JP4456130B2 - Manufacturing method of decorative resin molded products - Google Patents

Description

  The present invention relates to a method for manufacturing a decorative resin molded product, a decorative resin molded product, and a mold for molding a decorative resin molded product, and in particular, a decorative material that has been decorated to express a wood texture more realistically. The present invention relates to a method for producing a resin molded product, such a decorated resin molded product, and a mold for molding a decorated resin molded product that is advantageously used for molding the resin molded product.

  Traditionally, decorative resin molded products that have been decorated to simulate the texture of wood have been widely used as surface materials for various products and articles such as automotive interior parts, furniture, building materials, and home appliances. (For example, refer to Patent Document 1 below). This is because by using this decorative resin molded product, the texture and luxury of wood can be obtained easily and at low cost.

  Such a decorative resin molded product can be obtained by, for example, printing a wood grain pattern or the like on the surface of the resin molded product, or imitating a fine groove-shaped recess existing on the surface of the present wood. By forming a so-called wood grain texture on the surface of the resin molded product, the predetermined resin molded product is decorated to express the texture of the wood with the appearance and feel It is manufactured.

  By the way, in the case of manufacturing a decorative resin molded product having a decoration that expresses a wood texture by forming a grain-like texture on the surface of such a decorative resin molded product, etching is generally performed on the cavity surface. A mold for processing is used (see, for example, Patent Documents 1 and 2 below). That is, for example, first, based on the shape of the fine groove-shaped recess on the surface of the wood such as a veneer, masking is performed on the cavity surface of the molding cavity that gives the target decorative resin molded product, By performing the etching process, a molding die having a large number of fine protrusions on the cavity surface is formed. Then, after this molding die is used, for example, by molding a mold such as injection molding, a large number of grain-like textures consisting of concave portions corresponding to fine convex portions provided on the cavity surface are formed on the surface. The target decorative resin molded product thus formed is obtained. According to such a manufacturing method, there is an advantage that a desired decoration is applied to the surface simultaneously with the molding of the target resin molded product.

  However, in such a conventional method for producing a decorative resin molded product, since the fine convex portions of the cavity surface of the molding cavity are formed by etching, all of the many convex portions are constant. For this reason, all the grain-like textures formed on the surface in a shape corresponding to each convex portion are inevitably at a certain depth simultaneously with the molding of the resin molded product. On the other hand, many fine groove-like recesses existing on the surface of the present wood (natural wood) have different depths between different groove-like recesses, or shallow portions of one groove-like recess. It has various depths, such as a deep part. Therefore, it has been unavoidable that the decorative resin molded product produced with a grain-like texture on the surface by a conventional method is not realistic.

  In addition, according to the conventional method, the cavity surface is masked and etched based on the shape of the groove-like recesses on the surface of the wood, so that many fine groove-like recesses existing on the surface of the wood are formed. The opening shape and cross-sectional shape tend to be a monotonous shape that is slightly different from the actual complex shape, which is also unnatural because the surface of the decorative resin molded product obtained by the conventional method is different from that of a natural object. It was the cause of things.

Japanese Patent Laid-Open No. 9-240386 JP-A-9-155971 Japanese Patent Laid-Open No. 9-202979

  Here, the present invention has been made in the background as described above, and the problem to be solved is an advantageous production of a decorative resin molded product in which the wood texture is expressed more realistically. It is an object to provide a method, a decorative resin molded product having a more realistic wood texture, and a mold for molding a decorative resin molded product that is advantageously used in manufacturing such a decorative resin molded product.

And, in the present invention, in order to solve the problems relating to the method for producing a decorative resin molded product, the gist of the present invention is that it has the same shape as the fine groove-like recesses present on the surface of the wood. A method for producing a decorative resin molded product that is decorated to express a wood texture by forming a recess on the surface, wherein (a) plasticizing at a temperature lower than the combustion temperature of the wood By molding the fine groove-shaped recess from the surface of the main wood using a resin material, the fine groove-shaped recess is transferred to form a first protrusion corresponding to the groove-shaped recess. Forming a first mold-molding body having a first mold-carrying surface; and (b) using a predetermined ceramic material, the first projection from the first mold-carrying surface of the first mold-molding body. The first convex portion is transferred by molding the portion, and the front corresponding to the first convex portion is transferred. Forming a second mold-molding body having a second mold-carrying surface in which a groove-shaped recess having the same shape as the fine groove-shaped recess on the surface of the book wood is formed, and (c) a predetermined ceramic Using the material, the groove-shaped recess is transferred from the second mold-taking surface of the second mold-molding body so that the groove-shaped recess is transferred to the second protrusion corresponding to the groove-shaped recess. A step of forming a third mold-molding body having a third mold-carrying surface on which a portion is formed; and (d) the formed third mold-molding body on the side opposite to the third mold-carrying surface. On the surface, by sticking to the cavity surface of the molding cavity of the molding die, a convex portion corresponding to the fine groove-shaped concave portion of the surface of the main wood is formed in the molding cavity by the second convex portion. forming, (e) a predetermined molten resin material the molding mold in forming the shape in the cavity Filled with, by solidifying, the recess corresponding to the second protrusion of the third type cavity molding body fixed to key Yabiti surface of the shaped cavity, with the fine recessed grooves similar shape And a step of forming a resin molded product that is formed on the surface and is decorated to express the wood texture.

