JP4158871B2 - Method and apparatus for manufacturing metal decorative body - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention is used for, for example, a method of manufacturing a metal decorative body in which a colored pattern is formed on a metal base material and used for an elevator landing door, a car door, a car room wall, and the like. The present invention relates to a manufacturing apparatus.
[0002]
[Prior art]
Conventionally, when manufacturing metal decorative panels such as elevator landing doors, car doors, and car room walls, for example, a colored sheet printed pattern sheet on a metal substrate with a base coating on the surface There was a method of sticking through an adhesive. In this method, an ink receiving layer is formed on a transparent polyester film, and a colored sheet is printed on the ink receiving layer to produce a pattern sheet.
[0003]
[Problems to be solved by the invention]
In the conventional method of manufacturing a decorative metal panels as described above, even a pattern sheet and paint layer although more adhered to the adhesive, no sufficient adhesive force can be obtained merely adhere, also in the entire is to bond difficult, it is necessary to bond the the pattern sheet coating layer more firmly and evenly to.
[0004]
The present invention has been made in order to solve the above-described problems, and a manufacturing method of a metal decorative body capable of firmly and evenly bonding a pattern sheet on a coating layer and manufacturing used in the method. The object is to obtain a device.
[0005]
[Means for Solving the Problems]
The method for producing a metal decorative body according to the invention of claim 1 includes a step of forming a coating layer by a resin paint on a metal substrate, a thermoplastic resin sheet, and an adhesive layer on the thermoplastic resin sheet. The pattern sheet is used as a base material so that the thermoplastic resin sheet is joined to the coating layer. The step of stacking, the step of placing the base material on which the pattern sheet is stacked on the vacuum evacuation table having the exhaust passage and covering the pattern sheet with the sheet-like cover through the sheet-like elastic body having air permeability The process of pressing the pattern sheet against the substrate through the elastic body and the cover by exhausting the space between the vacuum evacuation table and the cover through the exhaust passage, and closely contacting the thermoplastic resin sheet to the coating layer, and the pattern sheet It is intended to include the step of welding the thermoplastic resin sheet coated layer by heating.
[0006]
According to the second aspect of the present invention, there is provided a method for producing a metal decorative body in which a large number of minute irregularities are provided on the surface of an ink receiving layer in the process of producing a pattern sheet.
[0007]
According to a third aspect of the present invention, there is provided a method for producing a metal decorative body comprising: applying an ink receiving layer to a surface of a separator having a large number of minute irregularities; Forming unevenness.
[0008]
According to a fourth aspect of the present invention, there is provided a method for producing a metal decorative body comprising a long fiber sheet made of long fibers interposed between an elastic body and a pattern sheet .
[0009]
According to a fifth aspect of the present invention, there is provided a method for producing a metal decorative body comprising: applying an ink receiving layer to a surface of a separator having a large number of minute irregularities; and placing a thermoplastic resin sheet on the ink receiving layer via an adhesive layer. A process of bonding, a process of forming a large number of minute irregularities on the surface of the ink receiving layer by peeling the separator, and printing a colored pattern on the surface of the exposed ink receiving layer to form a pattern sheet, A step of forming a coating layer by a resin paint on a base material, a step of stacking a pattern sheet on a base material so that the thermoplastic resin sheet is bonded to the coating layer, and a thermoplastic resin sheet by heating the pattern sheet The process includes welding to the coating layer.
[0010]
The apparatus for manufacturing a metal decorative body according to the invention of claim 6 is for pressing a pattern sheet on which a colored pattern by a coloring material is formed to a metal substrate in a panel shape, and the pattern sheet is on the substrate. A vacuum evacuation table having a flat surface portion on which the stacked panel body is placed, a concave portion provided in the flat surface portion, and an exhaust passage for exhausting the inside of the concave portion, is placed on the flat surface portion. Packing provided on the flat portion so as to surround the panel body and the concave portion, a sheet-like elastic body having air permeability to be put on the panel body placed on the flat portion, and covering the elastic body all around A sheet-like cover that is in contact with the packing and maintains airtightness with the flat surface portion, and a pressing frame that sandwiches the cover between the packing and the packing are provided.
