JP5915980B2 - Manufacturing method of design members - Google Patents

Description

The present invention is, for example, a method of manufacturing the meaning Takumi member such as a cover suitable for use in interior materials for automobiles.

  For example, a design member formed by molding a resin plate material such as an acrylic plate having a design on its surface into a desired shape has been provided as an interior material for automobiles. As such a conventional design member, for example, as disclosed in Patent Document 1, a composite sheet is prepared by laminating a printed sheet provided with a pattern by digital printing on the surface of an acrylic resin sheet. Examples include those formed by vacuum suction on a plastic molded article and bonded.

JP 2005-305761 A

  However, in the above-mentioned conventional design member, since the pattern printed on the composite sheet transmits the transparent acrylic resin sheet to form the design, it is difficult to differentiate only by the design based on the pattern. There was a problem that there was. Therefore, the present applicant has made a distinction as a design by providing a predetermined uneven shape on the surface, and has intensively studied what can form the uneven shape easily and accurately.

The present invention has been made in view of such circumstances, it is to provide a method of manufacturing a meaning Takumi member that can be formed easily and highly accurately design consisting of irregularities having a predetermined shape on the surface.

According to the first aspect of the present invention, there is provided a cutting process in which a predetermined portion on the back surface of the resin plate material is cut into a predetermined shape, and a mold having a smooth surface is pressed against the back surface of the resin plate material that has undergone the cutting process. And forming a desired shape by sucking air between the resin plate and the mold, and forming irregularities corresponding to the predetermined shape on the surface of the resin plate. To do.

Invention of Claim 2 has the colored layer formation process which forms an opaque colored layer in the back surface of a transparent or semi-transparent resin board material in the manufacturing method of the design member of Claim 1 , The said cutting process Is characterized by cutting a predetermined portion of the colored layer formed in the colored layer forming step into a predetermined shape.

The invention according to claim 3 is the method for producing a design member according to claim 2 , wherein the colored layer forming step forms the colored layer by adhering an opaque film to the back surface of the resin plate material. To do.

Invention of Claim 4 is a manufacturing method of the design member as described in any one of Claims 1-3 . WHEREIN: The said cutting process is a laser processing which cuts by irradiating a laser along a predetermined shape. It is characterized by cutting.

According to the invention of claim 1, after cutting a predetermined portion on the back surface of the resin plate material into a predetermined shape, the mold plate having a smooth surface is pressed against the back surface of the resin plate material and the resin plate material Air between the mold and the mold is sucked to form a desired shape, and irregularities corresponding to the predetermined shape are formed on the surface of the resin plate material. Can be formed.

According to the invention of claim 2 , the resin plate material is formed by forming an opaque colored layer on the back surface of the transparent or translucent resin plate material, and after cutting a predetermined portion of the colored layer into a predetermined shape, Since molding with a mold is performed, the portion where the colored layer is removed by cutting is a concave portion on the surface of the design member, and the portion where the colored layer remains is a convex portion on the surface of the design member, and the irregularities corresponding to the colored layer are Can be formed.

According to the invention of claim 3, since the colored layer is formed by adhering an opaque film to the back surface of the resin plate material, a design such as a desired pattern or letters can be applied to the film, and it is easier. Arbitrary designs can be applied.

According to the invention of claim 4, since the cutting process is a laser process for cutting by irradiating a laser along a predetermined shape, even a small-lot design member can be easily handled. At the same time, it is possible to perform cutting of the predetermined portion more accurately and smoothly.

The whole top view and front view showing the design member concerning the embodiment of the present invention II-II sectional view in FIG. Schematic diagram showing the manufacturing process (colored layer formation process) of consented takumi members Schematic diagram showing the manufacturing process (the state after the cutting process) of the consensus member VV line sectional view in FIG. Schematic diagram showing the manufacturing process (molding process) of consented takumi members Flowchart for explaining a method for manufacturing a consent member

Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
The design member according to the present embodiment includes a cover that covers a desired part such as an automobile interior material. As shown in FIGS. 1 and 2, the design plate member 2, the colored layer 3, and the predetermined portion A are provided. It is configured. The design member 1 has a box shape with an opening at the bottom, and a design having an uneven shape (the predetermined portion A corresponds to a recess) is formed on the upper surface thereof.

  The resin plate 2 is made of a transparent or translucent resin member, and in the present embodiment, is made of an acrylic plate. The surface 2a of the resin plate 2 is a surface C (see FIG. 2) facing the outside in a state of covering a desired component, and a colored layer 3 is formed on the back surface 2b. The colored layer 3 is made of an opaque film. In the present embodiment, the colored layer 3 is made of a black thin film. Specifically, the colored layer 3 is formed by applying an adhesive or a solvent over the entire back surface 2b of the resin plate member 2 and adhering a film to the back surface 2b.

  The predetermined portion A is a portion corresponding to a predetermined portion A ′ (see FIGS. 4 and 5) formed by cutting the colored layer 3 on the back surface 2 b side of the resin plate material 2 into a predetermined shape. As shown in FIGS. 1 and 2, the predetermined portion A according to the present embodiment has a rectangular shape (substantially square) formed on the upper surface of the design member 1, and cuts the colored layer 3 on the back surface 2 b of the resin plate material 2. A processed region (a region corresponding to the predetermined part A ′) is used. In the present embodiment, three predetermined portions A are formed in parallel, a region between adjacent predetermined portions A is a portion B, and the portion B is a portion B ′ (see FIGS. 4 and 5). ). The portion B 'is in a state where the colored layer 3 is not cut and a black film remains.

  The predetermined portion A ′ according to the present embodiment is formed by laser processing in which the colored layer 3 is cut by irradiating the back surface 2b of the resin plate material 2 with a laser along a predetermined shape. Specifically, numerical data based on a desired predetermined shape is input to a terminal such as a personal computer (PC), the laser irradiation unit is operated according to the numerical data, and the colored layer is irradiated with the laser irradiated from the laser irradiation unit. By using a laser processing machine that cuts 3 into a predetermined shape, the cutting process for the predetermined part A ′ is performed.

  Then, the laser is irradiated along the predetermined portion A ′, and the film in the predetermined portion A ′ is cut into a rectangular shape as shown in FIGS. 4 and 5 to obtain the rectangular design. Yes. In the present embodiment, as shown in FIG. 5, when the colored layer 3 in the predetermined portion A ′ is cut, the back surface 2b of the resin plate 2 in the predetermined portion A ′ is also a predetermined dimension in the thickness direction. However, only the colored layer 3 may be cut by arbitrarily changing the setting of a laser processing machine that performs laser processing. Moreover, in this embodiment, although it cuts into a rectangular shape, as long as it is a predetermined shape based on arbitrary designs, any shape may be sufficient.

  In the present embodiment, the predetermined portion A ′ is transparent or translucent (a part of the resin plate 2) by cutting the colored layer 3 at the predetermined portion A ′. You may make it apply | coat the coloring paint of a desired color with respect to the said predetermined part A 'in the back surface 2b of the board | plate material 2. As shown in FIG. In this case, the colored paint may be either an opaque color that does not transmit light or a translucent color that transmits light, as long as it is other than the color (black) of the colored layer 3.

  Here, in the present embodiment, as shown in FIG. 6, the resin K is pressed while the mold K having a smooth surface is pressed against the back surface 2 b of the resin plate material 2 on which the predetermined portions A ′ and B are formed. The air between the plate-making material 2 and the mold K is sucked and formed into a desired shape (box shape as shown in FIGS. 1 and 2), and the unevenness corresponding to the predetermined shape (rectangular shape) of the predetermined portion A ′ is the resin. It is formed on the surface of the plate material 2.

  That is, the mold K has a smooth surface (smooth surface regardless of the predetermined portion A ′ and the portion B) while the overall shape corresponds to the desired shape, and this is formed from the back surface 2b of the resin plate 2. By pressing, a portion other than the predetermined portion A ′ on the back surface 2b is pushed out to the front surface 2a side. Thus, on the surface of the resin plate material 2, a relative height dimension is generated between the predetermined portion A and other portions (the portion B and the surface C), and irregularities are formed. Accordingly, the predetermined portion A becomes a concave portion and the portion B becomes a convex portion, and irregularities corresponding to the predetermined shape of the predetermined portion A are formed on the surface 2 a of the resin plate material 2.

Next, the manufacturing method of the design member 1 according to the above embodiment will be described based on the flowchart of FIG.
First, a colored layer forming step S1 for forming an opaque colored layer 3 on the back surface 2b of the transparent or translucent resin plate material 2 is performed. In the colored layer forming step S1, as shown in FIG. 3 (a), a resin plate material 2 having a predetermined size and a black film (opaque film) constituting the colored layer 3 are prepared and made of resin. A predetermined adhesive or solvent is applied to the back surface 2b of the plate member 2, and after the film is brought into close contact with the back surface 2b of the resin plate member 2, as shown in FIG. Both are adhered by solidifying.

  Next, a cutting step S2 for cutting the predetermined portion A ′ of the colored layer 3 formed in the colored layer forming step S1 into a predetermined shape is performed. In the cutting step S2, as described above, the predetermined portion A 'on the back surface 2b of the resin plate material 2 is cut into a predetermined shape, and the colored layer 3 in the region is removed. Specifically, as shown in FIGS. 4 and 5, the colored layer 3 in the region of the predetermined portion A ′ is cut by irradiating the laser beam from the laser processing machine along the predetermined portion A ′ of the colored layer 3. It is supposed to be removed. The predetermined portion A ′ is cut to have a smooth surface over the entire predetermined portion A ′. However, the predetermined portion A ′ may be roughened and formed into a frosted glass shape.

  Then, while pressing the molding die K having a smooth surface against the back surface 2b of the resin plate material 2 that has undergone the cutting step S2, air between the resin plate material 2 and the molding die K is sucked into a desired shape. A forming step S3 is performed in which the unevenness corresponding to the predetermined shape is formed on the surface 2a of the resin plate material 2. Specifically, in this molding step S3, as shown in FIGS. 6A to 6D, the resin plate material 2 is installed in a vacuum molding machine. As shown in the figure, the vacuum forming machine includes a main body F in which a sealed space is formed, a heater H capable of heating the resin plate member 2 installed on the upper portion of the main body F, and a main body. Blow bubble V capable of introducing air into part F, molding die K having an outer contour corresponding to a desired shape, and vacuum capable of sucking air through through-hole Ka formed in molding die K And means D.

  And as shown to the figure (a), while installing the resin-made board | plate material 2 (The state which orient | assigned the colored layer 3 below) to the upper part of the main-body part F, the said resin-made board | plate material 2 is heated with the heater H. After being softened by this, the blow valve V is opened to introduce air into the main body F and the resin plate material 2 is expanded and deformed as shown in FIG. Thereafter, as shown in FIG. 3C, the mold K is raised to press the mold K against the resin plate 2 and the surface of the mold K and the resin plate 2 by the vacuum means D. The air between the back surface (colored layer 3) is sucked (vacuum forming).

  By undergoing such vacuum forming, the outer contour of the forming die K is accurately transferred to the resin plate material 2, so that the resin plate material 2 is formed into a desired shape. At this time, the portion B ′ (see FIG. 5) of the back surface 2b is pushed out to the front surface 2a side to form a portion B (see FIG. 2) consisting of convex portions, and the predetermined portion A ′ (see FIG. 5) of the back surface 2b. ) Corresponds to a concave portion on the surface 2 a, and an uneven shape along the predetermined portion A is formed on the surface 2 a of the resin plate material 2.

  Then, after the resin plate material 2 is cooled and hardened, as shown in FIG. 1 (d), the mold K is lowered to the initial position, and the resin plate material 2 is taken out from the main body F, as shown in FIG. 2, a resin plate 2 formed into a desired shape (specifically, formed into a box shape opened downward) can be obtained. Note that after the forming step S3, an extra portion such as a flange portion can be removed by cutting (for example, laser processing).

  According to the design member 1 obtained through the above steps, the surface is smooth with respect to the back surface 2b of the resin plate material 2 after the predetermined portion A ′ on the back surface 2b of the resin plate material 2 is cut into a predetermined shape. While the mold K is pressed, air between the resin plate 2 and the mold K is sucked into a desired shape, and irregularities corresponding to a predetermined shape are formed on the surface 2a of the resin plate 2. Therefore, a design composed of irregularities of a predetermined shape can be easily and accurately formed on the surface 2a.

  In particular, in the molding step S3, since the molding is performed by the vacuum molding as described above, the back surface 2b (the inner peripheral surface of the design member 1) of the resin plate material 2 can be molded smoothly following the surface of the molding die K. The target component to be covered can be smoothly and accurately covered. That is, the design which consists of unevenness | corrugation can be given to an outer peripheral surface (in this embodiment, upper surface), smoothing the inner peripheral surface of the design member 1. FIG. In addition, by shaping | molding by vacuum forming like this embodiment, type | molds other than the shaping | molding die K can be made unnecessary, and the design member to which various designs were provided by one type | mold (molding die K) is manufactured. can do.

  The resin plate material 2 is formed by forming an opaque colored layer 3 on the back surface 2b of a transparent or translucent resin plate material. After molding a predetermined portion A ′ of the colored layer 3 into a predetermined shape, the resin plate material 2 is molded. Since molding by the mold K is performed, the portion where the colored layer 3 is removed by cutting is a concave portion on the surface of the design member 1, and the portion where the colored layer 3 remains is a convex portion on the surface of the design member 1. Irregularities corresponding to the thickness can be formed. That is, the design can be made by associating the colored portion by the colored layer 3 with the uneven shape.

  Furthermore, according to the present embodiment, the cutting in the cutting step S2 is laser processing in which the colored layer 3 is cut by irradiating a laser along a predetermined shape. However, it is possible to easily cope with this, and it is possible to perform cutting of a predetermined portion more accurately and smoothly. In addition, since the colored layer 3 is formed by adhering an opaque film to the back surface 2b of the resin plate material 2, a design such as a desired pattern or characters can be applied to the film, and an arbitrary design can be more easily applied. Can be applied.

  As mentioned above, although this embodiment was described, this invention is not limited to these, For example, without passing through the colored layer formation process which forms the opaque colored layer 3 in the back surface 2b of the resin-made board | plate materials 2, it cuts. You may make it perform process S2 and shaping | molding process S3 sequentially. In this case, although the design by a colored layer cannot be obtained, the unevenness | corrugation corresponding to a predetermined shape can be formed in the surface 2a of the resin-made board | plate materials 2. FIG.

  Moreover, in the said embodiment, although the cutting process in cutting process S2 is made into laser processing, if it is the processing method which cuts the predetermined site | part of a colored layer into a predetermined shape, the other general purpose which used the cutting blade A cutting method may be used. In addition, the laser processing machine for laser processing can use the thing of various forms, an operator has a laser irradiation means by hand, and cuts the colored layer in the predetermined part of a desired shape by hand. It may be a thing.

  Further, the colored layer according to the above embodiment is formed by adhering an opaque film to the back surface of the resin plate material. However, if an opaque colored layer can be formed, an opaque paint may be applied. Good. Further, the color of the colored layer is not limited to black as in the above embodiment, and can be any color.

  In addition, the design member which concerns on this embodiment is not limited to what is applied to the interior material of a motor vehicle as mentioned above, It can apply to various design members. For example, it can be applied to a cover that covers a mobile phone or a cover that covers a remote controller (remote controller) for home appliances, etc., and also has surface irregularities that have a predetermined function in addition to those that constitute a design exclusively ( It may be a convex or braille function indicating the direction of the covered component.

After a predetermined part on the back surface of the resin plate material is cut into a predetermined shape, air between the resin plate material and the mold is sucked while a mold having a smooth surface is pressed against the back surface of the resin plate material. are molded into a desired shape is, if the manufacturing method of the design member formed on the surface of the irregularities the resin sheet corresponding to a predetermined shape, it may be applied such as those other functions are added .

DESCRIPTION OF SYMBOLS 1 Design member 2 Resin board 3 Colored layer A, A 'Predetermined part B, B' Part K Mold

Claims (4)

A cutting process for cutting a predetermined portion of the back surface of the resin plate material into a predetermined shape;
While pressing the molding die having a smooth surface against the back surface of the resin plate material that has undergone the cutting process, the air between the resin plate material and the molding die is sucked into a desired shape, and the predetermined shape is obtained. A molding process for forming corresponding irregularities on the surface of the resin plate material,
The manufacturing method of the design member characterized by having. A colored layer forming step of forming an opaque colored layer on the back surface of the transparent or translucent resin plate material, wherein the cutting step forms a predetermined portion of the colored layer formed in the colored layer forming step into a predetermined shape; the process according to claim 1, wherein the design member, characterized by cutting. The said colored layer formation process adheres an opaque film to the back surface of the said resin-made board | plate material, and makes it the said colored layer, The manufacturing method of the design member of Claim 2 characterized by the above-mentioned. The method of manufacturing a design member according to any one of claims 1 to 3 , wherein the cutting process is performed by laser processing in which a laser is irradiated along a predetermined shape to perform cutting.

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