JP2017209840A - Manufacturing method of decorative molded article and trimming method of decorative molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a decorative molded article capable of providing the decorative molded article good in workability and of which a decorative film is hardly released from an outer edge of a core material.SOLUTION: There is provided a manufacturing method of a decorative molded article having a process for adhering a decorative film to a core material and a process for removing a surplus part of the decorative film squeezed out from an outer edge of the core material by using an ultrasonic cutter, the ultrasonic cutter has an ultrasonic generation mechanism and a tooth point part, the tooth point part contains a cut part and a pair of guide parts extruding from the cut part, the process for removing the surplus part of the decorative film including cutting the decorative film along the outer edge of the core material while melting the same by sandwiching the outer edge of the core material by the pair of the guide part, maintaining a status that the cut part is pushed to the outer edge of the core material and moving the tooth point part along the outer edge of the core material.SELECTED DRAWING: Figure 7

Description

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

In various products such as cellular phones and other electrical appliances, covers, interior parts for vehicles, motorcycle cowlings, etc., designs such as patterns, designs, letters, etc. are applied to the surface of molded products. . For example, a decorative molded product is manufactured by pasting a decorative film on the surface of a core material having a complicated surface shape such as a three-dimensional curved surface using vacuum forming, vacuum / pressure forming, etc. Yes. Here, as the decorative film, a film in which a printed layer is formed on one surface of a base film and an adhesive layer is formed on the other surface is generally used.

In such a method for producing a decorative molded product using vacuum forming or vacuum / pressure forming, after a decorative film is attached to the surface of the core material, the decorative material remaining in the vicinity of the outer edge of the region where the core material is decorated is used. It is necessary to perform a trimming process for removing the surplus part of the decorative film (the part that is not attached to the core material). In the trimming step, a method using a general cutter blade made of metal, a method using a laser, a method using an ultrasonic cutter, or the like is used.

Further, in vacuum / pressure forming, a heating wire is attached to a receiving jig on which a core material is placed, and the heating wire is energized to melt off an excess portion of the decorative film (for example, Patent Document 1) ) After sticking the decorative film to the core by vacuum pressure / air forming, cut the end of the decorative film with a cutter and press the film decorative molded product against the tool post with a Thomson blade on the surface. The method (for example, patent document 2 etc.) which excises the terminal part of a decoration film is examined.

JP 2013-072711 A JP 2010-228143 A

The method using the cutter blade is suitable for trimming a decorative molded product having a linear shape because the blade is fixed and cut with respect to the outer edge of the core material at a constant angle. On the other hand, if the fixed angle of the blade is shifted or the cutting speed is changed, the decorative film may not be cut cleanly. For this reason, when trimming a decorative molded product having a curved shape, workability may be reduced or the cut may not be cleanly performed. Moreover, since the cut surface of the decorative film is sharp, the decorative film may be easily peeled off from the core material.

Since the method using the laser and the method using the ultrasonic cutter dissolve and cut the cut surface of the decorative film, the cut surface of the decorative film is rounded and is difficult to peel off from the core material. In the method using the ultrasonic cutter, not only a decorative film made of a thermoplastic resin, but also a decorative film made of a thermosetting resin can be cut, and it is beautiful regardless of the thickness of the decorative film. Can be cut. On the other hand, in the method using the laser and the method using the ultrasonic cutter, a receiving jig for converting the data to be cut or fixing the core material is necessary. For example, the data of the location to be cut corresponds flexibly because the location to be cut differs depending on the composition of the decorative film, thickness, hardness, shape of the core material, product standards according to the use of the decorative molded product, etc. It was difficult. Further, since the receiving jig differs depending on the shape of the core material, it has been difficult to respond flexibly. The trimming methods described in Patent Documents 1 and 2 also require a receiving jig or a tool post that matches the shape of the core material, and it is difficult to flexibly cope with the shape of the core material.

From the above, there is provided a method for producing a decorative molded product that can flexibly correspond to the shape of the core material, has good workability, and provides a decorative molded product in which the decorative film is difficult to peel off from the outer edge of the core material. It was sought after.

This inventor examined the method of removing the excess part of a decorating film, without using a receiving jig etc., and paid attention to using an ultrasonic cutter. The inventor examines the configuration of the blade edge portion of the ultrasonic cutter, and includes a cut portion and a pair of guide portions protruding from the cut portion, so that the core material is formed of the pair of guide portions. It can be cut while melting the excess part of the decorative film while moving the blade edge part along the outer edge of the core material while sandwiching the outer edge and maintaining the state where the cut portion is pressed against the outer edge of the core material I found. Thereby, workability | operativity improved and it discovered that the decorative molded product from which a decorating film was hard to peel from the outer edge of a core material was obtained, and completed this invention.

The method for producing a decorative molded product of the present invention includes a step of attaching a decorative film to a core material, and a step of removing an excess portion of the decorative film protruding from the outer edge of the core material using an ultrasonic cutter. The ultrasonic cutter has an ultrasonic generation mechanism and a blade edge portion, and the blade edge portion includes a cut portion and a pair of guide portions protruding from the cut portion, The step of removing the surplus portion of the decorative film includes sandwiching the outer edge of the core material between the pair of guide portions, and maintaining the state in which the cut portion is pressed against the outer edge of the core material, By moving along the outer edge of the core material, the decorative film is cut while being melted along the outer edge of the core material.