[0011]
The apparatus for manufacturing a metal decorative body according to the invention of claim 7 includes a long fiber sheet made of long fibers interposed between the elastic body and the panel body.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
Embodiment 1 FIG.
FIG. 1 is a cross-sectional view of a metal decorative body manufactured by a manufacturing method according to Embodiment 1 of the present invention. Here, an example of a decorative panel for an elevator is shown. In the figure, a coating layer 12 is formed on the surface of a substrate 11 bent into a panel shape. The base material 11 consists of metals, such as iron or an aluminum alloy, for example. The coating layer 12 is made of, for example, melamine, acrylic, urethane, or epoxy resin paint. In addition, a large number of minute irregularities are formed on the surface of the coating layer 12 to be roughened.
[0013]
A thermoplastic resin layer 13 is formed on the coating layer 12. On the thermoplastic resin layer 13, a transparent ink receiving layer 15 is bonded via an adhesive layer 14. The ink receiving layer 15 is made of, for example, a water dispersible resin, a polyester resin, a polyurethane resin, or the like. The ink receiving layer 15 is formed with a colored pattern 16 of pigment ink as a coloring material. A transparent protective film layer 17 is formed on the ink receiving layer 15.
[0014]
Next, FIG. 2 is a cross-sectional view of an essential part of the pattern sheet 18 used for manufacturing the metal decorative body of FIG. In the figure, an ink receiving layer 15 is bonded to a thermoplastic resin sheet 13A via an adhesive layer. A colored pattern 16 is printed on the ink receiving layer 15.
[0015]
Next, the manufacturing method of the pattern sheet 18 of FIG. 2 will be described. First, as shown in FIG. 3, a resin as a material for the ink receiving layer 15 is applied to the surface of the polyester film 19 as a separator. By drying the resin, the ink receiving layer 15 is formed. Moreover, as shown in FIG. 4, the surface of the polyester film 19 used here is in a state where minute irregularities are formed on one surface, that is, a so-called mat state.
[0016]
Thereafter, as shown in FIG. 5, an adhesive layer 14 is applied on the ink receiving layer 15, and further, a thermoplastic resin sheet 13A is adhered thereon as shown in FIG. After bonding of the thermoplastic resin sheet 13A, the sheet laminate 20 is wound up through a drying process.
[0017]
Thereafter, as shown in FIG. 7, the polyester film 19 is peeled off from the wound sheet laminate 20, and the colored pattern 16 is printed on the exposed ink receiving layer 15 before curing. The illustrated pattern sheet 18 is manufactured. At this time, the colored pattern 16 is printed by the inkjet printer 22 connected to the computer 21. Further, the matte surface state of the polyester film 19 is copied on the surface of the ink receiving layer 15 exposed by the peeling of the polyester film 19, as shown in FIG.
[0018]
Next, a method for manufacturing a metal decorative body using the pattern sheet 18 will be described. First, the coating layer 12 is formed on the substrate 11. Next, the surface of the coating layer 12 is roughened by forming minute irregularities due to plastic deformation. This roughening step is performed by a method of spraying a number of transparent glass beads (not shown) onto the coating layer 12 from a shot blast nozzle (not shown), that is, shot blasting.
[0019]
Further, the roughening step of the coating layer 12 may be performed by a knurling process in which a knurl (not shown) having minute irregularities formed on the outer peripheral surface is rolled against the coating layer 12 while rolling.
[0020]
After the surface of the coating layer 12 is plastically deformed to a predetermined surface roughness, the pattern sheet 18 is overlaid at a predetermined position on the coating layer 12. At this time, the thermoplastic resin sheet 13 </ b> A of the pattern sheet 18 is bonded to the coating layer 12. And between the thermoplastic resin sheet 13A and the coating layer 12 is vacuum-pressurized, and further the thermoplastic resin sheet 13A is heated and melted.
