JP2966882B2 - Manufacturing method of products with pseudo three-dimensional pattern - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for producing a product having a pseudo three-dimensional pattern, and more particularly to a method for producing a ceramic, plastic, or other product having a colored pattern with a precise and three-dimensional appearance.

[Prior Art] Conventionally, as a method of manufacturing a product having a pattern with a three-dimensional appearance, there is a method of manufacturing a ceramic using a technique called openwork. In this method, first, on a transparent plate, after forming a layer having a substantially uniform thickness of a material having light scattering properties, for example, a wax,
A desired portion of the wax layer is carved to form an uneven image. At this time, the wax is carved while observing the model product and the like while irradiating light from the transparent substrate side. This makes it possible to perceive the degree of transmission of light that varies according to the layer thickness of the wax as a reflection of the three-dimensional effect of the model when carving the uneven image on the wax. As a result, the three-dimensional effect of the model can be very faithfully reflected on the wax layer.

In the next step, gypsum kneaded with water is poured onto the wax layer and solidified, and then the wax is peeled off to form a gypsum mold on which the uneven image is transferred. Using this gypsum mold, a slurry of a ceramic raw material composition (kneaded clay) is cast and molded to produce a thin molded body having an uneven surface corresponding to an uneven image. Thereafter, the molded body subjected to a drying treatment or the like is fired to produce a ceramic having a pattern. When firing the formed body, a transparent thin glaze having an uneven surface reflecting the uneven surface of the fired body may be formed.

An uneven image carved with a layer of wax is almost faithfully transferred to the ceramic, so that when light is passed through from the back of the ceramic, a watermark pattern with a three-dimensional effect appears.
This is based on the result that the amount of light transmitted from the back to the front of the ceramic changes according to the change in the thickness of the ceramic, the part with a large amount of transmission appears to be raised, and the part with a small amount of transmission looks like a shadow. It is.

[Problem to be Solved by the Invention] When the pattern portion of the ceramics formed by the conventional method is viewed from behind without passing through light, the unevenness is minute, but it is merely miscellaneous. And no three-dimensional effect. However, there are many cases where the porcelain is placed in such a state. In order to avoid this problem, it is necessary to arrange a lighting illuminator so that light is always applied to the ceramic.

Also, in a place where the entire surroundings are bright, the watermark pattern may not be clearly perceived. Furthermore, the presence of a three-dimensional pattern on the ceramic may itself go unnoticed.

In addition, although ceramics having a watermark pattern are practically used for shaping fluorescent lamps, there are not many uses that can make use of the three-dimensional pattern.

Furthermore, the method using openwork has been able to produce only ceramic products.

The present invention solves the above problems, and provides a method for producing a product having a pseudo three-dimensional pattern that can be used for various applications, in which a pattern similar to a fine openwork pattern full of three-dimensional appearance is exposed without irradiating light from the back surface. The purpose is to provide.

Another object of the present invention is to provide a manufacturing method capable of manufacturing products having a pseudo three-dimensional pattern and made of various materials.

[Means for Solving the Problems] The above object can be achieved by the present invention described below. That is, the present invention provides a step of carving a plate exhibiting light transmission and light scattering properties while irradiating light from below to form a master having a desired uneven image; A step of injecting a flowable raw material or filling a powdery raw material or a plastic raw material with respect to a mold in which an image is reproduced through the transfer thereof; and solidifying the flowable raw material or compressing the powder raw material or the plastic raw material, thereby forming the irregularities. Forming a molded body having an uneven surface corresponding to an image; forming a transparent layer on the uneven surface; and forming a light-transmitting colored layer in which a coloring substance is dispersed, making the surface substantially smooth, Forming a product having a pseudo three-dimensional pattern comprising: forming on the transparent layer.

[Effect] In the product (FIG. 2) produced by such a method, a fine and three-dimensional pattern similar to the watermark pattern can be visually perceived without irradiating light from the back of the product. The appearance of a pattern full of a three-dimensional effect is considered as follows.