  Moreover, according to one of the preferable aspects of the manufacturing method of the decorated resin molded product according to this invention, the said timber is comprised with a veneer.

Furthermore, according to one of the desirable embodiments of the method for producing a decorative resin molded product according to the present invention, the thin skin material provided with a design surface having a wood grain pattern in the molding cavity of the molding die, housed in a state in which the design surface contact to the third type up surface of the fixed to the key Yabiti surface of the shaped cavities third type cavity molding body were opposed, after placement, in molding cavities, said melting the resin material injection, is filled by the injection pressure of the molten resin material, the entire said surface skin material be to close the third type up surface of the third type cavity molding body, of said surface skin material該意Takumi the surface, thereby forming a recess corresponding to said second protrusion of said third type up surface, and solidifying the molten resin material, by fixing the said surface skin material to the surface, to the second protrusion The corresponding recess has a shape similar to that of the fine groove recess on the surface. Has been configured to mold the resin molded article decorated to represent has been performed the wood texture.

  As described above, when a convex portion is formed on a thin skin material, and this skin material is fixed to the surface of the resin molded body, the desired decorative resin molded product is manufactured. As the material, a resin film having a wood grain pattern printed on a design surface or a thin main tree sheet is advantageously used.

  According to another preferred embodiment of the method for producing a decorated resin molded product according to the present invention, after molding the resin molded product that has been decorated to express the wood texture, A step of forming a transparent coating film on the surface on which the concave portion is formed is further performed.

  Furthermore, when the process of forming such a transparent coating film is implemented, for example, such a transparent coating film is formed using a transparent matte paint.

  That is, in the method for producing a decorative resin molded product according to the present invention, when forming a desired decorative resin molded product, a molding in which a convex portion obtained by transferring a fine groove-shaped concave portion on the surface of the wood is provided on the cavity surface. Since a molding die having a cavity is used, the surface of a resin molded product molded in the molding cavity is different from each other, or a single one, like the groove-shaped recess on the surface of the wood. In this case, groove-shaped recesses having various depths and various complicated opening shapes and cross-sectional shapes are formed.

  Therefore, according to such a method for producing a decorated resin molded product according to the present invention, a decorated resin molded product having a more realistic wood texture, which cannot be obtained by any conventional production method, is extremely advantageously produced. To get.

  Further, in the decorative resin molded product according to the present invention, it is obtained by using a molding die used in the manufacturing method exhibiting the above excellent characteristics, or a large number of fine surfaces on the surface of the wood. Since many concave portions having the same shape as the groove-shaped concave portions are formed on the surface including those having different depths, the wood texture can be expressed more realistically, and the texture of the wood A high-class feeling can be obtained even more advantageously.

  Furthermore, even in the mold for the decorative resin molded product according to the present invention, the convex portion formed by transferring the fine groove-shaped concave portion on the surface of the wood is provided on the cavity surface, or The texture of the wood is expressed more realistically because the convex portions of the shape corresponding to the fine groove-shaped concave portions on the surface of the present wood are provided on the cavity surface, including those having different heights. The decorative resin molded product can be obtained very advantageously.

  Hereinafter, in order to clarify the present invention more specifically, an embodiment of the present invention will be described in detail with reference to the drawings.

  First, in FIGS. 1 and 2, as an example of a decorative resin molded product manufactured according to the method of the present invention, a cover panel (cover) of a storage box, which is a kind of interior parts for automobiles, has a perspective form and a longitudinal section. Each of the forms is schematically shown. As is clear from these drawings, the cover panel 10 has a base material 12 constituting the back side portion thereof and a skin material 14 constituting the surface side portion, and these are integrally laminated. It is configured as a laminated product.

  The base material 12 has a rectangular housing shape having a predetermined thickness as a whole, and is a thermoplastic resin material (for example, ABS resin or the like) that is generally used as a material for forming automobile interior parts. ).

  On the other hand, the skin material 14 as a whole has a resin film 16 having a rectangular housing shape that is slightly larger than the base material 12 and a wood grain pattern printed and formed on the entire surface of the resin film 16 by a known printing method. It is comprised as a laminated body which consists of the printing layer 18 which has. The resin film 16 is made of a thermoplastic resin material having a higher melting point and transparency than the resin material constituting the substrate 12 (for example, an acrylic resin or the like when the substrate 12 is made of ABS resin). Used to form.

