JP2019130728A - Method for manufacturing decorative article and molding device - Google Patents

Abstract

To provide a method for manufacturing a decorative article capable of suppressing reduction in metallic design during molding.SOLUTION: The present disclosure provides a method for manufacturing a decorative article which comprises steps of: preparing a member to be molded including at least a decorative sheet having a resin layer and a metal thin film layer; molding the member to be molded by pressing to a mold; and expanding the decorative sheet in the opposite direction to a direction in which the decorative sheet contracts due to the molding.SELECTED DRAWING: Figure 1

Description

  The present disclosure relates to a method for manufacturing a decorative article using a decorative sheet having a metallic design, and a molding apparatus.

Instead of applying metal plating, a decorative sheet with a metal thin film layer is placed on the surface of the article as a technology to give a metallic design to various articles such as interior and exterior parts of vehicles, interior materials for building materials, and housings for home appliances. The technology to do is attracting attention. In the decorative sheet, the metal thin film layer is used for imparting a metallic design.
For example, Patent Document 1 discloses a metal decoration sheet having a metal holding film layer in which an indium thin film made of indium particles is formed on at least one surface, and is made of indium formed on the surface of the metal holding film. A metallic decorative sheet is disclosed in which the particle size of the metal particles is 100 nm or more and 250 nm or less.

JP 2007-30249 A

A decorative sheet having a metal thin film layer is likely to have a metallic design that tends to deteriorate during molding.
This indication is made in view of the above-mentioned situation, and provides the manufacturing method of the decoration article which can control that the metallic design nature of a decoration sheet falls at the time of fabrication. Main purpose.

  In order to solve the above-described problems, the inventors of the present disclosure have conducted extensive research and found that the shrinkage of the decorative sheet caused by the forming process greatly affects the deterioration of the metallic design. The present disclosure is an invention based on the above findings.

  That is, the present disclosure includes a preparation step of preparing a molded member including at least a decorative sheet having a resin layer and a metal thin film layer, a molding process step of pressing the molded member against a molding die, and a molding process step. There is provided a method for producing a decorative article, comprising: an extension treatment step of extending the decorative sheet in a direction opposite to a direction in which the decorative sheet is contracted by the forming process.

  According to this indication, by having the above-mentioned extension processing process, it can suppress that the design nature of the metallic tone of a decoration sheet falls, and can manufacture a decoration article.

  In the above disclosure, the metal thin film layer preferably has a sea-island structure. The metal thin film layer having a sea-island structure is likely to be whitened at the time of forming, and the metallic design is likely to deteriorate. Therefore, it is because whitening of a metal thin film layer can be suppressed suitably by applying the manufacturing method of this indication.

  In the above disclosure, the molding step is a step of integrating the molded member and the article by using an article as the mold and pressing the molded member against the article for molding. Also good. This is because a decorative article having a good metallic design can be obtained.

  The present disclosure relates to a heat treatment portion for heat-treating a molded member including at least a sheet having a resin layer, a pressing portion for pressing the molded member against a molding die, and extending the molded member. And a control unit that controls the extension processing unit to extend the sheet in a direction opposite to a direction in which the sheet is contracted by the forming process. I will provide a.

  The present disclosure includes the above-described extension processing unit and control unit. For example, when a decorative sheet having a resin base layer and a metal thin film layer is used as a sheet, the metallic design of the decorative sheet is provided. It can be set as the shaping | molding processing apparatus which can suppress a fall and can manufacture a decorative article.

  The manufacturing method of the decorative article according to the present disclosure has an effect that the decorative article can be manufactured while suppressing the metallic design property of the decorative sheet from being lowered.

It is process drawing which shows an example of the manufacturing method of the decorating article of this indication. It is process drawing which shows the other example of the manufacturing method of the decorating article of this indication. It is process drawing which shows the other example of the manufacturing method of the decorating article of this indication. It is explanatory drawing which shows an example of the expansion | extension direction of the decorating sheet in this indication. It is explanatory drawing explaining an example of the identification method of the expansion | extension direction of a decorating sheet in this indication. It is process drawing which shows the other example of the manufacturing method of the decorating article of this indication. It is a schematic sectional drawing which shows an example of the shaping | molding processing apparatus of this indication. It is a schematic sectional drawing which shows the other example of the shaping | molding processing apparatus of this indication. It is a schematic diagram explaining the shaping | molding die used in Example 1, 2 and the comparative example.

In the following description, embodiments of the present disclosure will be described with reference to the drawings and the like. However, the present disclosure can be implemented in many different modes and should not be construed as being limited to the description of the embodiments exemplified below. Further, in order to clarify the description, the drawings may be schematically represented with respect to the width, thickness, shape, and the like of each part as compared to the actual form, but are merely examples and limit the interpretation of the present disclosure. Not what you want. In addition, in the present specification and each drawing, elements similar to those described above with reference to the previous drawings are denoted by the same reference numerals, and detailed description may be omitted as appropriate.
Hereinafter, the manufacturing method of the decorative article and the molding apparatus of the present disclosure will be described in detail.
In this specification, “sheet” and “film” are synonymous, and for the sake of explanation, the terms “sheet” and “film” may be used.