The cutting edge part preferably has a concave shape by integrating the cut part and the pair of guide parts.

The shape of the blade edge part is preferably a U-shape or a V-shape.

The decorative film preferably has a base film made of a thermoplastic resin.

The trimming method for a decorative molded product according to the present invention is a trimming method for a decorative molded product in which a decorative film is attached to a core material, and the decoration projecting from the outer edge of the core material using an ultrasonic cutter. A step of removing an excess portion of the film, wherein the ultrasonic cutter includes an ultrasonic generation mechanism and a blade edge portion, and the blade edge portion includes a cut portion and a pair of guides protruding from the cut portion. The step of removing the surplus portion of the decorative film includes the outer edge of the core material between the pair of guide portions, and maintains the state in which the cut portion is pressed against the outer edge of the core material. However, the cutting edge portion is moved along the outer edge of the core material to cut the decorative film while melting the decorative film along the outer edge of the core material.

Since the manufacturing method of the decorative molded product of the present invention and the trimming method of the decorative molded product of the present invention use an ultrasonic cutter, the cut surface of the decorative film is melted and rounded, and peeled off from the core material. It becomes difficult. Further, the outer edge of the core material is sandwiched between the pair of guide portions, and the cutting edge portion is moved along the outer edge of the core material while maintaining the state where the cut portion is pressed against the outer edge of the core material. Thus, the boundary between the core material and the decorative film can be smoothly slid, and the workability in the process of removing the excess portion of the decorative film is improved.

It is the schematic explaining the example of the manufacturing method of the decorative molded product of this invention. It is sectional drawing which showed the decorative molded product typically. It is the schematic diagram explaining the method of sticking a decorating film on a core material. It is the schematic diagram explaining the method of sticking a decorating film on a core material. It is sectional drawing explaining the whole structure of the ultrasonic cutter. It is the expansion schematic diagram which showed an example of the blade part. It is the expansion schematic diagram which showed another example of the blade edge | tip part. It is the schematic diagram explaining the process of removing the excess part of a decoration film. 6 is a schematic diagram of a cutter blade used in Comparative Example 1. FIG. 6 is a schematic diagram of a cutter blade used in Comparative Example 2. FIG. 10 is a schematic diagram of a cutter blade used in Comparative Example 3. FIG.

The method for producing a decorative molded product of the present invention includes a step of attaching a decorative film to a core material, and a step of removing an excess portion of the decorative film protruding from the outer edge of the core material using an ultrasonic cutter. And have. FIG. 1 is a schematic diagram illustrating an example of a method for producing a decorative molded product according to the present invention. As shown in FIG. 1, the decorative film 10 is obtained by sticking the decorative film 10 to the core material 20 and then removing the excess portion of the decorative film 10 that protrudes from the outer edge of the core material 20. .

Below, an example of the decorative molded product obtained with the manufacturing method of the decorative molded product of this invention is demonstrated using FIG. FIG. 2 is a cross-sectional view schematically showing a decorative molded product. The decorative molded product 100 is obtained by attaching the decorative film 10 to the core material 20.

<Decorative film>
As shown in FIG. 2, the decorative film 10 includes, for example, a side on which a base film 11 and a first adhesive layer 12 are laminated, and the first adhesive layer 12 of the base film 11 is formed. The printed layer 13 may be provided on the opposite surface. Furthermore, you may have the surface protective layer 14 on the upper surface of the base film 11 or the printing layer 13. FIG. When the decorative film 10 includes the surface protective layer 14, the surface protective layer 14 may be laminated with the base film 11 or the printing layer 13 via the second adhesive layer 15. In addition, the surface protective layer 14 is not necessarily laminated via the second adhesive layer 15, and may be laminated directly on the base film 11 or the printing layer 13.

The base film 11 may be made of a thermoplastic resin or a thermosetting resin. In the ultrasonic cutter described later, the cutting edge portion has a cut portion, and the cut portion can cut the decorative film 10 even in a state where ultrasonic waves are not generated. Therefore, even if the cut portion is made of a thermoplastic resin. Even if it is made of a thermosetting resin, it can be cut. The base film 11 is made of a thermoplastic resin from the viewpoint of being suitable for vacuum / pressure forming, which will be described later, and capable of dissolving the cut surface of the decorative film 10 by generating ultrasonic waves by an ultrasonic generation mechanism of an ultrasonic cutter. Is more preferable.

Examples of the thermoplastic resin include acrylonitrile / butadiene / styrene copolymer (ABS resin), polypropylene resin, polyethylene resin, polymethyl methacrylate resin (PMMA), polyvinyl chloride resin, polycarbonate, or Examples thereof include polyethylene terephthalate (PET).

Examples of the thermosetting resin include epoxy resins and phenol resins.