As shown in FIG. 1, since the surface of the colored layer 1 is smooth, the thickness of the colored layer 1 is
(Depending on the exact opposite relationship) corresponding to the thickness change (thickness change based on surface irregularities). The change in the thickness of the colored layer 1 determined in this way is almost proportional to the change in the thickness of the prototype layer that faithfully reflects the three-dimensional effect of the model.

In the colored layer 1 exhibiting such a change in thickness, the thinner the portion, the smaller the total amount of the coloring substance, and therefore, the higher the light transmittance. Therefore, the surface of the molded body 2 underneath appears to be prominent. On the other hand, the thick portion of the colored layer has a small amount of light transmission because the total amount of the colored substance is large, and the surface of the molded article 2 is hard to see through, and looks like a shadow due to the colored substance. As a result, it is considered that a product having a three-dimensional appearance appears in the product manufactured by the method of the present invention. In particular, in the present invention, the transparent layer 3 comprises the molded body 2 and the colored layer 1
It is provided between. Therefore, the transparent layer 3 seeps into the coloring layer 1, and as a result, the coloring layer 3 is blurred (blurred), and an interesting aesthetic feeling is obtained.

Hereinafter, a typical embodiment of a method for producing a product having a pseudo three-dimensional pattern according to the present invention will be described.

First, a board exhibiting translucency and light scattering properties is carved while irradiating light from below to form a prototype having a desired concavo-convex image (step 1).

Here, the disc exhibiting translucency and light scattering property is a so-called translucent disc, that is, a disc other than a substantially completely transparent one (eg, silica glass) and a substantially completely opaque one (eg, iron). It is a board that consists of: Examples of the material of this board include wax, synthetic wax; translucent resin such as vinyl chloride;
Translucent ceramics made of alumina, magnesia, or the like having a small particle size and high density may be used.

In order to carve a board made of such a material, a hand method using an iron brush or a method using physical means such as a laser or a mechanical means can be used. What is necessary is just to select the method according to ease etc. suitably.

In this step 1, light is irradiated from the lower side of the board, that is, from the opposite side of the board surface on which an image of irregularities is to be drawn, because the degree of light transmission from the board according to its thickness is determined by eyes or sensors. This is because the three-dimensional effect of the model is reflected very faithfully on the translucent board by engraving the uneven image while perceiving by the mechanical means.

Next, a flowable raw material is introduced into the above-described mold, or a powder raw material or a plastic raw material is filled (step 2).

The fluid raw material may be one which is hardened by an appropriate treatment such as standing, heating, addition of a hardener after flowing into the prototype. Examples include flowable plastics (eg, unsaturated polyester, melamine resin, polyamide resin, silicone resin, epoxy resin, acrylic resin), flowable polymerizable low molecular weight compounds (eg, styrene,
Methacrylic acid ester), fluid rubber (for example, butyl rubber, nitrile rubber), molten glass, cement raw material, molten metal, and slurry for porcelain.

Examples of the powder raw material include various materials such as plastic powder, wood and paper fine powder, and starch. A binder or the like may be mixed with such a powder raw material. Examples of the plastic raw material include clay and the like.

Next, when a fluid raw material is used in the above step, the raw material is cured by a process such as standing, heating, or adding a curing agent. When a powder raw material or a plastic raw material is used, the raw material is compressed using a mold or the like that is paired with the original mold. Thus, a molded body having an uneven surface corresponding to the uneven image of the prototype is formed (step 3).

The molded body may be subjected to a heat treatment, a sintering treatment, or the like as necessary.

Depending on the combination of the material of the prototype and the raw material of the molded body to be used in the above steps 1, 2 and 3, the prototype may be damaged if they come into contact with each other, or the molded body may be released from the prototype even if a release agent is used. In some cases, it may be difficult to mold the molded body because of difficulty in performing molding. In addition, the prototype itself may be easily damaged and may not be used repeatedly. When such inconvenience occurs, a mold that reproduces the concave-convex image of the original pattern by transfer (hereinafter, referred to as a reproduction mold) is produced, and the molded article having the concave-convex surface corresponding to the concave-convex image is produced using the mold. What is necessary is just to manufacture.