A. Manufacturing method of decorative article The manufacturing method of the decorative article of the present disclosure includes a preparation step of preparing a molded member including at least a decorative sheet having a resin layer and a metal thin film layer, and the molded member as a molding die. It has the shaping | molding process process which presses and shape | molds, and the extending | stretching process process of extending | stretching the said decorating sheet in the direction opposite to the direction where the said decorating sheet shrink | contracts by the said forming process, It is characterized by the above-mentioned.

The manufacturing method of the decorative article of this indication is explained using figures. Fig.1 (a)-FIG.1 (f) are process drawings which show an example of the manufacturing method of the decorating article of this indication. FIGS. 1B, 1D, and 1F are cross-sectional views taken along line AA in FIGS. 1A, 1C, and 1E, respectively. The method for manufacturing a decorative article according to the present disclosure includes a preparation process, a molding process, and an extension process.
In the preparation step in the present disclosure, for example, as illustrated in FIGS. 1A and 1B, a molded member 10 including at least a decorative sheet 1 having a resin layer 11 and a metal thin film layer 12 is prepared. FIGS. 1A and 1B show an example in which the molded member 10 includes only the decorative sheet 1.
In the extension treatment step in the present disclosure, for example, as shown in FIGS. 1A and 1B, a mold 20 is prepared, and as shown in FIGS. 1C and 1D, the mold 20 is prepared. The decorative sheet 1 is extended in the direction opposite to the direction in which the decorative sheet 1 shrinks by the molding process used. FIG. 1C shows an example in which the direction opposite to the direction in which the decorative sheet 1 is contracted is the x-axis direction and the y-axis direction.
In the molding process in the present disclosure, the decorative sheet 1 is pressed against the molding die 20 and molded as shown in FIGS.
The manufacturing method of the decorative article according to the present disclosure includes at least the above-described preparation process, molding process, and extension process.

  According to this indication, by having the above-mentioned extension processing process, it can suppress that the design nature of the metallic tone of a decoration sheet falls, and can manufacture a decoration article.

Here, “metal-like design” and “metal-like design” refer to the design and design properties that make the user of the decorative article using the decorative sheet feel the metal surface. Examples of metallic designs include, but are not limited to, metal color and metallic luster.
In addition, examples of “degradation of metallic design” include, but are not limited to, metal discoloration such as a metal thin film layer appearing white (whitening) and a decrease in metallic luster. The manufacturing method of the present disclosure can suitably suppress whitening of the metal thin film layer among the deterioration of the metallic design.

Here, the decorative sheet having a metal thin film layer is liable to have a metal-like design property that deteriorates during molding by a molding die. In particular, a decorative sheet having a metal thin film layer in which a metal thin film is uniformly formed is cracked in the film during molding, so a sea-structured metal thin film is often used. A decorative sheet having a layer tends to cause whitening of a metal thin film layer during molding.
When the inventors of the present disclosure have studied the problem, the reason for the whitening of the sea-island-structured metal thin film layer in the molded decorative sheet is that light tends to diffusely reflect on the surface of the metal thin film layer. I found out that there was.
Further, the inventors of the present disclosure further researched that the metal thin film is caused by the shrinkage of the resin layer of the decorative sheet as compared with that before the molding process as a factor that easily causes irregular reflection of light on the surface of the metal thin film layer having a sea island structure. It was found that the surface of the layer was distorted. Specifically, in the decorative sheet, in the portion where the resin layer is shrunk compared to before molding, the metal of the island portion overlaps or the distance between the metal of the island portion is reduced, for example, a metal thin film It was found that the surface of the metal thin film layer was distorted such that fine wrinkles or irregularities occurred on the surface of the layer.

  In addition, it is presumed that the change in the reflection characteristics due to the distortion of the surface of the metal thin film layer also has a great influence on the deterioration of the metallic design other than the whitening of the metal thin film layer.

  In this indication, it can control that a decoration sheet shrinks rather than the original length at the time of fabrication by extending a decoration sheet in an extension processing process. Moreover, it can suppress that a decorating sheet is distorted by the tension | tensile_strength applied to a sheet | seat when extending | stretching a decorating sheet. As a result, the distortion of the metal thin film layer can be reduced, and the deterioration of the metallic design can be suppressed.

  Hereinafter, each process in the manufacturing method of the decorative article of this indication is explained.

1. Stretching process step The stretching process step in the present disclosure is a process of stretching the decorative sheet in a direction opposite to the direction in which the decorative sheet is shrunk by the molding process.

  In general, the stretching process may be performed before the molding process described later or simultaneously with the molding process. Among these, in the present disclosure, it is preferable that the stretching process is performed before the molding process.

When the stretching process is performed before the molding process, it may be performed before the preparation process described later, or after the preparation process and before the molding process.
The timing of the extension treatment step can be appropriately selected depending on the configuration of the member to be molded.
For example, when the member to be molded includes only the decorative sheet, as shown in FIGS. 1 (a) to 1 (f), the stretching process steps (FIGS. 1 (c) and (d)) are usually prepared. It is performed after the process (FIGS. 1A and 1B) and before the molding process (FIGS. 1E and 1F).
On the other hand, when the member to be molded is a laminated body including a decorative sheet and another sheet, for example, the stretching process may be performed before the preparation process. Specifically, the order of steps shown in FIGS. 2A to 2D can be adopted. That is, as shown in FIGS. 2A and 2B, the decorative sheet 1 is stretched in the stretching process. Next, as shown in FIG. 2 (c), in the preparation step, the molded member 10 is formed by placing the stretched decorative sheet 1 on another sheet 13. Next, as shown in FIG. 2D, in the molding process, the molded member 10 including the stretched decorative sheet 1 is pressed against the molding die 20 and molded.
On the other hand, when the member to be molded is the above-described laminated body, the stretching process may be performed after the preparation process and before the molding process. Specifically, the order of steps shown in FIGS. 3A to 3D can be adopted. That is, as shown to Fig.3 (a), in the preparatory process, the to-be-molded member 10 of the laminated body containing the decorating sheet 1 and the other sheet | seat 13 is prepared. Next, as shown in FIG. 3B, in the stretching step, the molded member 10 of the laminate is stretched. Next, as shown in FIG. 3C, in the molding process, the molded member 10 of the stretched laminate is pressed against the mold 20 and molded.

