can be kept constant.
[0095]
Then, the balloon pressurizing body 21 is arranged above the outer balloon body 22, and the balloon pressurizing body 21 is moved toward the resin film 4 to sufficiently press the outer balloon body 22 and the inner balloon body 23. .
[0096]
The outer balloon body 22 and the inner balloon body 23 pressed by the balloon pressurizing body 21 are uniformly adhered along the entire surface of the resin film 4 to heat and press the resin film 4 to form a resin on the surface of the molded article body 2. The decorative transfer layer 3 formed on the film 4 is transferred.
[0097]
In the third embodiment, the inside of the inner balloon 20 is filled with air. However, the present invention is not limited to this, and a liquid can be filled instead of air as in the second embodiment. .
[0098]
As described above, the heating and pressurizing of the resin film 4 is performed using the fluid balloon body, which is double-structured and can maintain a constant temperature, as the heating and pressurizing body. Heat and pressure can be uniformly applied along the molded surface, and the temperature of the heating and pressing body can be kept constant, so that the transfer can be performed more stably without being affected by the outside air temperature. it can.
[0099]
Other configurations and operations are the same as those of the first or second embodiment of the present invention, and a duplicate description will be omitted.
[0100]
[Embodiment 5]
FIG. 13 shows a fifth embodiment of the present invention, and is a view showing another transfer step of the first embodiment.
[0101]
In the fifth embodiment, the heating and pressurizing of the surface of the resin film 4 in the transfer step is performed by using a heating and pressing body, and the decorative transfer layer 3 formed by printing on the resin film 4 is transferred to the surface of the molded article main body 2. It is to let.
[0102]
The heating and pressurizing body includes a frame 26 formed in an annular shape around the resin film 4 and a heat-resistant gel 27 in a gel state filled in an internal space 26a of the frame 26 formed in an annular shape. I have.
[0103]
Examples of the material of the frame 26 include stainless steel and aluminum as long as the material is a metal-based material. Further, if it is a plastic, engineering plastics such as polyacetal, polycarbonate, polyethersulfone, polyetheretherketone, and a fluorine-based resin represented by PTFE may be used.
[0104]
Then, similarly to the first embodiment, the frame 26 is formed in a ring shape on the upper surface of the resin film 4 arranged so as to cover the surface of the molded article main body 2 arranged on the positioning jig 18. The frame 26 formed in an annular shape has a water stopping effect such that the heat-resistant gel 26 does not leak from the internal space 26a when the internal space 26a of the frame 26 is filled with the heat-resistant gel 26.
[0105]
Next, the heat-resistant gel 27 is heated when the heat-resistant gel 27 is filled in the inner space 26a of the ring-shaped frame 26.
[0106]
As the material of the heat-resistant gel 27, polymer gels, particularly heat-resistant, are desirable. Specific examples include a vinyl chloride gel, a polyvinyl chloride gel, a silicone gel, and a fluorine gel. The temperature for heating the heat-resistant gel 27 is preferably set to a temperature in the range of 100 to 150 ° C.
[0107]
Then, the heated heat-resistant gel 27 is filled in the internal space 26a of the frame 26 formed in a ring shape. The resin film 4 is heated by uniformly filling the heated heat-resistant gel 27 along the entire surface of the resin film 4, and the resin film 4 is uniformly pressed by the weight of the filled heat-resistant gel 27. The decorative transfer layer 3 formed on the resin film 4 is transferred to the surface of the molded article main body 2. The amount of the heat-resistant gel 27 to be filled is such that at least the resin film 4 is sufficiently pressed to transfer the decorative transfer layer 3 to the molded article main body 2.
[0108]
As described above, since the heat and pressure of the resin film 4 is performed by using the heat-resistant gel 27 in the gel state as the heating and pressurizing body, the resin film 4 easily conforms to the curved surface of the resin film 4 and the entire surface of the resin film 4 Can be uniformly pressed, so that more stable transfer can be performed.
[0109]
Other configurations and operations are the same as those of the first embodiment of the present invention, and a duplicate description will be omitted.
