JP2018034336A - Manufacturing method of decorative resin product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method capable of manufacturing a decorative resin product in which a decorative film is jointed to a surface of a resin substrate having an uneven shape at small scale production at low cost without reducing quality.SOLUTION: A decorative film 5 is size enlarged to an uneven shape of a surface of a resin substrate 4, then a resin layer is laminated in a back surface side of the decorative film 5 by a lamination molding method and the resin substrate 4 integrated with the decorative film 5 is molded, According to the manufacturing method, because a product with equal quality to manufacturing by a film insert molding can be manufactured without using an injection molding mold, manufacturing cost can be reduced in a small scale production.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a method for producing a decorative resin product in which a decorative film is bonded to the surface of a resin substrate having an uneven shape.

  Decorative resin products in which the surface of a resin base material is covered with a decorative film are used in various fields such as automobiles and electrical appliances. As a method for producing such a decorative resin product, film insert molding is often used (for example, Patent Document 1). In film insert molding, a molded decorative film is set in an injection mold, and a resin base material is injection-molded on the back side of the decorative film. A decorative film is integrally bonded to the surface. According to this manufacturing method, since the integrity of the resin base material and the decorative film is higher than when the decorative film is joined after the molding of the resin base material, a high-quality product can be obtained.

JP 2010-030053 A (see FIGS. 8 and 9)

  Decorative resin products manufactured by film insert molding are good in quality, but are not suitable for small-scale production of prototypes and parts due to the high manufacturing cost of injection molds.

  The present invention has been made in view of the present situation, and an object of the present invention is to provide a production method capable of producing a small amount of a decorated resin product at a low cost without deteriorating the quality.

  The present invention relates to a method for producing a decorative resin product in which a decorative film is bonded to the surface of a resin substrate having an uneven shape, the forming step for forming the decorative film into an uneven shape, and the forming After the process, it includes a layered modeling process of modeling a resin base material integrally bonded to the decorative film by laminating a resin layer on the back surface side of the decorative film by a layered modeling method. It is a manufacturing method of a decorative resin product.

  According to such a manufacturing method, a decorative resin product can be manufactured without using an injection mold, so that in the case of small-scale production, a decorative resin product can be manufactured at a lower cost than a manufacturing method using film insert molding. it can. Moreover, in this manufacturing method, since the resin layer which comprises a resin base material is laminated | stacked on the back surface side of the decorative film shape | molded by the uneven | corrugated shape, when the resin base material is modeled in the layered modeling process, the resin base material Is in close contact with the back surface of the decorative film and integrated with the decorative film. Therefore, according to this manufacturing method, it is possible to manufacture a decorated resin product having the same quality as the manufacturing method by film insert molding.

  As a specific method of the additive manufacturing process, the decorative film is held in a jig with the back side facing up, and a resin material is injected from the nozzle to the back side of the decorative film to form a resin layer with the required cross-sectional shape It is proposed to repeat the process. Such an additive manufacturing process can be realized by a three-dimensional printer. Since a general three-dimensional printer is one that forms a three-dimensional object by laminating a resin layer on a flat modeling stage, the decorative film is used as a jig as in the additive manufacturing process of the present invention. In the case of holding, a jig may be fixed on the stage of the three-dimensional printer or a jig may be provided in place of the stage. In addition, in this additive manufacturing process, the nozzle does not interfere with the decorative film by adopting a tapered nozzle, increasing the distance between the nozzle and the decorative film, or adjusting the locus of the nozzle. Proposed to be.

  The additive manufacturing method includes a stereolithography method, a hot melt lamination method, an ink jet method, a gypsum powder method, a powder sintering method, and the additive manufacturing method in the additive manufacturing process of the present invention is a hot melt lamination method. It is desirable to be legal. The hot melt lamination method is the cheapest additive manufacturing method at the present time, and is a method of injecting a resin material from a nozzle, so a resin layer is laminated on the back side of a decorative film shaped into a concavo-convex shape. This is because it is easy.

