JP4015768B2 - Manufacturing method of decorative molded products - Google Patents

Description

【００２１】
この表１から明らかなように、従来品（比較例のもの）では成形品の角隅部に皺が発生しているが、本願発明に係る実施例品１及び２では、加飾成形品の原形において角隅部（最終的に除去する部分）に若干の皺が見られるが、最終成形品の角隅部には皺の発生がみられなかった。
【００２２】
なお、この実施例では、加飾成形品の原形５において、略Ｌ字型の凸部５１を形成し、この部分に皺５２を寄せ集めるように構成したが、図６に示すような凹部６１、６２を形成した上（雌）金型（特に、この形状のものに限定しない）６を使用し、これによって図７に示すような凸部７１、７２を形成した加飾成形品の原形７を成形し、この原形７から皺７３のある凸部７１、７２を切除して最終成形品７´を形成してもよい。
【００２３】
また、この実施例では、シート体として、透明フィルムと加飾シートとを重ね合わせた二重シート構造としたが、特にこの構成のものに限らず、例えば透明フィルムや加飾シートのみの単層シート構造として成形品の表面層を構成しても構わない。
【００２４】
【発明の効果】
以上説明してきたように、この発明によれば、成形後に表面層の少なくとも角隅部を含む領域を形成する単数若しくは複数のシートを金型内にセットし、この金型により前記シートと一体に接着された状態で成形品を形成する成形品の製造方法であって、金型の少なくとも３面が交わる角隅部分近傍に窪んだ凹部を形成し、成形時に前記シート体に発生する皺を凹部に集めるとともに、その凹部に対応して形成された成形品の角部近傍の凸部を除去して最終成形品を形成するので、成形時に角隅部の表面側に接着するシート体に皺が発生することが有効に防止でき、ひいては高品質の加飾成形品等が提供できる。
【図面の簡単な説明】
【図１】この発明に係る加飾成形品の製造方法に使用する金型を示す断面図。
【図２】同金型のの要部を示す斜視図。
【図３】同断面図。
【図４】同加飾成形品の製造方法を示す説明図。
【図５】この発明に係る方法で形成した成形品の原形を示す要部斜視図。
【図６】同金型の変形例を示す要部斜視図。
【図７】この金型で形成した成形品の原形を示す要部斜視図。
【図８】従来の方法で形成した成形品を示す要部斜視図。
【符号の説明】
１ 下金型（雄金型）
２，６ 上金型（雌金型）
２２，６１，６２ 凹部
３ 透明シート
４ 加飾シート
５，７ 成形品（原形）
５，７ 成形品（最終成形品）
５１，７１，７２ 凸部
５２，７３ 皺[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a molded product to which a surface layer sheet is attached, and particularly to a method for manufacturing a decorative molded product in which wrinkles are not generated at corners.
[0002]
[Prior art]
For example, resin components having a decorative surface such as wood grain and marble have been developed and widely used as building materials such as wall materials and outer wall materials in buildings, or in dashboards in automobiles.
[0003]
Conventionally, in the decoration technique for such a resin molded product, for example, a transparent sheet body such as acrylic serving as a surface layer is set in an injection mold, and adhesion with a vinyl chloride or ABS resin is used to adhere to the surface layer. Apply the agent, set the decorative sheet body that is the lower layer to which the pattern is given by printing, hot stamping, etc. on top of it, and perform injection molding to adhere the sheet body to the molded product at the same time as the attaching mold, A method for obtaining a decorative molded body is performed.
[0004]
[Problems to be solved by the invention]
However, when the decorative molded body is molded by this method, wrinkles may be generated on the surface of the sheet body due to pressure or the like at the time of injection. In particular, as shown in FIG. Wrinkles) 101 occur frequently. This is because distortions from the three surfaces are likely to gather at the corners, and it is considered that wrinkles are inevitably concentrated there.
[0005]
Therefore, as a countermeasure against this, measures have been examined to prevent the generation of wrinkles by applying tension to the sheet body at the time of molding. It is desired.
[0006]
Then, this invention aims at providing the manufacturing method of the decorative molded product which can prevent that a wrinkle generate | occur | produces in the corner | angular corner part of the sheet | seat body used as a surface layer at the time of shaping | molding in view of the above situation. is there.
[0007]
[Means for Solving the Problems]
That is, according to the first aspect of the present invention, one or a plurality of sheets forming a region including at least the corners of the surface layer is set in a mold after molding, and the mold is bonded integrally with the sheet. A molded product manufacturing method for forming a molded product in a state in which a concave portion is formed in the vicinity of a corner portion where at least three surfaces of the mold intersect, and wrinkles generated in the sheet body during molding are formed in the concave portion. While collecting, the convex part of the corner | angular part vicinity of the molded product formed corresponding to the recessed part is removed, and a final molded product is formed.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 shows a molding die used in the method for producing a decorative molded product according to the present invention. As this molding die, a cavity C (see FIG. 1) is formed with a lower die (male die) 1. 4), recesses 22 having a substantially L-shaped cross section as shown in FIGS. 2 and 3 are formed in the vicinity of the four corners α of the inner surface 21 portion. A formed product is used, and a desired product is formed by injection molding (of course, not limited to this molding method).
In addition, the code | symbol 3 in a figure shows a transparent film, 4 shows a decorating sheet, These form a decorating layer.
[0009]