There is no particular limitation on the method of obtaining the reproducible mold. For example, a first mold having a concavo-convex image and a reversed concavo-convex image is produced by molding using a prototype, and then the first mold is used. It can be easily obtained as a molded product. In addition, the reproduction type can be obtained by a method in which a concavo-convex image of a prototype is analyzed by a computer and the image is reproduced on a suitably selected material by mechanical means.

As the raw materials of the first mold and the reproduction mold, those within the same range as the raw materials of the above-mentioned molded body can be used. Among them, the material of the prototype, the material of the molded body to be molded by the reproduction mold, and the like are used. In consideration of the above, it may be appropriately selected so as not to cause the above inconvenience.

Examples of combinations of materials for the original mold, the first mold, the transfer mold, and the molded body that are preferable for preventing the above-mentioned inconveniences will be described below.

In Example 3, in order to mold a metal mold from a gypsum mold, sand, wax, and sand were laminated in this order on the uneven surface of the gypsum mold to a uniform thickness, and molten metal was directed toward the wax. Just let it flow. This causes the molten metal to melt the wax and fill it between the sands instead of the wax. The filling becomes a metal mold.

Next, a transparent layer is formed on the uneven surface of the molded article molded by the original mold or the reproduction mold (Step 4). Here, the transparent layer can be made of a translucent glassy solid, transparent plastic, or the like.

Next, a light-transmitting colored layer in which a coloring substance is dispersed is formed on the transparent layer with the surface thereof being substantially smooth (Step 5).

The coloring substance according to the present invention may be a coloring molecule, or a coloring particle having a diameter of about 0.1 to 0.001 μm, that is, a colloid coloring particle (for example, a pigment particle). The coloring layer is a solid in which the coloring particles are transparent (glassy solid,
(A transparent solid plastic or the like) or a light-transmissive fluid (water or a transparent fluid plastic or the like). When the main constituent of the colored layer is solid, it is preferable that the colored layer is easily viscous if it is vitreous, and it is preferable that the colored layer is plastic because the colored layer can be easily formed. It is desirable that the dispersion system of the colored layer is uniform because the three-dimensional image of the prototype formed in step 1 can be faithfully reproduced.

In order to form a colored layer, the colored layer material is applied, flowed in, and placed on the molded body, and then, if necessary, heated,
What is necessary is just to implement processing, such as baking.

Through the above steps, a product having a smooth surface and a colored layer in which a coloring substance is dispersed can be manufactured. In that product, the change in thickness of the product body (molded body) corresponds almost exactly to the change in thickness of the prototype on which the uneven image is formed. Therefore, the thickness of the colored layer covering the product body and having a smooth surface is approximately proportional to the thickness of the original mold. The thinner the colored layer is, the smaller the total amount of the dispersed coloring substance is and the light transmitting property of the colored layer is. The surface of the product main body is seen through and emerges, and the thicker the colored layer is, the more transparent the colored layer is. There is no light and the color of the colored substance appears dark and looks like a shadow. For this reason, the product displays a three-dimensional pattern even if it is not transparent to light.

Examples of uses of the product having such a pseudo three-dimensional pattern include tableware, ashtrays, vases, ornaments, interior tiles, cosmetic containers, ceramic plates, foreheads, and the like.

As is clear from the above description, the method of manufacturing a product having a pseudo three-dimensional pattern according to the present invention can produce products of various materials unlike the conventional method of openwork engraving, but a product with particularly high durability An example in which the present invention is applied to the production of a ceramic product as described above will be described in more detail below.

First, a layer of wax is laminated on a transparent substrate such as a glass plate to a substantially uniform thickness (usually about 2 to 4 mm) (Step 1).
1).

Next, irradiate light from the transparent substrate side, and perceive the three-dimensional appearance of the wax surface by the degree of light transmission from the wax, and carve irregularities according to the model on the wax layer with an iron brush etc. Is formed (Step 1-2).

The reason why a wax is used in this step is that the wax is translucent and that a precise image can be easily formed. Therefore, instead of wax, wax-like substances having such properties, such as glue and machinable synthetic resin, can be preferably used.