[0021]
The molten thermoplastic resin sheet 13 </ b> A is cured again by being returned to room temperature, and becomes a thermoplastic resin layer 13, and is welded to the coating layer 12 by an anchor effect. Thereby, the ink receiving layer 15 on which the colored pattern 16 is formed is also firmly fixed to the surface of the coating layer 12 through the adhesive layer 14 and the thermoplastic resin layer 13. Further, the ink receiving layer 15 is cured by heating, whereby the colored pattern is fixed.
[0022]
Next, a protective film layer 17 is formed by applying a thermosetting clear coating onto the ink receiving layer 15 and curing by heating. The clear coating material of the protective film layer 17 is selected so that the heat curing temperature is lower than the melting temperature of the thermoplastic resin layer 13. Finally, the surface of the protective film layer 17 is polished to increase the flatness, and the metal decorative body having the cross section shown in FIG. 1 is completed.
[0023]
Next, the process of vacuum-bonding the pattern sheet 18 to the substrate 11 will be specifically described. First, FIG. 9 is a perspective view showing an evacuation table used for manufacturing the metal decorative body of FIG. In the figure, a flat vacuum evacuation table 31 includes a planar portion 31a on which the substrate 11 is placed, a plurality of concave portions 31b provided in the planar portion 31a, and a plurality of portions for exhausting the concave portions 31b. And an exhaust passage 31c. A packing 32 for keeping the air tightness of the flat surface portion 31a is continuously provided on the peripheral edge portion of the flat surface portion 31a over the entire circumference.
[0024]
FIG. 10 is an exploded perspective view showing a main part of a metal decorative body manufacturing apparatus having the vacuum exhaust table 31 of FIG. 9, that is, a vacuum pressure bonding apparatus. A plurality of exhaust pipes 33 for connecting the exhaust passage 31 c to an exhaust pump (not shown) are connected to the side surface portion of the vacuum exhaust stand 31. On the flat surface portion 31a, a panel body 34 in which the pattern sheet 18 is superimposed on the base material 11 is placed. In this panel body 34, the thermoplastic resin sheet 13A of the pattern sheet 18 is joined to the coating layer 12 plastically deformed to a predetermined surface roughness.
[0025]
The panel body 34 is covered with a sheet-like elastic body 35 having air permeability. Examples of the material of the elastic body 35 include silicon rubber sponge, Teflon sponge, polyamide sponge, silicon fiber sheet, Teflon fiber sheet, polyamide fiber sheet, glass fiber sheet, glass fiber cotton, stainless steel wool, titanium wool, or aluminum wool. For example, a resin, glass, metal or the like having heat resistance and flexibility is used.
[0026]
On the elastic body 35, a sheet-like cover 36 that covers the packing 32 over the entire circumference and keeps airtight between the flat surface portion 31 a is covered. As the cover 36, for example, a rubber sheet, a polyethylene sheet, or a silicon sheet is used. The peripheral edge of the cover 36 is sandwiched between the pressing frame 37 and the packing 32. As the material of the presser frame 37, a material having sufficient rigidity and heat resistance such as metal, FRP, polyamide resin, or cement is used.
[0027]
FIG. 11 is a perspective view showing an assembled state of the vacuum pressure bonding apparatus of FIG. A plurality of pressers 38 for pressing the presser frame 37 against the packing 32 are mounted on the side of the assembly of the vacuum exhaust table 31 and the presser frame 37. Each presser bar 38 is provided with a pressure adjusting mechanism 39 such as a spring.
[0028]
For example, as shown in FIG. 12, one side of the pressing frame 37 and one side of the vacuum evacuation table 31 may be connected by a hinge mechanism, and the positioning of the pressing frame 37 with respect to the vacuum evacuation table 31 is facilitated, and workability is improved. Will improve. Further, the holding frame 37 and the vacuum evacuation table 31 may be connected by a pantograph mechanism (not shown) or the like.