  Moreover, when performing a layered shaping | molding process by a hot melt lamination method as mentioned above, it is proposed that the process of forming a thermoplastic contact bonding layer on the back surface of a decorative film is included before a layered shaping | molding process. Examples of the method for forming the adhesive layer include printing of acrylic ink or urethane ink, application of a hot melt adhesive, and the like. According to this configuration, when the resin material is injected onto the back surface of the decorative film in the layered manufacturing process, the resin base material is easily joined to the back surface of the decorative film by melting the adhesive layer with the heat of the resin material. It becomes possible.

  Moreover, when forming a thermoplastic adhesive layer on the back surface of the decorative film as described above, while holding the decorative film on a jig and adjusting the temperature of the jig, It is proposed to adjust the temperature. In such a case, since the temperature of the decorative film can be adjusted more precisely than adjusting the temperature via the ambient temperature, the degree of melting of the adhesive layer can be controlled more precisely, and the decorative film and the resin base material can be controlled. It becomes possible to join more appropriately.

  As described above, according to the present invention, it is possible to manufacture a small amount of a decorated resin product at a low cost without deteriorating the quality.

It is explanatory drawing which shows the use condition of the decorative resin product. It is (a) front view, (b) back view, (c) side view, (d) center longitudinal cross-sectional view of the decorative resin product 1. (A) Front view, (b) Rear view, (c) AA line sectional view in FIG. 2, (d) BB line sectional view in FIG. It is a cross-sectional enlarged view of the decorative resin product 1. It is explanatory drawing which shows the manufacturing method of the decorative resin product 1. FIG. It is explanatory drawing which shows the manufacturing method of the decorative resin product 1 continued from FIG.

  The decorative resin product 1 manufactured by the manufacturing method of the present embodiment is a panel-shaped upper cover that is mounted on the upper portion of an armrest R disposed inside a door D of an automobile, as shown in FIG. .

  As shown in FIGS. 2 and 3, the decorative resin product 1 is formed by bonding a decorative film 5 to the surface of a resin substrate 4. The decorative resin product 1 has an outer peripheral portion that is curved to the back side, so that the entire front side has a convex shape and the entire back side has a concave shape. In the center of the decorative resin product 1, a rectangular opening 6 for mounting the operation switch S (see FIG. 1) is provided. Further, on the back side of the decorative resin product 1, a plurality of locking protrusions 7 that lock the decorative resin product 1 to the armrest R are disposed at a plurality of locations. In addition, the shape of the decorative resin product 1 in FIGS. 2 and 3 is a model of the actual product, and the thickness of the decorative resin product 1 excluding the locking projection 7 is about 5 to 10 mm, and the decorative film. 5 is about 125 to 475 μm, and the depth of the recess on the back side of the decorative resin product 1 is about 3 to 5 mm.

  The resin base material 4 is made of ABS resin. Although illustration is omitted, as will be described later, the resin base material 4 is a laminate formed by laminating a number of ABS resin layers having a thickness of about 100 μm, which is formed by a three-dimensional printer. The material of the resin base 4 may be a PC-ABS resin or the like instead of the ABS resin.

  The decorative film 5 is shaped so as to follow the concave-convex shape on the front side of the resin base material 4, and is integrally joined to the resin base material 4 so as to cover the entire front side of the resin base material 4. As shown in FIG. 4, the decorative film 5 has a design layer 9 for forming a design printed on the back side of a film substrate 8 made of a transparent resin, and a hot melt adhesive on the back side of the design layer 9. The surface of the decorative resin product 1 is glossy on the surface of the decorative resin product 1 by visually recognizing the design formed by the design layer 9 through the transparent film substrate 8. Is forming. The transparent film base 8 can be made of polycarbonate, PET resin, acrylic resin, ABS resin, or the like. The design layer 9 may be formed by gravure printing or laminating. The adhesive layer 10 may be formed by printing with acrylic ink or urethane ink instead of applying the hot melt adhesive.

Below, the manufacturing method of the said decorative resin product 1 is demonstrated.
The manufacturing method of the said decorative resin product 1 produces the resin film 4 on the back surface side of the decorative film 5 after the decorative film manufacturing process and the decorative film manufacturing process which produce the decorative film 5 and shape. A resin base material manufacturing process for modeling.

