JP2023074383A - Decorative component - Google Patents

Abstract

To provide a decorative component that can form various types of decorative films using a common formation mold regardless of the type of decorative material.SOLUTION: The decorative component in one aspect of the present invention, Includes: a decorative layer made of a decorative material; a decorative protective layer that comprises at least a thermoplastic resin and is laminated on one end face in a thickness direction of the decorative layer; and a resin substrate that is integrally formed on an end face of the decorative protective layer side of the decorative film having at least the decorative layer and the decorative protective layer. Bending resistance of the decorative protective layer is changed according to the type of the decorative material.SELECTED DRAWING: Figure 1

Description

The present invention relates to decorative parts.

Conventionally, in the fields of various products such as automobiles, electrical equipment, and furniture, decorative parts for adding decorations to interiors and exteriors have been proposed. In general, a decorative part has a decorative film with a multilayer structure including a layer made of a decorative material that serves as the base of a decorative pattern, and the decorative film is formed into a desired shape using a molding die. It is obtained by integrating with the resin base material. Specific examples of decorative parts in the field of automobiles include instrument panel ornaments, door trim switch bases, console upper panels, accessory/ashtray door panels, and the like. For example, Patent Document 1 discloses a three-dimensional decorative part obtained by insert molding a decorative film and a resin base material by setting the decorative film in a molding die and performing injection molding. It is

In addition, a wide variety of decorative materials such as a woodgrain decorative material, a leather-like decorative material, or a metallic-like decorative material can be used for the decorative layer of the decorative film. By changing the decorative material employed in the decorative layer of the decorative component, the decorative pattern can be changed according to the application. For example, in recent years, decorative parts for automobiles have been required to exhibit genuine texture as high-grade decorative parts.

WO2018/225780

However, in the above-described conventional decorative parts, the characteristics of the decorative material used for the decorative layer, such as ease of bending and flexibility, differ depending on the type of decorative material. The cavity structure of the molding die to be used must be changed according to the characteristics of the decorative material. In other words, a dedicated molding die with a different cavity structure is prepared for each type of decorative material. Decorative parts must be formed by using them properly. For this reason, not only does preparation of a dedicated molding die require a great deal of cost, but also a great deal of time and labor is required to replace the dedicated molding die in the process of molding decorative parts. There is a problem that the manufacturing cost of decorative parts increases.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and provides a decorative part capable of molding various types of decorative films using a common molding die regardless of the type of decorative material. intended to

In order to solve the above-described problems and achieve the object, a decorative part according to the present invention includes a decorative layer made of a decorative material and at least a thermoplastic resin, and a decorative protective layer laminated on an end face; and a resin substrate integrally molded on the end face of a decorative film having at least the decorative layer and the decorative protective layer on the decorative protective layer side, The bending resistance of the decorative protective layer is characterized in that it is set according to the type of the decorative material.

Moreover, the decorative component according to the present invention is characterized in that, in the above invention, the bending resistance of the decorative film is 32 mN or more and 47 mN or less.

Further, in the decorative component according to the present invention, in the above invention, the bending resistance of the decorative protective layer is set in the range of 2.0 mN or more and 30 mN or less according to the type of the decorative material. It is characterized by

In the above invention, the decorative part according to the present invention is such that the decorative material is a wood material, a leather material, a textile material, or a metal sheet material, and the decorative material is a wood material or a leather material. , the decorating protective layer has a bending resistance of 2.0 mN or more and 15 mN or less, and when the decorating material is a textile material or a metal sheet material, the decorating protective layer has a bending resistance of 15 mN or more and 30 mN or more. It is characterized by the following.

Moreover, the decorative component according to the present invention is characterized in that, in the above invention, the decorative protective layer is made of a resin-impregnated nonwoven fabric sheet impregnated with the thermoplastic resin.

ADVANTAGE OF THE INVENTION According to this invention, it is effective in being able to shape|mold many kinds of decoration films using a common molding die, regardless of the kind of decoration material.

FIG. 1 is a schematic cross-sectional view showing one configuration example of a decorative component according to an embodiment of the present invention. FIG. 2 is a diagram showing an example of bending resistance of a laminate sheet of a decorative material sheet and a decorative protective sheet in the embodiment of the present invention. FIG. 3 is a diagram showing an example of the correlation between bending resistance and thickness of the decorative protective sheet according to the embodiment of the present invention. FIG. 4 is a schematic diagram showing an example of the molding method of the decorative component according to the embodiment of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION A preferred embodiment of a decorative component according to the present invention will be described in detail below with reference to the accompanying drawings. It should be noted that the present invention is not limited by this embodiment. Also, it should be noted that the drawings are schematic, and the dimensional relationship of each element, the ratio of each element, and the like may differ from the actual ones. Even between the drawings, there are cases where portions with different dimensional relationships and ratios are included. Moreover, in each drawing, the same code|symbol is attached|subjected to the same component.

(Composition of decorative parts)
First, the configuration of the decorative component according to the embodiment of the present invention will be described. FIG. 1 is a schematic cross-sectional view showing one configuration example of a decorative component according to an embodiment of the present invention. FIG. 1 shows an example of a laminated structure of a decorative component 10 according to this embodiment. As shown in FIG. 1, a decorative component 10 according to the present embodiment is a component for adding decoration to the exterior or interior of a target product. A substrate 2 that holds the molded shape of the film 1 is provided.

In this embodiment, for convenience of explanation, the thickness direction D1, the vertical direction D2 and the horizontal direction D3 of the decorative component 10 are set, but these directions do not limit the present invention. The thickness direction D1 is the same as the lamination direction of the decorative film 1 and the base material 2, and one end side of the thickness direction D1 (the positive side of the thickness direction D1 in FIG. 1) is the front side. is the back side (the negative side in the thickness direction D1 in FIG. 1). The longitudinal direction D2 and the lateral direction D3 are directions perpendicular to each other and also perpendicular to the thickness direction D1. The thickness direction D1, the vertical direction D2 and the horizontal direction D3 are the same for each component of the decorative component 10 as well.

