JP2009107211A - Decorative molded object and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative molded object with high quality, heat resistance and productivity, and a manufacturing method of the decorative molded object. <P>SOLUTION: This decorative molded object is of such a structure that the surface side of a resin base material is covered with a sheet-like decorative material. In addition, the surface layer of the resin base material and the sheet-like decorative material are formed of a resin of controlled type or of the same kind with the deflection temperature under load (0.46 MPa) of 120°C or higher and the coefficient of water absorption of not more than 0.5%, or a resin obtained by reinforcing the former. Besides, the decorative molded object is obtained through the process of bonding the sheet-like decorative material to the resin base material using by vacuum pressure molding process. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a decorative molded product and a method for manufacturing a decorative molded product.

  As shown in FIG. 6, a motorcycle or a scooter two-wheeled vehicle 100 is covered with a muffler cover 110 so that a rider's feet or the like directly touch a muffler (not shown) to cause a burn. The muffler cover 110 is formed by combining a plurality of cover materials such as a muffler side cover 111 as shown in FIG. 7 and an end cap 112 as shown in FIG.

Conventionally, the muffler side cover 111, the end cap 112, and the like are plated on the surface of a resin base material formed of polyamide resin (nylon 6 or the like), and the plated surface is protected with a protective layer made of a transparent resin as necessary. The one coated with is used.
However, in the case of plating, since the waste liquid treatment is troublesome, there is a tendency for the number of plating treatment companies to decrease, and a different manufacturing method is required.

  On the other hand, if the metallic sheet-like decorative material is adhered to the surface of the resin base material, the plating step can be omitted, but the decorative layer made of the sheet-like decorative material is attached to the surface of the resin base material. There are an in-mold method (see Patent Document 1) and a vacuum / pressure forming method (see Patent Document 2) that have been used conventionally as methods for providing an in-mold method. However, the in-mold method has the following problems.

That is, in the in-mold method, generally, as shown in FIG. 9A, a sheet-like decorating material 300 preformed along the cavity surface 201 of the mold 200 is shown in FIG. After being set in the mold 200 as shown in FIG. 9C, the mold 200 is closed as shown in FIG. 9C, and the resin 300 serving as a resin base material is injected and filled into the mold 200. As shown in FIG. As shown in the figure, after the filled resin 300 is cooled and solidified, it is taken out from the mold 200, whereby a decorative molded product 400 is obtained.
However, in the case of the in-mold method, it is necessary to preform the sheet-shaped decorating material 300 in advance as described above, it is difficult to position the preformed sheet-shaped decorating material 300 in the mold 200, The boundary (core ball edge) line with the back side cannot be made clean, mass production continuous molding is difficult (automatic molding is difficult, especially medium to large molded products), the gate structure of the mold 200 is complicated, etc. There is a problem.

  On the other hand, in the case of the vacuum / pressure forming method, as shown in FIG. 10 (a), a sheet-like decorative material 310 with an adhesive and a pre-molded resin base material 500 are set in the vacuum forming apparatus 600, While heating the sheet-like decorating material 310 with the heater 630 and making the inside of the upper and lower chambers 610 and 620 of the vacuum forming apparatus 600 partitioned by the sheet-like decorating material 310 into a vacuum, it is shown in FIG. As described above, the resin base material 500 was pushed up to the sheet-shaped decorating material 310 side, and the adhesive layer of the sheet-shaped decorating material 310 was pressed against the surface of the resin base material 500 while deforming the sheet-shaped decorating material 310. State. Next, as shown in FIG. 10C, the interior of the lower chamber 620 of the vacuum forming apparatus 600 is kept in a vacuum state, and the interior of the upper chamber 610 is changed to atmospheric pressure or a pressurized state from atmospheric pressure. After bringing 310 into close contact with the entire surface to be decorated of the resin substrate 500, as shown in FIG. 10 (d), the entire interior of the vacuum forming apparatus 600 is returned to atmospheric pressure, and the non-adhesion of the sheet-like decorative material 310 is removed. A portion is cut out to obtain a decorative molded product 700.

  Therefore, in the case of this vacuum pressure forming method, the preform of the sheet-like decoration material is unnecessary, the positioning of the sheet-like decoration material is unnecessary, mass production continuous molding is possible, the boundary between the product surface and the back side (core ball edge part) ) Has a considerable advantage compared to the in-mold method, such as a clean line and no need to work on the mold.