  When the stretching process is performed simultaneously with the molding process, for example, the decorative sheet or the member to be molded may be stretched in a state where a part of the decorative sheet or the member to be molded is brought into contact with the mold.

In the stretching process, the decorating sheet is stretched in the direction opposite to the direction in which the decorating sheet shrinks by the molding process.
Here, “the shrinkage of the decorative sheet by the forming process” means that the length of the decorative sheet in a predetermined direction becomes shorter than the original decorative sheet by the forming process. “Shrinking of the decorative sheet by molding” is a vector having an amount (length) of shrinking from the original decorative sheet and a predetermined direction.
In addition, “the direction in which the decorative sheet shrinks by the molding process” means a predetermined direction in the above-described “shrinkage of the decorative sheet by the molding process”, that is, compared to the length of the original decorative sheet, The vector direction in which the length of the decorative sheet is shortened.
For example, when the member to be molded includes only the decorative sheet, the original decorative sheet refers to the member to be molded before the molding process. For example, when a to-be-molded member is a laminated body of a decorating sheet and another member, the decorating sheet before making it into a laminated body is said. In the following description, “the direction in which the decorative sheet is shrunk by molding” may be referred to as the “shrinking direction”.

In the present disclosure, “extend the decorative sheet in the direction opposite to the direction in which the decorative sheet shrinks” is a vector opposite to the “shrink direction”, and not only when the decorative sheet is stretched, The term “shrink direction” includes a case where a vector in the reverse direction is decomposed into a plurality of components and the decorative sheet is expanded.
An example of “extending the decorative sheet in the direction opposite to the direction in which the decorative sheet shrinks” will be described with reference to the drawings. In the present disclosure, for example, as shown in FIG. 4A, the vector direction −D1 (direction indicated by a thick arrow) opposite to the shrinking direction D1 (direction indicated by a white arrow) of the decorative sheet 1 is provided. The decorative sheet may be extended. On the other hand, for example, as shown in FIG. 4B, the vector -D1 opposite to the shrinking direction D1 of the decorative sheet 1 is decomposed into a plurality of components -D1x and -D1y (directions indicated by thin line arrows). The decorative sheet 1 may be extended.

  The specific extending direction of the decorative sheet in the expansion treatment step is not particularly limited as long as the decorative sheet can be extended in the direction opposite to the shrinking direction of the decorative sheet described above, and may be in a specific direction. , It may be in all directions. When the extending direction of the decorative sheet is a specific direction, the extending direction may be, for example, a uniaxial direction or a biaxial direction. In the present disclosure, the extension direction is preferably a biaxial direction. It is because it is easy to adjust the length of the decorative sheet to be extended by setting the extending direction of the decorative sheet to the biaxial direction. When the extension direction is a biaxial direction, it is preferable that one axial direction and the other axial direction are orthogonal to each other. This is because the length of the extended decorative sheet can be adjusted with high accuracy.

The extent to which the decorative sheet is extended in the extension process is appropriately determined according to the configuration of the decorative sheet, the configuration of the member to be molded, the shape of the molding die, and the like.
When the length of the original decorative sheet in the shrinking direction of the decorative sheet is x1 and the length of the expanded decorative sheet is x2, the ratio of x2 to x1 (x2 / x1) is, for example, 1 It may be 1 to 3 times, 1.20 to 2.5 times, or 1.20 to 2.0 times.
This is because it is possible to sufficiently suppress a decrease in the metallic design due to stretching, and to sufficiently suppress the shrinkage of the decorative sheet due to the forming process.

  Moreover, when the length of the decorative sheet after the molding process in the shrinking direction of the decorative sheet is x3, the ratio of x3 to the original decorative sheet length x1 (x3 / x1) is a metallic tone. It will not specifically limit if it is a grade which can suppress the fall of a design, According to the kind of metal layer in a decorating sheet, the kind of resin layer, etc., it adjusts suitably. The x3 / x1 may be 0.90 times or more, for example, or 0.95 times or more. The x3 / x1 may be 1 time (100%).

The decorative sheet is usually subjected to heat treatment so as to be softened to such an extent that it can be stretched. In the present disclosure, the decorative sheet may be stretched after being softened by heat treatment, or heat treatment may be performed simultaneously with the stretching treatment. Further, the heat treatment may be a heat treatment of the member to be molded.
The heat treatment temperature of the decorative sheet is appropriately selected according to the type of the decorative sheet, the layer configuration, and the like.