  In particular, as shown in FIGS. 2 and 3, a large number of wood grain textures 22 are formed on the surface of the skin material 14. Apart from the wood grain pattern given to the skin material 14 by the printed layer 20 of the resin film 16, these many wood grain textures 22 are composed of fine groove-like recesses extending with various lengths. And, in such wood grain texture 22, in particular, the cross-sectional shape is various shapes such as a triangular shape, a U shape, a trapezoidal shape, or an indeterminate shape, and the opening shape is also Different wood grain textures 22 have relatively complicated shapes that are different from each other. Further, the depth of the grain-like grain 22 is also different in depth between different ones. Further, although not shown in the drawing, even in one wood grain grain 22, there are a shallow portion and a deep portion.

Thus, in the cover panel 10 of the present embodiment, the veneer made of the present wood (natural wood) in addition to the wood pattern being given to the skin material 14 by the printed layer 18 of the resin film 16. Similar to the fine groove-like recesses existing on the surface, the grain-like grain 22 composed of groove-like recesses having various lengths and depths and various complicated opening shapes and cross-sectional shapes is provided on the surface of the skin material 14. Are formed in large numbers. As a result, the surface of the cover panel 10 is decorated so that the wood texture can be expressed more realistically.

  Further, in the cover panel 10, the clear coating is applied to the entire surface of the skin material 14 on which a large number of wood grain marks 22 are formed, that is, the entire surface of the skin material 14 opposite to the resin film 16 side of the printing layer 18. A film 20 is further laminated. The clear coating film 20 is formed to have a smooth surface by covering the entire surface of the skin material 14 by applying a known transparent matte paint by a known method. As a result, the tactile sensation on the surface of the cover panel 10 can be regarded as a soft feeling of wood, not a hard feeling of resin, and the weather resistance and impact resistance of the surface of the cover panel 10 are enhanced, and this is applied. It is difficult for the surface of the cover panel 10 to be wrinkled. For example, by making the thickness of the clear coating film 20 thinner, the surface of the clear coating film 20 may be provided with fine groove-shaped recesses corresponding to the many grain-like textures 22. I can do it. As a result, a tactile sensation closer to that of Motoki can be obtained.

  By the way, when manufacturing the cover panel 10 having such a structure, for example, first, a molding die having a molding cavity corresponding to the outer shape of the target cover panel 10 is formed, and then this formation is performed. The cover panel 10 is molded in the molding cavity of the molded mold.

  More specifically, when forming a molding die having a molding cavity corresponding to the outer shape of the cover panel 10, first, as shown in FIG. 4, various depths and various complex opening shapes and cross-sectional shapes are used. A veneer 26 made of the present wood having a large number of fine groove-like recesses 24 having a surface is prepared. As this veneer board 26, what has the same grain pattern as the grain pattern of the printing layer 18 printed and formed on the surface of the resin film 16 of the skin material 14, for example is used suitably. In other words, the veneer plate 26 from which image data for forming a printing plate used for forming the printing layer 18 is collected is preferably used here.

  Then, based on the prepared veneer 26, the first, second, and third mold forming steps as shown in FIGS. 5 to 7 are sequentially performed, and a large number of surfaces of the veneer 26 are obtained. A mold-molding body (third mold-molding body 40 to be described later) provided with a convex part (second convex part 44 to be described later) corresponding to the groove-shaped recess 24 is formed.

  That is, in the first mold making process, as shown in FIG. 5, a number of fine groove-like recesses 24 are made of a predetermined resin material from the surface using the prepared veneer plate 26. A plurality of first convex portions 32 corresponding to a large number of groove-shaped concave portions 24 are formed on the first mold-taking surface 30 of the mold-molding body 28.

  In addition, although the specific operation which should be implemented is not specifically limited, for example, the first molding process is performed according to the following procedure. That is, first, in the molding cavity of the molding die composed of the upper and lower molds, the thrust plate 26 has the surface opposite to the surface on which many fine groove-shaped recesses 24 exist as the cavity surface of the lower mold. It is accommodated and placed in a state of contact. Next, in the molding cavity in which the veneer 26 is accommodated, a predetermined resin material that gives the first mold-molding molded body 28 is in a molten or plasticized state, and there are many fine groove-like recesses 24 of the veneer 26. It fills so that it may touch on the surface to do. Then, if necessary, the resin material in the molding cavity is solidified or cured in a state where the resin material is pressed by the upper mold to form a resin molded body. Thereafter, after the resin molded body and the veneer 26 are released from the molding die, the veneer 26 is peeled off from the resin molded body.

  Thus, in this step, the first mold-molding molded body 28 is formed from the resin molded body molded as described above, and at the same time, it is composed of a contact surface with the veneer plate 26 in the molding cavity. A large number of fine groove-like recesses 24 on the surface of the veneer 26 are transferred to the first mold-carrying surface 30, and a large number of first protrusions 32 corresponding to the many groove-like recesses 24 are formed.