The decorative film manufacturing process is realized by sequentially performing the following processes (1) to (3).
(1) Design layer formation process The design layer 9 which consists of ink is printed on the back surface side of the flat film base material 8 which consists of transparent resin.
(2) Adhesive layer formation process The adhesive layer 10 which consists of a hot-melt-adhesive agent is printed on the back surface side of the design layer 9, and the flat decorating film 5 which consists of the film base material 8, the design layer 9, and the adhesive layer 10 is obtained. .
(3) Shaping Step As shown in FIGS. 5A to 5B, the flat decorative film 5 is shaped into a concavo-convex shape that follows the concavo-convex shape on the front side of the resin substrate 4 by pressure forming. In addition, in this manufacturing method, since the decorating film 5 is not shape | molded after this shaping process, the decorating film 5 is shape | molded by the high voltage | pressure in this process, and the decorating film 5 is the surface of the decorating resin product 1. Mold precisely into shape.

  In the resin base material manufacturing process, the resin base material 4 is formed on the back surface of the shaped decorative film 5 by a hot melt lamination method using a three-dimensional printer. In the three-dimensional printer, a jig 12 is usually fixed on a stage 13 on which a three-dimensional object is directly formed, so that the decorative film 5 can be accurately held at a predetermined position of the stage 13. Specifically, the jig 12 has a concave portion on the upper surface, and holds the decorative film 5 by fitting a convex shape on the front side of the decorative film 5 into the concave portion. The three-dimensional printer is provided with a temperature adjusting device (not shown) below the stage 13, and the temperature held by the jig 12 is adjusted by adjusting the temperature of the stage 13 and the jig 12 by the temperature adjusting device. It is comprised so that the decoration film 5 can be heated to predetermined temperature. Note that the jig 12 is preferably formed of a metal having high thermal conductivity in order to facilitate temperature adjustment.

The resin base material manufacturing process is realized by sequentially performing the following processes (1) to (3).
(1) Preparatory process As shown in FIG.5 (c), by fitting the convex shape of the surface side of the decorating film 5 to the recessed part of the jig | tool 12, the decorating film 5 in the state which turned the back side upwards Is held on the jig 12. The three-dimensional printer heats the decorative film 5 to a temperature at which the adhesive layer 10 is easily melted by heating the jig 12 and the stage 13 to a predetermined temperature using a temperature adjusting device. The temperature adjustment of the decorative film 5 is continued until the following layered manufacturing process is completed.
(2) Layered modeling process As shown in FIGS. 5 (d) → 6 (a) → 6 (b), the melted filamentary ABS resin is fed from the tip of the nozzle 14 of the three-dimensional printer to the back side of the decorative film 5. The resin base material 4 is shaped by repeating the step of forming a resin layer having a required cross-sectional shape on the back surface side of the decorative film 5 and laminating the resin layer on the back surface side of the decorative film 5. The thickness of the resin layer is not particularly limited, but is preferably about 100 μm. In the present layered manufacturing process, when the resin base material 4 and the decorative film 5 inject the molten resin material on the back surface of the decorative film 5, the adhesive layer 10 is temporarily melted by the heat of the resin material. They are joined together. In this additive manufacturing process, a method for moving the nozzle 14 so that the nozzle 14 and the decorative film 5 do not interfere with each other is programmed in advance in the three-dimensional printer. In this process, the nozzle 14 is moved relative to the back surface of the decorative film 5 in a three-dimensional direction. However, the relative movement of the nozzle 14 is realized by moving one or both of the stage 13 and the nozzle 14. The
(3) Post-processing process As shown in FIG.6 (c), the decorating resin product 1 is removed from the jig | tool 12, and the excess part of the decorating film 5 is cut. Moreover, the decorative film 5 is cut and the part of the opening part 6 is opened. The cutting of the decorative film 5 and the opening of the opening 6 may be performed in the decorative film manufacturing process. Moreover, in this process, you may perform the grinding | polishing of the resin base material 4, formation of a screw hole, removal of a support material, etc. as needed.