A decorative film 1 is a film for decorating a target product, and has at least a decorative layer 3 and a decorative protective layer 4 . Specifically, as shown in FIG. 1, the decorative film 1 includes a decorative layer 3, a decorative protective layer 4, an adhesive layer 5, and a top film layer 6. It is configured in the form of a multi-layered film having a For example, the bending resistance of the decorative film 1 is 32 mN or more and 47 mN or less, and is set within the range according to the type of the decorative material of the decorative layer 3 or the like. The decorative film 1 presents a decorative pattern on the front side in the thickness direction D1, and is molded into a desired designed shape by injection molding using a molding die.

The base material 2 is a resin base material made of resin, and as shown in FIG. It is formed integrally with the rear surface of the decorative film 1). Specifically, the base material 2 is formed by injection molding a resin so that the decorative film 1 is pressed from the back side along the cavity shape of the molding die, so that the back side of the decorative film 1 is formed as shown in FIG. Laminated. In this embodiment, for example, the base material 2 is integrated with the decorative film 1 so as to cover the back surface of the decorative protective layer 4 of the decorative film 1 . The substrate 2 retains the design shape of the decorative film 1 after molding by curing. Examples of the resin that constitutes the base material 2 include polypropylene resin and ABS resin (acrylonitrile-butadiene-styrene copolymer).

Further, in the decorative film 1 shown in FIG. 1, the decorative layer 3 is a layer presenting a pattern for decoration. Specifically, the decorative layer 3 is a layer made of a decorative material that forms a decorative pattern, and is laminated on the front side of the decorative protective layer 4 as shown in FIG. Examples of the decorative material that constitutes the decorative layer 3 include actual materials such as wood materials exhibiting wood grain patterns, leather materials exhibiting skin patterns, textile materials exhibiting textile patterns such as mesh, and metal sheet materials exhibiting metallic patterns. is mentioned.

The wooden material of the decorative layer 3 may be a sheet material made of natural wood or the like. Examples of natural wood used for the wooden material include bird's eye maple, claro walnut, ashwood, and bamboo. Examples of the leather material of the decorative layer 3 include sheet materials made of genuine leather, synthetic leather, or the like. Genuine leather used for the leather material includes raised leather such as suede (hereinafter referred to as raised leather) and non-raised leather. Similarly, the synthetic leather used for the leather material includes raised leather and non-raised leather.

As the fabric material of the decorative layer 3, a sheet-like fiber fabric formed using organic fibers or inorganic fibers can be used. Examples of organic fibers used for the woven material include natural fibers such as hemp and cotton, and synthetic fibers such as polyester and acrylic. Carbon fibers, glass fibers, metal fibers, and the like are examples of inorganic fibers used in the woven material. Examples of the metal sheet material for the decorative layer 3 include sheet-like metal thin films such as metal foils, metal coating films, and metal deposition films. The metal sheet material may be formed on a base material, or may be formed of a single metal without using a base material. Examples of metals used for the metal sheet material include aluminum, titanium, copper, and brass.

Also, the thickness of the decorative layer 3 is set according to the type of decorative material used for the decorative layer 3, taking into account characteristics such as ease of bending and resistance to breakage. For example, when the decorative material of the decorative layer 3 is a metal sheet material, the thickness of the metal sheet material is 150 μm or more. More specifically, when the metal sheet material is a metal foil, the metal sheet material is composed of a metal foil and a substrate supporting the metal foil. Among the thicknesses of the metal sheet material, the thickness of the metal foil is preferably 70 μm or more and 100 μm or less. When the metal sheet material is a metal coating film, the metal sheet material is composed of a metallic coating film and a substrate on which the coating film is formed. Among the thicknesses of the metal sheet material, the thickness of the coating film is preferably 70 μm or more and 100 μm or less. When the metal sheet material is a metal vapor deposition film, the metal sheet material is composed of a metal vapor deposition film and a substrate on which metal is vapor deposited. Among the thicknesses of the metal sheet material, the thickness of the deposited film is preferably several nanometers. The thickness of the metal sheet material is preferably 200 μm or more and 300 μm or less because it is not necessary to shape the metal sheet material in advance when molding the decorative film 1 .

The decorative protective layer 4 is a layer that protects the decorative layer 3 from problems such as damage during molding, and imparts rigidity suitable for molding to the decorative layer 3 . Specifically, the decorative protective layer 4 is a layer containing at least a thermoplastic resin, and as shown in FIG. It is laminated on one end surface (rear surface) in the thickness direction D1. In this embodiment, for example, the surface of the decorative protective layer 4 is adhered to the rear surface of the decorative layer 3 with an adhesive layer 5 made of an adhesive. The substrate 2 is laminated on the rear surface of the decorative protective layer 4 by injection molding of resin using a molding die.

In addition, the decorative protective layer 4 has a bending resistance within a predetermined range, and when laminated on the back surface of the decorative layer 3, the three-dimensional cavity shape (target design shape) of the molding die To improve the followability of the decorative layer 3 to the shape and the retainability of the design shape of the formed decorative layer 3. Specifically, the bending resistance of the decorative protective layer 4 is set in the range of 2.0 mN or more and 30 mN or less according to the type of the decorative material forming the decorative layer 3 . At this time, the bending resistance of the decorative protective layer 4 is appropriately changed and set according to the bending resistance of the decorative layer 3 set for each type of decoration material.

For example, if the decorative material is wood or leather, the surface of the wood or leather has irregularities, so the thickness of the wood or leather obtained by cutting from the raw material should be increased. I have to. The bending resistance of such wood material and leather material is greater than that of the fabric material and metal sheet material described above. Therefore, the bending resistance of the decorative protective layer 4 when the decorative material is a wood material or a leather material is set lower than when the decorative material is a textile material or a metal sheet material. It is 2.0 mN or more and 15 mN or less.

In addition, when the decorative material is a woven fabric material or a metal sheet material, both the woven fabric material and the metal sheet material are softer than the wood material and leather material described above, and are less likely to retain the molded shape. Therefore, the bending resistance of the decorative protective layer 4 when the decorative material is a textile material or a metal sheet material is set higher than when the decorative material is a wood material or a leather material. It is 15 mN or more and 30 mN or less.