As shown in FIG. 2, the concave portion 22 has a dimension a in the height direction from the position (ceiling surface) of the corner portion α of the upper mold 22 (this dimension a is a polycarbonate or acrylic resin as the hard transparent film 3). Is used at a lower portion of 0.5 to 3 mm, preferably 1 to 2 mm, and the soft transparent film 3 has an allowable dimension of 0.5 to 5 mm, preferably 1 to 3 mm). Yes. This dimension a is more important than the other dimensions b and c, and is less likely to become wrinkles below the minimum allowable dimension, but is a convex part of the molded product (a part formed corresponding to the concave part 22 of the upper mold 2) ), The molded product is easily damaged. Further, if the size is larger than the maximum allowable dimension, wrinkles easily enter the corners of the molded product.
[0010]
Further, as shown in FIGS. 2 and 3, the recess 22 has dimensions b and b 'from the inner surface 21 (the dimensions b and b' are 2.5 to 50 mm, preferably 5 to 40 mm, most preferably An allowable dimension of 10 to 30 mm is set, but it may not necessarily be the same dimension) and is formed from the inner wall surface to the inside (back part). If the dimensions b and b ′ are 2.5 mm or less, the convex portions of the molded product may be too close to the corners of the final molded product, and wrinkles may easily enter there. Moreover, if the dimension of b and b 'is 50 mm or more, the loss part of the decoration layer which will become unnecessary after excision increases and it is uneconomical.
[0011]
Further, the recess 22 has dimensions c and c 'from each inner surface (the dimensions c and c' have an allowable dimension of 5 to 100 mm, preferably 10 to 80 mm. Good). When the dimensions c and c ′ are 5 mm or less, the convex portion formed on the molded product becomes too short, and the wrinkles of the decorative layer tend to enter the corners of the final molded product, and are 100 mm or more. It is difficult to cut out the convex portion in the next process.
[0012]
Next, a method for producing a decorative molded product according to the present invention will be described using the molding die of the previous embodiment.
(1) As shown in FIG. 3, on the inner surface 21 of the upper mold 2 forming a part of the cavity C, the transparent film 3 is set in such a state that all four corners α are included. In this case, the transparent film 3 is also set in the recess 22, and an optimum tension is applied by an appropriate suction means such as a vacuum suction device (not shown), and the inner surface 21 of the upper mold 2 is wrinkled. It is attached so that there is no.
[0013]
(2) Next, after applying an appropriate adhesive to one surface of the transparent film 3, a decoratively printed vinyl chloride sheet is used as the decorative sheet 4, and this is set on the inner surface of the transparent film 3. . In this way, these sheets are set in the inner surface area including the concave portion 22 of the upper mold 2.
[0014]
(3) In such a state, as shown in FIG. 4, the upper mold 2 is moved toward the lower mold 1 (or vice versa), and both are polymerized and closed. 1 and 4, N represents a nozzle, G represents a gate, and R represents a runner.
[0015]
(4) Thereafter, using, for example, ABS resin as a molding material, the molding material is injected toward the cavity C (from a nozzle N of an appropriate injection machine), and the original shape 5 of a desired decorative molded product as shown in FIG. Form. In this decorative molded product, the occurrence of wrinkles 52 on the convex portion 51 is slightly seen as will be described later. However, wrinkles are generated on the entire surface including the corner portion 51 'in the portion to be the final molded product 5'. Is not seen.
[0016]
(5) Next, when the four convex portions 51 of the original shape 5 of the decorative molded product are cut out by an appropriate cutting means such as a cutter, a desired final molded product 5 ′ is formed.
[0017]
Next, a comparison experiment between a molded product manufactured by the molding method according to the present invention (Example 1 and Example 2) and a molded product formed by a conventional method (comparative example) will be described.
[0018]
In this comparative experiment, a flat plate molded product having a length of 1 m, a width of 0.5 m, and a thickness of 0.03 m was used as a sample. The transparent film 3 is an acrylic film (Mitsubishi Rayon Co., Ltd.) having a thickness of 100 to 200 μm, and the decorative sheet 4 is a decorative sheet printed on a top surface using a vinyl chloride sheet having a JISA hardness of 70. It was used. Further, ABS resin (manufactured by JSR) was used as the molding resin material, and an injection machine of 3000 tons (manufactured by Mitsubishi Heavy Industries) was used.
[0019]
The following results were obtained for a molded product using such a material and formed using a conventional mold having no recess and a mold having a recess according to the present invention.
[0020]
[Table 1]