[0110]
【The invention's effect】
As described above, according to the first aspect of the present invention, a molded article body having a three-dimensional shape having irregularities or a curved surface on at least a part of its surface, and a part of the surface of the molded article body is heated and pressed. A decorative transfer layer that has been transferred, and the decorative transfer layer protects the print layer by contacting the print layer on which decorations such as letters, numbers, symbols, and patterns are formed, and the upper surface of the print layer Since it has a protective layer and an adhesive layer that is in contact with the lower surface of the printing layer and adheres to the surface of the molded article main body, it is inexpensive without using an expensive injection molding die, and easily has irregularities or curved surfaces. The surface of the molded article body having a three-dimensional shape can be finely printed and decorated, and it can easily cope with a molded article body that requires uniform decoration in order to provide differentiation and individuality. In addition, the decorative transfer layer has a protective layer on the outer surface, so it has excellent wear resistance and abrasion resistance. Can be transferred to the surface.
[0111]
According to the invention as set forth in claim 2, in the method of manufacturing a surface decorative molded product in which a decorative transfer layer is transferred to a surface of a molded product body having a three-dimensional shape having irregularities or curved surfaces at least in part of the surface, A decorative transfer layer is formed on one surface of the resin film, and a molding step of molding the decorative transfer layer side of the resin film with the decorative transfer layer into a shape according to the outer shape of the molded article body with the decorative transfer layer side inward, A transfer step of covering the resin film formed in the molding step on the molded article body, heating and pressurizing the decorative transfer layer and transferring the decorative transfer layer to the molded article body, so that an expensive injection molding die is provided. Without using, it is possible to manufacture simple and inexpensive products, and it is possible to easily and precisely print and decorate the surface of the molded product body with irregularities or curved three-dimensional shapes, etc., and to provide differentiation and individualization One piece uniform decoration for Also in molding body required it can be easily accommodated.
[0112]
According to the invention described in claim 3, in the method for producing a surface decorative molded product in which a decorative transfer layer is transferred to a surface of a molded product body having a three-dimensional shape having irregularities or curved surfaces at least in part of the surface, The decorative transfer layer is formed on one surface of the resin film, and the shape of the resin film with the decorative transfer layer is adjusted to the outer shape of the molded product body using the molded product body with the decorative transfer layer side inward. And a transfer step of heating and pressing the decorative transfer layer adhered to the molded article body to transfer the decorative transfer layer to the molded article body by the molding step. Without using a molding die, the molding die can be made into a simpler shape, so it is a very inexpensive facility, and furthermore, it is possible to reduce the number of working steps, so that it is possible to easily manufacture an inexpensive product, Uneven or curved solid The can be easily precise print decoration on the surface of the molded article body shape can be easily accommodated in the molded article body required dish uniform decoration in order to provide differentiated and individualized.
[0113]
According to the invention as set forth in claim 4, the heating and pressurizing in the transfer step heats the resin film, pressurizes only a predetermined range of the heated resin film, and pressurizes the predetermined range. Since only the decorative transfer layer corresponding to (1) is transferred to the molded article main body, the decorative transfer layer can be formed only at a necessary place in addition to the effect according to claim 2 or 3. Therefore, an arbitrary decoration can be performed at an arbitrary position on a molded product body having a three-dimensional shape such as a curved surface shape, a complicated hole, and a notch.
[0114]
According to the fifth aspect of the present invention, the heating and pressurizing in the transfer step is performed by using a heating and pressurizing body having a fluid substance, so that in addition to the effects described in any one of claims 2 to 4, In addition, since the surface of the resin film can be uniformly heated and pressed, stable transfer can be performed on the molded article main body.
[Brief description of the drawings]
FIG. 1 is a longitudinal sectional view of a main part of a surface decorative molded product according to Embodiment 1 of the present invention.
FIG. 2 is an enlarged longitudinal sectional view of a main part of the decorative transfer layer according to the first embodiment.