The decorative protective layer 4 is a layer having heat resistance, and is interposed between the base material 2 and the decorative layer 3 as shown in FIG. Suppresses the transfer of molding heat. Specifically, the melting point of the decorative protective layer 4 is higher than the molding heat, and the softening point of the decorative protective layer 4 is lower than the molding heat. Therefore, when molding heat is applied from the base material 2 side, the decorative protective layer 4 is softened so as to be moldable without being melted (liquefied). The molding heat is the temperature of the resin injected into the cavity of the molding die when the decorative film 1 and the base material 2 are integrally molded. The decorative protective layer 4 reduces the molding heat transmitted to the decorative layer 3, thereby preventing thermal damage to the decorative layer 3 (burning of the decorative material, etc.). At the same time, the decorative protective layer 4 receives the molding heat from the base material 2 and is heated, thereby softening and fitting easily into the cavity shape of the molding die. In other words, the decorative protective layer 4 is heated by the molding heat, and is easily formed into the desired design shape together with the decorative layer 3 .

Examples of materials constituting the decorative protective layer 4 include a resin-impregnated nonwoven fabric sheet, a polyethylene terephthalate (PET) resin sheet, a polyamide 66 (PA66) resin sheet, a polyphenylene sulfide (PPS) resin sheet, and the like.

The resin-impregnated nonwoven fabric sheet is a nonwoven fabric sheet impregnated with a predetermined thermoplastic resin. Examples of thermoplastic resins contained in the nonwoven fabric sheet include olefin resins and polyester resins. Examples of fibers of the nonwoven fabric forming the nonwoven fabric sheet include organic fibers and inorganic fibers. When the decorative protective layer 4 is made of the resin-impregnated nonwoven fabric sheet, the bending resistance of the decorative protective layer 4 can be easily adjusted by adjusting the amount of the thermoplastic resin impregnated into the nonwoven fabric. Furthermore, in the insert molding of the decorative film 1 and the base material 2, the resin material of the base material 2 penetrates into the non-woven fabric sheet of the decorative protective layer 4, so that the base material 2 and the decorative protective layer 4 are tightly adhered to each other. You can make your sexuality stronger.

Further, when the decorative protective layer 4 is made of a PET resin sheet, a PA66 resin sheet or a PPS resin sheet, the bending resistance of the decorative protective layer 4 is determined by the thickness of the decorative protective layer 4 (the thickness of the resin sheet that is the constituent material). thickness).

The top film layer 6 is the layer located on the frontmost side of the decorative film 1 . Specifically, the top film layer 6 is made of a light-transmitting resin that is transparent or translucent to visible light, and is laminated on the surface of the decorative layer 3 as shown in FIG. 1, for example. The top film layer 6 covers and protects the decorative material of the decorative layer 3, and makes the pattern of the decorative material (decorative pattern) visible from the outside. Examples of the constituent resin of such a top film layer 6 include acrylic resins. In particular, from the viewpoint of preventing thermal damage to the decorative layer 3, the constituent resin of the top film layer 6 is preferably a photocurable resin that is cured by light irradiation such as ultraviolet rays.

(Bending resistance of decorative film)
Next, the bending resistance of the decorative film 1 in the embodiment of the present invention will be explained in detail. The bending resistance of the decorative film 1 is defined, for example, by the bending resistance of the laminate of the decorative layer 3 and the decorative protective layer 4 described above. The bending resistance can be measured by the following measurement method using a Gurley bending resistance tester.

Specifically, in the bending resistance measurement method, first, a sheet for measuring the decorative material used for the decorative layer 3 (hereinafter referred to as a decorative material sheet) and a constituent material of the decorative protective layer 4 are measured. A plurality of each of the protective sheets (hereinafter referred to as decorative protective sheets) are prepared. Each of these plurality of decorative material sheets and decorative protective sheets is formed in a strip shape having a predetermined length and width. Each of the plurality of decorative material sheets has the same thickness as the decorative layer 3 . For example, in the case of a decorative material sheet made of wood material, the thickness of the decorative material sheet was set to about 250 μm. Each of the plurality of decorative protective sheets has a different thickness within a predetermined range, and is divided into a predetermined number (for example, 5 sheets) of decorative protective sheets by thickness. For example, in the case of a decorative protective sheet made of a PET resin sheet, the predetermined range of thickness of the decorative protective sheet is 10 μm or more and 300 μm or less.

Next, for each of the plurality of decorative protective sheets, the bending resistance was measured for each thickness of the decorative protective sheet using a Gurley bending resistance tester. Then, based on the measurement results of the bending resistance, the correlation between the bending resistance and the thickness of the decorative protective sheet was derived. After that, using these plurality of decorative protective sheets and the above-described plurality of decorative material sheets, the decorative protective sheets and the decorative material sheets are bonded together with an adhesive (hereinafter referred to as a laminate sheet), A plurality of decorative protective sheets were prepared for each thickness. Each of these plurality of laminate sheets has a laminate structure similar to that in which the decorative layer 3 and the decorative protective layer 4 are laminated in the thickness direction D1 via the adhesive layer 5 as shown in FIG. have.

Subsequently, using a Gurley bending resistance tester, the bending resistance of each of the plurality of laminate sheets was measured according to the thickness of the decorative protective sheet. Based on the bending resistance measurement results, the correlation between the bending resistance of the laminate sheet and the thickness of the decorative protective sheet included in the laminate sheet was derived.

After that, each of the plurality of laminate sheets was injection-molded using a molding die, thereby insert-molding the resin base material on the end surface of the laminate sheet on the decorative protective sheet side. This molding die was a molding die having a common cavity shape for each of the plurality of laminate sheets. In this manner, a plurality of molded samples of the laminate sheet and the resin base material were produced for each thickness of the decorative protective sheet in the laminate sheets. Each of these molded samples has a laminated structure similar to that in which the substrate 2, the decorative protective layer 4, the adhesive layer 5, and the decorative layer 3 are laminated in the thickness direction D1 as shown in FIG. have.

Next, appearance evaluation was performed for each of a plurality of molded samples. In this appearance evaluation, attention was focused on the end surface of each molded sample on the side of the decorative material sheet (that is, the surface of the decorative material), and the presence or absence of defective shape and the presence or absence of resin fogging of each molded sample were visually confirmed.