  However, although the above-described muffler side cover 111 and end cap 112 were tried to be manufactured by using this vacuum / pressure forming, the same as the polyamide resin constituting the base material of the muffler cover in consideration of heat resistance, the sheet-like base material is made of polyamide resin. When using a polyamide resin metal-deposited decorative sheet with a material part, the polyamide resin has a large water absorption rate, and voids may occur on the surface of the resulting decorative molded product, and the metal layer during metal deposition There were problems in terms of productivity and quality, such as poor adhesion due to sheet adhesion and sheet shrinkage.

JP-A-9-57992 JP 2006-35540 A

  In view of the above circumstances, an object of the present invention is to provide a decorative molded product that is excellent in heat resistance and excellent in productivity and quality and a method for manufacturing the decorative molded product.

In order to achieve the above object, the decorative molded product according to the present invention is a decorative molded product in which the surface side of the resin base material is coated with a sheet-like decorative material,
The surface layer of the resin base material and the sheet-like decorating material are the same or similar, and are formed of a resin having a deflection temperature under load (0.46 MPa) of 120 ° C. or higher and a water absorption of 0.5% or less, or a reinforced resin thereof. It is characterized by being.

  On the other hand, the method for producing a decorative molded product according to the present invention is characterized in that the decorative molded product of the present invention is obtained through a process of attaching a sheet-like decorative material to a resin base material using a vacuum / pressure forming method. It is said.

In the present invention, the water absorption was measured by the method of ASTM D570.
The deflection temperature under load (0.46 MPa) was measured by the method of ASTM D648.

  The resin having a deflection temperature under load (0.46 MPa) of 120 ° C. or more and a water absorption of 0.5% or less is not particularly limited as long as this condition is satisfied. For example, polytrimethylene terephthalate (PTT), polycarbonate (PC), polycarbonate / polybutylene terephthalate (PBT), polycarbonate / polyethylene terephthalate (PET), and the like. Among them, polytrimethylene terephthalate (unreinforced, deflection temperature under load (0.46 MPa) is 165 ° C., water absorption is 0. 0.04%, 30% glass fiber reinforcement, and a deflection temperature under load (0.46 MPa) of 224 ° C. and a water absorption of 0.05% are preferable.

  In the present invention, the similar resin means a resin having a similar molecular structure. For example, as a polyester resin, polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate are similar, and similarly as polyamide resins, PA6 and PA66. , PA6I, MXD6 can be regarded as similar. Polycarbonate and polycarbonate / acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-butadiene-styrene copolymer and polycarbonate / acrylonitrile-butadiene-styrene copolymer can also be regarded as similar.

The resin base material only needs to be formed of the same or similar resin on the surface side as the sheet-like decorating material main body, and may be a sandwich molded product, for example.
Moreover, when the resin base material has a shape having a concave surface on the back surface side, it is preferable to trim the sheet-like decorative material within the concave surface on the back surface side in consideration of the appearance of the product and the workability of trimming.
In addition, although not particularly limited, when trimming the sheet-like decorating material in the concave surface as described above, as a resin base material, a configuration in which the outer edge portion of the concave surface on the back surface is formed on a flat surface over the entire circumference, A configuration in which a groove along the outer peripheral edge of the concave surface is provided on the flat surface, a configuration in which a protrusion having a flat surface toward the outside of the concave surface is provided in the concave surface along the outer peripheral edge of the concave surface, and It is preferable to use a configuration in which a groove is provided along the flat surface of the protrusion.

Further, a transparent protective layer may be provided on the surface of the decorative layer.
The transparent protective layer is not particularly limited, and examples thereof include polyester resins, polymethylmethacrylate resins, polyurethane resins, etc. When used for muffler cover muffler side covers, end caps, etc., those having an pencil hardness of H or higher. Is preferably selected.

The decorative molded product according to the present invention is a decorative molded product in which the surface side of the resin base material is coated with a sheet-shaped decorative material,
The surface layer of the resin base material and the sheet-like decorating material are the same or similar, and are formed of a resin having a deflection temperature under load (0.46 MPa) of 120 ° C. or higher and a water absorption of 0.5% or less, or a reinforced resin thereof. Therefore, it is excellent in heat resistance and in productivity and quality.
In particular, when polytrimethylene terephthalate is used, the deflection temperature under load (0.46 MPa) is 165 ° C. when unreinforced and 224 ° C. when 30% glass fiber is reinforced, which shows higher heat resistance.

Hereinafter, the present invention will be described in detail with reference to the drawings showing embodiments thereof.
FIG. 1 shows a first embodiment of a decorative molded product according to the present invention.

As shown in FIG. 1, the decorative molded product 6a includes a resin base material 1a and a sheet-like decorative material layer 3a that covers the surface of the resin base material 1a.
The resin base material 1a is obtained by injection molding polytrimethylene terephthalate, which is a heat-resistant resin, and has a concave surface 11 on the back surface side and a tapered surface 12 as a flat surface on the periphery of the concave surface 11 over the entire circumference. ing.