[0029]
Next, FIG. 13 is a cross-sectional view showing an assembled state of the vacuum pressure bonding apparatus of FIG. 10, and evacuation has not yet started in this state. From this state, the exhaust pump is driven to evacuate the recess 31b through the exhaust passage 31c. Thereby, the air between the cover 36 and the vacuum evacuation table 31 is discharged, and as shown in FIG. 14, the cover 36 is pressed against the panel body 34 at atmospheric pressure, and the elastic body 35 is compressed. Further, the pattern sheet 18 and the coating layer 12 are also deaerated, and the adhesion is improved.
[0030]
Thereafter, the vacuum pressure bonding apparatus is placed in a drying furnace (not shown) while being evacuated, and the panel body 34 is heated together with the vacuum pressure bonding apparatus. By such heating, the flexibility of the cover 36 is increased, and the cover 36 is pressed against the panel body 34 at atmospheric pressure to a finer portion. Thereby, the pattern sheet 18 is pressed against the surface of the base material 11 through the elastic body 35 with an equal pressure. Therefore, the pattern sheet 18 is pressure-bonded onto the substrate 11 with sufficient and uniform strength.
[0031]
According to such a method of manufacturing a metal decorative body, the panel body 34 is placed on the vacuum evacuation table 31, and the inside of the cover 36 is evacuated by covering the elastic body 35 and the cover 36 from above. The pattern sheet 18 can be uniformly crimped to the substrate 11, and workability and quality can be improved.
[0032]
In addition, since the surface of the ink receiving layer 15 located on the surface of the pattern sheet 18 is in a matte state, the friction coefficient is high, the sides of the elastic body 35 and the cover 36 are prevented, and the pressure applied by vacuuming is increased by the pattern sheet 18. The pattern sheet 18 can be evenly pressed against the substrate 11 while suppressing the elongation of the pattern sheet 18 and the generation of wrinkles.
[0033]
Further, since the surface of the ink receiving layer 15 is matted, the surface area of the ink receiving layer 15 is increased, and a solvent such as moisture excluding coloring components such as pigments is absorbed, dispersed and dried several times faster than before. The As a result, the recording density can be increased, and a beautiful image with a fineness and sharpness can be provided.
[0034]
Furthermore, since the matte surface state of the polyester film 19 is copied to the ink receiving layer 15, it is easy to make the surface of the ink receiving layer 15 matte.
[0035]
Embodiment 2. FIG.
Next, FIG. 15 is a sectional view showing a method for manufacturing a metal decorative body according to Embodiment 2 of the present invention. In this example, when the pattern sheet 18 is vacuum-bonded onto the base material 11, a breathable long fiber sheet 41 is interposed between the elastic body 35 and the ink receiving layer 15 of the pattern sheet 18. The long fiber sheet 41 is a sheet composed of long fibers. Other manufacturing methods are the same as those in the first embodiment.
[0036]
By interposing such a long fiber sheet 41, it is possible to prevent the elastic body 35 from adhering to the ink receiving layer 15 during vacuum pressure bonding. In order to prevent such adhesion, a method of applying a chemical having a peeling effect on the ink receiving layer 15 is generally used. However, a protective film layer 17 is formed on the ink receiving layer 15 in a later step. Since it is applied, the method of applying a drug having a peeling effect adversely affects the adhesion of the protective film layer 17. On the other hand, according to the method using the long fiber sheet 41, there is no influence on the adhesion of the protective film layer 17.
[0037]
Although the long fiber sheet 41 is provided separately from the elastic body 35 in the second embodiment, the elastic body 35 may be formed of long fibers. Alternatively, a sheet in which the long fiber sheet 41 is bonded to and integrated with one surface of the elastic body 35 may be used.
Furthermore, although the panel-shaped metal decoration body was shown in Embodiment 1, 2, the shape of a metal decoration body is not limited to this.