Here, if the bending resistance of the laminate sheet is excessively low, the laminate sheet set in the molding die may be affected by the injection pressure of the resin in the insert molding of the laminate sheet and the resin base material. Once molded along the cavity shape of the mold. However, since the laminate sheet is too soft, it is swept away by the resin injected into the molding die, and as a result, wrinkles occur on the surface of the decorative material, resulting in the intended design shape of the laminate sheet. can no longer be maintained. In the appearance evaluation of the molded sample, the molded sample with wrinkles on the surface of the decorative material as described above was determined to be a sample with a defective shape.

In addition, when the bending resistance of the laminate sheet is excessively high, the laminate sheet set in the molding die is too hard in the insert molding of the laminate sheet and the resin base material. Even if it is added, it cannot follow the shape of the mold cavity. As a result, a gap is generated between the surface of the decorative material of the laminate sheet and the cavity surface of the molding die, and the resin flows into this gap and adheres to the surface of the decorative material. In the appearance evaluation of the molded samples, the molded samples in which the resin adhered to the surface of the decorative material as described above were judged to be resin-fogged samples.

After that, based on the appearance evaluation results of the plurality of molded samples described above, the range of bending resistance of the laminate sheet in which neither the shape defect nor the resin fogging occurs in the molded samples, that is, the appropriate range of the decorative film 1 The bending resistance range was derived.

FIG. 2 is a diagram showing an example of bending resistance of a laminate sheet of a decorative material sheet and a decorative protective sheet in the embodiment of the present invention. In FIG. 2, the bending resistance Bt is the bending resistance of the laminate sheet, and the thickness A is the thickness of the decorative protective sheet included in the laminate sheet. A correlation line L1 indicates the correlation between the bending resistance Bt of the laminate sheet and the thickness A of the decorative protective sheet.

In the present invention, the appropriate range of bending resistance of the decorative film 1 was derived by the method shown below. Specifically, among the plurality of molded samples subjected to the appearance evaluation described above, a molded sample with a defective shape and a molded sample with a good appearance without both a defective shape and resin fogging were used. A minimum thickness A1 of the decorative protective sheet included in the laminate sheet is derived so that the sample does not have a shape defect. Also, using a molded sample with resin fogging and a molded sample with good appearance, the maximum thickness A2 of the decorative protective sheet included in the laminate sheet at which resin fogging does not occur in the molded sample is derived.

Next, using the minimum thickness A1 and the maximum thickness A2 of the decorative protective sheet in the molded sample with good appearance, the bending resistance Bt of the laminate sheet and the thickness of the decorative protective sheet shown in FIG. From the correlation with A, the lower limit bending resistance and the upper limit bending resistance of the laminate sheet (hereinafter referred to as "appropriate laminate sheet") where neither the shape defect nor the resin fogging occurs in the molded sample are derived. For example, as shown in FIG. 2, using the minimum thickness A1 of the decorative protective sheet, from the correlation line L1 between the bending resistance Bt of the laminate sheet and the thickness A of the decorative protective sheet, the minimum thickness A bending resistance Bt corresponding to the thickness A1, that is, a proper laminate sheet lower limit bending resistance Bt1 is derived. In the present invention, the lower limit of bending resistance Bt1 is 32 mN. Further, as shown in FIG. 2, using the maximum thickness A2 of the decorative protective sheet, from the correlation line L1, the bending resistance Bt corresponding to the maximum thickness A1, that is, the appropriate laminate sheet to derive the upper limit of bending resistance Bt2. In the present invention, the upper bending resistance Bt2 is 47 mN.

The lower limit of bending resistance Bt1 and the upper limit of bending resistance Bt2 derived as described above are upper and lower limit values that define the range of appropriate bending resistance Bt of the laminate sheet. In the present invention, the bending resistance of the decorative film 1 corresponds to the bending resistance Bt of the laminate sheet. Therefore, the proper bending resistance range of the decorative film 1 is a range defined by the lower bending resistance Bt1 and the upper bending resistance Bt2, specifically, 32 mN or more and 47 mN or less.

The appropriate range of bending resistance of the decorative film 1 described above is the same regardless of whether the material constituting the decorative protective layer 4 is a resin sheet or a resin-impregnated nonwoven fabric sheet. For example, when the material constituting the decorative protective layer 4 is a resin-containing nonwoven fabric sheet, the thickness of the decorative protective sheet is replaced with the resin impregnated amount of the nonwoven fabric sheet, and a plurality of decorative protective sheets with different resin impregnated amounts are used. By using this method, a molded sample is produced and the appearance is evaluated in the same manner as described above, so that the appropriate range of bending resistance of the above-described decorative film 1 can be derived.

(Bending resistance of decorative protective layer)
Next, the bending resistance of the decorative protective layer 4 in the embodiment of the present invention will be explained in detail. The decorative protective layer 4 must have a bending resistance in order to set the bending resistance of the decorative film 1 to a value within the proper bending resistance range (32 mN or more and 47 mN or less). is the bending resistance to be used. For the bending resistance of the decorative protective layer 4, for example, the minimum thickness A1 and the maximum thickness A2 of the decorative protective sheet obtained when deriving the bending resistance of the decorative film 1 are used. , can be derived from the correlation between the bending resistance and the thickness of the decorative protective sheet.

FIG. 3 is a diagram showing an example of the correlation between bending resistance and thickness of the decorative protective sheet according to the embodiment of the present invention. In FIG. 3, a correlation line L2 indicates the correlation between the bending resistance Ba and the thickness A of the decorative protective sheet.

For example, when the decorative material sheet is a wood material sheet and the decorative protective sheet is a PET resin sheet, the minimum thickness A1 (Fig. 2) is 100 μm. Also, the maximum thickness A2 (see FIG. 2) of the decorative protective sheet corresponding to the upper limit bending resistance Bt2 of the decorative film 1 is 210 μm. The lower limit of bending resistance of the decorative protective layer 4 is a value obtained by converting the minimum thickness A1 (=100 μm) of the decorative protective sheet into bending resistance based on the formula representing the correlation line L2 in FIG. , specifically 2.0 mN. The upper limit of bending resistance of the decorative protective layer 4 is a value obtained by converting the maximum thickness A2 (=210 μm) of the decorative protective sheet into bending resistance based on the formula representing the correlation line L2 in FIG. , specifically 15 mN.

From the above, when the decorative material of the decorative layer 3 is a wooden material and the constituent material of the decorative protective layer 4 is a PET resin sheet, the appropriate bending resistance range of the decorative protective layer 4 is 2. 0 mN or more and 15 mN or less. In addition, when the constituent material of the decorative protective layer 4 is a resin sheet other than the PET resin sheet, the minimum thickness A1 and the maximum thickness A2 described above are different from those of the PET resin sheet. The proper bending resistance range of the protective layer 4 is the same as that of the PET resin sheet if the type of the decorative material is the same. That is, when the decorative material of the decorative layer 3 is a wooden material, the appropriate bending resistance range of the decorative protective layer 4 is 2.0 mN or more regardless of the resin sheet constituting the decorative protective layer 4. 15 mN or less.

In addition, when the decorative material of the decorative layer 3 is a leather material, the appropriate bending resistance range of the decorative protective layer 4 is 2.0 mN or more and 15 mN or less, as in the case of the wooden material described above. . When the decorative material of the decorative layer 3 is a fabric material or a metal sheet material, the appropriate bending resistance range of the decorative protective layer 4 is 15 mN or more regardless of the resin sheet constituting the decorative protective layer 4. 30 mN or less.

When the decorative protective layer 4 is made of a resin-impregnated nonwoven fabric sheet, the appropriate bending resistance range of the decorative protective layer 4 is determined by the minimum thickness A1 and the maximum thickness A1 of the decorative protective sheet. It is derived by replacing A2 with the resin impregnation amount of the nonwoven fabric sheet. In the decorative protective layer 4 made of such a resin-impregnated nonwoven fabric sheet, the appropriate range of bending resistance is the same as in the case of the resin sheet described above.

(Molding method for decorative parts)
Next, a method for molding a decorative component according to an embodiment of the present invention will be described in detail. FIG. 4 is a schematic diagram showing an example of the molding method of the decorative component according to the embodiment of the present invention. The decorative component 10 (see FIG. 1) is molded into a desired designed shape and manufactured by, for example, sequentially performing a series of steps shown in FIG.

Specifically, as shown in FIG. 4, first, the decorative film 1 is set in the molding die 11 (step S1). The molding die 11 is an injection molding die that is commonly used for a plurality of types of decorative films 1. For example, as shown in FIG. A second mold 13 having a resin injection part 13a is provided. The cavity 12a is formed in a desired design shape of the decorative film 1 (for example, a three-dimensional shape such as a curved surface or steps). The second mold 13 has a protrusion that can be fitted into the cavity 12 a of the first mold 12 . The injection part 13 a is provided in the second mold 13 so as to pass through the convex part of the second mold 13 and direct the injection port toward the cavity 12 a of the first mold 12 . The types of the decorative film 1 are classified according to the type of decorative material that is alternatively adopted for the decorative layer 3 (see FIG. 1) of the decorative film 1 from a wide variety of decorative materials. .

In the process of this step S1, as shown in FIG. and the second mold 13, the decorative film 1 is conveyed. Next, the decorative film 1 is inserted into the cavity 12a of the first mold 12 by a method such as evacuation. At this time, the decorative film 1 is, for example, a film before the top film layer 6 (see FIG. 1) is formed, and the end face (decorating material surface) on the decorative layer 3 side and the surface of the cavity 12a are separated. They are facing each other. The decorative film 1 is inserted into the cavity 12a while deforming along the surface of the cavity 12a.

Next, as shown in FIG. 4, the molding die 11 in which the decorative film 1 is set is closed (step S2). In the process of step S2, the protrusions of the second mold 13 are fitted into the cavities 12a of the first mold 12 into which the decorative film 1 is inserted, and the first mold 12 and the second mold 13 are separated. and clamp the mold. In this state, in the cavity 12a of the first mold 12, between the back surface of the decorative film 1 (the end surface on the side of the decorative protective layer 4 shown in FIG. 1) and the convex portion of the second mold 13, A gap is formed through which the resin is injected.

Thereafter, as shown in FIG. 4, molten resin 15 is injected into molding die 11 to integrally mold decorative film 1 and base material 2 (step S3). In the process of step S3, as shown in FIG. 4, the molten resin 15 is filled into the injection part 13a of the second mold 13, and the resin is injected into the cavity 12a of the first mold 12 from the injection part 13a. Shoot 15. As a result, the resin 15 is injected into the gap between the back surface of the decorative film 1 and the convex portion of the second mold 13 in the cavity 12a. The decorating film 1 receives the injected resin 15 from the side of the decorating protective layer 4 and is molded by the molding heat and injection pressure of the resin 15 so as to follow the shape of the cavity 12a. Specifically, in the decorative film 1, the decorative protective layer 4 is softened by the molding heat of the resin 15, and deformed together with the decorative layer 3 by the injection pressure of the resin 15 to follow the shape of the cavity 12a. , is molded into the desired design shape. In parallel with the molding of the decorative film 1, as shown in FIG. 4, a base material 2 made of a resin 15 is integrally formed on the back surface of the decorative film 1 by, for example, insert molding. Thereafter, the resin 15 forming the base material 2 is cooled, thereby solidifying the base material 2 .

Here, the decorative film 1 has a bending resistance of 32 mN or more and 47 mN or less due to the laminate structure of the decorative layer 3 and the decorative protective layer 4 . Therefore, the decorative film 1 can easily follow the shape of the cavity 12a of the molding die 11 by the injection pressure of the resin 15, and even if the injection pressure of the resin 15 is continuously applied, , the intended designed shape can be maintained without causing wrinkles on the surface of the decorative material. In addition, since the decorative film 1 can follow the shape of the cavity 12a due to the injection pressure of the resin 15 as described above, there is an unintentional gap between the surface of the decorative material of the decorative film 1 and the surface of the cavity 12a. 15 never flows. Furthermore, the decorative protective layer 4 reduces molding heat transmitted from the resin 15 to the decorative layer 3 . Therefore, it is possible to prevent appearance defects such as shape defects due to wrinkles, resin fogging, and heat damage of the decorative layer 3 from occurring in the molded decorative film 1 .

After integrally molding the decorative film 1 and the base material 2 in the process of step S3, as shown in FIG. S4). In the process of step S4, the second mold 13 is separated from the first mold 12 to open the molding die 11, and the molded product of the decorative film 1 and the base material 2 is removed from the molding die 11. Release the mold. After that, a top film layer 6 is formed on the surface of this molded product, whereby a decorative part 10 composed of the decorative film 1 and the substrate 2 is obtained.

The decorative component 10 as described above is obtained by changing the decorative material constituting the decorative layer 3 of the decorative film 1 to another type of decorative material (for example, changing from a wooden material to a metal sheet material). However, the molding can be performed by sequentially performing the steps S1 to S4 using the common molding die 11. FIG. That is, a plurality of types of decorative parts 10 having different decorative patterns of the decorative layer 3 but having the same target design shape can be successively molded using a common molding die 11. It is possible.

As described above, in the decorative component 10 according to the embodiment of the present invention, the decorative protective layer 4 containing at least a thermoplastic resin is provided on one end face in the thickness direction D1 of the decorative layer 3 made of a decorative material. is laminated, and the base material 2 is integrally formed on the end surface of the decorative film 1 having a laminated structure of at least the decorative layer 3 and the decorative protective layer 4 on the decorative protective layer 4 side, and the decorative protective layer 4 is set according to the type of the decorative material of the decorative layer 3.

Therefore, even when a plurality of types of decorative films 1 made of different decorative materials are to be molded, the decorative layer 3 is protected by the injection pressure of the resin 15 forming the base material 2. Together with the layer 4, the cavity shape of the molding die 11 having the intended design shape can be naturally followed. As a result, it is possible to prevent appearance defects such as wrinkles, cracks, or resin fogging of the decorative layer 3, and to produce a plurality of types of decorative films 1 using a common molding die 11 regardless of the type of decorative material. It can be molded into a design shape. This eliminates the need to prepare a dedicated molding die with a cavity shape set according to the type of decorative material. Since it is possible to omit the trouble of exchanging molds even if the type of the molding is changed, the cost required for preparing the molding mold 11 and the man-hours required for molding the decorative component 10 are reduced, and the manufacturing cost of the decorative component 10 is reduced. can be reduced.

EXAMPLES Hereinafter, the present invention will be described more specifically by showing examples of the present invention and comparative examples for the present invention. The present invention should not be construed as being limited to the following examples.

(Type of decorative material)
In each example and each comparative example described later, a plurality of samples for evaluation of the decorative component 10 are prepared for each type of the decorative material forming the decorative layer 3, and the appearance of each of the plurality of samples for evaluation is evaluated. gone. As shown in Table 1, there are four types of decorative materials used for the evaluation samples: wooden materials, leather materials, textile materials, and metal sheet materials.

Specifically, as shown in Table 1, natural wood having a thickness of 0.3 mm or more and 0.4 mm or less was used as the wooden material. As leather materials, genuine leather and synthetic leather were used. The thickness of the leather material was 0.3 mm or more and 0.4 mm or less for both genuine leather and synthetic leather. Genuine leather and synthetic leather as leather materials include brushed leather and non-brushed leather. As the woven material, a material made of organic fibers and a material made of inorganic fibers were used. The organic fibers include natural fibers, and the inorganic fibers include carbon fibers. The thickness of the woven material was 0.05 mm or more and 0.2 mm or less for both the organic fibers and the inorganic fibers. As the metal sheet material, a metal sheet having a thickness of 0.15 mm or more and 0.3 mm or less was used. Table 1 shows the decorative materials.

(Method for preparing sample for evaluation)
A method of preparing an evaluation sample in each of Examples and Comparative Examples will be described. In the evaluation sample preparation method, a plurality of decorative protective layers 4 having different thicknesses were prepared in advance, and the bending resistance of each decorative protective layer 4 having each thickness was measured using a Gurley bending resistance tester. Next, the decorative layer 3 and the decorative protective layer 4 are laminated while changing the bending resistance of the decorative protective layer 4 according to the type of decorative material (see Table 1) constituting the decorative layer 3. A plurality of decorative films 1 having a structure (see FIG. 1) were produced for each combination of the type of decorative material and the bending resistance of the decorative protective layer 4 . For each of the plurality of decorative films 1 thus obtained, the bending resistance was measured using a Gurley bending resistance tester, and then the decorative film 1 and the base material 2 were integrally formed by insert molding to form a decorative film. A plurality of evaluation samples of the component 10 were produced. Evaluation samples in each example and each comparative example are summarized in Table 2 below.

(Evaluation method)
The evaluation method for each example and each comparative example will be described. In each example and each comparative example, appearance evaluation was performed on each of the plurality of samples for evaluation produced as described above. In this appearance evaluation, attention was focused on the surface of the decorative material of each evaluation sample, and wrinkles, thermal damage (mold burn, etc.), creases, and resin fogging of the decorative layer 3 were visually inspected. As a criterion for judging the quality of the appearance evaluation, when neither wrinkles, heat damage, creases, nor resin fogging is confirmed in the decorative layer 3, it is regarded as good (hereinafter, may be described as “◯”). When at least one of wrinkles, heat damage, creases and resin fogging was observed, it was judged as defective (hereinafter sometimes indicated as "x"). Table 2 summarizes the results of appearance evaluation in each example and each comparative example.

(Example 1)
In Example 1, a wooden material (see Table 1) was used as the decorative material constituting the decorative layer 3 , and a material with a bending resistance of 2.0 mN or more and 15 mN or less was used as the decorative protective layer 4 . As a result, the bending resistance of the decorative film 1 in Example 1 was 32 mN or more and 47 mN or less. Further, in the appearance evaluation of Example 1, no wrinkles, heat damage, creases, or resin fogging were observed in the decorative layer 3, and the evaluation result was good.

(Example 2)
In Example 2, a leather material (see Table 1) was used as the decorative material constituting the decorative layer 3 , and a material with a bending resistance of 2.0 mN or more and 15 mN or less was used as the decorative protective layer 4 . As a result, the bending resistance of the decorative film 1 in Example 2 was 32 mN or more and 47 mN or less. Further, in the appearance evaluation of Example 2, no wrinkles, heat damage, creases, or resin fogging were observed in the decorative layer 3, and the evaluation result was good.

(Example 3)
In Example 3, a fabric material (see Table 1) was used as the decorative material constituting the decorative layer 3 , and a material with a bending resistance of 15 mN or more and 30 mN or less was used as the decorative protective layer 4 . As a result, the bending resistance of the decorative film 1 in Example 3 was 32 mN or more and 47 mN or less. Further, in the appearance evaluation of Example 3, no wrinkles, heat damage, creases, or resin fogging were observed in the decorative layer 3, and the evaluation result was good.

(Example 4)
In Example 4, a metal sheet material (see Table 1) was used as the decorative material constituting the decorative layer 3 , and a material having a bending resistance of 15 mN or more and 30 mN or less was used as the decorative protective layer 4 . As a result, the bending resistance of the decorative film 1 in Example 4 was 32 mN or more and 47 mN or less. Further, in the appearance evaluation of Example 4, no wrinkles, heat damage, creases, or resin fogging were observed in the decorative layer 3, and the evaluation result was good.

(Comparative example 1)
In Comparative Example 1, a wooden material (see Table 1) was used as the decorative material constituting the decorative layer 3, and a material having a bending resistance of less than 2.0 mN was used as the decorative protective layer 4. As a result, the bending resistance of Decorative Film 1 in Comparative Example 1 was less than 32 mN. Moreover, in the appearance evaluation of Comparative Example 1, wrinkles were confirmed in the decorative layer 3 . Therefore, the evaluation result of Comparative Example 1 was poor.

(Comparative example 2)
In Comparative Example 2, a wooden material (see Table 1) was used as the decorative material constituting the decorative layer 3, and a material having a bending resistance of more than 15 mN was used as the decorative protective layer 4. As a result, the bending resistance of Decorative Film 1 in Comparative Example 2 was over 47 mN. Further, in the appearance evaluation of Comparative Example 2, resin fogging was confirmed on the surface of the decorative layer 3 . Therefore, the evaluation result of Comparative Example 2 was poor.

(Comparative Example 3)
In Comparative Example 3, a leather material (see Table 1) was used as the decorative material constituting the decorative layer 3 , and a material having a bending resistance of less than 2.0 mN was used as the decorative protective layer 4 . As a result, the bending resistance of Decorative Film 1 in Comparative Example 3 was less than 32 mN. Moreover, in the appearance evaluation of Comparative Example 3, wrinkles were confirmed in the decorative layer 3 . Therefore, the evaluation result of Comparative Example 3 was poor.

(Comparative Example 4)
In Comparative Example 4, a leather material (see Table 1) was used as the decorative material constituting the decorative layer 3, and a material having a bending resistance of more than 15 mN was used as the decorative protective layer 4. As a result, the bending resistance of Decorative Film 1 in Comparative Example 4 was over 47 mN. Moreover, in the appearance evaluation of Comparative Example 4, resin fogging was confirmed on the surface of the decorative layer 3 . Therefore, the evaluation result of Comparative Example 4 was poor.

(Comparative Example 5)
In Comparative Example 5, a fabric material (see Table 1) was used as the decorative material constituting the decorative layer 3, and a material having a bending resistance of less than 15 mN was used as the decorative protective layer 4. As a result, the bending resistance of Decorative Film 1 in Comparative Example 5 was less than 32 mN. Further, in the appearance evaluation of Comparative Example 5, wrinkles were confirmed in the decorative layer 3 . Therefore, the evaluation result of Comparative Example 5 was poor.

(Comparative Example 6)
In Comparative Example 6, a woven fabric material (see Table 1) was used as the decorative material constituting the decorative layer 3, and a material having a bending resistance of more than 30 mN was used as the decorative protective layer 4. As a result, the bending resistance of Decorative Film 1 in Comparative Example 6 was over 47 mN. Further, in the appearance evaluation of Comparative Example 6, resin fogging was confirmed on the surface of the decorative layer 3 . Therefore, the evaluation result of Comparative Example 6 was poor.

(Comparative Example 7)
In Comparative Example 7, a metal sheet material (see Table 1) was used as the decorative material constituting the decorative layer 3, and a material having a bending resistance of less than 15 mN was used as the decorative protective layer 4. As a result, the bending resistance of Decorative Film 1 in Comparative Example 7 was less than 32 mN. Moreover, in the appearance evaluation of Comparative Example 7, wrinkles were confirmed in the decorative layer 3 . Further, creases were confirmed in part of the decorative layer 3 . Therefore, the evaluation result of Comparative Example 7 was poor.

(Comparative Example 8)
In Comparative Example 8, a metal sheet material (see Table 1) was used as the decorative material constituting the decorative layer 3, and a material having a bending resistance of more than 30 mN was used as the decorative protective layer 4. As a result, the bending resistance of Decorative Film 1 in Comparative Example 8 was over 47 mN. Further, in the appearance evaluation of Comparative Example 8, resin fogging was confirmed on the surface of the decorative layer 3 . Therefore, the evaluation result of Comparative Example 8 was poor.

(Comparative Example 9)
In Comparative Example 9, a wooden material (see Table 1) was used as the decorative material constituting the decorative layer 3, and the decorative protective layer 4 of the present invention was not employed, and a decorative film made of this decorative layer was produced. bottom. At this time, in order to increase the bending resistance of the single decorative layer that is not laminated with the decorative protective layer, the thickness of the wooden material constituting the single decorative layer was made thicker than that of the wooden material in Example 1 above. . As a result, the bending resistance of the decorative film in Comparative Example 9 was 5.0 mN. Further, in the appearance evaluation of Comparative Example 9, thermal damage such as scorching during molding was confirmed in the decorative layer. Therefore, the evaluation result of Comparative Example 9 was poor.

In addition, since the decorative protective layer 4 was not adopted in Comparative Example 9, "-" indicating that it is out of scope is described in the "bending resistance of the decorative protective layer" column in Table 2. ing. This also applies to Comparative Examples 10 to 12, which will be described later.

(Comparative Example 10)
In Comparative Example 10, a leather material (see Table 1) was used as the decorative material constituting the decorative layer 3, and the decorative protective layer 4 of the present invention was not adopted, and a decorative film made of this decorative layer was produced. bottom. At this time, the thickness of the leather material constituting the single decorative layer was made thicker than that of the wooden material in Example 2 in order to increase the bending resistance of the single decorative layer on which the decorative protective layer was not laminated. . As a result, the bending resistance of the decorative film in Comparative Example 10 was 4.0 mN. Further, in the evaluation of the appearance of Comparative Example 9, thermal damage was confirmed in the decorative layer. Therefore, the evaluation result of Comparative Example 10 was poor.

(Comparative Example 11)
In Comparative Example 11, a woven material (see Table 1) was used as the decorative material constituting the decorative layer 3, and the decorative protective layer 4 of the present invention was not adopted, and a decorative film made of this decorative layer was produced. bottom. At this time, in order to increase the bending resistance of the single decorative layer on which the decorative protective layer is not laminated, the thickness of the woven material constituting the single decorative layer was made thicker than that of the woven material of Example 3 above. . As a result, the bending resistance of the decorative film in Comparative Example 11 was 0.1 mN or more and 0.2 mN or less. Moreover, in the appearance evaluation of Comparative Example 11, wrinkles were confirmed in the decorative layer. Therefore, the evaluation result of Comparative Example 11 was poor.

(Comparative Example 12)
In Comparative Example 12, a metal sheet material (see Table 1) was used as the decorative material constituting the decorative layer 3, and the decorative protective layer 4 of the present invention was not adopted, and a decorative film made of this decorative layer was used. made. At this time, in order to increase the bending resistance of the single decorative layer on which the decorative protective layer is not laminated, the thickness of the metal sheet material constituting the single decorative layer is set to be lower than that of the metal sheet material in Example 4. thickened. As a result, the bending resistance of the decorative film in Comparative Example 12 was 0.5 mN or more and 1.0 mN or less. Moreover, in the appearance evaluation of Comparative Example 12, creases were confirmed in the decorative layer. Therefore, the evaluation result of Comparative Example 12 was poor.

In the above-described embodiment, the bending resistance of the laminate of the decorative layer 3 and the decorative protective layer 4 is the bending resistance of the decorative film 1, but the present invention is not limited to this. do not have. For example, the bending resistance of the decorative film 1 may be the bending resistance of a laminate of the decorative layer 3 , the decorative protective layer 4 and the top film layer 6 .

Further, in the above-described embodiment, the top film layer 6 is provided on the decorative film 1 after molding into the intended design shape, but the present invention is not limited to this. For example, the top film layer 6 may be provided on the decorative film 1 before molding with the molding die 11, and the decorative film 1 including the top film layer 6 may be molded into the design shape.

Further, in the above-described embodiment, the substrate 2 is provided on the back surface of the decorative protective layer 4, but the present invention is not limited to this. For example, another layer may be interposed between the back surface of the decorative protective layer 4 and the substrate 2 .

In addition, in the above-described embodiment, actual materials such as wood materials, leather materials, woven materials, and metal sheet materials were exemplified as types of decorative materials that constitute the decorative layer 3, but the present invention is limited to these. not to be For example, the decorative material may be composed of a coating film such as open pore, metallic coating, or suede coating and a base material (fabric, resin or metal base material) on which the coating film is formed. , baby skin, hair-implanted or laser-decorated skin sheet. The skin sheet may be manufactured by processing a sheet as a raw material, or may be manufactured by attaching it onto a base material made of fabric, resin, or metal. Alternatively, the decorative material may be another real material such as cork.

Further, in the above-described embodiment, the case where the unshaped decorative film 1 is inserted into the molding die 11 and molded is illustrated, but the present invention is not limited to this. For example, the decorative film 1 may be shaped in advance and then inserted into the mold 11 for molding.

Further, in the above-described embodiment, the decorative film 1 and the substrate 2 are insert-molded, but the present invention is not limited to this. For example, the decorative film 1 and the substrate 2 may be integrally molded by a technique other than insert molding, such as in-mold molding, hot press molding, compression molding, or BMC (Bulk Molding Compound) molding.

In addition, the present invention is not limited to the above-described embodiment, and the present invention also includes a configuration in which the above-described constituent elements are appropriately combined. In addition, other embodiments, examples, operation techniques, etc. made by those skilled in the art based on the above-described embodiments are all included in the scope of the present invention.

REFERENCE SIGNS LIST 1 decorative film 2 base material 3 decorative layer 4 decorative protective layer 5 adhesive layer 6 top film layer 10 decorative part 11 mold 12 first mold 12a cavity 13 second mold 13a injection part 15 resin D1 thickness Vertical direction D2 Vertical direction D3 Horizontal direction L1, L2 Correlation line

Claims (5)

a decorative layer made of a decorative material;
a decorative protective layer that contains at least a thermoplastic resin and is laminated on one end face in the thickness direction of the decorative layer;
a resin base integrally formed on an end face of a decorative film having at least the decorative layer and the decorative protective layer on the decorative protective layer side;
with
The bending resistance of the decorative protective layer is set according to the type of the decorative material,
A decorative part characterized by: The decorative film has a bending resistance of 32 mN or more and 47 mN or less.
The decorative part according to claim 1, characterized by: The bending resistance of the decorative protective layer is set in the range of 2.0 mN or more and 30 mN or less depending on the type of the decorative material.
The decorative part according to claim 1 or 2, characterized in that: The decorative material is a wood material, a leather material, a textile material or a metal sheet material,
When the decorative material is a wood material or a leather material, the bending resistance of the decorative protective layer is 2.0 mN or more and 15 mN or less,
When the decorative material is a fabric material or a metal sheet material, the bending resistance of the decorative protective layer is 15 mN or more and 30 mN or less.
The decorative part according to any one of claims 1 to 3, characterized in that: The decorative protective layer is made of a resin-impregnated nonwoven fabric sheet impregnated with the thermoplastic resin,
The decorative part according to any one of claims 1 to 4, characterized in that:

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