Further, a groove 13 having a substantially right-angled triangular cross section is formed at an end portion (upper end side in the drawing) of the tapered surface 12.
As shown in FIG. 2, the sheet-like decorating material layer 3a is provided with an indium vapor-deposited layer, and the sheet-like decorating material body 3 is made of polytrimethylene terephthalate. Is formed by cutting and removing unnecessary portions.

That is, as shown in FIG. 2 (a), the decorative molded product A is manufactured by placing the resin base material 1a on the jig 2, and vacuuming the conventional vacuum forming method and the sheet-shaped decorative material 3 together. In a molding apparatus (not shown), the resin base material 1a is molded along the surface, and a portion along the resin base material 1a is attached to the resin base material 1a. The material 3 is once roughly cut.
Next, as shown in FIG. 2 (b), the remaining non-adhesive portion of the sheet-like decorating material 3 is manually inserted into the concave surface 11 and attached to the tapered surface 12.

Then, as shown in FIG.2 (c), the ultrasonic welding horn 5 of an ultrasonic welding apparatus is pressed on the part along the taper surface 12 of the sheet-like decorating material 3, and the sheet-like decorating material 3 is shown. A portion along the tapered surface 12 is ultrasonically fused to the tapered surface 12.
Finally, as shown in FIG. 2 (d), the Thomson blade 4b is advanced into the groove 13 along the side wall of the groove 13, and the unnecessary portion 31 of the sheet-shaped decorating material 3 is cut off. The decorative molded product A whose surface as shown is decorated in a metal plating tone is obtained.
In FIG. 1 and FIG. 2, the thickness of the sheet-like decorating material 3 is drawn to be considerably thicker than the actual thickness in order to make the invention easier to understand, but it is actually about 50 to 200 μm.

In the decorative molded product A thus obtained, the sheet-like decorating material body part of the sheet-like decorating material 3 forming the resin base material 1a and the sheet-like decorating material layer 3a is formed of polytrimethylene terephthalate. Therefore, it is not thermally deformed even at 200 ° C, and there is no abnormality in appearance even at 130 ° C x 24H. There is no occurrence of voids. Polytrimethylene terephthalate has a high surface hardness and physical properties such as chemical resistance are equivalent to those of nylon resins. Therefore, it becomes more excellent in productivity and quality.
Moreover, since decoration is performed by sticking the sheet-like decorating material 3 on the surface of the resin base material 1a as described above, there is no concern about environmental pollution such as plating. And since the edge part of the sheet-like decorating material 3 exists in the concave surface 11 which is the back surface side of the resin base material 1a, it looks good. And since the edge part of the sheet-like decorating material 3 is melt | fused by the taper surface 12, peeling from the edge part of the sheet-like decorating material 3 can be prevented.

FIG. 3 shows a second embodiment of the decorative molded product and the manufacturing method thereof according to the present invention.
As shown in FIG. 3, in this decorative molded product B, the resin base material 1 b includes a protrusion 14 having a flat surface 14 a on the opening side of the concave surface 11 over the entire periphery along the outer edge portion of the concave surface 11. It is the same as that of the decorative molded product A, except that the trimming of the sheet-shaped decorative material 3 is performed as follows.

  That is, as shown in FIG. 3A, the decorative molded product B is a flat surface of the protrusion 14 from the surface of the resin base material 1b in the vacuum forming apparatus in the same manner as in the first embodiment. After sticking the sheet-like decorating material 3 to 14a, as shown in FIG. 3 (b), the sheet-like decorating material 3 is pierced through the sheet-like decorating material 3 until the Thomson blade 4c hits the flat surface 14a. The unnecessary part 31 is cut off to obtain a decorative molded product B provided with the sheet-like decorative material layer 3a.

FIG. 4 shows a third embodiment of the decorative molded product and the manufacturing method thereof according to the present invention.
As shown in FIG. 4, in this decorative molded product C, the resin base material 1c is provided with a substantially V-shaped groove 15b on the flat surface 15a of the protrusion 15 over the entire circumference, and the others are the resin base material. It is the same as 1b, and is the same as the above-mentioned decorative molded product A except that the trimming of the sheet-like decorative material 3 is performed as follows.
That is, as shown in FIG. 4 (a), this decorative molded product C is projected from the surface of the resin base material 1c in the vacuum molding apparatus in the same manner as in the first and second embodiments. After sticking the sheet-like decorating material 3 to the flat surface 15a, as shown in FIG. 4 (b), the cutter blade 4d is pierced through the sheet-like decorating material 3 until the blade tip hits the bottom of the groove 15b. By moving the cutter blade 4d along the groove 15b, the unnecessary portion 31 of the sheet-like decorating material 3 is cut off to obtain a decorative molded product C provided with the sheet-like decorating material layer 3a.
According to this method, when the operator manually holds the cutter and cuts out the sheet-like decorative material 3, a groove serving as a guide is provided, so that anyone can create a decorative molded product that looks good with the same accuracy. Obtainable.