Next, surround the periphery of the wax layer with a frame or the like, and on that layer,
For example, a gypsum mixed with water is poured, the gypsum is hardened, and after the hardening, the wax is removed to form a first gypsum mold having an image or a transferred image (step 2-1). Note that another material, for example, a resin may be used instead of the first gypsum mold.

Further, on the first gypsum mold, gypsum mixed with water is poured, and the gypsum is solidified to form a second gypsum mold (one of the transfer molds) on which the image is transferred again (Step 2-). 2).

Next, the slurry of the porcelain clay is cast and molded using the second gypsum mold (step 3-1).

A molded article having an uneven surface corresponding to the uneven image on the wax layer is formed by the casting.

Thereafter, the molded body having the uneven surface is fired and a transparent layer is formed (Step 4-1). More specifically, a transparent layer is formed by applying and pouring a vitreous solid or a transparent plastic. Usually, a pigment without adding a pigment to a conventional glaze can be used as it is as a transparent layer.

Next, a light-transmitting colored layer in which a coloring substance is dispersed is formed on an uneven surface by substantially smoothing the surface to obtain a fired body (step 5-1). The firing in this step and the formation of the colored layer may be simultaneous or not.

This step 5-1 can take any of several modes depending on the type of the coloring layer.

The typical procedure of the present step 5-1a in the case where the coloring layer is a glaze layer in which the coloring particles are suspended in the vitreous phase and the light transmittance is not lost will be described.

First, a maximum temperature of 600 to 9 is applied to the compact formed in step 3-1.
Unglazing at about 00 degrees is performed. After glazing the unglazed body,
And bake it. When applying the glaze, it is necessary to use an amount of glaze that is sufficient to make the glaze thicker after the main firing and that the surface is smooth without reflecting the unevenness of the ceramic body. Even if the glaze material is thick (about 3 mm or more),
It is necessary to use a material that does not cause defects such as cracks. An example of a combination of a glaze material and a ceramic clay for this purpose is shown below.

Porcelain clay component parts feldspar 20-25 quartzite 10 Pottery Stone 10 clay (kaolin) 40 Alumina 0-5 talc 0-5 glaze component parts feldspar 50 Silica 20 dolomitic 5 lime 15 zinc white 9 barium carbonate 1 cobalt oxide 0.2 Note that the firing conditions for the main firing need to be determined in consideration of the above combination and the like. Followed by firing in a reducing atmosphere (seme)
Then, the temperature is raised to around 1200 ° C., and then the temperature is raised to 1250 to 1300 ° C. by firing in a near neutral atmosphere (aim), and then cooling is started.

Through the above steps, it is possible to manufacture a ceramic having a smooth surface and a transparent glaze formed thereon. In this pottery, the thinner the glaze, the smaller the total amount of dispersed coloring substances and the translucency of the glaze.The surface of the ceramic body is seen through, and the glaze is darker. The color of the colored substance appears dark and looks like a shadow. Therefore, a ceramic product has a three-dimensional appearance even if it is not transparent to light. Further, the transparent substance constituting the transparent layer permeates into the coloring layer, and as a result, the boundary between the coloring layer and the transparent layer is not clear, and the appearance becomes blurred or blurred, which is more aesthetic.

When the coloring layer is a layer in which coloring molecules and coloring particles are dispersed in transparent plastic, this step 5-1 is performed by the following procedure (5-1b).

First, a fired body is formed in substantially the same manner as in the above step 5-1a, but without glazing. Next, a plastic fluid in which a suitably selected coloring substance (dye, pigment, etc.) is dispersed is poured onto the uneven surface of the fired body whose side surface is surrounded by a frame or the like, and solidified while the surface is smoothed. In this way, a ceramic product having a three-dimensional pattern similar to the above-mentioned ceramic is obtained.

The material of the plastic may be a material having a light transmitting property and exhibiting adhesiveness to the fired body by solidification. For example, an epoxy resin or the like can be used.

In addition, as another embodiment of Step 5-1, an embodiment is provided in which colorable suspended particles or coloring molecules are dispersed in water, and this is filled in a transparent container containing a fired body.

The ceramic product having a pseudo three-dimensional pattern manufactured in this way is used for various applications as described above.