[0038]
【The invention's effect】
As described above, in the method for manufacturing a metal decorative body according to the first aspect of the present invention, the base material on which the pattern sheets are stacked is placed on a vacuum evacuation table having an exhaust passage and is air permeable. Since the sheet-like cover is placed on the pattern sheet via the elastic body, and then the space between the vacuum exhaust stand and the cover is exhausted via the exhaust passage, the pattern sheet is firmly and evenly applied to the base material. Can be pressure-bonded and welded to each other, and workability and quality can be improved.
[0039]
In the manufacturing method of the metal decorative body of the invention of claim 2, since the surface of the ink receiving layer is provided with a large number of minute irregularities in the process of producing the pattern sheet, the friction coefficient of the ink receiving layer becomes high, The elastic body and the cover are prevented from slipping, the pressure applied by evacuation is transmitted well to the pattern sheet, and the pattern sheet can be pressed against the substrate evenly while suppressing the elongation and wrinkle of the pattern sheet. In addition, the surface area of the ink receiving layer is increased, and a solvent such as moisture excluding coloring components such as pigments is absorbed, dispersed, and dried several times faster than before. As a result, the recording density can be increased, and a beautiful image with a fineness and sharpness can be provided.
[0040]
According to a third aspect of the present invention, there is provided a method for producing a metal decorative body comprising: applying an ink receiving layer to a surface of a separator having a large number of minute irregularities; Since irregularities are formed, it is easy to form minute irregularities on the surface of the ink receiving layer.
[0041]
In the method for producing a metal decorative body according to the fourth aspect of the invention, since the long fiber sheet made of long fibers is interposed between the elastic body and the pattern sheet , the elastic body adheres to the ink receiving layer at the time of vacuum pressure bonding. Is prevented.
[0042]
According to a fifth aspect of the present invention, there is provided a method for producing a metal decorative body, in which an ink receiving layer is applied to the surface of a separator having a large number of minute irregularities, and then the separator is peeled off to thereby form a large number of minute objects on the surface of the ink receiving layer. Since the unevenness is formed, the surface area of the ink receiving layer is increased, and the solvent such as moisture excluding coloring components such as pigments is absorbed, dispersed and dried several times faster than before. As a result, the recording density can be increased, and a beautiful image with a fineness and sharpness can be provided.
[0043]
An apparatus for manufacturing a metal decorative body according to a sixth aspect of the present invention is a vacuum having a flat part on which a panel body is placed, a concave part provided in the flat part, and an exhaust passage for exhausting the inside of the concave part Exhaust stand, packing provided on the flat part so as to surround the concave part, a sheet-like elastic body having air permeability to be put on the panel body placed on the flat part, and covering the elastic body, Since it has a sheet-like cover that contacts the packing and keeps airtightness between the flat part and a holding frame that clamps the cover between the packing, the pattern sheet can be evenly applied to the base material with a simple configuration. It can be pressed.
[0044]
In the metal decoration body manufacturing apparatus according to the seventh aspect of the present invention, the long fiber sheet made of long fibers is interposed between the elastic body and the panel body, so that the elastic body adheres to the ink receiving layer during vacuum pressure bonding. Is prevented.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a metal decorative body manufactured by a manufacturing method according to Embodiment 1 of the present invention.
2 is a cross-sectional view of an essential part of a pattern sheet used for manufacturing the metal decorative body of FIG. 1;
3 is a perspective view showing a state in the middle of manufacturing the pattern sheet of FIG. 2. FIG.
4 is a cross-sectional view of the polyester film and ink receiving layer of FIG. 3;
5 is a perspective view showing a step of applying an adhesive layer on the ink receiving layer of FIG. 3. FIG.
6 is a perspective view showing a process of bonding a thermoplastic resin sheet on the adhesive layer of FIG. 5. FIG.
7 is a perspective view showing a step of printing a colored pattern on the ink receiving layer after the step of FIG. 6. FIG.
8 is an enlarged cross-sectional view showing a state where a polyester film is peeled from the sheet laminate of FIG.
9 is a perspective view showing an evacuation table used for manufacturing the metal decorative body of FIG. 1; FIG.