2. Specific process and determination process In this indication, it is preferred to have further the specific process which specifies the direction in which the above-mentioned decoration sheet shrinks by the above-mentioned forming processing before an extension processing process. Depending on the shape of the mold and the type of decorative sheet, the shrinking direction of the decorative sheet, which greatly affects the reduction of the metallic design, can be specified, and the decorative sheet is opposite to the shrinking direction in the stretching process. It is because the fall of the metallic design property can be suppressed suitably by extending | stretching.
Examples of the method for specifying the shrinking direction of the decorative sheet include the following methods. As shown in FIG. 5A, on the decorative sheet 1a for evaluation, a mesh having equal intervals is drawn in the vertical direction and the horizontal direction using an ink having elasticity. The square shape may be a square or a rectangle. Moreover, the shaping | molding die 20 is prepared. Next, the decorative sheet 1a for evaluation is molded using the mold 20 in a state where the decorative sheet 1a for evaluation is not stretched. As shown in FIG. 5 (b), among the deformations of the cells in the molded decorative sheet for evaluation 1a, the direction in which the interval is narrow (the direction of the white arrow in FIG. 5 (b)) is added. Specify the shrinkage direction of the decorative sheet.

  Moreover, as a method of specifying the shrinking direction of the decorative sheet, for example, it may be specified by measuring the thickness of the decorative sheet. Specifically, after molding a decorative sheet for evaluation using a mold, the thickness of the molded decorative sheet for evaluation is measured, and the direction in which the thickness increases becomes a decorative sheet. Specify the direction of shrinkage.

  Moreover, in this indication, you may further have the determination process which determines the extent of expansion | extension of a decorating sheet in an expansion | extension process process before an expansion | extension process process. As a method of determining the degree of extending the decorative sheet, for example, by adjusting the degree of extension of the decorative sheet relative to the direction opposite to the shrinking direction of the decorative sheet specified from the specific process described above. The degree of extension that can suitably suppress the deterioration of the metallic design is determined.

3. Preparation Step The preparation step in the present disclosure is a step of preparing a member to be molded that includes at least a decorative sheet having a resin layer and a metal thin film layer.

The molded member prepared in the preparation step only needs to include at least a decorative sheet, may include only the decorative sheet, and may further include other sheets described later.
Hereinafter, details of the member to be molded will be described.

(1) Decoration sheet The decoration sheet in this indication has a resin layer and a metal thin film layer at least.

(A) Metal thin film layer The metal thin film layer is a layer having a metallic design.
The metal thin film layer is not particularly limited as long as it can have a desired metallic design. For example, the metal thin film layer may be disposed continuously with respect to the surface of the resin layer, or discontinuously with respect to the surface of the resin layer. It may be arranged. Further, when the metal thin film layers are discontinuously arranged, for example, the metal thin film layer may have a sea-island structure or a pattern structure having a regular pattern.

  In the present disclosure, the metal thin film layer preferably has a sea-island structure. The metal thin film layer having a sea-island structure is likely to be whitened at the time of forming, and the metallic design is likely to deteriorate. Therefore, it is because whitening of a metal thin film layer can be suppressed suitably by applying the manufacturing method of this indication.

The thickness of the metal thin film layer is not particularly limited as long as a desired metallic design can be exhibited. The thickness of the metal thin film layer is usually 5 nm or more and 300 nm or less, for example, more preferably 10 nm or more and 150 nm or less, and particularly preferably 10 nm or more and 100 nm or less.
Here, the “thickness of the metal thin film layer” refers to a thickness obtained by a general measurement method. Thickness measurement methods include, for example, a stylus method that calculates the thickness by tracing the surface with a stylus, and an optical method that calculates the thickness based on the spectral reflection spectrum. Is mentioned. Specifically, the thickness can be measured using a stylus type film thickness meter P-15 manufactured by KLA-Tencor Corporation. In addition, as a thickness, the average value of the measurement result of the thickness in several places of the member used as object may be used. Hereinafter, the measuring method mentioned above shall be used also about the measuring method of the thickness of the layer which comprises a decorating sheet.

The metal used for the metal thin film layer is not particularly limited as long as a metallic design can be imparted to the decorative sheet. For the metal thin film layer, only one type of metal may be used, or two or more types of metals may be used. Examples of the metal in the metal thin film layer include a single metal of tin, indium, chromium, aluminum, and copper, or an alloy containing at least one of the above-described metals. Especially, it is preferable that the metal used for a metal thin film layer is a metal which takes a sea island structure at the time of film-forming. The metal having a sea-island structure at the time of film formation is preferably, for example, indium simple substance, tin simple substance, indium alloy, or tin alloy. In the case of an indium alloy, the ratio of indium to all metals contained in the metal thin film layer may be, for example, 30 mol% or more, or 95 mol% or more.
The metal having the sea-island structure at the time of film formation described above is formed as a metal thin film layer having a sea-island structure in the process of forming a film by, for example, vapor deposition.

  The method for forming the metal thin film layer is not particularly limited as long as a metallic design can be imparted to the decorative sheet, and examples thereof include a vapor deposition method such as a vacuum vapor deposition method, a sputtering method, and an ion plating method. it can. Moreover, as a formation method of a metal thin film layer, the method of apply | coating the paste containing the metal mentioned above and the plating method using the metal mentioned above may be sufficient. In the present disclosure, the vacuum deposition method is particularly preferable. This is because the cost is low and the damage to the deposition target is small. The conditions for vapor deposition may be appropriately set according to the melting temperature or evaporation temperature of the metal used. The metal thin film layer may be a metal vapor deposition layer, for example.