FIG. 3 is an essential part longitudinal cross sectional view of a state before setting the resin film in a mold, showing a method of forming the resin film by pressurized air vacuum forming according to Embodiment 1;
FIG. 4 is an essential part longitudinal cross sectional view of a state in which the resin film is set in a mold, showing a method of forming the resin film by pressurized air vacuum forming according to Embodiment 1;
FIG. 5 is a vertical cross-sectional view of a main part in a state where the molding of the resin film has been completed, illustrating a method of molding the resin film by compressed air vacuum molding according to the first embodiment.
FIG. 6 is an essential part longitudinal cross sectional view of a state before setting the molded article main body and the resin film in a jig, showing a method of transferring by heating and pressing according to the first embodiment.
FIG. 7 is a vertical cross-sectional view of a main part in a state in which transfer to a molded article body has been completed, illustrating a method of transferring by heating and pressing according to the first embodiment.
FIG. 8 is an essential part longitudinal cross sectional view showing a method of transferring by heating and pressing according to the first embodiment, in a state where transfer to a molded article main body having a through hole is completed.
FIG. 9 is a longitudinal sectional view of an essential part showing a method of transferring by heating and pressing according to the first embodiment, showing a state in which transfer to a molded article main body having a through hole is completed and a resin film is peeled off; .
FIG. 10 is a longitudinal sectional view of an essential part in a state in which molding of a resin film has been completed using a molded article main body, showing a method of molding a resin film by compressed air vacuum molding according to Embodiment 2 of the present invention.
FIG. 11 is a fragmentary longitudinal sectional view showing a method for transferring heat and pressure by a heating and pressurizing member of a balloon body according to Embodiment 3 of the present invention.
FIG. 12 is a vertical sectional view of a main part showing a method for transferring the heating and pressurization by a heating and pressurizing body of a balloon body having a double structure according to Embodiment 4 of the present invention;
FIG. 13 is a fragmentary longitudinal sectional view showing a method for transferring heat and pressure by a heat and pressure body of a heat-resistant gel and a frame according to Embodiment 5 of the present invention.
[Explanation of symbols]
1 Surface decoration molded product
2 Molded product body
3 Decorative transfer layer
4 Resin film
5 Printing layer
7 Protective layer
8 Adhesive layer

Claims (5)

A molded article main body having a three-dimensional shape having irregularities or a curved surface on at least a part of the surface, and a decorative transfer layer transferred by heating and pressing to a part of the surface of the molded article main body,
The decorative transfer layer is a print layer on which decorations such as letters, numbers, symbols, and patterns are formed, a protective layer that contacts the upper surface of the print layer to protect the print layer, and contacts the lower surface of the print layer. A surface decorative molded product, comprising: an adhesive layer that adheres to the surface of the molded product body. In the method for producing a surface decorative molded product in which a decorative transfer layer is transferred to a surface of a molded product body having a three-dimensional shape having irregularities or a curved surface at least in part of the surface, the decorative transfer layer is formed on one surface of a resin film A molding step in which the decorative transfer layer side of the resin film with a decorative transfer layer is formed inside to form a shape according to the outer shape of the molded article body,
A transfer step of covering the resin film molded in the molding step on the molded article body, heating and pressurizing the decorative transfer layer and transferring the decorative transfer layer to the molded article body. Manufacturing method. In the method for producing a surface decorative molded product in which a decorative transfer layer is transferred to a surface of a molded product body having a three-dimensional shape having irregularities or a curved surface at least in part of the surface, the decorative transfer layer is formed on one surface of a resin film A molding step in which the decorative transfer layer side of the decorative transfer layer-containing resin film is inwardly formed and molded into a shape conforming to the outer shape of the molded article body using the molded article body, and
A transfer step of heating and pressurizing the decorative transfer layer adhered to the molded article body in the molding step to transfer the decorative transfer layer to the molded article body. The heating and pressurizing of the transfer step heats the resin film, pressurizes only a predetermined range of the heated resin film, and applies only the decorative transfer layer corresponding to the pressurized predetermined range. The method for producing a surface decorative molded product according to claim 2, wherein the molded product is transferred to a molded product main body. The method for producing a surface decorative molded product according to any one of claims 2 to 4, wherein the heating and pressing in the transfer step is performed using a heating and pressing body having a fluid substance.

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