JP2020069780A - 多様なパターンのロゴの発光が可能な遮蔽層を備えた内装材及びその製造方法 - Google Patents

多様なパターンのロゴの発光が可能な遮蔽層を備えた内装材及びその製造方法 Download PDF

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Publication number
JP2020069780A
JP2020069780A JP2018215155A JP2018215155A JP2020069780A JP 2020069780 A JP2020069780 A JP 2020069780A JP 2018215155 A JP2018215155 A JP 2018215155A JP 2018215155 A JP2018215155 A JP 2018215155A JP 2020069780 A JP2020069780 A JP 2020069780A
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Prior art keywords
interior material
layer
transparent film
manufacturing
material layer
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JP2018215155A
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JP6726729B2 (ja
Inventor
ハ キム，クン
Keun Ha Kim
ハ キム，クン
ジェ チェ，ウォン
Wonjae Choi
ジェ チェ，ウォン
イル リ，ホン
Hongil Lee
イル リ，ホン
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Intops Co Ltd
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Intops Co Ltd
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Abstract

【課題】多様な形状のロゴ発光部を形成することができ、耐久力に優れ、製造が容易である内装材の製造方法を提供する。【解決手段】内装材の製造方法は、発光部の光を遮断する遮蔽層１４を透明フィルム２０に隣接して配列し、レーザーで食刻したライティング溝を透明フィルム成分で満たすことによって発光効果を多様で鮮かに具現することができる。アイランドを支持するテープ１８Ａを使うので、工程全体にわたって安定的な製作が可能である。【選択図】図３ｉ