(B) Resin layer The resin layer of the decorative sheet usually has a resin base layer.

(i) Resin Base Layer The resin base layer functions as a support that supports the metal thin film layer.
As resin which comprises a resin base material layer, it is preferable that it is a thermoplastic resin, for example. Examples of the thermoplastic resin include acrylonitrile-butadiene-styrene resin (hereinafter sometimes referred to as “ABS resin”), acrylonitrile-styrene-acrylate resin, and acrylic resin. Examples of the thermoplastic resin include polyolefin resins such as polypropylene and polyethylene, polycarbonate resins, vinyl chloride resins, and polyethylene terephthalate (PET) resins. As resin which comprises a resin base material layer, only 1 type may be used among the thermoplastic resins mentioned above, and 2 or more types may be mixed and used for it. In the present disclosure, the resin constituting the resin base material layer is preferably an ABS resin. This is because good three-dimensional formability can be imparted to the decorative sheet of the present disclosure.

  The thickness of the resin base material layer can be appropriately selected according to the shape of the decorative article and the molding method, and is not particularly limited. The thickness of the resin base material layer may be, for example, 50 μm or more and 3 mm or less. In addition, when laminating | decorating a decorative sheet on the other sheet | seat mentioned later and using it as a to-be-molded member, it is preferable that the thickness of a decorative sheet is 50 micrometers or more and 800 micrometers or less, for example, even if it is 50 micrometers or more and 600 micrometers or less. It may be 150 μm or more and 500 μm or less.

  In the decorative article obtained in the present disclosure, when the resin base material layer is disposed closer to the user than the metal thin film layer, the resin base material layer preferably has transparency. Transparency of the resin base means transparency that allows the desired metallic design to be observed, including colorless transparency and colored transparency that does not impede visibility, and is defined by strict transmittance Not.

(Ii) Other resin layers The decorative sheet in the present disclosure is not particularly limited as long as it has the metal thin film layer and the resin base material layer described above, and further includes other resin layers as necessary. Also good. As another resin layer, it is a layer used for a general decorating sheet, and is suitably selected according to a shaping | molding processing method. Examples of the other resin layer include a primer layer, a protective layer, an adhesive layer, and a color clear layer. About another resin layer, since it can be set as the same as the layer used in a general decorating sheet, description here is abbreviate | omitted.

(2) Other sheet | seat The molded member in this indication should just have at least the decorating sheet mentioned above, may contain only the decorating sheet, and may further contain the other sheet | seat. Examples of the other sheet include a molding sheet and a transfer sheet.

(A) Molding sheet The molded member of the present disclosure may further include a molding sheet. The molding sheet is a sheet used for increasing the molding processability and strength of the member to be molded.
As the molding sheet, a resin sheet is usually used. As resin used for the sheet | seat for shaping | molding, selecting and adding suitably from the thermoplastic resin demonstrated in the item of "(1) decoration sheet (b) resin layer (i) resin base material layer" mentioned above. Can do.
The thickness of the molding sheet is preferably thicker than the thickness of the entire decorative sheet, for example. The thickness of the forming sheet may be, for example, 1 mm or more and 5 mm or less.

(B) Transfer Sheet The molded member of the present disclosure may further include a transfer sheet.
The transfer sheet is used when a decorative sheet is formed by transferring the decorative sheet to an article. The transfer sheet is usually peeled off when the decorative article is manufactured.

As a material used for the transfer sheet, for example, a known plastic film conventionally used for a transfer film can be used. Examples of the plastic film include a polyester film, an acrylic film, a polyimide film, a polyamideimide film, a fluorine film, a polyethylene film, and a polypropylene film. Among these, a polyester film is preferable in terms of heat resistance and moisture resistance. Examples of the polyester film include a biaxially stretched polyethylene terephthalate film and a biaxially stretched polyethylene naphthalate film. Among these, a biaxially stretched polyethylene terephthalate film is preferable. This is because the biaxially stretched polyethylene terephthalate film has good heat resistance and is relatively inexpensive.
The thickness of the transfer sheet is, for example, about 10 μm or more and 100 μm or less.

The transfer sheet may be provided with a release layer on one surface side as necessary.
Examples of the material used for the release layer include phospholipid (lecithin), cellulose acetate, wax, fatty acid, fatty acid amide, fatty acid ester, rosin, acrylic resin, silicone, and fluorine resin. The thickness of the release layer is, for example, about 0.01 μm or more and 2 μm or less. The release layer can be formed by a conventionally known method such as a gravure coating method, a reverse coating method, or a die coating method.

(2) Preparatory process In a preparatory process, you may prepare by forming a to-be-molded member and may prepare a to-be-molded member of a commercial item.

4). Molding process The molding process in the present disclosure is a process in which the molded member is pressed against a mold and molded.
In the manufacturing method of the present disclosure, the stretching process is performed before the molding process. Therefore, in the molding process, the stretched decorative sheet is molded.

As a forming method for the member to be formed, a general sheet forming method can be used, and is not particularly limited. The forming method of the member to be formed may be, for example, a vacuum forming method or a pressure forming method. Examples of the forming method for the member to be formed include a straight method, a drape method, a plug assist method, and an air slip method.
A shaping | molding die is suitably selected according to the shape of a decorating article, a shaping | molding processing method, etc. Since a general mold or a resin mold can be used as the mold, description thereof is omitted here.