[0021]
As is apparent from Table 1, wrinkles are generated at the corners of the molded product in the conventional product (comparative example), but in the example products 1 and 2 according to the present invention, the decorative molded product In the original form, some wrinkles were observed at the corners (the part to be finally removed), but no wrinkles were observed at the corners of the final molded product.
[0022]
In this embodiment, in the original shape 5 of the decorative molded product, a substantially L-shaped convex portion 51 is formed and the ridges 52 are gathered together in this portion, but the concave portion 61 as shown in FIG. , 62 is used (female) 6 (not limited to this shape in particular) 6 is used, and thereby a decorative molded product original 7 in which convex portions 71 and 72 as shown in FIG. 7 are formed. And forming the final molded product 7 'by cutting out the convex portions 71 and 72 having the flange 73 from the original shape 7.
[0023]
In this embodiment, the sheet body has a double sheet structure in which a transparent film and a decorative sheet are overlapped. However, the sheet body is not particularly limited to this structure, for example, a single layer of only a transparent film or a decorative sheet. You may comprise the surface layer of a molded article as a sheet structure.
[0024]
【The invention's effect】
As described above, according to the present invention, after molding, one or more sheets forming a region including at least the corners of the surface layer are set in a mold, and the mold is integrated with the sheet. A method for manufacturing a molded product that forms a molded product in a bonded state, wherein a concave portion is formed in the vicinity of a corner portion where at least three surfaces of the mold intersect, and the wrinkles generated in the sheet body during molding are recessed. And forming the final molded product by removing the projections in the vicinity of the corners of the molded product corresponding to the recesses, so that the sheet body that adheres to the surface side of the corners during molding has wrinkles. Generation | occurrence | production can be prevented effectively and by extension, a high-quality decorative molded product etc. can be provided.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a mold used in a method for producing a decorative molded product according to the present invention.
FIG. 2 is a perspective view showing a main part of the mold.
FIG. 3 is a sectional view of the same.
FIG. 4 is an explanatory view showing a method for producing the decorative molded product.
FIG. 5 is a perspective view of a principal part showing an original shape of a molded product formed by the method according to the present invention.
FIG. 6 is a main part perspective view showing a modification of the mold.
FIG. 7 is a main part perspective view showing an original shape of a molded product formed with this mold.
FIG. 8 is a perspective view showing a main part of a molded product formed by a conventional method.
[Explanation of symbols]
1 Lower mold (male mold)
2,6 Upper mold (female mold)
22, 61, 62 Recess 3 Transparent sheet 4 Decorative sheet 5, 7 Molded product (original)
5,7 Molded product (final molded product)
51, 71, 72 Convex parts 52, 73 皺

Claims (2)

One or more sheets that form a region including at least the corners of the surface layer after molding are set in a mold, and a molded product is formed in a state of being integrally bonded to the sheet by the mold. A manufacturing method comprising:
Forming a recess recessed in the vicinity of a corner portion where at least three surfaces of the mold intersect,
While collecting wrinkles generated in the sheet body at the time of molding in the recess,
A method for producing a decorative molded product, wherein a final molded product is formed by removing convex portions near the corners of a molded product formed corresponding to the concave portions. The method for producing a decorative molded product according to claim 1, wherein the sheet comprises a transparent sheet forming a surface layer, and a decorative film positioned inside the sheet and forming an intermediate layer. .

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