JP4165623B2 - Manufacturing method of decorative sheet - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention has a three-dimensional design of the weft, etc., relates to the production how cosmetic sheet used for interior materials of vehicles.
[0002]
[Prior art]
Conventionally, a decorative sheet of this type is known that is printed on a surface of a resin sheet material in a shape (positive shape) that matches a target three-dimensional design (thermosetting resin or ionizing radiation curable resin). However, (see Japanese Patent Laid-Open No. 6-31296), in the climax printing, the boundary line / boundary angle of the unevenness of the three-dimensional design is easy to be slightly rounded, and the aesthetic appearance of the target three-dimensional design can be faithfully reproduced. It was difficult.
[0003]
In addition, it is conceivable to form irregularities having a shape that matches the target three-dimensional design on the surface of the sheet material made of thermoplastic resin, and to apply ink or paint to the surface. Therefore, it is necessary to laminate a transparent film on the surface of the sheet material. And even if the uneven shape itself on the surface of the sheet material exactly matches the target three-dimensional design, a minute gap remains between the transparent film at the corners of the unevenness, etc., so that it closely adheres to the transparent film Due to the difference in the reflection of light between the portion and the portion where the gap remains, the corners of the unevenness are blurred. Furthermore, it is difficult to apply ink or paint to the uneven surface with a uniform thickness, and due to variations in the film thickness of the coating film, the shape of the coating film surface does not match the uneven surface shape of the sheet material. Therefore, it is difficult to faithfully reproduce the aesthetics of the target three-dimensional design even with this.
[0004]
[Problems to be solved by the invention]
In view of the above points, and an object of the present invention to provide a manufacturing how cosmetic sheet was adapted to faithfully reproduce the appearance of the three-dimensional design to target.
[0006]
In addition, the method for producing a decorative sheet according to the present invention includes pressing the shaping member formed with positive unevenness of a target three-dimensional design onto one side of a sheet material made of a transparent thermoplastic resin, A heating and forming step for forming negative irregularities on the irregularities of the shaping member, a cooling step for cooling the sheet material, and an ink or paint containing a glittering material on one side are applied to the outer surface of the irregularities. It is characterized by comprising a coating process for forming an intimate coating film and a drying process for drying the coating film. In this case, a step of heating and vacuum forming the sheet material into a predetermined shape may be provided as a subsequent step of the drying step. Further, a pinching roller comprising a pressing roller and a shaping roller which is a shaping member having a positive three-dimensional design with a target three-dimensional design formed on the peripheral surface is used, and the pinching roller is rotated while being heated. passing the sheet material by to perform the heating-shaping process.
[0007]
Furthermore , the first manufacturing method according to the present invention includes a step of heat-vacuum forming the decorative sheet using a vacuum forming die so that the surface opposite to the one surface is in close contact with one surface of the vacuum forming die. A step of setting the decorative sheet on an injection mold having a mold surface of the same shape as the vacuum mold so that the opposite surface is in close contact with the mold surface, and injecting a molten thermoplastic resin into the injection mold And the second manufacturing method uses an injection mold having a vacuum suction mechanism, and the surface opposite to the one side of the decorative sheet is the mold surface of the injection mold. It is characterized by comprising a step of heat-vacuum molding so as to be in close contact and a step of injecting a molten thermoplastic resin into an injection mold.
[0009]
By the way, when manufacturing the decorative sheet, if the heating and shaping step is performed using the pinching rollers, irregularities can be continuously formed on the long sheet material by the shaping roller, and the productivity is improved. On the other hand, if the decorative sheet is small, the shaped die used in the hot press machine can be manufactured in a shorter period of time and cheaper than the shaped roll. It is advantageous to use it because the production efficiency is good and the cooling process can be performed using a hot press machine, so that no space is required. In addition, since the shaping mold is formed by forming positive irregularities on a flat plate, it is easy to clearly form negative irregularities on the sheet material, and the quality is improved.
[0010]
Further, according to the first and second method for producing the decorative sheet according to the present invention described above, the skin made of the decorative sheet to the surface of the molded article substrate to be formed by injected resin to form surface of the irregularities on the back side As a result, a molded product that is laminated is obtained, and the target three-dimensional design emerges on the surface of the skin. Here, the first manufacturing method requires a vacuum mold and an injection mold, which is costly, and requires a transfer of the decorative sheet from the vacuum mold to the injection mold. However, according to the second manufacturing method, it is possible to continuously perform the molding of the decorative sheet and the injection molding of the molded product using only the injection mold, which is advantageous in improving productivity.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 (A) shows a decorative sheet 1, and FIG. 1 (B) shows a molded article in which the decorative sheet 1 is laminated as a skin on the surface of a molded article substrate 2 made of injection-molded thermoplastic resin. Yes.
[0012]
The decorative sheet 1 forms negative irregularities 11 and 12 having a target three-dimensional design on one side of a sheet material 10 made of a transparent thermoplastic resin such as acrylic, PP, PET, PVC, and the like. An ink or paint containing a material is applied to form a coating film 13 that is in close contact with the outer surfaces of the irregularities 11 and 12. As the glittering material, pearl pigments such as mica and metallic pigments such as aluminum pieces can be used, and acrylic and urethane materials can be used as inks and paints.
[0013]
When the decorative sheet 1 is viewed with the formation surface of the irregularities 11 and 12 as the back surface, the luminous material contained in the coating film 13 on the inner surface of the coating film 13 in which the light incident from the surface adheres to the outer surface of the irregularities 11 and 12 It is irregularly reflected, and the concave portion 11 and the convex portion 12 are formed as a convex portion and a concave portion on the surface of the decorative sheet 1, respectively, so that the beauty of the target three-dimensional design is faithfully reproduced.
[0014]
When the decorative sheet 1 is laminated on the surface of the molded article substrate 2 as a skin, the molded article substrate 2 is brought into close contact with the concave and convex surfaces 11 and 12 of the decorative sheet 1 on the back side, and the surface of the decorative sheet 1 So that the three-dimensional design emerges. In this case, in order to improve the adhesion between the coating film 13 and the molded article substrate 2, the outer surface of the coating film 13 is subjected to primer treatment, or the ink or paint for forming the coating film 13 is applied to the molded article substrate 2. In order to impart affinity with the thermoplastic resin, and to prevent cracking of the coating film 13 during vacuum forming described later on the decorative sheet 1, high elongation is imparted to the ink and paint.
[0015]
FIG. 2 shows an apparatus for manufacturing the decorative sheet 1. This manufacturing apparatus includes a sandwiching roller 102, a cooling section 103, a coating machine 104, and a drying furnace 105 in order from the upstream side in a sheet traveling path between a roll 100 for sheet material and a roll 101 for decorative sheet. And is arranged. The sandwiching roller 102 includes a pressing roller 102a and a shaping roller 102b in which positive and concave portions of a target three-dimensional design are formed on the peripheral surface. Then, the pinching roller 102 is rotated while being heated, and the sheet material 10 fed from the sheet material roll 100 is passed through the pinching roller 102. According to this, the negative irregularities 11, 12 of the irregularities on the peripheral surface of the roller 102b are formed by pressing the shaping roller 102b as a shaping member on one side of the sheet material 10.
[0016]
Next, after naturally cooling the sheet material 10 in the cooling section 103, the ink or paint is applied to the formation surface of the irregularities 11, 12 of the sheet material 10 by the coating machine 104, and then the sheet material 10 is placed in the drying furnace 105. The coating film 13 is dried by passing, and the decorative sheet 1 thus obtained is wound on a roll 101 for decorative sheets.
[0017]
The sheet material 10 may be cut to a required length at the downstream end of the cooling section 103 before the coating film 13 is formed and dried.
[0018]
Moreover, in the said embodiment, although the unevenness | corrugations 11 and 12 were formed using the pinching roller 102 on the single side | surface of the sheet | seat material 10, you may form the unevenness | corrugations 11 and 12 using the hot press machine 110 shown in FIG. In detail, the heat press machine 110 includes a pair of lower and upper mold holders 110a and 110b that heat and cool by flowing steam and cooling water therein, and the lower mold holder 110a. A state in which the shaping mold 110c made of a silicon material on which the positive and concave portions of the target three-dimensional design are formed is placed on the upper surface of the sheet via the surface plate 110d, and the sheet material 10 is set on the shaping mold 110c. The upper mold holder 110b is lowered while heating both mold holders 110a and 110b with steam of about 180 to 190 ° C., and the sheet is placed between the surface plate 110e attached to the lower surface of the mold holder 110b and the shaping mold 110c. The material 10 is clamped at a pressure of ² to 20 kg / cm ² for 3 to 5 minutes to form negative irregularities of the irregularities of the shaping mold 110c on the lower surface of the sheet material 10, and then both mold holders 110a and 110b. Cooling water 3 5 diverted after cooling the sheet material 10, take out the sheet material 10 by increasing the upper mold carrier 110b. The shaping mold 110c may be made of an epoxy resin, an etched iron plate, or an electroformed plate made of metal such as Ni, Cu, or Fe. When using an iron plate or an electroformed plate, the temperature of the heating steam is made slightly lower than the above value. The mold holders 110a and 110b can be heated by electric heating.
[0019]
By the way, when using the hot press machine 110, it is necessary to attach and detach the sheet material 10 previously cut to a required length to the one-sheet hot press machine 110, whereas when using the pinching roller 102, the sheet material is used. Concavities and convexities 11 and 12 can be continuously formed on the long sheet material 10 fed out from the roll 100, so that productivity can be improved. On the other hand, when the decorative sheet is small, the shaping mold 110c can be manufactured in a shorter period of time and at a lower cost than the shaping roller 102b. Manufacturing is advantageous in that the manufacturing efficiency is good and the cooling process can be performed by the hot press machine 110, so that no space is required. Further, since the shaping die 110c is formed with positive irregularities on a flat plate, the negative irregularities 11 and 12 are easily formed on the sheet material 10 and the quality is improved.
[0020]
The molded product shown in FIG. 1B is manufactured using an injection mold 200 shown in FIG. The injection mold 200 includes a female mold 200a having a vacuum suction mechanism and a male mold 200b, and can enter the mold opening space of both molds 200a and 200b when the male and female molds 200a and 200b are opened. A heating device 200c is provided.
[0021]
When manufacturing the molded product, the decorative sheet 1 pulled out from the decorative sheet roll 101 is set and clamped at the opening end of the female mold 200a so that the formation surface of the irregularities 11 and 12 faces the male mold 200b (FIG. 4). Next, the heating device 200c is entered into the mold opening space to heat the decorative sheet 1, and the vacuum suction mechanism of the female mold 200a is operated to remove the decorative sheet 1 from the concave and convex portions 11 and 12. Heat vacuum forming is performed so that the surface opposite to the formation surface is in close contact with the mold surface of the female mold 200a (state of FIG. 4B). Next, the heating device 200c is moved away from the mold opening space, the male and female molds 200a and 200b are clamped, and a thermoplastic resin such as ABS resin is injected into the molding space between the molds 200a and 200b from the male mold 200b side. Then, the molded article substrate 2 is injection-molded so as to be in close contact with the formation surfaces of the irregularities 11 and 12 of the decorative sheet 1 via the coating film 13 (state of FIG. 4C). Next, while cutting the part by the side of the roll 101 of the decorative sheet 1, both the male and female molds 200a and 200b are opened, and the molded product is taken out (state shown in FIG. 4D).
[0022]
It is possible to heat-mold the decorative sheet 1 using a vacuum mold and then set the decorative sheet 1 to the injection mold and perform injection molding. If the molding of the sheet 1 and the injection molding of the molded article base material 2 are performed, the vacuum mold is not required and the transfer of the decorative sheet 1 is not required, so that the productivity can be improved.
[0023]
【Example】
The sheet material 10 is formed using a roller 102 with negative-shaped irregularities 11 and 12 of a carbon cloth cloth as a target three-dimensional design formed on one side of a sheet material 10 made of transparent acrylic resin having a thickness of 0.2 mm. After natural cooling, a coating material mainly composed of a polycarbonate non-yellowing polyurethane containing 5.2% of carbon black as a pigment and mica as a glittering material on the surface on which the irregularities 11 and 12 of the sheet material 10 are formed, and a composition Was coated with a 1: 2 mixture of 25% MEK, 30% n-butyl acetate, 20% DMF, 10% MIBK, and 15% cellosolve acetate to form a coating film 13, which was then dried in a drying oven 105. For 5 minutes at 80 ° C. When the decorative sheet 1 produced in this way was viewed with the surface on which the irregularities 11 and 12 were formed as the back side, as shown in FIG. 5 (A), an aesthetic feeling very close to that of a real carbon cloth was obtained.
[0024]
Further, as a comparative example, a positive shape unevenness of a carbon cloth cloth is formed on the surface of a molded product base made of a thermoplastic resin, and a paint having the same composition as above is applied to the surface where the unevenness is formed. Was formed, and a molded product was produced by laminating a transparent acrylic resin 0.2 mm thick film thereon. When this comparative product was viewed with the film surface as the surface, it was totally blurred as shown in FIG.
[0025]
【The invention's effect】
As is clear from the above description, according to the method for manufacturing a decorative sheet of the present invention, the aesthetics of a target three-dimensional design can be faithfully reproduced.
[Brief description of the drawings]
1A is a schematic cross-sectional view of a decorative sheet of the present invention, and FIG. 1B is a schematic cross-sectional view of a molded product having the decorative sheet of the present invention as a skin. FIG. FIG. 3 is a view showing a heat press for forming irregularities. FIG. 4 is a view showing a manufacturing process of a molded product. FIG. 5 is a view of the decorative sheet of the present invention imitating a carbon cloth from the surface. ) View of the comparison product from the surface [Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Decorative sheet 10 Sheet material 11 Concave part 12 Convex part 13 Coating film 2 Molded article base material 102 Pinch roller 102a Pressing roller 102b Forming roller 110 Hot press machine 110c Forming mold 200 Injection mold

Claims (4)

A method for producing a decorative sheet having a three-dimensional design,
By pressing a shaping member formed with positive irregularities of a target three-dimensional design onto one side of a sheet material made of a transparent thermoplastic resin, the negative irregularities of the irregularities of the shaping member are pressed on the one side. Forming with heating,
A cooling process for cooling the sheet material;
Applying an ink or paint containing a glittering material on one side and forming a coating film that adheres to the outer surface of the irregularities;
A drying process for drying the coating film;
Equipped with a,
The heating shaping step uses a pinching roller consisting of a pressing roller and a shaping roller that is a shaping member having a positive three-dimensional design with a target three-dimensional design on the peripheral surface, and rotates while heating the pinching roller. Let the sheet material pass through the pinching rollers,
The heating-shaping step, the cooling step, the coating step and the drying step, the decorative sheet manufacturing method of according to claim Rukoto performed during winding the sheet fed from the feeding roll at the take-up roll. Wherein as a step after the drying step, the decorative sheet manufacturing method according to claim 1, characterized in that it comprises a heating vacuum forming step of heating vacuum forming the sheet material into a predetermined shape. A decorative sheet manufacturing method according to claim 2,
The heating vacuum forming process, using a vacuum forming mold, the surface opposite the heated vacuum forming so as to be in close contact with the mold surface of the vacuum mold and the decorative sheet said one side,
After the heating vacuum forming step, the step of setting the molded decorative sheet to an injection mold having a mold surface of the same shape as the vacuum mold so that the opposite surface is in close contact with the mold surface;
Injecting molten thermoplastic resin into an injection mold;
Method for producing a decorative sheet, characterized in that it comprises a. A decorative sheet manufacturing method according to claim 2,
The heating vacuum forming process, using an injection mold comprising a vacuum suction mechanism, the opposite surface heating vacuum forming so as to be in close contact with mold surface of the injection mold and the decorative sheet said one side,
After the heating vacuum forming process, as engineering injecting molten thermoplastic resin into the injection mold,
Method for producing a decorative sheet, characterized in that it comprises a.

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