  Moreover, as a shaping | molding processing method of a to-be-shaped member, the method of using a goods as a shaping | molding die and arrange | positioning a to-be-shaped member may be used. As a method for forming such a member to be molded, for example, an overlay method can be cited.

  In the present disclosure, it is more preferable that the molding member is processed by using the article as a molding die and arranging the molding member. This is because when the member to be molded is used for decorating an article, the decorated article itself can be used as a mold. In this case, the molding process is a step of integrating the molded member and the article by using the article as the mold and pressing the molded member against the article for molding.

  A method for manufacturing a decorative article when the article is used as a mold will be described with reference to the drawings. FIG. 6A to FIG. 6F are process diagrams illustrating an example of a method for manufacturing a decorative article according to the present disclosure, and illustrates an example in which the mold 20 is used. FIGS. 1B, 1D, and 1F are cross-sectional views taken along line BB in FIGS. 1A, 1C, and 1E, respectively. The details of FIGS. 6A to 6D can be the same as those of FIGS. 1A to 1D, and thus the description thereof is omitted here. In the molding process, as shown in FIGS. 6E and 6F, an article 31 is used as the mold 20 and the molded member 10 is pressed against the article 31 to be molded. The article 31 is integrated. In the present disclosure, it is unnecessary when the decorative member 30 is formed in the member 10 as shown in FIGS. 6E and 6F and FIGS. 6G and 6H after the molding process. It is preferable to have a trimming step for removing the portion 14 to be. By performing the trimming process, the decorated article 30 having the article 31 and the molded member 10 can be obtained.

5). Other Steps The method for producing a decorative article according to the present disclosure is not particularly limited as long as it has the above-described stretching process, preparation process, and molding process, and can be added by appropriately selecting necessary processes. .
For example, you may have the mold release process of releasing the said to-be-shaped member from the said shaping | molding die after the said shaping | molding process process. Moreover, you may have the arrangement | positioning process which arrange | positions the said to-be-molded member released from mold on the surface of a to-be-adhered body. When the adherend to be placed in the placement step is an injection-molded body of resin, the placement step forms the adherend using an injection molding method, and the above-described adherend is molded. The process of arrange | positioning to a to-be-molded member and a to-be-adhered body may be sufficient. As a molding method used in the arrangement step, for example, an insert molding method or an injection molding simultaneous decorating method is preferably used. In addition, since it is the same as that of a well-known method about the insert molding method and the injection molding simultaneous decorating method, description here is abbreviate | omitted.

Moreover, in this indication, you may have the trimming process which removes the part which becomes unnecessary when it is set as a decoration article among to-be-molded members. The timing of the trimming process can be appropriately selected according to the molding method employed in the molding process or the arrangement process of the manufacturing method of the present disclosure.
For example, when the molding process is a process of integrating the molded member and the article described above, the trimming process is preferably performed after the molding process.
For example, when the insert molding method is used in the arrangement step, the molded member to be molded is released from the mold and then arranged in the injection mold. In the insert molding method, it is preferable to perform a trimming step after being released from the mold and before being placed on the injection mold. For example, when the injection molding simultaneous decorating method is used in the arranging step, the adherend and molding by injection molding and the integration of the molded member and the adherend are simultaneously performed. In this case, it is preferable to perform the trimming step after the molded member and the adherend are integrated. The details of the trimming process can be the same as those in a general method, and thus the description thereof is omitted here.

6). Decorated article The decorated article produced by the production method of the present disclosure only needs to have at least a molded member to be molded, and may have only the molded member. And may have an adherend. Further, the decorative article may have a member to be molded and a mold.

  As an application of the decorative article manufactured by the manufacturing method of the present disclosure, for example, as an application of the decorative article, for example, an application as an interior or exterior material of a vehicle such as an automobile, a window frame, a door frame, etc. Uses as joinery, use as interior materials for buildings such as walls, floors and ceilings, use as housings for home appliances such as television receivers and air conditioners, use as containers and the like.

B. Molding processing apparatus The molding processing apparatus of the present disclosure includes a heat treatment unit that performs heat treatment on a molded member that includes at least a sheet having a resin layer, and a pressing unit that performs molding processing by pressing the molded member against a molding die. A stretching processing unit that stretches the molded member, and a control unit that controls the stretching processing unit so as to stretch the sheet in a direction opposite to a direction in which the sheet shrinks due to the molding process. It is characterized by.

  The molding apparatus of the present disclosure will be described with reference to the drawings. Fig.7 (a)-FIG.7 (c) are schematic sectional drawings which show the other example of the shaping | molding processing apparatus of this indication. The molding apparatus 40 shown in FIGS. 7 (a) to 7 (c) molds a heat treatment portion 41 for heat-treating the molded member 10 including at least a sheet having a resin layer, and the molded member 10. A pressing part 42 that presses and molds the mold 20, an extension processing part 43 that performs an extension process on the member 10 to be molded, and an extension so that the sheet is extended in a direction opposite to the direction in which the sheet is contracted by the forming process. A control unit that controls the processing unit. In Fig.7 (a)-FIG.7 (c), the heat processing part 41 is a heater, for example. Further, the heat treatment part 41 may be movable inside and outside the decompression chamber 42 c in the pressing part 42. The molding die 20 includes, for example, a main body portion 20a, a hollow portion 20b, and a hole portion 20c that passes through the main body portion 20a and reaches the hollow portion 20b. Moreover, the pressing part 42 includes, for example, a pedestal part 42a on which the molding die 20 is placed, a support part 42b that supports the pedestal part 42a, a decompression chamber 42c, and a decompression part 42d that decompresses the decompression chamber 42c. The pedestal portion 42 a and the support portion 42 b include a tubular portion 42 e that connects the decompression portion 42 d and the hollow portion 20 a of the mold 20. The tubular part e has a hollow structure. The support portion 42b may have a distance adjustment function for adjusting the distance between the mold 20 and the member 10 to be molded. The decompression unit 42b is, for example, a vacuum pump.