FIG. 5 shows a fourth embodiment of a decorative molded product and a method for manufacturing the same according to the present invention.
As shown in FIG. 5, the decorative molded product D is the resin base material 1 d except that the groove is not formed on the tapered surface 16 as a flat surface provided on the outer edge side of the concave surface 11. It is the same as that of the resin base material 1a of 1 embodiment, and it is the same as that of the said decorative molded product A except the trimming of the sheet-like decorating material 3 being performed as follows. It has become.

  That is, as shown in FIG. 5 (a), the decorative molded product D has a tapered surface 16 from the surface of the resin base material 1d in the vacuum forming apparatus in the same manner as in the first to third embodiments. After sticking the sheet-like decorating material 3 until, the sheet-like decorating material 3 is pierced through the sheet-like decorating material 3 until the Thomson blade 4e hits the tapered surface 16 as shown in FIG. Unnecessary portions 31 are cut off to obtain a decorative molded product D provided with a sheet-like decorative material layer 3a.

The present invention is not limited to the above embodiment. For example, in the first embodiment, the sheet-like decorating material is fused only to the tapered surface, but if it does not affect the appearance, it is fused to the peripheral portion on the surface side. It doesn't matter.
Also, a protrusion is provided at the fusion part of the resin base material, and the protrusion is crushed over the sheet-like decoration material at the time of fusion so as to improve the adhesion between the sheet-like decoration material and the resin base material. It doesn't matter.

Furthermore, in said embodiment, although the back surface of the peripheral part of the resin base material is a flat surface, you may make it bead shape.
Moreover, in said embodiment, although the cutting means of the sheet-like decorating material was a Thomson blade or a cutter blade, other cutting means such as a laser cutter may be used.

  The use of the decorative molded product according to the present invention is not particularly limited. For example, the interior and exterior parts of a motorcycle such as a muffler cover muffler side cover and end cap, the interior and exterior parts of an automobile, the casing of a mobile phone and an electrical appliance. , Covers and the like.

It is principal part sectional drawing showing one embodiment of the decorative molded product concerning this invention. It is explanatory drawing explaining 1st Embodiment of the manufacturing method of the decorative molded product using the resin base material concerning this invention in order of a process. It is explanatory drawing explaining 2nd Embodiment of the manufacturing method of the decorative molded product using the resin base material concerning this invention in order of a process. It is explanatory drawing explaining 3rd Embodiment of the manufacturing method of the decorative molded product using the resin base material concerning this invention to process order. It is explanatory drawing explaining 4th Embodiment of the manufacturing method of the decorative molded product using the resin base material concerning this invention to process order. It is a side view of a two-wheeled vehicle. It is a perspective view of the muffler side cover of a two-wheeled vehicle. It is a perspective view of a muffler end cap of a motorcycle. It is explanatory drawing explaining the manufacturing method of the decorative molded product by in-mold shaping | molding in order of a process. It is explanatory drawing explaining the manufacturing method of the decorative molded product using a vacuum forming apparatus in order of a process.

Explanation of symbols

1a, 1b, 1c, 1d Resin base material 11 Concave surface 12 Tapered surface 13 Groove 14 Projection 14a Flat surface 15 of projection 14 Projection 15a Flat surface 15b of projection 15 Groove 16 of projection 15 Tapered surface (flat surface)
3 Sheet-shaped decorating material 3a Sheet-shaped decorating material layer 4a, 4b, 4c, 4d
A, B, C, D decorative molded products

Claims (4)

The surface side of the resin base material is a decorative molded product that is covered with a sheet-like decorative material,
The surface layer of the resin base material and the sheet-like decorating material are the same or similar, and are formed of a resin having a deflection temperature under load (0.46 MPa) of 120 ° C. or higher and a water absorption of 0.5% or less, or a reinforced resin thereof. Decorative molded product characterized by being made.   The decorative molded product according to claim 1, wherein the sheet-like decorative material is formed of polytrimethylene terephthalate.   The decorative molded product according to claim 1 or 2, wherein the resin base material is a sandwich molded product.   The manufacturing method of the decorative molded product of any one of Claims 1-3 provided with the process of affixing a sheet-like decorating material on a resin base material using a vacuum pressure forming method.

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