Description

本発明は多様なパターンのロゴの発光が可能な遮蔽層を備えた内装材及びその製造方法に関する。具体的に、本発明はロゴを適切に発光させるのに必要な遮蔽構造を改善した、ロゴ発光部を備えた内装材及びその製造方法に関する。
内装材とは製品の外部を仕上げるのに使われる材料を言う。内装材は製品の質感、触感などの外観を向上させ、騷音、火炎、酸素などを遮断して内部の構成を保護する役割をする。内装材は美的要素を外部に表現することができるように製造されることが好ましい。
韓国登録特許第１０−０９１３８１１号公報は、内装材としてリアルウッドフィルム（Ｒｅａｌｗｏｏｄ ｆｉｌｍ）を用いた成形品を開示している。成形品は、リアルウッドシート（Ｒｅａｌｗｏｏｄ ｓｅａｔ）の上下部に接着フィルムを熱圧着することによって製造され、このように製作された成形品は、自動車の内外装材、又は各種の電子製品のパネルなどに装着される。リアルウッド素材を使うことによって内装材が天然木材の質感を現し、よって内装材の外観を美麗に装飾することができる。
近年には、図１に示したように、リアルウッド素材の成形品に形成された“ＡＢＣＤＥ”のようなロゴ１０２’を発光させる内装材が提案されている。ロゴによって他の部分から孤立した領域をアイランド（ｉｓｌａｎｄ）と呼ぶ。
ロゴ１０２’を発光させるための方法として、本出願人の韓国登録特許第１０−１８８３０８０号公報は、主表面材であるリアルウッド層の下に遮光層を形成し、遮光層の下にタッチセンサー電極を形成し、タッチセンサー電極の下に光源を配置することによって、ロゴ部分を発光させる技術を開示している。しかし、この特許は、光が通過するライティング溝が空いており（ｈｏｌｌｏｗ）、空いている間隙を通じてほこりのような異物が累積して透光効果が低下するおそれがある。また、二重以上の複合フィルム構造に適用しにくくて耐久性が弱いし、多様なロゴの具現が難しい欠点がある。さらに、成形品の製作時にアイランド部分を支持する構造がないため、アイランド部分の精密な射出が難しい問題がある。
韓国登録特許第１０−０９１３８１１号公報 韓国登録特許第１０−１８８３０８０号公報
したがって、本発明は、多様な形状のロゴ発光部を形成することができ、耐久力に優れ、製造が容易である内装材の製造方法を提供することを目的とする。
本発明の内装材の製造方法は、（１−１）素材層の下部と熱融着層を接合する段階と、（１−２）素材層の上部にアイランドを支持するための支持テープを付着する段階と、（１−３）熱融着層から素材層まで光が透過する第１ライティング溝をレーザー食刻で加工する段階と、（２−１）透明フィルムの上部に光の透過を遮断する遮蔽層を印刷又は塗装して形成する段階と、（２−２）透明フィルムの下部にバインダーを付着する段階と、（２−３）前記遮蔽層に光が透過する第２ライティング溝をレーザー食刻で加工する段階と、（３−１）（１−３）で製作されたモジュールと（２−３）で製作されたモジュールを接合する段階と、（３−２）素材層の上部にアイランドを支持するための支持テープを交換する段階と、（３−３）（３−２）段階の製品を、母材層を備えた母材又は加工対象品と接合し、インサート射出成形工程で射出することによって内装材を完成する段階であって、高温雰囲気下の射出成形工程で前記透明フィルムの成分がメルティング及び延伸して前記第１ライティング溝及び第２ライティング溝を満たす段階とを含む。
また、本発明は以上の製造方法によって製造される内装材を提供する。
本発明によれば、複合層からなった内装材において、ライティング溝を満たした透明フィルムによってより鮮かなロゴの発光を期待することができ、ライティング溝に異物が流入することを防止することができる効果がある。
また、本発明によれば、透明フィルムに印刷又は塗装された遮蔽層にライティング溝を形成することによって多様なパターンのロゴ発光部を製作することができる。
本発明による内装材の製造方法は簡便で経済的であり、原価節減に有利である。
リアルウッド素材の成形品を示す図である。 本発明の実施例によるロゴ発光部を備えた内装材の製造方法を示す工程図である。 本発明の実施例によるロゴ発光部を備えた内装材の製造方法を示す工程図である。 本発明の実施例によるロゴ発光部を備えた内装材の製造方法を示す工程図である。 図２のそれぞれの工程によって製作される部材の断面図である。 図２のそれぞれの工程によって製作される部材の断面図である。 図２のそれぞれの工程によって製作される部材の断面図である。 図２のそれぞれの工程によって製作される部材の断面図である。 図２のそれぞれの工程によって製作される部材の断面図である。 図２のそれぞれの工程によって製作される部材の断面図である。 図２のそれぞれの工程によって製作される部材の断面図である。 図２のそれぞれの工程によって製作される部材の断面図である。 図２のそれぞれの工程によって製作される部材の断面図である。
以下、本発明の一実施例を例示的な図面に基づいて詳細に説明する。
各図の構成要素に参照符号を付けるにあたり、同じ構成要素に対しては、たとえ互いに異なる図に表示されても、できるだけ同じ符号を有するようにしていることに留意しなければならない。また、本実施例の説明において、関連した公知の構成又は機能についての具体的な説明が本実施例の要旨をあいまいにすることができると判断される場合にはその詳細な説明を省略する。
以下、本発明で記述する実施例は、ロゴ発光部の最終形状を決定する遮蔽層、すなわち遮光層を工程のどの段階に形成するか、そして光源から出る光が通過するガイドであるライティング溝を何の物質で満たすかを開示する点に特徴がある。
図２ａ〜図２ｃは本発明の実施例によるロゴ発光部を備えた内装材の製造方法を示す工程図、図３ａ〜図３ｉは図２のそれぞれの工程によって製作される部材の断面図である。
これらの図を一緒に参照すると、まず、内装材の外側には主要素材としてウッド層又は素材層１０が位置する。“ウッド”は一例を提示したものであり、纎維（ｆａｂｒｉｃ）、ストーン（ｓｔｏｎｅ）、人造皮革、炭素纎維強化プラスチック（ＣＦＲＰ）又はガラス纎維強化プラスチック（ＧＦＲＰ）であってもよい。素材層１０の下部には熱融着層１２が位置する。熱融着層（ｈｏｔｍｅｌｔ ｌａｙｅｒ）１２はパルプ、纎維又はメッシュのような不織布と、適当な熱反応特性を有する熱可塑性重合体組成物とを含むことができる。素材層１０と熱融着層１２は、例えばロールラミネーティング（ｒｏｌｌ ｌａｍｉｎａｔｉｎｇ）工程で接合する（Ｓ１００）。ついで、素材層１０の他面、すなわち上部にはアイランドを支持するために支持テープ１８を付着する（Ｓ１０２）。支持テープ１８はライティング溝形成工程でアイランドを支持して固定する役割をする。支持テープ１８は、例えばＰＥＴを基材とするシリコン素材から製作される。
ついで、レーザーを用いて熱融着層１２から素材層１０を貫いてエッチングすることによってライティング溝Ｌ１、Ｌ２を加工する（Ｓ１０４）。ライティング溝Ｌ１、Ｌ２は一例を示すものであり、一本又は多数本の線形に形成されることができる。
一方、以上の工程とは別個に、図３ｄに示したように、透明フィルム２０の上面に遮蔽層１４を印刷（ｐｒｉｎｔ）又は塗装（ｐａｉｎｔ）工程で形成する（Ｓ１２０）。印刷工程にはシルク印刷又はパッド印刷が用いられ、塗装工程にはエアスプレーが用いられる。透明フィルム２０の下部にはバインダー２２を付着する（Ｓ１２２）。透明フィルム２０は、例えば光学用透明フィルムであり、ポリカーボネート（ｐｏｌｙｃａｒｂｏｎａｔｅ、ＰＣ）、ポリイミド（ｐｏｌｙｉｍｉｄｅ、ＰＩ）、ポリエーテルスルホン（ｐｏｌｙｅｔｈｅｒｓｕｌｆｏｎｅ、ＰＥＳ）、ポリアリレート（ｐｏｌｙａｒｙｌａｔｅ、ＰＡＲ）、ポリエチレンナフタレート（ｐｏｌｙ（ｅｔｈｙｌｅｎｅ ｎａｐｈｔｈａｌａｔｅ）、ＰＥＮ）、ポリエチレンテレフタレート（ｐｏｌｙｅｔｈｙｌｅｎｅ ｔｅｒｅｐｈｔｈａｌａｔｅ）、ＰＥＴ）、シクロオレフィンコポリマー（ｃｙｃｌｏｏｌｅｆｉｎ ｃｏｐｏｌｙｍｅｒ）などの熱可塑性高分子から製作されることができる。バインダー２２はアクリル樹脂のような共重合体が好ましいが、母材層と接合するために金属又はセラミック物質から製作することも可能である。
ついで、レーザーを用いて遮蔽層１４にライティング溝Ｌ１’、Ｌ２’を加工する（Ｓ１２４）。
ついで、図３ｇに示したように、段階（Ｓ１０４）で出来上がった素材層１０と段階（Ｓ１２４）で出来上がった透明フィルム２０を熱圧着工程で接合する（Ｓ１３０）。このとき、ライティング溝Ｌ１、Ｌ２とライティング溝Ｌ１’、Ｌ２’はジグ（ｊｉｇ）を用いて垂直に整列させてロゴ発光部の位置が一致するようにする。
しかし、これとは違い、本発明の他の実施例では、例えばライティング溝Ｌ１、Ｌ２を広い断面を有するように形成した後、印刷又は塗装段階を経た遮蔽層１４のライティング溝Ｌ１’、Ｌ２’を最終ロゴの形状に合わせてエッチングすれば最終に視認されるロゴ発光部はライティング溝Ｌ１’、Ｌ２’の形状に合わせたものとなるので、必ずしもライティング溝Ｌ１、Ｌ２、Ｌ１’、Ｌ２’を垂直に整列する必要がなく、多様なパターンを具現することができる。ライティング溝Ｌ１、Ｌ２とライティング溝Ｌ１’Ｌ２’の適切な形状の組合せは多様な光パターンを形成するのに有利である。
ついで、素材層１０の上部に位置する支持テープ１８にはライティング溝Ｌ１、Ｌ２、Ｌ１’、Ｌ２’のエッチング中に発生した小さな屑が沈澱しているので、このような残余物を除去するために剥き出し、新しい支持テープ１８Ａを接合する（Ｓ１３２）。支持テープ１８Ａは後述する成形工程でアイランドを含む素材層１０の上部を保護する役割をする。
最後に、このように出来上がった部材を母材層２４を備えた母材又は加工対象品と接合し、インサート射出成形工程で射出することによって内装材を完成する（Ｓ１３４）。母材層２４の下部には光源（図示せず）が設けられるので、光が充分に透過するように、ポリカーボネート（ＰＣ）又はＡＢＳ（ａｃｒｙｌｏｎｉｔｒｉｌｅ ｂｕｔａｄｉｅｎｅ ｓｔｙｒｅｎｅ）樹脂のような透明又は半透明素材が適用される。高温雰囲気下の射出成形工程で、図３ｉに示したように、透明フィルム２０の樹脂成分が溶融及び延伸してライティング溝Ｌ１、Ｌ２、Ｌ１’、Ｌ２’を満たす。
以上本発明の好適な実施例を例として説明したが、これは例示のためのもので、本発明の権利範囲を制限しなく、本発明に対しては多様な変更が可能であり、これらも全て本発明の権利範囲に属し、本発明の権利範囲は添付の特許請求範囲によって規定される。
１０ 素材層
１２、１６ 熱融着層
１４ 遮蔽層
２０ 透明フィルム
２２ バインダー
２４ 母材層

Claims (5)

  1. 内装材の製造方法であって、前記方法は、
    （１−１）素材層の下部と熱融着層を接合する段階と、
    （１−２）素材層の上部にアイランドを支持するための支持テープを付着する段階と、
    （１−３）熱融着層から素材層まで光が透過する第１ライティング溝をレーザー食刻で加工する段階と、
    （２−１）透明フィルムの上部に光の透過を遮断する遮蔽層を印刷又は塗装して形成する段階と、
    （２−２）透明フィルムの下部にバインダーを付着する段階と、
    （２−３）前記遮蔽層に光が透過する第２ライティング溝をレーザー食刻で加工する段階と、
    （３−１）（１−３）で製作されたモジュールと（２−３）で製作されたモジュールを接合する段階と、
    （３−２）素材層の上部にアイランドを支持するための支持テープを交換する段階と、
    （３−３）（３−２）段階の製品を、母材層を備えた母材又は加工対象品と接合し、インサート射出成形工程で射出することによって内装材を完成する段階であって、高温雰囲気下の射出成形工程で前記透明フィルムの成分がメルティング及び延伸して前記第１ライティング溝及び第２ライティング溝を満たす段階と、
    を含むことを特徴とする、内装材の製造方法。
  2. 前記透明フィルム光学用透明フィルムは、ポリカーボネート（ｐｏｌｙｃａｒｂｏｎａｔｅ、ＰＣ）、ポリイミド（ｐｏｌｙｉｍｉｄｅ、ＰＩ）、ポリエーテルスルホン（ｐｏｌｙｅｔｈｅｒｓｕｌｆｏｎｅ、ＰＥＳ）、ポリアリレート（ｐｏｌｙａｒｙｌａｔｅ、ＰＡＲ）、ポリエチレンナフタレート（ｐｏｌｙ（ｅｔｈｙｌｅｎｅ ｎａｐｈｔｈａｌａｔｅ）、ＰＥＮ）、ポリエチレンテレフタレート（ｐｏｌｙｅｔｈｙｌｅｎｅ ｔｅｒｅｐｈｔｈａｌａｔｅ）、ＰＥＴ）、シクロオレフィンコポリマー（ｃｙｃｌｏｏｌｅｆｉｎ ｃｏｐｏｌｙｍｅｒ）などの熱可塑性高分子から製作されることを特徴とする、請求項１に記載の内装材の製造方法。
  3. 前記素材層は、ウッド、纎維（ｆａｂｒｉｃ）、ストーン（ｓｔｏｎｅ）、人造皮革、炭素纎維強化プラスチック（ＣＦＲＰ）又はガラス纎維強化プラスチック（ＧＦＲＰ）のいずれか一つであることを特徴とする、請求項１に記載の内装材の製造方法。
  4. 前記第１ライティング溝と第２ライティング溝は垂直方向に整列されることを特徴とする、請求項１に記載の内装材の製造方法。
  5. 請求項１〜４のいずれか一項に記載の方法で製造されることを特徴とする内装材。
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