JP2010234621A - Decorative member and manufacturing method for the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative member that expresses the design of gradation. <P>SOLUTION: A decorative member 10 includes: a substrate 5; and a first transparent resin layer 7 formed on the surface of the substrate 5 so that its thickness is increased as going toward a first direction in parallel with the surface. A decorative member 20 further includes a second transparent resin layer 8 formed on the surface of the first resin layer 7 so that its thickness is reduced as going toward the first direction. By this, it is possible to express the design of the gradation of two colors. Alternatively, it is possible to reduce a change in the total thickness of the first resin layer and the second resin layer. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a decorative member that can be used for a housing of a home appliance or the like.

  Conventionally, a lot of synthetic resins are used for housings and the like in home appliances such as televisions. Typical examples include polystyrene and thermoplastic resins such as high impact polystyrene (HIPS) with improved impact resistance, modified PPE, polypropylene, ABS, and PC / ABS.

A flat display is characterized by its thin depth, but in recent years, its depth tends to be even thinner. In that case, the casing is required to have higher strength and rigidity. Therefore, a conventional resin casing may not satisfy the required physical properties (strength, rigidity, etc.). In that case, a metal housing is useful.
JP-A-9-93514

  When a metal casing is used for a product, the surface thereof is a portion observed by the user. Therefore, the design is expressed on the surface of the metal casing. However, the method is limited.

  For example, as a method for enhancing the texture of a metal in a state where it is known that it is a metal, there are known processing methods for aluminum, such as alignment processing, alumite processing, and parker processing. However, metal members that express excellent design properties in addition to these have not been proposed.

  Then, this inventor invented the metal decoration member expressing the design of gradation. The present inventors have found that this decorative part is useful without being limited to metal. An object of the present invention is to provide a decorative member that expresses a gradation design.

The above purpose is
A substrate,
A first resin layer having transparency formed on the surface of the substrate so as to increase in thickness in a first direction parallel to the surface;
Can be achieved by a decorative member.

In addition, the method for manufacturing the decorative member includes:
Applying to the surface of the substrate a first resin having transparency that is melted so as to increase in thickness in a first direction parallel to the surface;
Curing the second resin so that the thickness of the surface of the first resin layer decreases as it goes in the first direction;
Have

  According to the present invention, it is possible to provide a decorative member that expresses a gradation design.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

<First Embodiment>
(Single-layer decorative member)
First, a single-layer decorative member 10 will be described as an embodiment of the decorative member. FIG. 1 is an overall perspective view of a single-layer decorative member 10. FIG. 2 is a cross-sectional view of the single-layer decorative member 10.

  The single-layer decorative member 10 includes a substrate 5 and a first resin layer 7 having transparency. The first resin layer 7 is formed on the surface of the substrate 5 so that the thickness increases in the first direction parallel to the surface.

  The single-layer decorative member 10 can express a gradation design on its surface. Further, by visually recognizing the state of the substrate surface, a design with a higher degree of freedom can be expressed.

  “Having transparency” means that the opposite side is visible through the first resin layer. Therefore, the first resin layer 7 may be colored or may be subjected to other treatments.

(Double-layer decorative member)
Furthermore, the two-layer decorative member 20 will be described as another embodiment of the decorative member. FIG. 3 is a cross-sectional view of the two-layer decorative member 20.

  The two-layer decorative member 20 is obtained by adding a second resin layer 8 to the single-layer decorative member 10. The second resin layer 8 has transparency. The second resin layer is formed on the surface of the first resin layer 7. Furthermore, the second resin layer 8 is formed so that the thickness decreases as it goes in the first direction.

  The single-layer decorative member 10 can express a two-color gradation design on its surface. Further, by visually recognizing the state of the substrate surface, a design with a higher degree of freedom can be expressed.

  “Having transparency” means that the opposite side is visible through the second resin layer. Therefore, the second resin layer 8 may be colored or may be subjected to other treatments. In addition, a better design can be expressed by making the coloring of the first resin layer 7 different from the coloring of the second resin layer 8.

(Method for manufacturing decorative member)
A method for manufacturing the single-layer decorative member 10 and the two-layer decorative member 20 will be described. In addition to the description of the manufacturing method, specific configurations of the single-layer decorative member 10 and the two-layer decorative member 20 will also be described. FIG. 4 is a diagram for explaining the manufacturing method.

  (1) First, as the substrate (core material) 5, a long metal material having the same cross section formed by roll forming an aluminum extruded material or a steel plate is prepared.

  (2) The substrate 5 is passed through the first crosshead die 2 of the first extruder 1. The first extruder 1 melts a transparent first resin and extrudes it to the first crosshead die 2. When the substrate 5 passes through the first crosshead die 2, the molten resin is laminated on the required surface in the required shape. Specifically, the first resin liquefied so as to increase in thickness in the first direction parallel to the surface is applied to the surface of the substrate 5 depending on the shape of the first crosshead die 2.

  In that case, when it is necessary to ensure the adhesive force between the first resin and the metal substrate 5, an adhesive is applied to the metal surface (surface of the substrate 5) where the resin is to be laminated in advance. In this application, the first crosshead die 2 has a double structure, and when the substrate 5 is passed through the first crosshead die 2, first, an adhesive is discharged as a precoat and applied to the surface of the substrate 5. Good. Alternatively, another extruder and a crosshead die may be used, and the substrate 5 may be passed through the crosshead die before passing through the first crosshead die 2 and the adhesive may be discharged from the extruder to perform coating. Is possible. Further, before passing the substrate 5 through the first crosshead die 2, coating by a roller, spray coating, transfer coating, coating by printing, coating by brush coating, and the like are also possible. The method of applying such an adhesive is preferably a method that can be uniformly applied with a constant thickness, but is not particularly limited to the above-described method. The adhesive material is transparent such as acrylic, polyester, olefin, urethane, vinyl, epoxy, etc., and it adheres between the material (metal) of the substrate 5 to be used and the first resin to be applied. It does not matter as long as it brings power.

  (3) After the steps (1) and (2) above, the first-type decorative member 10 is completed when the first resin is cured. The arrows in FIG. 4 indicate the moving direction of the substrate 5, and the part A is the single-layer decorative member 10.

  (4) Next, the substrate 5 is continuously passed through the second crosshead die 4 of the second extruder 3. The second extruder 3 melts the transparent second resin and extrudes it to the second crosshead die 4. When the substrate 5 passes through the second crosshead die 4, extrusion lamination is performed by changing the thickness of the second resin in an inclined manner on a desired surface. Specifically, the second resin liquefied so as to decrease in thickness in the first direction is applied to the surface of the first resin layer 7 depending on the shape of the second crosshead die 4. That is, another transparent resin is formed on the surface of the substrate 5 (metal material) obtained by laminating the first resin layer 7 of the first layer with a thickness gradient opposite to the thickness gradient of the first layer. Laminate.

  The second resin layer 8 may be applied after the first resin layer 7 is cured, but in the present embodiment, the second resin layer 8 is applied before the first resin layer 7 is cured.

  (5) Thereafter, the substrate 5 (metal material) on which the first resin layer 7 and the second resin layer 8 are laminated is passed through a cooling liquid or a cooling gas. Thereby, the melted first resin and second resin are cured to form a strong resin layer.

  The two-layer decorative member 20 is completed through the above steps. A portion B in FIG. 4 is a two-layer decorative member 20.

  When the surface of the decorative member, that is, the smoothness of the surface of the first resin layer or the second resin layer is strictly required, the polishing process is continuously performed after step (5). As a result, a smooth surface can be obtained, and a glossy and high-quality appearance quality can be obtained.

  In addition, since the 1st resin and 2nd resin used by this invention can express the gradation (color tone change) by the inclination of thickness if there is transparency more than fixed, acrylic type, polycarbonate type, PS type, ABS-type, nylon-type, PET-type, fluorine-type, and polyimide-type resins can be used, and there is no particular limitation on the material selection.

  The material of the substrate 5 is preferably a metal such as aluminum, iron, stainless steel, copper, tin, lead, nickel, zinc, chromium, gold, silver, platinum, magnesium, titanium, and various alloys. In this case, the surface of the substrate 5, that is, the metal surface can be visually recognized through the first resin layer 7 and / or the second resin layer, and high-quality appearance quality can be obtained. When the substrate 5 is a metal, it is preferable that the metal can form a uniform cross-sectional structure by extrusion or thin plate roll forming, and can form the substrate 5 as a long material. The material of the substrate 5 is not limited to metal, but may be other materials such as resin.

  In step (1), when the surface of the substrate 5 is mirror-finished and the surface of the substrate 5 is a mirror surface, external light is totally reflected by the mirror surface, so that the first resin layer and / or the second resin layer Since the gradation sharpness due to the change in thickness of the material becomes higher, it is possible to make the design features stand out.

  Further, in the above-described manufacturing method, two extruders (two) are used, but the extruder is not particularly concerned with a single screw or two screws. For example, a two-layered crosshead die may be used with the extruder as a single axis.

Example 1
Examples of the manufacturing method and the two-layer decorative member 20 will be described.

  (1) First, an aluminum extrusion material whose surface is mirror-finished is prepared as the substrate 5.

  It passed through the first crosshead die 2 of the first extruder 1.

  (2) The internal structure of the second crosshead die 2 is doubled. First, a polyester-based transparent adhesive is applied to the surface of the substrate 5 to a thickness of about 1 to 30 μm. Next, an acrylic transparent resin is extruded and laminated with a thickness of 0.3 to 1 mm as the first resin. A blue colorant is uniformly kneaded in this resin, and the transmittance is such that the wavelength of blue light is about 50% in a 1 mm thick portion. The lamination of the first resin was performed so that the thickness gradually increased from 0.3 in the width direction of the specific side in the cross-sectional shape of the first resin layer 7 and the thickest portion became 1 mm. In addition, the heating temperature of resin was the range of 180-250 degreeC.

  (3) Next, the substrate 5 coated with the first resin layer 7 was passed through an air cooling zone of several meters, and the first resin layer 7 was cured.

  (4) Thereafter, the substrate 5 coated with the first resin layer 7 is passed through the second crosshead die 4 of the second extruder 3. In this second crosshead die 4, the same acrylic colorless and transparent resin as the second resin was laminated on the surface of the first resin with a thickness gradient opposite to the thickness gradient of the first resin. That is, the second resin layer 8 was laminated on the surface of the first resin layer 7 so that the thickness of the second resin layer 8 increased as the thickness of the first resin layer 7 decreased from the thicker to the thinner. The second resin layer 8 had a thinnest part of 0.3 mm and a thickest part of 1 mm. As shown in FIG. 3, the cross-sectional shape of the two-layer decorative member 20 is such that the resin thickness on the surface of the substrate 5 (the total thickness of the first resin layer 7 and the second resin layer 8) is about 1 at any location. The thickness was 3 mm.

  (5) Thereafter, the second resin layer 8 was cooled and cured.

  Thus, a two-layer decorative member 20 in which the metal surface was decorated with a blue gradation on the surface of the substrate 5 was obtained.

(Example 2)
An embodiment of the two-layer decorative member 20 that expresses a two-color gradation design will be described.

  In step (4) of Example 1, a kneaded red colorant was used as the second resin. The second resin has such a transmittance that the red light wavelength is about 50% in a portion having a thickness of 1 mm. Other configurations are the same as those in the first embodiment.

  The appearance of the two-layer decorative member 20 obtained in this way changed in gradation in proportion to the resin thickness. That is, the portion where the first resin layer is 1 mm thick and the second resin layer is 0.3 mm thick appears to be a little reddish blue, and the redness gradually increases from there, and the first resin layer is 0.65 mm thick, The two resin layers also had a purple color tone at the 0.65 mm portion. Further, the red color became stronger at the portion where the thickness of the second resin layer was increased, and the first resin layer was 0.3 mm thick and the second resin layer was 1 mm thick, it looked a little bluish red. In other words, it was possible to obtain a design-specific appearance in which the ratio of blue to red gradually changed. Moreover, such a decorative member could be obtained by a relatively simple process.

<Second Embodiment>
An embodiment in which the above-described decorative member is used as a display frame will be described. As an example, the two-layer decorative member 20 is used for a display frame provided around the display area 31 of the television 30. FIG. 5 is a perspective view of a television using the two-layer decorative member 20 as a display frame.

  By using the two-layer decorative member 20, it is possible to realize a television 30 having high quality appearance quality. Further, by using a metal for the substrate 5 of the two-layer decorative member 20, it is possible to realize a television having high design and high strength or rigidity.

  Further, a high-strength or rigid substrate 5 can be used, and a safe television can be realized even when touched by a user. Specifically, even if the heat inside the television 30 is transferred to the substrate 5, the transfer of heat to the surface of the two-layer decorative member 20 by the first resin layer 7 and / or the second resin layer 8 on the surface thereof. Even if the user touches the surface of the two-layer decorative member 20, the risk of burns is low.

(Experimental results on heat transfer)
A comparative experiment was performed between the aluminum substrate 5 on which the first resin layer 7 and the second resin layer 8 obtained in Example 1 were laminated and only the aluminum substrate 5 without resin. Under a 20 ° C. environment, a heater of 100 w output is applied at a distance of 50 cm from the surface of the substrate 5 on which the resin is not laminated in the cross-sectional shape of the two-layer decorative member 20, and the temperature of the opposite surface becomes constant. Until the temperature of the surface was measured, it was 45 ° C. On the other hand, when the same location was measured with an aluminum substrate 5 without a resin laminate under the same conditions, it was 60 ° C. Thus, by laminating the resin with a thickness of about 1.3 mm, the surface temperature could be lowered by 15 ° C. Furthermore, when a plurality of subjects touched the temperature measurement location and heard the temperature, the metal surface without the resin laminate was 10 ° C or more on average more than the actual temperature difference of 15 ° C with the resin laminate surface. I found it to be hot.

<Other embodiments>
The present invention is not limited to the above-described embodiment, and various modifications and changes can be made without departing from the spirit of the present invention.

  The first resin layer 7 and the second resin layer 8 are formed on the surface of the substrate 5 so that the thickness changes in the first direction parallel to the surface. In the embodiment, the first direction is a direction substantially equal to the short direction (short side direction) orthogonal to the long direction (long side direction) of the substrate 5. However, the first direction may be any direction parallel to the surface of the substrate 5.

  In the embodiment, the first resin layer 7 and the second resin layer 8 are substantially equal in thickness as they go in the second direction that is parallel to the surface of the substrate 5 and orthogonal to the first direction. It is formed as follows. Specifically, the second direction is a direction substantially equal to the longitudinal direction (long side direction) of the substrate 5. However, the first resin layer 7 and the second resin layer 8 may be formed so as to have different thicknesses in the second direction.

<Features of the embodiment>
Characteristic parts in the above embodiment are listed below. The invention included in the above embodiment is not limited to the following.

[C1]
The decorative member
A substrate,
A transparent first resin layer formed on the surface of the substrate so as to increase in thickness in a first direction parallel to the surface;

  Thereby, the decoration member expressing the design of gradation can be provided.

[C2]
The decorative member according to C1,
A transparent second resin layer is further provided on the surface of the first resin layer so as to be thinner as it goes in the first direction.

  Thereby, the design of the gradation of two colors can be expressed. Alternatively, the change in the total thickness of the first resin layer and the second resin layer can be reduced.

[C3]
The decorative member according to C1 or C2, wherein the surface of the substrate is a mirror surface. As a result, it is possible to express a design with a higher gradation sharpness.

[C4]
The decorative member according to any one of C1 to C3, wherein the substrate is made of metal. Thereby, it is possible to provide a safe member that can express an excellent design while having high strength and rigidity, and that is difficult to transmit temperature to the surface.

[C5]
The decorative member according to C2, wherein the first resin layer and the second resin layer have a thickness parallel to a surface of the substrate and in a second direction perpendicular to the first direction. Substantially equal.

[C6]
The decorative member according to C2, wherein the first resin layer or the second resin layer has a thickness parallel to a surface of the substrate and in a second direction perpendicular to the first direction. Substantially different.

[C7]
A method of manufacturing a decorative member,
Applying to the surface of the substrate a first resin having transparency that is melted so as to increase in thickness in a first direction parallel to the surface;
Applying to the surface of the first resin layer a second resin having transparency that is melted so that the thickness decreases as it goes in the first direction.

  Thereby, the decorative member expressing the design of gradation can be manufactured easily.

[C8]
A method for producing a decorative member according to C7,
The step of applying the second resin is performed before the first resin is cured,
The method further includes the step of curing the first resin and the second resin after the step of applying the second resin.

  Thereby, two layers can be hardened in a lump and extremely high productivity can be realized.

[C9]
A method for producing a decorative member according to C7,
Curing the first resin after applying the first resin and before applying the second resin;
And a step of curing the second resin after the step of applying the second resin.

  Thereby, the boundary surface between the first resin layer and the second resin layer becomes extremely smooth, and an excellent design can be expressed.

[C10]
The method for manufacturing a decorative member according to any one of C7 to C9, further comprising a step of mirror-finishing the surface of the substrate.

[C11]
The method for manufacturing a decorative member according to any one of C7 to C10, wherein the substrate is made of metal.

[C11]
A display frame using the decorative member according to any one of C1 to C6.

[C12]
A television using the decorative member according to any one of C1 to C6 as a casing.

  The decorative member of the present invention can be used for any article such as other electronic devices and home appliances in addition to being used as a display frame for a television or the like.

Whole perspective view of single-layer decorative member 10 Cross-sectional view of single-layer decorative member 10 Cross-sectional view of the two-layer decorative member 20 Diagram for explaining the manufacturing method A perspective view of a television using the two-layer decorative member 20 as a display frame.

DESCRIPTION OF SYMBOLS 1 1st extruder 2 1st crosshead die 3 2nd extruder 4 2nd crosshead die 5 Substrate 6 Mirror surface 7 First resin layer 8 Second resin layer 10 Single layer type decorative member 20 Two layer type decorative member 30 TV 31 display area

Claims (11)

A substrate,
A first resin layer having transparency formed on the surface of the substrate so as to increase in thickness in a first direction parallel to the surface;
A decorative member comprising:   2. The decorative member according to claim 1, further comprising: a transparent second resin layer formed on the surface of the first resin layer so as to become thinner as going in the first direction.   The decorative member according to claim 1, wherein a surface of the substrate is a mirror surface.   The decorative member according to any one of claims 1 to 3, wherein the substrate is made of metal.   The thickness of the said 1st resin layer and the said 2nd resin layer is substantially equal as it goes to the 2nd direction parallel to the surface of the said board | substrate and orthogonal to the said 1st direction. Decoration member.   The thickness of the said 1st resin layer or the said 2nd resin layer is substantially different as it goes to the 2nd direction parallel to the surface of the said board | substrate and orthogonal to the said 1st direction. Decoration member. Applying to the surface of the substrate a first resin having transparency that is melted so as to increase in thickness in a first direction parallel to the surface;
Applying a second resin having transparency, which is melted so as to decrease in thickness as it goes in the first direction, on the surface of the first resin layer. The step of applying the second resin is performed before the first resin is cured,
The method for manufacturing a decorative member according to claim 7, further comprising a step of curing the first resin and the second resin after the step of applying the second resin. Curing the first resin after applying the first resin and before applying the second resin;
The method for manufacturing a decorative member according to claim 7, further comprising a step of curing the second resin after the step of applying the second resin.   The method for manufacturing a decorative member according to claim 7, further comprising a step of mirror-finishing the surface of the substrate.   The method for manufacturing a decorative member according to claim 7, wherein the substrate is made of metal.

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