  In this step, as the resin material for forming the first mold-molded molded body 28, a material that is melted or plasticized at a temperature lower than the combustion temperature of the veneer 26 is preferably used. Among such resin materials, those having a suitable rubber-like elasticity in a cured state, such as silicon resin, are more preferably used. When the former resin material is used, when the resin material comes into contact with the veneer plate 26 in a molten or plasticized state, the veneer plate 26 does not burn, and the surface of the veneer plate 26 is molded. It can be done reliably. Further, when the latter resin material is used, even if the inner surface shape of the groove-like recess 24 of the thrust plate 26 is an undercut shape, the first projecting portion 32 is elastically deformed, so that the thrust plate 26 is Thus, the mold can be reliably released from the first mold-molding body 28. Further, in this step, a known release agent is applied to the surface of the veneer plate 26 as required before the molding resin in which the veneer plate 26 is accommodated is filled with a predetermined resin material. As a result, a release agent layer is formed. As a result, the releasability of the first mold-molding body 28 from the veneer 26 is improved.

  Next, in the second mold taking step, as shown in FIG. 6, a number of first molds are formed from the first mold taking surface 30 using the first mold-formed molded body 28 formed as described above. The convex portion 32 is molded on the second mold-taking surface 36 of the second mold-molding molded body 34 made of a predetermined ceramic material (for example, alumina or the like). A large number of groove-like recesses 38 corresponding to the protrusions 32 are formed.

  The specific operation of the second mold forming step performed here is not particularly limited, for example, a type of ceramic material molding method using the first mold molding 28 and a predetermined ceramic material. The operation is advanced by performing a known die press molding.

  That is, first, for example, in the molding cavity of a molding die composed of an upper mold and a lower mold, the first mold-forming molded body 28 has a surface opposite to the first mold-carrying surface 30 on the surface of the lower mold cavity. It is accommodated and placed in a state where it is in contact with. Next, the predetermined ceramic material that provides the second mold-molding body 34 is, for example, in a dry powder state, and the first mold-taking surface 30 and the upper mold of the first mold-molding body 28 in the molding cavity of the molding die. After filling in the gap between the cavity surface of the first mold and the lower mold, compression molding is performed between the upper mold and the lower mold, and the contact surface with the first mold surface 30 of the first mold-molding body 28 is formed. An intermediate molded body in which a large number of concave portions corresponding to the large number of first convex portions is formed. Thereafter, the intermediate molded body and the first mold-molded molded body 28 are released from the molding die and the first mold-molded molded body 28 is peeled from the intermediate molded body, and then the intermediate molded body is fired. As a result, a sintered body is obtained.

  Thus, in this step, the second mold-molded molded body 34 is formed from the sintered body obtained as described above, and from the contact surface with the first mold-carrying surface 30 in the molding cavity. A large number of first convex portions 32 of the first mold taking surface 30 are transferred to the second mold taking surface 36 to correspond to the first convex portions 32 and a large number of groove-like concave portions on the surface of the abutting plate 26. Thus, a large number of groove-like recesses 38 having the same shape as 24 are formed. Also in this step, the first mold of the first mold-molded body 28 is optionally filled before the predetermined ceramic material is filled into the molding cavity in which the first mold-molded molded body 28 is accommodated. A release agent layer is formed on the mold surface 30 by, for example, applying a known release agent. Thus, the releasability of the intermediate molded body that gives the second mold-molded molded body 34 from the first mold-molded molded body 28 is enhanced.

  Subsequently, in the third mold taking step, as shown in FIG. 7, a number of grooves are formed from the second mold taking surface 36 using the second mold taking formed body 34 formed in the second mold taking step. A recess 38 is formed on the third mold-taking surface 42 of the third mold-molding body 40 made of a predetermined ceramic material (for example, alumina or the like). Many second convex portions 44 corresponding to the concave portions 38 are formed.

  The specific operation of the third mold taking step is not particularly limited. For example, the second mold is used except that the second mold taking molded body 34 is used instead of the first mold taking molded body 28. The same operation as that performed in the taking process is performed. That is, the third mold-molding body is a sintered body of an intermediate molded body obtained by performing a known mold press molding similar to the above using the second mold-molding body 34 and a predetermined ceramic material. A molded body 40 is formed, and a number of groove-like recesses 38 on the second mold-carrying surface 36 are transferred to a third mold-carrying surface 42 that is a contact surface with the second mold-carrying surface 36 in the molding cavity. Thus, a large number of second convex portions 44 corresponding to the groove-shaped concave portions 38 and also corresponding to the many groove-shaped concave portions 24 on the surface of the thrust plate 26 are formed. Here, the third mold-molding body 40 is formed with a relatively thin plate-like form. Also in this step, prior to filling the molding cavity in which the second mold-molded molded body 34 is accommodated with a predetermined ceramic material, the second mold-molded molded body 34 of the second mold-molded molded body 34 is optionally set. A release agent layer is formed on the mold surface 36 by applying a known release agent. As a result, the releasability of the intermediate molded body giving the third molded body 40 from the second molded body 34 is enhanced.

In addition, as shown in FIG. 8, the upper mold 46 as the first mold having the rectangular cavity forming concave portion 45 and the operation for forming the third mold-molding body 40 are performed. under both the and a lower die 48 as a second mold, in the mold mating state of a mutual and their upper mold 46 and lower mold 48, a cavity forming recesses 45 of the upper die 46, which faces the bottom surface thereof A molding die 52 in which a rectangular molding cavity 50 is formed is prepared by covering with a facing surface (lower mold side cavity surface 56) of the mold 48.

  As shown in FIG. 9, the third mold-molding body 40 formed as described above constitutes a part of the upper mold side cavity surface 54 in the upper mold 46 of the prepared mold 52. The cavity forming recess 45 is fixed to the entire bottom surface by being bonded via an adhesive layer 58 on the surface opposite to the third mold-carrying surface 42.

  As a result, the second protrusions corresponding to the numerous fine groove-like recesses 24 on the surface of the veneer 26 are formed on the entire surface of the upper mold-side cavity surface 54 formed by the bottom surface of the cavity-forming recess 45 facing the lower mold-side cavity surface 56. A molding die in which a large number of portions 44 are formed, and thus a molding cavity 50 having an inner surface shape corresponding to the outer shape of the cover panel 10 is formed between the upper die 46 and the lower die 48 that are matched with each other. 52 is made.

  In this embodiment, such a molding die 52 is used as an injection molding die, and the target cover panel 10 is injection-molded. First, as shown in FIG. In addition, a rectangular casing-shaped skin material 14 (a laminate of the resin film 16 and the printing layer 18) in the cover panel 10 is set in the cavity forming recess 45 of the upper mold 46 of the mold 52 that has been opened. The At this time, in the skin material 14, the rectangular housing-shaped top plate portion of the surface on the printed layer 18 side is fixed to the bottom surface of the cavity forming recess 45 (a part of the upper mold side cavity surface 54). It arrange | positions facing the 3rd shaping | molding surface 42 of the shaping body 40. FIG.

  Note that the rectangular casing-shaped skin material 14 used here is, for example, pressure-molded with respect to a thin rectangular plate-shaped raw material film made of a thermoplastic resin material (here, acrylic resin) on which the resin film 16 gives it. Or by performing vacuum molding or the like, or by performing stamping molding or the like using such a thermoplastic resin material, after being molded in advance so as to exhibit a rectangular housing shape, on the entire surface of the resin film 16, The printed layer 18 having a wood grain pattern can be easily obtained by being printed by, for example, a screen printing method or the like.

  Thereafter, as shown in FIG. 11, the upper die 46 and the lower die 48 are closed to form a molding cavity 50 therebetween, and the skin material 14 is placed in the molding cavity 50. The back surface (the surface opposite to the printing layer 18) is opposed to the lower mold side cavity surface 56, and is housed and arranged in a state of being exposed in the molding cavity 50. At this time, in the skin material 14, the side surface portion (surface on the printing layer 18 side) of the side wall portion of the rectangular housing shape is the side surface (upper die side) of the cavity forming recess 45 of the upper die 46 over the entire circumference. A part of the cavity surface 54 is disposed in contact with the cavity surface 54. As a result, as will be described later, when the resin material is injected into the molding cavity 50, the resin material can be prevented from wrapping around the surface of the skin material 14.

  When the skin material 14 is accommodated in the molding cavity 50, so-called film-in-mold molding is performed. That is, as shown in FIG. 12, a molten resin having a lower melting point than that of the resin film 16 of the skin material 14, for example, a thermoplastic resin (here, ABS resin is used) is used as a nozzle of an injection molding machine (not shown). Is injected into the molding cavity 50 with a predetermined injection pressure from the lower mold side cavity surface 56 in the molding cavity 50 and filled between the back surface of the skin material 14 accommodated in the molding cavity 50 and solidified. The resin molded product 60 is molded by caulking.

  In the molding process of the resin molded product 60, the resin film 16 of the skin material 14 is heated and softened by contact with a high-temperature molten resin, and under such a softened state of the resin film 16. A pressing force based on the injection pressure of the molten resin is applied to the back surface of the skin material 14 so that the skin material 14 is fixed to the bottom surface of the cavity forming recess 45 on the upper side 46. Is pressed substantially evenly toward the third mold-taking surface 42 side. As a result, the skin material 14 is plastically deformed, and a large number of second protrusions 44 provided on the third mold-carrying surface 42 are transferred to the surface of the skin material 14 on the printed layer 18 side. A large number of wood grain marks 22 corresponding to the two convex portions 44 are formed.

  And, such a large number of grain-like textures 22 each have a shape corresponding to the second convex portion 44, so that the cross-sectional shape is similar to the fine groove-shaped concave portion 24 existing on the surface of the veneer 26. However, it has various shapes such as a triangular shape, a U-shape, a trapezoidal shape, and an indeterminate shape, and the shape of the opening portion is different from each other between the different grained grain marks 22 and is relatively complicated. It is a simple shape. Further, the depth of the grain-like grain 22 is also different in depth between different ones. Further, although not shown in the drawing, even in one wood grain grain 22, there are a shallow portion and a deep portion.

  Thus, a large number of grain-like textures 22 having the same shape as the numerous fine groove-like recesses 24 existing on the surface of the veneer 26 are formed on the surface, so that the resin molded product 60 is decorated to express the wood texture. Is molded in the mold 52 (molding cavity 50). Thereafter, as shown in FIG. 13, the resin molded product 60 is released from the molding die 52. Subsequently, although not shown, after removing burrs and the like, a transparent matte paint is applied to the entire surface of the resin molded product 60 to form the clear coating film 20. The Thus, the target cover panel 10 having the structure shown in FIGS. 1 to 3 is obtained. Also in this step, the third mold of the third mold body 40 fixed to the upper mold 46 of the molding die 52 prior to the injection of the molten resin 54 into the molding cavity 50 of the molding die 52. A release agent layer is formed on the surface 42 by applying a known release agent. Thereby, the releasability from the molding die 52 of the resin molded product 60 is improved.

  Thus, in the present embodiment, the cover panel 10 having a large number of grain-like textures 22 formed on the surface can be manufactured relatively easily by injection molding. Similar to the groove-like recesses 24 on the surface of the veneer 26, different depths or even a single one has various depths and various complicated opening shapes and cross-sectional shapes.

  Therefore, according to the present embodiment as described above, the cover panel 10 can be manufactured very advantageously with a more realistic wood texture that cannot be obtained in the past. The cover panel 10 thus obtained can be widely applied to uses and the like that have been difficult to use in the past due to lack of luxury, for example.

  In the present embodiment, when the cover panel 10 is molded, the second convex portion 44 that forms the wood grain texture 22 on the surface thereof uses the veneer plate 26 and the fine groove-shaped concave portion 24 that exists on the surface thereof. Because the cover panel 10 has a shape that has been transferred a plurality of times, it gives the cover panel 10 a real feeling as if it were formed using the actual veneer 26. I can do it.

  Further, in the present embodiment, the cover panel 10 is formed by film-in-mold molding using injection molding, and the cover material 14 (a laminate of the resin film 16 and the print layer 18) and the base material on which a wood grain pattern is printed. Since it is formed as an integrally laminated product with the material 12, the cover panel 10 in which the realism of the wood texture is further advantageously enhanced by the wood grain pattern can be manufactured more easily and efficiently. .

  Furthermore, in this embodiment, the first mold-molded molded body 28 having the first convex portion 32 to which the groove-like concave portion 24 on the surface of the veneer 26 is transferred is plasticized at a temperature lower than the combustion temperature of the veneer 26. After forming with the resin material to be formed, a second mold-molded molded body 34 having a groove-shaped recess 38 to which the first convex section 32 of the first mold-molded molded body 28 is transferred is formed with a ceramic material, Further, a third mold-molded molded body 40 having a second convex portion 44 to which the groove-shaped concave portion 38 of the second mold-molded molded body is transferred is formed of a ceramic material, and a predetermined mold 52 is formed. By fixing to the mold side cavity surface 54, a molding die 52 used for molding the target cover panel 10 is formed. Therefore, the second convex portion 44 is formed on the surface of the cover panel 10 to give the wood grain texture 22 on the surface of the cover panel 10 without burning the thrust plate 26, and thereby the wood grain texture 22. This shape can be exactly matched with the groove-like recess 24 on the surface of the veneer 26. Moreover, since the 2nd convex part 44 is comprised with a ceramic material, the 2nd convex part 44 is made to deform | transform by the flow pressure (here injection pressure) of a resin material at the time of shaping | molding of the cover panel 10, for example. This is advantageously avoided, and this also makes it possible for the shape of the grain-like grain 22 to exactly match the shape of the groove-like recess 24 on the surface of the veneer 26.

  The specific configuration of the present invention has been described in detail above. However, this is merely an example, and the present invention is not limited by the above description.

  For example, in the embodiment, the skin material 14 having a wood grain pattern is integrally laminated on the surface of the base material 12, and a large number of wood grain textures 22 are formed on the surface of the skin material 14. Such a skin material 14 may be omitted, and a number of wood grain textures 22 may be formed directly on the surface of the substrate 12.

  Further, even when the skin material 14 is integrally laminated on the surface of the substrate 12, the material and structure of the skin material 14 are not limited to those illustrated. Therefore, for example, as the skin material 14, a thin-film mainwood sheet can be used. This makes it possible to give a more realistic wood texture to the cover panel 10 that is a decorative resin molded product.

  Further, as the skin material 14, only the base material 12 made of a single-layer or multiple-layer laminate, or the surface of the base material 12 on which the print layer 18 is printed in a plurality of layers, etc. Can also be used as appropriate.

  Of course, the types, shapes, thicknesses, and the like of the constituent materials of the resin film 16 and the base material 12 that give the skin material 14 are not particularly limited to those illustrated.

  Furthermore, there is no problem even if the clear coating film 20 formed on the surface of the cover panel 10 as a decorative resin molded product is omitted. Even when the clear coating film 20 is formed, the clear coating film 20 can be formed using a general transparent paint that is not matt. Thereby, a high-class feeling that the surface is mirror-finished can be effectively imparted to the cover panel 10.

  Furthermore, as the molding method of the base material 12, a known mold molding method other than the exemplified injection molding method is appropriately employed.

  In the above embodiment, the veneer 26 is used as the material to be transferred of the fine groove-shaped recess 24. However, various kinds of wood other than the veneer 26 can be used as the material to be transferred. is there.

  Further, the method of transferring the groove-like recess 24 of the veneer 26 to the first mold-carrying surface 30 of the resin-made first mold-molding body 28 is a molding of various known resin molded products other than the exemplified method The method is used as appropriate. In addition, a method of transferring the first convex portion 32 of the first mold molding 28 to the second mold surface 36 of the ceramic second mold molding 34, As a method of transferring the groove-shaped concave portion 38 to the third mold-carrying surface 42 of the ceramic third mold-molded molded body 40, various known molding methods of ceramic molded products other than the exemplified methods can be appropriately used. Is done.

  Furthermore, methods other than the exemplified methods can be appropriately employed when forming the molding die 52 used for molding the cover panel 10 which is a target decorative resin molded product.

  For example, from a surface of the wood using a molding material that is plasticized at a temperature lower than the combustion temperature of the wood and does not re-plasticize by contact with the molten resin material after curing from the plasticized state. By molding the fine groove-shaped concave portion, the fine groove-shaped concave portion is transferred to form a mold-molding body having a mold-forming surface on which a convex portion corresponding to the groove-shaped concave portion is formed. Then, using this mold-molding molded body as the first mold, a second mold that forms a molding cavity with the mold-carrying surface as a part of the cavity surface is formed between the first mold and the first mold. A mold for molding can be formed by combining with a mold. As a result, the target mold can be formed more easily and at a lower cost. For example, a thermosetting resin material, a ceramic material, or the like is appropriately used as a material for providing a molding die formed by such a method.

  In addition, the mold-molded product obtained in the same manner as described above is fixed to the cavity surface of the molding cavity of a predetermined molding die, so that the projection corresponding to the fine groove-shaped recess on the surface of the wood is formed on the cavity surface. It is also possible to form a target mold by forming the portion. As a result, compared to the case where the convex portion corresponding to the fine groove-shaped concave portion on the surface of the wood is formed directly on the cavity surface of the molding die, the convex portion is formed directly on the cavity surface of the large molding die. Therefore, it can be carried out more easily and with excellent workability.

  Further, the fixing part of the third die-molding body 40 to the molding die 52 is not particularly limited to the illustrated one, and the decorative resin molded product (cover panel 10) has the skin material 14 In the molding of the base material 12, the third die-molding molded body 40 is fixed to the cavity surface portion that is brought into contact with the surface of the skin material 14, and the decorative resin molded product is the base material 12 only. When comprised, the 3rd die-molding molded object 40 will adhere to the cavity surface part which provides the surface of this decorative resin molded product.

  In addition, in the above-described embodiment, the present invention has been shown as a specific example of a storage box cover panel which is a kind of automobile interior parts, a manufacturing method thereof, and a molding die used therefor. For other interior parts for automobiles, parts or components other than automobile interior parts, and methods for producing decorated resin molded products, and molds for decorated resin molded products and decorative resin molded products Of course, it can be advantageously applied.

  In addition, although not enumerated one by one, the present invention can be carried out in a mode to which various changes, modifications, improvements, etc. are added based on the knowledge of those skilled in the art. It goes without saying that all are included in the scope of the present invention without departing from the spirit of the present invention.

It is an isometric view explanatory drawing which shows the cover panel as one Embodiment of the decorative resin molded product manufactured according to this invention method. It is II-II sectional explanatory drawing in FIG. It is the elements on larger scale in FIG. FIG. 2 is a longitudinal sectional view showing a veneer prepared for manufacturing the cover panel shown in FIG. 1 according to the method of the present invention. FIG. 4 is an explanatory view showing an example of a process for forming a molding die when the cover panel shown in FIG. 1 is manufactured according to the present invention. The state which formed the single-molding molded object is shown. It is explanatory drawing which shows the example of a process implemented following FIG. 5, Comprising: The state which shape | molded the 1st convex part formed in a 1st mold-molding body and formed the 2nd mold-molding body is shown. ing. It is explanatory drawing which shows the example of a process implemented following FIG. 6, Comprising: The state which shape | molded the groove-shaped recessed part formed in a 2nd mold-molding molded object, and formed the 3rd mold-molding molded body is shown. Yes. Fig. 3 shows a molding die prepared for fixing a third die-molding molded body in manufacturing according to the method of the present invention. FIG. 9 shows a state in which a third mold-molding body is fixed to the molding die shown in FIG. 8. FIG. 10 is an explanatory diagram showing an example of a process when the cover panel shown in FIG. 1 is manufactured using the molding die shown in FIG. 9 according to the method of the present invention, and in the cavity forming recess of the molding die. Shows the state in which the skin material is set. It is explanatory drawing which shows the example of a process implemented following FIG. 10, Comprising: While showing the state which closed the shaping | molding metal mold | die and formed the shaping | molding cavity, and accommodated and arrange | positioned the skin material in this shaping | molding cavity Yes. It is explanatory drawing which shows the example of a process implemented following FIG. 11, Comprising: The molten resin is inject | poured in the shaping | molding cavity, and it has shown the state solidified and solidified. It is explanatory drawing which shows the example of a process implemented following FIG. 12, Comprising: The state which released the resin molded product shape | molded in the shaping | molding cavity is shown.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Cover panel 12 Base material 14 Skin material 16 Resin film 18 Print layer 20 Clear coating film 22 Grain-like grain 24 Groove-shaped recessed part 26 Veneer 28 First mold-molding molded body 34 Second mold-molding molded body 40 Third mold-molding molding Body 44 Second convex portion 50 Molding cavity 52 Mold for molding 60 Resin molded product

Claims (7)

A method of manufacturing a decorative resin molded product that has been decorated to express a wood texture by forming a concave portion having a shape similar to a fine groove-like concave portion present on the surface of the wood,
Using the resin material that is plasticized at a temperature lower than the combustion temperature of the main wood, the fine groove-shaped concave portions are transferred by molding the fine groove-shaped concave portions from the surface of the main wood. A step of forming a first mold-molding body having a first mold-carrying surface on which a first convex portion corresponding to the groove-shaped concave portion is formed;
Using the predetermined ceramic material, the first convex portion is transferred by molding the first convex portion from the first mold-taking surface of the first mold-molding body. Corresponding to the step of forming a second mold-molding body having a second mold-carrying surface formed with a groove-shaped recess having the same shape as the fine groove-shaped recess on the surface of the wood,
Using the predetermined ceramic material, the groove-shaped recess is transferred from the second mold-taking surface of the second mold-molding body, so that the groove-shaped recess is transferred and corresponds to the groove-shaped recess. Forming a third mold-molding body having a third mold-carrying surface on which a second convex portion is formed;
By fixing the formed third die-molding molded body to the cavity surface of the molding cavity of the molding die on the surface opposite to the third mold-carrying surface, the main wood is placed in the molding cavity. Forming a convex portion corresponding to the fine groove-shaped concave portion on the surface of the second convex portion;
Filling a predetermined molten resin material into the forming shape cavity the molding mold, by solidifying, corresponding to the second protrusion of the third type cavity molding body fixed to key Yabiti surface of the molding cavity Forming a resin molded product in which the concave portion is formed on the surface with the same shape as the fine groove-shaped concave portion and decorated to express the wood texture;
The manufacturing method of the decorative resin molded product characterized by including.   The method for producing a decorated resin molded product according to claim 1, wherein the main wood is a veneer. Wherein the mold wherein the molding cavity of a thin skin material having a decorative surface having a grain pattern, the said that該意Takumi surface is secured to the key Yabiti surface of the shaped cavities third type cavity molding member After being accommodated and arranged in contact with or facing the third mold- carrying surface, the molten resin material is injected and filled into the molding cavity, and the skin material is injected by the injection pressure of the molten resin material. whole be to close the third type up surface of the third type cavity molding body, the該意Takumi surface of said surface skin material, thereby forming a recess corresponding to said second protrusion of said third type up surface , solidified the molten resin material, by fixing the said surface skin material to the surface, the recess corresponding to the second convex portion, is formed on the surface with the fine recessed grooves similar shape, the Molded resin molded products with decorations that express wood texture Method for producing a decorated resin molded article according to Motomeko 1 or claim 2.   The method for producing a decorated resin molded product according to claim 3, wherein the skin material is a resin film having a wood grain pattern printed on the design surface.   The method for producing a decorated resin molded product according to claim 3, wherein the skin material is a thin wood sheet.   The method further comprises forming a transparent coating film on the surface of the resin molded product on which the concave portion is formed after molding the resin molded product with a decoration that expresses the wood texture. The manufacturing method of the decorating resin molded product of any one of thru | or 5 thru | or 5.   The method for producing a decorative resin molded product according to claim 6, wherein the transparent coating film is formed using a transparent matte paint.

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