  A method for forming a member to be formed using the forming apparatus 40 shown in FIGS. 7A to 7C will be described. First, as shown in FIG. 7A, the molding die 20 is arranged on the pedestal portion 42 a in the pressing portion 42, and the molding target member 10 is fixed to the extension processing portion 43. Next, the molded member 10 is heat-treated using the heat treatment part 41. After the heat treatment, as shown in FIG. 7B, the heat treatment portion 41 is moved from the inside of the decompression chamber 42c to the outside. Next, the member to be molded 10 is extended using the extension processing unit 43. Next, by lowering the position of the extension processing portion 43 toward the pedestal portion 42 a, the member 10 to be molded is placed along the mold 20. Next, as illustrated in FIG. 7C, the molding member 10 is brought into close contact with the molding die 20 by forming the decompression chamber 42 c under reduced pressure using the decompression unit 42 d, thereby performing molding processing. In FIG.7 (c), by using the pressure reduction part 42d, the air of the pressure reduction chamber 42c is pulled from the hole 20b of the shaping | molding die 20 to the hollow part 20a, and the to-be-molded member 10 is closely_contact | adhered to the shaping | molding die 20, Molding process.

  Fig.8 (a)-FIG.8 (c) are schematic sectional drawings which show the other example of the shaping | molding processing apparatus of this indication. The molding apparatus 40 shown in FIGS. 8A to 8C molds a heat treatment portion 41 that heat-treats the molded member 10 including at least a sheet having a resin layer, and the molded member 10. A pressing part 42 that presses and molds the mold 20, an extension processing part 43 that performs an extension process on the member 10 to be molded, and an extension so that the sheet is extended in a direction opposite to the direction in which the sheet is contracted by the forming process. A control unit that controls the processing unit. 8A to 8C, the heat treatment unit 41 is, for example, a heater. The pressing part 42 includes, for example, a pedestal part 42a on which the mold 20 is placed, a support part 42b that supports the pedestal part 42, a decompression chamber 42c, and a decompression part 42d that decompresses the decompression chamber 42c. The mold 20 is a mold that does not have a hollow portion, for example.

  A method for forming a member to be formed using the forming apparatus 40 shown in FIGS. 8A to 8C will be described. As shown in FIGS. 8A and 8B, the member to be formed 10 is heat-treated and stretched, and then along the mold 20. Note that FIGS. 8A and 8B can be the same as FIGS. 8A and 8B described above, and a description thereof is omitted here. Next, as illustrated in FIG. 8C, the molding member 10 is brought into close contact with the molding die 20 by forming the decompression chamber 42 c under reduced pressure using the decompression unit 42 d, thereby performing molding processing. Specifically, the molding process is performed by bringing the molding target 10 into close contact with the molding die 20 using the pressure change in the decompression chamber 42c.

The present disclosure includes the above-described extension processing unit and control unit. For example, when a decorative sheet having a resin base layer and a metal thin film layer is used as a sheet, the metallic design of the decorative sheet is provided. It can be set as the shaping | molding processing apparatus which can suppress a fall and can manufacture a decorative article. Further, the stretch processing unit can be formed by stretching the sheet with tension in the left-right direction or all directions, for example. Therefore, the sheet can be made difficult to shrink, and the occurrence of sheet distortion can be suppressed.
Hereinafter, the molding apparatus according to the present disclosure will be described for each configuration.

1. Heat-treatment part A heat-treatment part is the structure which heat-processes with respect to the to-be-molded member containing the sheet | seat which has a resin layer at least.

  The heat treatment part is not particularly limited as long as it can heat-treat the member to be molded so that the member to be molded can be formed into a desired shape. An example of the heat treatment part is a heater. The details of the heat treatment section can be the same as the configuration used in a general molding apparatus, and thus the description thereof is omitted here.

2. Press part A press part is the structure which presses the said to-be-molded member to a shaping | molding die, and is shape | molded.
The pressing part is not particularly limited as long as the member to be molded can be pressed against the mold and can be molded. For example, the member to be pressed is placed on the mold and placed under a reduced pressure. It may be configured to do so. Moreover, the structure which presses a to-be-molded member to a shaping | molding die using compressed air may be sufficient as a press part.

  For example, the pressing portion may be configured to press a molding member against a molding die in a vacuum molding method, and for example, to press a molding member against a molding die in an overlay method. The structure used may be sufficient. As a structure used for a vacuum forming method, the structure of the press part shown by Fig.7 (a)-(c) can be mentioned, for example. As a structure used for the overlay method, for example, the structure of the pressing portion shown in FIGS. In addition, as a press part, the structure used for a general shaping | molding apparatus can be mentioned.