Among the above thermoplastic resins, those made of a polyvinyl chloride resin are more preferable because they have good elongation, are not easily broken, and can be easily attached to a three-dimensional curved surface. Examples of the vinyl chloride resin include vinyl chloride homopolymers and copolymers of vinyl chloride with other monomers copolymerizable with vinyl chloride. Examples of the other copolymerizable monomers include vinyl esters such as vinyl acetate and vinyl propionate; olefins such as ethylene, propylene and styrene; methyl methacrylate, ethyl acrylate and methyl methacrylate (meta ) Acrylic acid esters; maleic acid diesters such as dibutyl maleate and diethyl maleate; fumaric acid diesters such as dibutyl fumarate and diethyl fumarate; vinyl cyanides such as acrylonitrile and methacrylonitrile; vinylidene chloride and vinyl bromide Examples of the vinyl halide include vinyl ethers such as methyl vinyl ether and ethyl vinyl ether. These may be used alone or in combination of two or more.

The content of the other copolymerizable monomer in the copolymer is usually 50% by weight or less, preferably 10% by weight or less. When it exceeds 50% by weight, the bending resistance of the decorative film 10 is lowered, and for example, it may not be suitable for being attached to the core material 20. Among the vinyl chloride resins, a vinyl chloride homopolymer is preferable from the viewpoints of excellent printability and visibility, and excellent dimensional stability.

The vinyl chloride resin preferably has an average degree of polymerization of 700 to 1400. In this case, it is excellent in printability (for example, coloring property at the time of printing, ink fixing property, etc.) when the printing layer 13 is formed using a solvent-based ink. On the other hand, if the average degree of polymerization is less than 700, the solvent-based ink is absorbed too much, and the ink oozes in a swollen state in the base film 11, so that the color developability and sharpness during printing are high. It becomes insufficient. On the other hand, when the average degree of polymerization exceeds 1400, the solvent-based ink has low absorbability, and the ink hardly permeates the base film 11 and adheres to the surface of the base film 11. May be damaged. In the present invention, the average degree of polymerization of the vinyl chloride resin means the average degree of polymerization measured according to JIS K-6721 “Testing method for vinyl chloride resin”.

For example, the vinyl chloride resin may contain a plasticizer to form a vinyl chloride resin composition. The plasticizer preferably has a molecular weight of 350 to 3000. When the molecular weight is less than 350, it is easy to bleed from the base film 11, and when the plasticizer bleeds, it moves to the first adhesive layer 12 to reduce the adhesive force of the first adhesive layer 12, When moving to the surface of the film 11 to form the printing layer 13, printing unevenness may occur. On the other hand, when the molecular weight exceeds 3000, the plasticizer absorbs ink too much, and when the printing layer 13 is formed, an image may blur and the sharpness of the printing layer 13 may be deteriorated.

In addition, when the said plasticizer consists of a high molecular compound, the molecular weight is a number average molecular weight. The number average molecular weight is a measured value in terms of polystyrene by GPC (gel permeation chromatograph) measurement. The GPC measurement is performed according to a standard method. For example, a dilute tetrahydrofuran solution of a plasticizer to be measured is prepared and measured using a GPC measuring device “HLC-8220GPC” manufactured by Tosoh Corporation under a flow rate condition of 0.6 ml / min. As the column, “KF606M” and “KF603” manufactured by Showa Denko KK are used.

Specific examples of the plasticizer include phthalic acid diesters such as octyl phthalate (di-2-ethylhexyl phthalate (DOP)), dibutyl phthalate and dinonyl phthalate; cyclohexane dicarboxylic acid ester, dioctyl adipate, and sebacic acid. Aliphatic dibasic acid diesters such as dioctyl; phosphoric acid triesters such as tricresyl phosphate and trioctyl phosphate; epoxy plasticizers such as epoxidized soybean oil and epoxy resins; and high-molecular polyester plasticizers.

Examples of the polymer polyester plasticizer include polyalkylene glycol diesters such as polyethylene glycol diester, polypropylene glycol diester, and polyethylene glycol polypropylene glycol diester of phthalic acid; polyethylene glycol diesters of aliphatic dibasic acids such as adipic acid and sebacic acid. Polyalkylene glycol diesters such as polypropylene glycol diester and polyethylene glycol polypropylene glycol diester; These may be used alone or in combination of two or more.

The blending amount of the plasticizer is preferably 5 to 30 parts by weight with respect to 100 parts by weight of the vinyl chloride resin. When the blending amount of the plasticizer is less than 5 parts by weight, the absorbability of the solvent-based ink in the base film 11 becomes insufficient, so that misery occurs and the printing suitability of the solvent-based ink may be poor. On the other hand, if the amount exceeds 30 parts by weight, the absorbability of the solvent-based ink in the base film 11 becomes too good, so that the ink dots may overlap during printing and the color development of the ink may be impaired.

The above-mentioned vinyl chloride resin composition is filled with stabilizers, colorants, foaming agents, lubricants, modifiers, inorganic particles, inorganic fibers, etc., which are generally used for vinyl chloride resin compositions as necessary. You may contain various additives, such as an agent and a diluent.

Although the thickness of the base film 11 is not specifically limited, 40-300 micrometers is preferable. If the thickness of the base film 11 is less than 40 μm, the strength of the film is insufficient and the decorative formability may be inferior. On the other hand, if it exceeds 300 μm, it may not be possible to follow the surface shape of the core material 20. More preferably, it is 80-200 micrometers.

The print layer 13 is composed of an image such as an arbitrary pattern, character, or design. The print layer 13 is preferably formed on the surface of the base film 11 using a solvent-based ink. The printing layer 13 formed using the solvent-based ink is fixed on the surface of the base film 11 in a state in which it has soaked into the base film 11. Therefore, the image is excellent in sharpness and fastness.

As the solvent-based ink, a conventionally known solvent-based ink mainly composed of a solvent, a pigment, a vehicle, and an auxiliary agent blended as necessary can be used. Among them, as a vehicle, a vinyl resin such as vinyl chloride-vinyl acetate copolymer resin, acrylic-vinyl acetate copolymer resin, or a solvent-based ink containing an acrylic resin adheres to the base film 11. It is preferable at the point which is excellent in property. Two or more of the above vehicles may be used in combination.

Examples of the solvent include glycol ether solvents such as diethylene glycol diethyl ether, tetraethylene glycol dimethyl ether, and tetraethylene glycol monobutyl ether; lactone solvents such as γ-ptyrolactone; low-boiling aromatic naphtha, propylene glycol monomethyl ether acetate, and the like. Is mentioned.

Examples of the pigment include carbon black (black), copper phthalocyanine (cyan), dimethylquinacridone (magenta), pigment yellow (yellow), titanium oxide, aluminum oxide, zirconium oxide, nickel compound, and the like. Various other pigments are already known as the pigment, and are not limited to those described above.

Specific examples of such solvent-based inks include, for example, SS21 ink, ES3 ink (both manufactured by Mimaki), Eco-Sol MAX (manufactured by Roland).

The method for forming the printing layer 13 is not particularly limited, and a conventionally known printing method such as direct gravure printing, offset printing, screen printing, flexographic printing, electrostatic printing, and inkjet printing can be used. Of these, inkjet printing is preferred. This is because it is easy to deal with multi-product and small-lot production. Although the inkjet apparatus used by the said inkjet printing is not specifically limited, For example, CJV-30, TPC-1000 (both made by Mimaki), XC-540, SP-3 (both made by Roland) etc. are mentioned.

The first adhesive layer 12 is preferably a layer made of a hot melt adhesive (hot melt adhesive layer). Examples of the hot melt adhesive include polyester hot melt adhesives, acrylic hot melt adhesives, rubber hot melt adhesives, and silicone hot melt adhesives. Since the hot-melt adhesive layer does not contain a solvent, it is suitable for attaching the decorative film 10 by vacuum forming or vacuum / pressure forming.

The thickness of the first adhesive layer 12 is preferably 25 to 50 μm. If the thickness of the 1st adhesive bond layer 12 is less than 25 micrometers, sufficient adhesive force between the core materials 20 may not be ensured. On the other hand, if it exceeds 50 μm, cohesive failure is likely to occur in the first adhesive layer 12, or it may be difficult to apply the first adhesive layer 12 so that the surface thereof is smooth. is there.

In addition, the decorative film 10 may be subjected to surface treatment such as embossing on the surface of the base film 11 or the printing layer 13 as necessary.

The surface protective layer 14 is a layer formed using, for example, a vinyl chloride resin composition or an acrylic resin composition, and is transparent. The surface protective layer 14 may be formed using a commercially available vinyl chloride resin film or acrylic resin film.

Examples of the surface protective layer 14 formed using the vinyl chloride resin composition include a layer made of a vinyl chloride resin composition in which a plasticizer and a stabilizer are blended with a vinyl chloride resin. Here, the average degree of polymerization of the vinyl chloride resin is preferably 700 to 1500. The plasticizer is preferably a plasticizer having an average molecular weight of 350 to 3000, such as diethylhexyl phthalate (DOP). Furthermore, the blending amount of the plasticizer is preferably 5 to 30 parts by weight with respect to 100 parts by weight of the vinyl chloride resin.

Examples of the surface protective layer 14 formed using the acrylic resin composition include those formed using acrylite, acrylene (both manufactured by Mitsubishi Rayon Co., Ltd.), sand durene (manufactured by Kaneka Co., Ltd.), and the like. . The surface protective layer 14 is preferably a layer formed using an acrylic resin composition from the viewpoint of excellent transparency. The thickness of the surface protective layer 14 is usually about 40 to 200 μm.

The second adhesive layer 15 is a layer formed using, for example, an acrylic adhesive, a rubber adhesive, or a polyester adhesive, and is transparent. Examples of the acrylic adhesive include those containing a C1 / C4 acrylic ester copolymer, a C4 acrylic ester copolymer, a C8 acrylic ester copolymer, etc. as the composition of the acrylic component, What is necessary is just to select suitably the combination of a composition of an acrylic component, and a hardening | curing agent according to uses, such as adhesiveness and heat resistance.

The decorative film 10 can be produced by the following method. First, a vinyl chloride resin composition is prepared, and then the obtained vinyl chloride resin composition is formed into a base film 11. The vinyl chloride resin composition can be prepared by melt-kneading a predetermined amount of each compounding component using a continuous kneader, a Banbury mixer, a kneader, an extruder, or the like. The film formation can be performed by calendar molding, extrusion molding, injection molding, or the like. The film formation is preferably performed by calendering. This is because calender molding makes it easy to make the thickness of the base film 11 uniform, can form a film regardless of the composition of the vinyl chloride resin composition, and it is easy to handle small lots. Examples of the calendar format used for the calendar molding include an inverted L shape, a Z shape, an upright two shape, an L shape, and an inclined three shape. Moreover, the roll temperature at the time of calendar molding may be appropriately selected according to the composition of the vinyl chloride resin composition, but is usually 140 to 190 ° C, and preferably 160 to 180 ° C.

Next, the first adhesive layer 12 is formed on one side of the base film 11. When the first adhesive layer 12 is made of a hot melt adhesive, the first adhesive layer 12 may be formed by a conventionally known method. A hot melt applicator or the like is directly used for the base film 11. It may be formed by coating, or it may be formed by coating once on a separately prepared support and then transferring. If a separator is used as the support, the separator can be laminated simultaneously with the formation of the hot melt adhesive layer.

Furthermore, the printing layer 13 is formed in the surface on the opposite side to the side in which the 1st adhesive bond layer 12 was formed of the base film 11 as needed. The printing layer 13 is formed using solvent-based ink or the like as described above. The method for forming the print layer 13 is as described above. Note that the order of forming the first adhesive layer 12 and forming the print layer 13 may be reversed.

Furthermore, the surface protective layer 14 is laminated | stacked on the base film 11 or the printing layer 13 as needed. For example, after producing a transparent film to be the surface protective layer 14 by calendar molding or the like, an adhesive is applied to one side of the transparent film, and this is pasted on the surface of the base film 11 on which the printing layer 13 is formed. The surface protective layer 14 is laminated via the second adhesive layer 15. Further, for example, after the transparent film is produced, the surface protective layer 14 may be laminated by directly sticking the transparent film on the printing layer 13 by a heat laminating method. These methods can be suitably used in any method when the print layer 13 is not formed or when the design of the print layer 13 is a pattern pattern or a solid print pattern. When the design of the layer 13 is a logo or a photographic image, a method of laminating the surface protective layer 14 via the second adhesive layer 15 is preferable. This is because in the case of laminating by the thermal laminating method, the base film 11 is stretched during the thermal laminating, and the design of the printing layer 13 may be distorted. The decorative film 10 can be manufactured through such a process.

<Core>
The core material 20 is not particularly limited as long as it is generally used for the decorative molded product 100, and for example, a core material made of resin, metal, or ceramic can be used.

The core material made of the resin is not particularly limited. For example, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal type. Examples thereof include resins, polycarbonate resins, acrylonitrile / butadiene / styrene copolymers (ABS resins), ionomer resins, and resin compositions obtained by adding various additives such as inorganic fibers to these resins.

The material for the core made of the metal is not particularly limited, and examples thereof include iron, aluminum, copper, and stainless steel (SUS).

<Attaching decorative film>
The method for attaching the decorative film 10 to the core material 20 is not particularly limited, and for example, vacuum forming, pressure forming, vacuum / pressure forming, in-mold forming, film insert forming, laminating, or the like can be used. Especially, since the sticking of the decorating film 10 is easy also with respect to the core material 20 which has complicated surface shapes, such as a three-dimensional curved surface, it is preferable to use vacuum and pressure forming.

Below, the method of sticking the nodule film 10 on the surface of the core member 20 will be described with reference to FIG. 3A and FIG. FIGS. 3A and 3B are schematic diagrams illustrating a method of attaching a decorative film to a core material. A vacuum / pressure forming apparatus 200 shown in FIGS. 3A and 3B includes upper and lower forming chambers (upper forming chamber 210 and lower forming chamber 220), and cores are formed by vacuum / pressure forming in these forming chambers. The decorative film 10 is pasted on the surface of the material 20.

First, in a state where the upper molding chamber 210 is raised (not shown), the core material 20 is set on the table 221 in the lower molding chamber 220, and the decorative film 10 attached to the core material 20 is placed on the upper surface of the lower molding chamber 220. set. Thereafter, the upper molding chamber 210 is lowered by the driving device 230, and the upper and lower molding chambers are respectively airtight (see FIG. 3-1 (a)).

Next, each of the upper and lower molding chambers is evacuated from the vacuum tank 240 through the pipe 241 to be in a vacuum state (very low pressure state) (see FIG. 3B). Thereafter, the heater 250 is turned on to heat the decorative film 10 (see FIG. 3-1 (c)). Thereby, the decorative film 10 is softened and the core material 20 can be attached along the surface shape.

Next, the table 221 in the lower molding chamber 220 is raised by the driving device 230, and the core material 20 is brought into contact with the softened decorative film 10 (see FIG. 3-2 (d)). Subsequently, the vacuum on the upper molding chamber 210 side is released to an atmospheric pressure state (the inside of the lower molding chamber 220 is in a vacuum state), and further, compressed air is put into the upper molding chamber 210 from the pressurized air tank 260, thereby decorating the film. 10 is pressed against the core member 20 and pasted along its shape (see FIG. 3-2 (e)). As a result, the decorative film 10 is attached only at a predetermined position on the surface of the core member 20.

Thereafter, the upper molding chamber 210 and the lower molding chamber 220 are each returned to the atmospheric pressure state, the upper molding chamber 210 is raised, and the core material 20 covered with the decorative film 10 is taken out (FIG. 3-2 (f)). reference). By using such a method, the decorative film 10 can be attached to the core material 20.

<Removal of excess part of decorative film>
The surplus portion of the decorative film 10 that protrudes from the outer edge of the core material 20 is removed using an ultrasonic cutter. By using an ultrasonic cutter, the cut surface of the film is melted and rounded, so that it is difficult to peel off from the core material.

Below, an example of a structure of an ultrasonic cutter is demonstrated using FIGS. FIG. 4 is a cross-sectional view illustrating the overall configuration of the ultrasonic cutter. As illustrated in FIG. 4, the ultrasonic cutter 300 includes, for example, an ultrasonic generation mechanism 310, a cutter blade 320, and an ultrasonic control unit 340. The tip of the cutter blade 320 is a blade edge portion 330. The ultrasonic generation mechanism 310 is connected to the ultrasonic control unit 340 by the lead wire W.

Since the ultrasonic cutter of the present invention is characterized by the tip (blade edge portion 330) of the cutter blade 320, the configurations of the ultrasonic generation mechanism 310 and the ultrasonic control unit 340 are not particularly limited. As an ultrasonic cutter provided with the ultrasonic generation mechanism 310 and the ultrasonic control unit 340, for example, a tabletop ultrasonic cutter KW-430C manufactured by Nippon Alex Co., Ltd. may be mentioned.

The ultrasonic generation mechanism 310 includes an ultrasonic oscillator 311. The ultrasonic oscillator 311 includes electrodes 312 and 313 connected to the ultrasonic control unit 340 and ultrasonic vibrators 314 and 315 connected to the electrodes 312 and 313. A cutter blade horn 351 is attached to the ultrasonic oscillator 311. The cutter blade 320 is fixed to the cutter blade horn 351 by a cutter blade holder 352. The ultrasonic control unit 340 controls the ON / OFF of the ultrasonic vibration and the output of the ultrasonic vibration. Under the control of power supply and output from the ultrasonic control unit 340, the ultrasonic vibrators 314 and 315 ultrasonically vibrate at an arbitrary output.

FIG. 5 is an enlarged schematic view showing an example of the blade edge portion, and FIG. 6 is an enlarged schematic view showing another example of the blade edge portion. As shown in FIGS. 5 and 6, the blade edge portion 330 includes a cut portion 331 and a pair of guide portions 332 that protrude from the cut portion 331.

The cut part 331 can cut the decorative film 10 by moving the blade edge part 330 along the outer edge of the core member while maintaining the state of being pressed against the outer edge of the core member. The cut part 331 has a sharp structure, and has a function of cutting the decorative film 10 even in a state where no ultrasonic wave is generated by the ultrasonic wave generation mechanism 310. By generating ultrasonic waves by the ultrasonic generation mechanism 310, the cut portion 331 can be cut while melting the excess portion of the decorative film 10.

The shape of the pair of guide portions 332 is not particularly limited as long as the outer edge of the core material can be sandwiched. The pair of guide portions 332 may be integrated with the cut portion 331, or may be a separate member from the cut portion 331. As shown in FIG. 5, the cutting edge portion 330 preferably has a concave shape in which a cut portion 331 and a pair of guide portions 332 are integrated. When the shape of the cut part 331 is a concave shape, the cut part 331 can be easily placed along the outer edge of the core member 20, and workability can be further improved.

As shown in FIG. 5, the shape of the cutting edge portion 330 may be a U-shape in which the cut portion 331 has a curve, or as shown in FIG. 6, the cut portion 331 is a V-shape formed by a straight line. There may be. The shape of the blade edge portion 330 can be appropriately selected depending on the outer edge shape of the core material. When the width of the outer edge of the core material is narrow, the V-shape is preferable, and the width of the outer edge of the core material is wide. Is preferably U-shaped. Considering the workability when removing the surplus portion of the decorative film, the shape of the cutting edge portion 330 may be V-shaped because it can be easily fixed to the outer edge of the core and can be stably processed.

The ultrasonic cutter 300 can be used as follows. The power source of the ultrasonic control unit 340 is turned on to arbitrarily control the output of the ultrasonic vibration, and the ultrasonic vibrators 314 and 315 of the ultrasonic oscillator 311 are ultrasonically vibrated. The ultrasonic vibrations oscillated from the ultrasonic vibrators 314 and 315 cause the cutter blade horn 351, the cutter blade holder 352, and the cutter blade 320 that are integrally attached to resonate and cut an object that contacts the cutter blade 320. .

The energy required to cut an object using an ultrasonic cutter can be expressed by the following formula (1).
Energy = Amplitude x Pressure x Frequency x Time (1)

The amplitude, pressure, frequency, and time are not particularly limited, and can be adjusted according to the material, thickness, and the like of the object.

Drawing 7 is a mimetic diagram explaining the process of removing the surplus part of a decoration film. In FIG. 7, the arrow represents the traveling direction of the ultrasonic cutter. As shown in FIG. 7, the process of removing the excess portion of the decorative film 10 includes a state in which the outer edge of the core material 20 is sandwiched between the pair of guide portions 332 and the cut portion 331 is pressed against the outer edge of the core material 20. The decorative film 10 is cut while melting the decorative film 10 along the outer edge of the core material 20 by moving the blade edge portion 330 along the outer edge of the core material 20 while maintaining.

The method for producing a decorative molded product of the present invention is effective for removing the decorative film 10 protruding from the outer edge of the core material 20. According to the method for producing a decorative molded product of the present invention, since there is no need for data on the cut portion of the decorative film, a receiving jig, etc., the structure of the decorative film and the shape of the core material can be handled flexibly. Can do. The method for manufacturing a decorative molded product of the present invention cuts an excess portion of the decorative film 10 along the outer edge of the core material 20. Therefore, the shape of the core member is preferably a shape having an outer edge that can be sandwiched between the pair of guide portions 332.

Specific examples of the decorative molded article 100 are not particularly limited, and electrical appliances such as mobile phones, smartphones, tablets, or covers thereof; interior designs for vehicles, motorcycle cowlings, etc., designs such as patterns, designs, characters, etc. on the surface Various decorative molded products decorated with can be mentioned.

The trimming method of the decorative molded product 100 is also one aspect of the present invention. The trimming method for a decorative molded product according to the present invention is a trimming method for a decorative molded product in which a decorative film is attached to a core material, and the decoration projecting from the outer edge of the core material using an ultrasonic cutter. A step of removing an excess portion of the film, wherein the ultrasonic cutter includes an ultrasonic generation mechanism and a blade edge portion, and the blade edge portion includes a cut portion and a pair of guides protruding from the cut portion. The step of removing the surplus portion of the decorative film includes the outer edge of the core material between the pair of guide portions, and maintains the state in which the cut portion is pressed against the outer edge of the core material. However, the cutting edge portion is moved along the outer edge of the core material to cut the decorative film while melting the decorative film along the outer edge of the core material.

EXAMPLES Hereinafter, although an Example is hung up and demonstrated in more detail about this invention, this invention is not limited only to these Examples.

(Production Example 1: Production of a decorative film)
To 100 parts by weight of a vinyl chloride resin (Kaneka, Kanevinyl S1008: average polymerization degree 800), 15 parts by weight of a plasticizer (JPLUS, DOP) is blended and melt-kneaded with a Banbury mixer. A vinyl resin composition was prepared. Then, it passed through each roll (roll temperature, 160-180 degreeC) of a reverse L type | mold calendar apparatus, and formed a 100-micrometer-thick vinyl chloride resin film (base film).

Next, a hot-melt adhesive (manufactured by Hitachi Chemical Co., Ltd., Hibon 7663) is coated on a release paper so as to have a thickness of 40 μm after drying, and this is transferred to the base film, and the base film and adhesive A decorative film in which layers and release paper were laminated in this order was produced.

(Examples and Comparative Examples)
In Examples and Comparative Examples, a decorative molded product having a smartphone cover as a core material was produced using the decorative film produced in Production Example 1.

Example 1
Using a TOM molding machine (manufactured by Fuse Vacuum Co., Ltd., NGF-0406), at a heating temperature of the heater of 80 to 120 ° C., the above-mentioned is placed at a predetermined position on the surface of the core material made of ABS resin (the core material of the smartphone cover). The decorative film produced in Production Example 1 was attached.

Next, the core material to which the decorative film is attached is taken out from the molding machine, and then the excess portion of the decorative film is removed using an ultrasonic cutter (desktop ultrasonic cutter KW-430C manufactured by Alex Japan). The decorative molded product (cover for smartphone) was completed. As shown in FIG. 5, the ultrasonic cutter used a blade edge portion 330 in which a cut portion 331 and a pair of guide portions 332 are integrated, and the shape of the blade edge portion 330 is U-shaped. The amplitude of the ultrasonic cutter was 36 μm and the frequency was 20 kHz.

(Comparative Example 1)
In Comparative Example 1, a decorative molded product was produced in the same manner as in Example 1 except that an ultrasonic cutter having a different cutter blade shape was used. FIG. 8 is a schematic diagram of the cutter blade used in Comparative Example 1. FIG. As shown in FIG. 8, the cutter blade used in Comparative Example 1 does not have a guide part, and the tip has a convex shape.

(Comparative Example 2)
In Comparative Example 2, a decorative molded product was produced in the same manner as in Example 1 except that an ultrasonic cutter having a different cutter blade shape was used. FIG. 9 is a schematic diagram of the cutter blade used in Comparative Example 2. As shown in FIG. 9, the cutter blade used in Comparative Example 2 does not have a guide portion and has a rounded tip.

(Comparative Example 3)
In Comparative Example 3, a decorative molded product was produced in the same manner as in Example 1 except that the shape of the cutter blade was different and a cutter without an ultrasonic generation mechanism was used. FIG. 10 is a schematic diagram of the cutter blade used in Comparative Example 3. The cutter blade used in Comparative Example 3 does not have a guide part, and the tip forms 30 °. Moreover, since the cutter used in Comparative Example 3 does not have an ultrasonic generation mechanism, it cannot melt the cross section of the decorative film.

(Evaluation of decorative molded products)
The following evaluation was performed about the decorative molded product produced in the Example and the comparative example. The results are shown in Table 1.

(1) Linearity of the film cross section The shape of the cut surface of the decorative film of the decorative molded product produced in the examples and comparative examples was observed with a microscope and magnified 100 times. Evaluation was based on 4 criteria. 4 is the best evaluation. In the following evaluation, the “linear portion” refers to the outer periphery of the core shown in FIG. 1, and the “round” refers to a circular opening located at the center of the core shown in FIG.
4: Although the cross section of the film has linearity and the cross section is smooth at the straight portion of the core material, the roundness of the core material is inferior in linearity although the film cross section is smooth.
3: Although the cross section of a film is smooth in the linear part and round part of a core material, linearity is a little inferior.
2: Although the cross section of a film is smooth in the linear part and round part of a core material, linearity is inferior.
1: There is no linearity in the cross section of the film at the straight part and the round part of the core material, and the cross section is sharp.

(2) Hardness of peeling of film cross section The difficulty of peeling of the decorative film of the decorative molded product produced in Examples and Comparative Examples was evaluated according to the following criteria. When the outer edge of the decorative molded product is rubbed by hand, if the cross section of the decorative film is rounded, the decorative film is less likely to be detached from the core. On the other hand, when the cross section of the decorative film is sharp, the decorative film is easily peeled off from the core material because of the catch. Therefore, the difficulty in peeling of the film cross section was evaluated by visually observing the shape of the cross section of the decorative film.
○: The decorative film has a round cross section and is difficult to peel off from the core material.
X: The decorative film has a sharp cross section and is easily peeled off from the core material.

From the result shown in the said Table 1, in Example 1, since the ultrasonic cutter was used, the cut surface of the decorative film melt | dissolved and rounded, and it was hard to peel off from a core material. On the other hand, although the comparative example 4 was excellent in the linearity of a film cross section, since it did not melt | dissolve the cut surface of a film, it was easy to peel from a core material. Moreover, the ultrasonic cutter used in Example 1 has a cutting edge portion and a pair of guide portions that protrude from the cutting portion. The outer edge of the core material is sandwiched by the guide portion, and the cutting edge portion is moved along the outer edge of the core material while maintaining the state where the cut portion is pressed against the outer edge of the core material. Since the decorative film can be cut, Example 1 is excellent in workability as compared with Comparative Examples 1 to 3. Furthermore, in Example 1, since the cutting edge portion had a concave shape (U shape), the cut portion was easily along the outer edge of the core material, and the workability was more favorable. In Example 1, when an ultrasonic cutter having a V-shaped cutting edge is used, the linearity of the film cross section can be further improved.

10: decorative film 11: base film 12: first adhesive layer 13: printed layer 14: surface protective layer 15: second adhesive layer 20: core material 100: decorative molded product 200: vacuum / compressed air Molding device 210: Upper molding chamber 220: Lower molding chamber 221: Table 230: Drive device 240: Vacuum tank 241: Pipe 250: Heater 260: Pressure air tank 300: Ultrasonic cutter 310: Ultrasonic generator 311: Ultrasonic oscillator 312 313: Electrodes 314, 315: Ultrasonic vibrator 320: Cutter blade 330: Cutting edge part 331: Cut part 332: Guide part 340: Ultrasonic control part 351: Cutter blade horn 352: Cutter blade holder

Claims (5)

A process of attaching a decorative film to the core material;
Using an ultrasonic cutter, and removing the excess portion of the decorative film protruding from the outer edge of the core material,
The ultrasonic cutter has an ultrasonic generation mechanism and a blade edge part,
The blade edge part includes a cut part and a pair of guide parts protruding from the cut part,
The step of removing the excess portion of the decorative film includes sandwiching the outer edge of the core material between the pair of guide portions, and maintaining the state in which the cut portion is pressed against the outer edge of the core material, A method for producing a decorative molded product, wherein the decorative film is cut while being melted along the outer edge of the core material by being moved along the outer edge of the core material. 2. The method for manufacturing a decorative molded product according to claim 1, wherein the cutting edge portion has a concave shape in which the cut portion and the pair of guide portions are integrated. The method of manufacturing a decorative molded product according to claim 1 or 2, wherein the shape of the cutting edge portion is U-shaped or V-shaped. The said decorative film has a base film which consists of thermoplastic resins, The manufacturing method of the decorative molded product in any one of Claims 1-3 characterized by the above-mentioned. A trimming method for a decorative molded product in which a decorative film is attached to a core material,
Using an ultrasonic cutter, and having a step of removing an excess part of the decorative film protruding from the outer edge of the core material;
The ultrasonic cutter has an ultrasonic generation mechanism and a blade edge part,
The blade edge part includes a cut part and a pair of guide parts protruding from the cut part,
The step of removing the excess portion of the decorative film includes sandwiching the outer edge of the core material between the pair of guide portions, and maintaining the state in which the cut portion is pressed against the outer edge of the core material, A trimming method for a decorative molded product, wherein the decorative film is cut while being melted along the outer edge of the core material by being moved along the outer edge of the core material.

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