  According to the above manufacturing method, since the decorative resin product 1 can be manufactured without using an injection mold, it can be manufactured at a lower cost in the case of small-scale production than in the case of manufacturing by film insert molding. . As described above, the decorative resin product 1 according to this embodiment is an automobile interior product (upper cover of the armrest R). Therefore, when manufacturing a custom part with a small number of productions, the manufacturing method of this embodiment is This is more effective than the case of manufacturing by film insert molding.

  Moreover, according to the said manufacturing method, since the resin base material 4 joins to the back surface of the decorating film 5 at the time of modeling the resin base material 4 at the lamination modeling process, and is integrated with the decorating film 5, According to this manufacturing method, the decorative resin product 1 having the same quality as that manufactured by film insert molding can be manufactured. In addition, if it is the resin base material 4 modeled with the three-dimensional printer, the intensity | strength required for the interior goods of a motor vehicle can fully be ensured.

  In addition, this invention is not limited to the form of the said Example, In the range which does not deviate from the summary of this invention, it can change suitably. For example, the decorative resin product 1 of the above embodiment is an upper cover of an armrest of an automobile door, but the present invention is applicable to the manufacture of various decorative resin products, particularly for the manufacture of small-quantity products. It is valid. For example, in the case of other interior parts of automobiles, it can be applied to manufacture of door trims and shift panels of custom parts.

  Also, the decorative film is not limited to the decorations, materials, layer structures, and thicknesses of the above embodiments, and can be changed as appropriate. For example, the decorative film may be a metallic decorative film. Moreover, although the decorating film of the said Example became the concave shape on the whole back surface side, as for the decorating film which concerns on this invention, the partial convex shape may be formed in the back surface side, and a back surface A convex shape may be formed on the entire side. Moreover, the decorative resin product may be covered with a plurality of types of decorative films. In some standards, those having a thickness of less than 250 μm are classified as “film”, and those having a thickness of 250 μm or more are classified as “sheets”. However, the decorative film according to the present invention has a thickness of less than 250 μm. It is not limited to that, but includes a thickness of 250 μm or more. However, if the decorative film is too thick, the difficulty of shaping becomes high, so the thickness of the decorative film is preferably 500 μm or less.

  In addition, the layered manufacturing method of the resin base material is not limited to the hot melt layered method of the above embodiment, and other layered modeling methods can be appropriately employed, and the material of the resin base material is also appropriately selected according to the layered modeling method. It can be changed. In addition, the resin base material is not limited to one formed with one type of resin, and may be formed with various types of resins.

DESCRIPTION OF SYMBOLS 1 Decorated resin product 4 Resin base material 5 Decorated film 6 Opening part 7 Locking protrusion 8 Film base material 9 Design layer 10 Adhesive layer 12 Jig 13 Stage 14 Nozzle D Door R Armrest S Operation switch

Claims (5)

A method for producing a decorative resin product in which a decorative film is bonded to the surface of a resin substrate having an uneven shape,
A shaping process for shaping the decorative film into a concavo-convex shape;
After the shaping step, by laminating a resin layer on the back side of the decorative film by the additive manufacturing method, including an additive manufacturing step of forming a resin base material integrally joined with the decorative film. A method for producing a decorated resin product.   In the layered modeling process, the process of holding the decorative film on the jig with the back side facing upward and injecting the resin material from the nozzle to the back side of the decorative film to form the resin layer having the required cross-sectional shape is repeated. The manufacturing method of the decorative resin product of Claim 1 characterized by the above-mentioned.   The method for producing a decorated resin product according to claim 1 or 2, wherein the layered manufacturing method is a hot melt lamination method.   The method for producing a decorative resin product according to claim 3, comprising a step of forming a thermoplastic adhesive layer on the back surface of the decorative film before the layered manufacturing process.   5. The decorative resin according to claim 4, wherein in the additive manufacturing process, the decorative film is held in a jig, and the temperature of the decorative film is adjusted by adjusting the temperature of the jig. Product manufacturing method.

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