10 is an exploded perspective view showing a main part of a vacuum pressure bonding apparatus having the vacuum evacuation table of FIG. 9;
11 is a perspective view showing an assembled state of the vacuum pressure bonding apparatus of FIG.
12 is a perspective view showing another example of the assembled state of the vacuum pressure bonding apparatus of FIG.
13 is a cross-sectional view showing an assembled state of the vacuum pressure bonding apparatus of FIG.
14 is a cross-sectional view showing a state where the vacuum pressure bonding apparatus of FIG. 13 is evacuated. FIG.
FIG. 15 is a cross-sectional view showing a method for manufacturing a metal ornament according to Embodiment 2 of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 11 Base material, 12 Paint layer, 13 Thermoplastic resin layer, 13A Thermoplastic resin sheet, 14 Adhesive layer, 15 Ink receiving layer, 16 Colored pattern, 18 Pattern sheet, 19 Polyester film (separator), 31 Vacuum exhaust stand, 31a Plane part, 31b Recessed part, 31c Exhaust passage, 32 Packing, 35 Elastic body, 36 Cover, 37 Holding frame.

Claims (7)

Forming a paint layer with a resin paint on a metal substrate;
A step of producing a pattern sheet having a thermoplastic resin sheet and an ink receiving layer formed on the thermoplastic resin sheet through an adhesive layer and having a colored pattern formed by a coloring material;
A step of stacking the pattern sheet on the substrate so that the thermoplastic resin sheet is bonded to the coating layer;
Placing the base material on which the pattern sheet is stacked on a vacuum evacuation table having an exhaust passage, and covering a sheet-like cover on the pattern sheet via an air-permeable sheet-like elastic body;
The pattern sheet is pressed against the base material via the elastic body and the cover by exhausting between the vacuum exhaust stand and the cover via the exhaust passage, and the thermoplastic resin sheet is applied to the coating layer. And a step of welding the thermoplastic resin sheet to the coating layer by heating the pattern sheet.   2. The method of manufacturing a metal decorative body according to claim 1, wherein in the step of manufacturing the pattern sheet, a number of minute irregularities are provided on the surface of the ink receiving layer.   3. The ink receiving layer is applied to the surface of a separator having a large number of minute irregularities, and then the separator is peeled to form a number of minute irregularities on the surface of the ink receiving layer. The manufacturing method of the metal ornament of description. Method for manufacturing a decorative metal body according to any one of claims 1 to 3, characterized in that the interposition of long fiber sheet made of long fibers between the elastic body and the pattern sheet. Applying an ink receiving layer to the surface of a separator having a large number of minute irregularities;
Adhering a thermoplastic resin sheet on the ink receiving layer via an adhesive layer;
Forming a large number of minute irregularities on the surface of the ink receiving layer by peeling the separator, and printing a colored pattern on the exposed surface of the ink receiving layer to form a pattern sheet;
Forming a paint layer with a resin paint on a metal substrate;
A step of stacking the pattern sheet on the substrate so that the thermoplastic resin sheet is bonded to the coating layer, and a step of welding the thermoplastic resin sheet to the coating layer by heating the pattern sheet. A method for producing a metal decorative body, comprising: A metal decorative body manufacturing apparatus for pressing a pattern sheet on which a colored pattern by a coloring material is formed to a metal substrate in a panel shape,
A vacuum evacuation table having a flat part on which a panel body in which the pattern sheet is superimposed on the base material is placed, a concave part provided in the flat part, and an exhaust passage for exhausting the inside of the concave part ,
A packing provided on the planar portion so as to surround the panel body and the concave portion placed on the planar portion,
A sheet-like elastic body having air permeability that covers the panel body placed on the plane portion;
A sheet-like cover that covers the elastic body and is in contact with the packing over the entire circumference and maintains airtightness with the flat surface portion, and a pressing frame that sandwiches the cover with the packing. An apparatus for producing a metal decorative body, comprising:   7. The apparatus for producing a metal decorative body according to claim 6, further comprising a long fiber sheet made of long fibers interposed between the elastic body and the panel body.

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