[Examples] In order to further clarify the present invention described above, specific examples of a method for producing a product having a pseudo three-dimensional pattern according to the present invention will be described below.

Example 1 First, molten wax was flowed and solidified on transparent glass,
A layer of wax having a thickness of about 3 mm was laminated. Next, while irradiating light from the glass plate side, the statue of the ship was carved in a wax with an iron brush.

Next, plaster mixed with water (100 parts by weight of plaster, water 1
00) is poured onto the layer of wax surrounded by the frame and solidified.
A first gypsum mold with the image transferred was formed. The first gypsum mold had a rectangular plate shape, and the peripheral portion had a shape protruding from the portion where the image was formed.

The same gypsum mixed with water as described above was poured into the gypsum mold and solidified to form a second gypsum mold.

Using the second gypsum mold, casting molding of the following porcelain clay was performed.

Porcelain clay commercially available component parts feldspar 23 slip for pottery stone 10 Silica 10 clay (kaolin) 40 Alumina 3 Talc 3 casting, compared porcelain clay 100 parts by weight of water 30
Were mixed and further mixed with water glass of 2/1000 weight of the amount of water as a dispersant. With a casting time of 40 minutes, a rectangular plate-like molded body having a maximum thickness of about 5 mm of the uneven surface corresponding to the image was formed.

After drying, the molded body was sintered. In the sintering process, the temperature was gradually increased to 500 ° C. over about 4 hours mainly for removing water, and further raised to 800 ° C. over 2 and a half hours, followed by cooling. As a result, 15 × 13 cm square, the thickness of the uneven surface 0.
A plate-shaped unglazed body weighing about 3 cm and weighing 290 grams and having a raised peripheral portion was formed.

 Next, a transparent component comprising the following components was prepared.

Ingredient Parts by weight feldspar 50 Silica 20 dolomitic 5 lime 15 zinc white 9 100 parts by weight of water was mixed into barium carbonate 1 The 100 parts by weight, which was formulated by rubbing an electric mill. This was applied to the unglazed surface.

 On the other hand, the following ingredients were mixed with glaze.

After component polymerization unit feldspar 50 Silica 20 dolomitic 5 lime 15 zinc white 9 barium carbonate 1 cobalt oxide 0.2 by mixing 100 parts by weight of water to the 100 parts by weight, it was rubbed for about 22 hours it an electric mill, followed by drying I mixed.

Place 45 grams of this glaze in the center of the uneven surface of the unglazed body,
I baked it. In this firing, the temperature is raised to 900 ° C. over 9 hours by oxidation firing, followed by reduction firing (seme).
The temperature was raised to 1200 ° C. over 7 hours, and then the temperature was raised to 1250 ° C. over 3 hours by baking in a near neutral atmosphere (cooling), followed by cooling (10 hours).

In this way, the glaze layer was spread over the entire uneven surface of the ceramic body, and the ceramic plate having a smooth horizontal surface and a ship pattern full of three-dimensional feeling was produced. The glaze was transparent and blue, had a maximum thickness of about 3 mm, and had no cracks on its surface.

A product in which powdered glass is fused to bone china at about 1000 ° C. is known, but one manufactured according to the present embodiment is fired at 1200 ° C. or higher, and is a high-temperature fired porcelain having high wear resistance and strength. There is also a product that has a thick glaze (the glaze of conventional high-temperature fired porcelain is about 1.5 mm), no cracks, and the glaze exhibits a special action (the action of raising a three-dimensional pattern) (porcelain and It can be thought of as a combination product with glaze), and this is a product that has never been seen before.

Example 2 First, a molten wax was flowed and solidified on a transparent glass,
A layer of wax having a thickness of about 3 mm was laminated. Next, while irradiating light from the glass plate side, the image of Mona Lisa was carved in a wax with an iron brush.

Next, plaster mixed with water (100 parts by weight of plaster, water 1
00) is poured onto the layer of wax surrounded by the frame and solidified.
A first gypsum mold with the image transferred was formed. The first gypsum mold had a rectangular plate shape, and its peripheral portion was in a shape protruding from the portion where the image was formed.