3. Extension processing unit The extension processing unit is configured to extend the sheet.
The extension processing unit in the present disclosure is not particularly limited as long as the sheet can be extended, but it is preferable that the extension processing unit be configured to extend the sheet in two orthogonal axial directions. Examples of the configuration of the extension processing unit include a configuration having a pair of chucks arranged in the x-axis direction and the y-axis direction, respectively.
The details of the stretching processing unit can be the same as the configuration used in a general sheet stretching apparatus, and thus description thereof is omitted here.

4). Control unit The control unit is configured to control the expansion processing unit to expand the sheet in a direction opposite to a direction in which the sheet is contracted by the forming process.
The stretching direction and the degree of stretching of the sheet controlled by the control unit are the same as those described in the section “A. Method for producing decorative article 1. Stretching process step”. The same is preferable.

5). Others It is preferable that the shaping | molding processing apparatus of this indication is used for the manufacturing method of the decorative article described in the term of the "A. manufacturing method of a decorative article" mentioned above, for example.

  In addition, this indication is not limited to the said embodiment. The above-described embodiment is an exemplification, and the present invention has the same configuration as the technical idea described in the claims of the present disclosure and has the same function and effect regardless of the present embodiment. It is included in the technical scope of the disclosure.

  The present disclosure will be described in more detail with reference to the following examples.

[Comparative example]
A PMMA resin film (Sanduren, film having a thickness of 75 μm) of Kaneka Corporation was prepared. The above film was vapor-deposited by a vacuum vapor deposition method so that In had a film thickness of 50 nm. The deposited surface was observed by SEM, and it was confirmed that the In layer had a sea-island structure.
The surface side of the In layer in the film was bonded to an ABS resin plate (2 mm) via heat sealing. An evaluation sample was obtained by the above procedure. The glossiness (evaluation at 8 °) of the evaluation sample observed from the ABS resin plate side was 1080.
The glossiness was measured using a CM-700d manufactured by Konica Minolta as a measuring instrument.

Vacuum forming was performed using the obtained sample for evaluation. A mold shown in FIG. 9 was prepared as a mold. The dimension of the top surface of the mold shown in FIG. 9 is 30 mm × 50 mm, the dimension of the bottom surface is 50 mm × 90 mm, and the height is 50 mm (5 cm).
The surface temperature of the sample for evaluation was raised to about 200 ° C. with a vacuum forming machine, and vacuum forming was performed using the mold shown in FIG. At this time, the sample for evaluation was vacuum-formed without being stretched.
The glossiness of the side surface in the evaluation sample after molding was about 830 or more and 880 or less, and the glossiness of the top surface was about 970. The sample for evaluation after the forming process has a shrinkage of about 12.5% in the C direction in FIG. 9 and an elongation of about 25% in the D direction which is perpendicular to the C direction. confirmed. On the other hand, with respect to the top surface, it was confirmed that an elongation of about 6% to 10% occurred in the X direction and the Y direction, and it was confirmed that the evaluation sample did not shrink. In addition, the said ratio has shown the ratio of the length of the sample for evaluation after the shaping | molding process with respect to the sample for evaluation before a shaping | molding process.
From the result of the comparative example, it was confirmed that the glossiness greatly decreased on the side surface where shrinkage occurred, and the glossiness did not decrease significantly on the top surface where shrinkage did not occur.

[Example 1]
An evaluation sample was obtained in the same manner as in the comparative example.
Prior to vacuum forming, the surface temperature of the sample for evaluation was raised to about 200 ° C. and stretched by about 12% in the direction C in FIG. 8, and then vacuum forming was performed. In the evaluation sample after the molding process, the glossiness of the side surface was about 950. Moreover, the glossiness of the top surface was similar to that of the comparative example. From this result, it was confirmed that the glossiness can be maintained higher in the examples even after the molding process than in the comparative examples.

[Example 2]
An evaluation sample was obtained in the same manner as in the comparative example.
When the surface temperature of the evaluation sample is raised to about 200 ° C. and vacuum forming is performed using the mold shown in FIG. 8, the evaluation sample is pulled while applying tension in the direction C in FIG. 8. Went. In the sample for evaluation after molding, the glossiness of the side surface was about 930. Moreover, the glossiness of the top surface was similar to that of the comparative example. From this result, it was confirmed that the glossiness can be maintained higher in the examples even after the molding process than in the comparative examples.

DESCRIPTION OF SYMBOLS 1 ... Decorating sheet 1 ... Molded member 11 ... Resin layer 12 ... Metal thin film layer 40 ... Molding apparatus 41 ... Heat-treatment part 42 ... Press part 43 ... Extension process part

Claims (4)

A preparation step of preparing a molded member including at least a decorative sheet having a resin layer and a metal thin film layer;
A molding process step of pressing the molded member against a mold and molding the molding member;
And a stretching process step of stretching the decorative sheet in a direction opposite to a direction in which the decorative sheet shrinks by the forming process.   The said metal thin film layer has a sea island structure, The manufacturing method of the decorative article of Claim 1 characterized by the above-mentioned.   The molding process step is a step of integrating the molded member and the article by using an article as the mold and pressing the molded member against the article for molding. The manufacturing method of the decorating article of Claim 1 or Claim 2. A heat treatment part for heat-treating a molded member including at least a sheet having a resin layer,
A pressing portion that presses the molding target against a molding die and performs a molding process; and
An extension processing section for extending the molding member;
A control unit that controls the extension processing unit so as to extend the sheet in a direction opposite to a direction in which the sheet is contracted by the molding process;
A molding apparatus characterized by comprising: