JP5786125B2 - Film decoration parts - Google Patents

Description

  The present invention relates to a decorative molded part in which a film is bonded and decorated by vacuum forming or vacuum / pressure forming.

  As a means for improving the appearance quality of a molded part, decorating the appearance surface with a film having a design property is performed. Generally, methods for decorating a molded product having a three-dimensional shape include vacuum molding or vacuum / pressure forming, insert molding, and in-mold molding. Vacuum forming is to soften the film by applying heat and drawing the air between the film and the molded product from the component side to create a state close to vacuum and to adhere to the component. Further, the air pressure is applied from the film side on the upper part of the component (hereinafter referred to as vacuum forming). In insert molding, a film is shaped in advance, inserted into a mold, heated molten resin is applied under pressure (injection molding), cooled and solidified, and the film and molded product are integrated. This is a method for producing a component. Further, in-mold molding is performed by inserting a film with design printing into a mold through a release layer, injection molding and cooling and solidifying, and then peeling the film to transfer the design to produce an integrated part. Is the method. The insert molding and in-mold molding are characterized by being decorated at the same time as the molding of the part and firmly integrated.

  In the decorating method by vacuum forming, the film adhesion is a problem because the film is bonded after the molded part is completed. That is, when a molded part is used, there is a possibility that peeling of the film may occur when a finger or the like touches the cut part (hem part) of the film.

  Conventionally, in order to suppress peeling of the film, the film has been wound around the end of a molded product (for example, Patent Document 1). Here, FIG. 8 shows a cross-sectional view of the film decorative component described in the same document. This document describes a method of undercutting from the back surface after the bottom portion of the skin 21 (film) is wound around the end portion of the core material 22 (molding base material) when vacuum forming is performed.

JP 60-49928 A

  However, although the film can be wound around the end of the molded product, the finger can be prevented from being twisted. However, since the film is wound, the elongation of the film increases and the thickness of the adhesive layer decreases (in inverse proportion to the elongation). A decrease in the adhesion force and a decrease in the adhesion force due to shrinkage after molding due to an increase in the elongation of the film occur, and the film is easily peeled off. Further, by entraining, a film material having a larger area is necessary and wasted.

  The present invention has been made to solve such a problem, and the film is cut so that the end portion of the film is exposed to the design surface of the molding substrate, and the projection is formed at the end portion of the molding substrate. By providing, it aims at suppressing the waste of a film usage amount and setting it as the structure which a film does not peel easily.

In order to solve the above-mentioned conventional problems, the film decorative part of the present invention is decorated by vacuum forming, and the hem of the film is exposed to the design surface, and the molded base material constituting the part The protrusion has a protrusion, the protrusion is disposed so as to surround the skirt of the film, and the tip of the protrusion has a triangular shape .

The protrusion of the end portion of the molded base material that is exposed can prevent the finger from being caught on the bottom of the film.
However, the protrusion can suppress the film skirt from being caught, but the formed substrate is caught by the protrusion, and stress is easily applied to the formed substrate during use. Thereby, there exists a possibility that the deformation | transformation of a shaping | molding base material and the failure | damage of a shaping | molding base material (especially protrusion part) may generate | occur | produce. In order to prevent this, a triangular shape is used so that the catching force is reduced.

  The film decorative component of the present invention improves the appearance quality of the component with the decorative film, and can suppress waste of the amount of the film used and suppress peeling of the film.

Whole perspective view of the vacuum cleaner in Embodiment 1 of this invention The perspective view of the vacuum cleaner main body in Embodiment 1 of this invention Sectional drawing of the film decorating components in Embodiment 1 of this invention Sectional drawing of the projection part of the film decorating components in Embodiment 1 of this invention Sectional drawing explaining the film decoration process in Embodiment 1 of this invention Sectional drawing explaining the film decoration process in Embodiment 1 of this invention Sectional drawing explaining the film decoration process in Embodiment 1 of this invention Sectional view of conventional film decoration parts

The film decorative part of the first invention is decorated by vacuum forming, and the hem part of the film is exposed to the design surface, and a protrusion is provided at the end of the molding substrate constituting the part. And the protrusion is disposed so as to surround the skirt of the film, and the tip of the protrusion has a triangular shape .

  Here, the film decorative part is a part in which a film having a design property is adhered by vacuum forming, and the hem part of the film is a part of the cut line after removing the excess film after vacuum forming, The design surface is a surface that is touched by human eyes.

Since the skirt of the film is not wound up to the inside of the end of the molding substrate, the amount of film material used can be minimized, and the amount of film elongation can also be suppressed. It is possible to suppress peeling due to a decrease in adhesive strength. Further, the protrusions arranged so as to surround the film hem can prevent the fingers from being in contact with the fingers during use.
However, the protrusion can suppress the film skirt from being caught, but the formed substrate is caught by the protrusion, and stress is easily applied to the formed substrate during use. Thereby, there exists a possibility that the deformation | transformation of a shaping | molding base material and the failure | damage of a shaping | molding base material (especially protrusion part) may generate | occur | produce. In order to prevent this, a triangular shape is used so that the catching force is reduced.

In the second invention, in particular, the height of the apex of the triangular shape of the tip of the first invention is greater than the film thickness and less than three times the film thickness, and further, the intersection with the perpendicular from the apex to the base And the apex on the film skirt side is at least half of the film thickness and at most 1.5 mm.

  If the height of the tip is less than or equal to the film thickness, there is a risk of touching the hem that is the cut surface of the film with a finger, causing peeling. On the other hand, if the thickness is larger than three times the film thickness, there is a risk that a force is applied from the film surface side to the center of gravity (1/3 of the apex distance) of the protrusion, causing damage to the protrusion. Furthermore, if the distance between the tip portion and the skirt portion of the film is as large as 1.5 mm or more, a human nail may artificially enter, causing peeling. Further, when the bottom side is shorter than the height, the gap into which the nail enters is reduced, but breakage such as cracking of the protruding portion occurs.

  Therefore, the present invention can maintain the strength of the triangular protrusions, which is the feature of the second invention, by optimizing the height of the triangular shape and the distance to the film skirt portion. The film can be prevented from being caught and the film can be prevented from peeling off.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the present invention is not limited to the embodiments.

(Embodiment 1)
As an example of an embodiment of a film decorative component, a case where a dust cover of a vacuum cleaner is decorated with a film will be described.

  FIG. 1 is a perspective view of a cleaner according to the first embodiment of the present invention, FIG. 2 is a perspective view of a cleaner body with a dust lid open, and FIG. 3 is a dust lid of FIG. FIG. 3 is a cross-sectional view taken along the X plane.

  In FIG.1 and FIG.2, the cleaner body 1 has the shaping | molding base material 2 which comprises a dust cover. The dust lid is a lid for taking out the dust scraps sucked by the vacuum cleaner, and can be freely opened and closed. Further, the molded base 2 is decorated with a decorative film 3 and constitutes a film decorative component 4.

  Here, since the film decoration component 4 is a component that opens and closes, the cut portion of the film does not hide inside, but appears on the surface that can be seen by human eyes.

  In FIG. 3, the film skirt portion 5, which is a cut portion of the decorative film 3, appears on the side of the design surface that touches the human eye, and is cut so as to be surrounded by the protrusion 6.

  Hereinafter, the film decoration method of the dust lid which is the film decoration component 4 is demonstrated.

  The decorative film 3 to be used is not particularly limited as long as it is a resin film that is softened by heating. For example, acrylic (polymethyl methacrylate, polyethyl methacrylate, polypropyl methacrylate, polybutyl methacrylate, etc.), ABS (acrylonitrile-butadiene-styrene), PC (polycarbonate), polyester (polyethylene terephthalate, polybutylene terephthalate, polyethylene) Naphthalate, polycyclohexyldimethylene terephthalate, etc.), polyolefin, etc. can be used. Two or more kinds of films can be laminated. At that time, the lower layer film provided below the printing layer is preferably black. This is because the cut surface at the film skirt portion 5 is less noticeable.

  As the outermost layer, regardless of the constitution of one layer or two or more layers, the acrylic film is excellent in terms of transparency, scratch resistance, and weather resistance, so it is preferable as a film used for the outermost layer for decoration purposes. .

  In the printing method for the decorative film 3, gravure printing, silk screen printing, offset printing, and the like can be used, and can be selected depending on the required design of appearance, printability on the film, and the number of films produced.

  Examples of the adhesive layer include a hot melt system, a pressure sensitive system, a reactive type, and the like, but a pressure sensitive type is desirable because of its ability to follow a three-dimensional shape. Moreover, since the pressure sensitive system can be bonded and peeled off at room temperature, it is easy to cut off (trim) the excess film. Furthermore, since peeling occurs at the interface with the molding substrate at the time of peeling, no adhesive remains on the surface of the molding substrate, and the appearance quality is not impaired.

  Here, the material of the adhesive layer is not particularly specified, and examples thereof include acrylic, silicone, rubber, and urethane. In particular, an acrylic resin having excellent adhesion, weather resistance, heat resistance, and solvent resistance is desirable.

  The molding substrate 2 is not particularly specified, and for example, ABS resin, polystyrene resin, PC resin, acrylic resin, polyphenylene ether resin, PET resin, polypropylene resin and the like can be used. In particular, an ABS resin is preferable from the viewpoint of mechanical strength (surface hardness), surface smoothness (sink is unlikely to occur), and the like.

  Here, the edge part of the shaping | molding base material 2 has a projection part. It can be molded integrally with the molding substrate or can be a separate part. Furthermore, it is better that the protrusion has a triangular tip. FIG. 4 is a cross-sectional view of the protruding portion 6 of the molding substrate 2. The triangular shape is a structure having an acute apex 7 of less than 90 degrees, and is arranged so as to protect the film skirt 5.

  Next, the height of the apex 7 at the tip is set to H, the distance between the intersection of the perpendicular drawn from the apex to the base and the corner 8 at the base of the film and X is set to X, and the thickness of the film is set to T The dimensions of the triangular shape in the case will be described.

  The height H is not less than the thickness T of the decorative film 3 and is preferably not more than 3 times T. By being more than the thickness, the film can be prevented from being caught by the film skirt portion 5. However, H may be too high because it may cause damage such as cracking of the tip. Experiments to be described later have revealed that breakage can be suppressed if the thickness of the film is equal to or greater than the triangular center of gravity.

  If the distance X between the apex and the film is too wide, a nail (having a thickness of about 1.5 to 2.0 mm) enters, which causes intentional peeling. Note that the smaller the distance X, the better. However, assuming that the triangular shape is about an isosceles triangle, the base becomes shorter when X becomes shorter, and the apex becomes remarkably acute when the base becomes shorter than H, and the tip is cracked. It is desirable that the base is equal to or higher than the height H.

  Using the above materials, film decoration can be performed by a general vacuum / pressure forming method. Next, the film decoration process will be described.

  First, as shown in FIG. 5, the receiving jig 11 on which the molding substrate 2 is placed is placed on the lower table 13 in the lower box 12, and the decorative film 3 is set on the upper surface of the lower box 12. Thereafter, the upper box 14 is lowered to make the upper and lower boxes airtight.

  And the inside of an upper and lower box is made into a vacuum state (decompression state) with the vacuum pump 15 (arrow), the heater 16 is turned on, and the decoration film 3 is heated.

When the temperature reaches a predetermined temperature at which the decorative film 3 softens, the lower table 13 in the lower box 12 rises as shown in FIG. 6, and the molding substrate 2 comes into contact with the decorative film 3. Thereafter, by opening the vacuum of the upper box 14 to an atmospheric pressure state, the decorative film 3 can be uniformly pressed against the molding substrate 2 by the atmosphere, and thereby the coating can be applied along the shape. At this time, the decorative film 3 can be brought into close contact with the molded substrate 2 with a larger force by putting compressed air from the compressed air tank 17 into the upper box 14.

  Then, the heater 16 is turned off and cooled. As shown in FIG. 7, the inside of the lower box 12 is returned to the atmospheric pressure state, and the upper box 14 is raised.

  After that, along the protruding portion of the molding substrate 2, a cutting line is cut from the side by the cutting jig 18 to perform trimming. As a result, the protrusions serve as guides, and the excess film can be removed with good workability in a single process. It is also possible to perform rough cutting in the box, take it out of the box, fix it to a trimming jig or the like, and perform trimming. The cutting jig 18 used for trimming only needs to be able to cut a resin film. For example, a sharp metal cutter (cutter), a hot knife, an ultrasonic cutter, a laser, or the like can be used.

  Hereinafter, the result of having derived | led-out by experiment about the dimension appropriate value of protrusion shape is demonstrated.

  The molding substrate 2 used in the experiment was made of ABS resin, and the protrusions were also molded at the same time. Polishing adjustment was performed using a microscope so that the shape of the protrusions had a predetermined size. The decorative film 3 was a laminated film of acrylic and ABS, and the total thickness of the film skirt was 0.4 mm. As the ABS color, a black film was used in order to make the skirt inconspicuous in design. Trimming was performed with a cutter so as to be perpendicular to the molding substrate 2 at the corner 8 of the protrusion 6.

  The evaluation experiment was conducted by a scratch test using a reciprocating movable tester. An acrylic pseudo nail (tip thickness: 1.5 mm) was installed on the movable part of the testing machine, and the weight was adjusted so that a force of 500 g weight was applied perpendicularly to the film surface by the weight. The pseudo nail will reciprocate beyond the protrusion. Judgment is made when the film is moved 420 times, and when the film can be used continuously without any peeling, breakage or protrusion damage, it is usable. When the appearance abnormality such as breakage was apparently impossible to use, it was marked as x.

  Here, 420 times is assumed to be taken out once a week and used for 8 years.

  The experimental results are shown in Table 1 below.

As shown in the experimental results, when the film thickness is 0.4 mm and the height H is 0.2 mm (corresponding to 1/2 of the film thickness), how should the distance X be changed? In both cases, the film was peeled off. On the other hand, when the height H is 0.4 mm (corresponding to the thickness of the film), depending on the distance X, the distance X is 0.2 mm (corresponding to 1/2 of the thickness of the film) or more, If it was 1.5 mm or less, good results were shown. When the height H is 0.8 mm (corresponding to twice the film thickness) and 1.2 mm (corresponding to three times the film thickness), the height H is 0.4 mm (corresponding to the film thickness). The result was the same as in the case of equivalent). On the other hand, when the height H is 1.6 mm (corresponding to 4 times the film thickness) and when the height H is 2.0 mm (corresponding to 5 times the film thickness), the distance X No dependency was shown, and in either case, damage was observed.

  Considering the above elements, when the height H is 0.2 mm (corresponding to 1/2 of the thickness of the film), the shape of the protrusions is arranged at a position lower than the film. Therefore, it is considered that the film is received by the end face of the film with respect to the force from the protruding portion side such as a finger touch, so that it is considered that peeling or breakage occurs. On the other hand, when the height H is 1.6 mm (corresponding to 4 times the thickness of the film), on the contrary, the film can be prevented from being damaged, but near the center of gravity of the protrusion against the force from the film side. Since it receives, it is thought that a projection part becomes easy to break. Therefore, it can be said that the height H needs to be not less than the thickness T and not more than 3T in relation to the film.

  Further, although the distance X has a balance with the height H, in the case of 0.1 mm (corresponding to 1/4 or less of the thickness of the film), the triangular inclination is too steep, so that it is a part in the circumferential direction. A part with weak adhesion is seen, and it is considered that the durability is inferior. In addition, when the distance X is 2.0 mm, the triangular inclination is too gentle, so that nails and the like are likely to enter from the protrusion side, and the triangular apex portion is based on the edge side of the base part, It is thought that damage is likely to occur. Therefore, it can be said that the distance X needs to be 1/2 times or more of the film thickness and 1.5 mm or less.

  In this experiment, the thickness of the film was 0.4 mm, but the triangular shape is the thickness of the film even if the thickness is other than that (assuming 0.1 to 1.0 mm as a decorative film). The above-mentioned conditions are considered to be applicable because the stress is applied in a similar manner.

  As described above, the decorative film part according to the present invention can be applied to a part with improved appearance design. For example, it can be used for household appliances such as a vacuum cleaner, an air conditioner, a warm water washing toilet seat, a refrigerator, and a washing machine. Furthermore, the configuration of the present invention is particularly suitably used for parts that can be touched by a person who can touch the film hem part. For example, it can be used for a dust cover of a vacuum cleaner or a panel of an air conditioner.

2 Molding Base 3 Decorating Film 4 Film Decorating Parts 5 Film Bottom 6 Protrusion

Claims (2)

It is a part decorated by vacuum forming or vacuum / pressure forming, and has a forming base material constituting a part main body, a film covering the forming base material, and an adhesive layer between the forming base material and the film. It is a film decorative part, the molding base has a configuration having a protrusion at an end, and the bottom of the film is configured to be exposed on the design surface of the molding base, and the projection is A film decorative component, wherein the decorative film component is disposed so as to surround a skirt portion of the film , and a tip end portion of the projection portion is triangular . In the triangular shape of the tip, the height of the apex of the tip is H, the distance between the intersection of the perpendicular line extending from the apex to the base and the corner on the base of the film is X, and the thickness of the film the is T, the following conditions (1) and a film decorative component according to claim 1, wherein a satisfying (2).
Condition (1) a <= H <= b (a = Tmm, b = 3 × Tmm)
Condition (2) c <= X <= d (c = 1/2 * Tmm, d = 1.5 mm)