Silicon resin (TSE350RTY (trade name),
(Toshiba Silicon) was poured and left for several hours to solidify, thereby forming a silicon mold in which the Mona Lisa image carved in the wax was reproduced. The silicone mold was easily released from the gypsum.

 Next, the following composition was prepared.

Composition Commercial product component parts by weight・ Calcium carbonate 1000 ・ Unsaturated polyester resin 700 (Ester 3115PA (trade name), manufactured by Mitsui Toatsu Chemicals, Inc.) ・ Curing agent 3.5 (Kayamec (trade name), Kayaku Akzo Co., Ltd.) )) The composition was stirred and about 1703.5 g of it was poured onto the framed silicon mold. If you leave it alone,
The composition was hardening. After standing for 40 minutes, the rectangular plate-like molded product formed by curing the composition was released. This release was also very easy. After allowing to stand for 30 hours, the same transparent component as in Example 1 was prepared, and this was applied to essential parts of the molded body. It did not require bokeh, such as near the eyes of Mona Lisa, and was not applied where strong contours were desired.

A mixture obtained by mixing and stirring 737.8 g of the following composition was poured onto a molded product. Thereafter, when left for 2 hours, the following composition was cured, and a brown transparent colored layer was formed on the molded product.

Ingredients by weight -Unsaturated polyester resin 700 (Esta-3115PA (trade name))-Aluminum hydroxide 10 aqueous solution 25-Curing agent (Kayamek (trade name)) 12.5-Coloring substance Iron oxide 0.1 Chromium oxide 0.2 Thus, the coloring layer , A rectangular plate-shaped plastic product that spreads over the uneven surface of the molded body, has a smooth horizontal surface, and has a three-dimensional Mona Lisa pattern (No. 2)
Figure) was produced. Clear acid was obtained near the eyes.

Although the embodiments of the present invention have been described above, the present invention is not limited to these embodiments at all, and it is needless to say that the present invention can be implemented in various modes without departing from the gist of the present invention.

[Effect of the Invention] According to the method for producing a product having a pseudo three-dimensional pattern of the present invention described above, a pattern that is as detailed and full of three-dimensional feeling as a conventional watermark pattern can be displayed without irradiating light from the back side of the product. Outgoing products can be formed. The product has a more natural feel to the colored areas than bleed. As a result, anyone can always perceive the three-dimensional pattern drawn on the product without any hassle in any place. Further, the material of the product is not limited to ceramics, but can be various.

Along with the above effects, it is possible to broadly expand the use of a product having a pattern full of a three-dimensional effect.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of a product manufactured according to a representative example of the present invention, and FIG. 2 is a plan view of the example. 1 ... Colored layer 2 ... Molded body 3 ... Transparent layer

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁶ , DB name) B44C 5/04 B44C 3/04 B28B 1/14 B29C 69/00

Claims (2)

(57) [Claims] 1. A step of engraving a board exhibiting translucency and light scattering properties while irradiating light from below to form a prototype having a desired concavo-convex image; A step of injecting a flowable raw material or filling a powdery raw material or a plastic raw material with respect to a mold reproduced through the transfer, and solidifying the flowable raw material or compressing the powder raw material or the plastic raw material, thereby forming the uneven image. Forming a molded body having an uneven surface corresponding to the step of: forming a transparent layer on the uneven surface; and forming a light-transmitting colored layer in which a coloring substance is dispersed, substantially smoothing the surface thereof, Forming on a transparent layer; and producing a product having a pseudo three-dimensional pattern comprising: 2. A step of laminating a wax on a transparent plate; a step of carving a desired portion of the wax layer while irradiating light from below the transparent plate to form an image; Transferring the image to a mold, transferring the image of the mold to a gypsum mold, using the gypsum mold to cast and mold a slurry for porcelain manufacture,
Forming a molded body having an uneven surface corresponding to the image; forming a transparent layer on the uneven surface; sintering the molded body to form a fired body; A method of producing a ceramic product having a pseudo three-dimensional pattern, comprising: forming a light-colored layer on the transparent layer by substantially smoothing the surface thereof to obtain a fired body.