JP6796669B2 - リアルウッドを含む成形品の製造方法 - Google Patents
リアルウッドを含む成形品の製造方法 Download PDFInfo
- Publication number
- JP6796669B2 JP6796669B2 JP2019031124A JP2019031124A JP6796669B2 JP 6796669 B2 JP6796669 B2 JP 6796669B2 JP 2019031124 A JP2019031124 A JP 2019031124A JP 2019031124 A JP2019031124 A JP 2019031124A JP 6796669 B2 JP6796669 B2 JP 6796669B2
- Authority
- JP
- Japan
- Prior art keywords
- real wood
- layer
- molded product
- film
- imd
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Links
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Images
Classifications
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
- B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0292—Polyurethane fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/06—Vegetal fibres
- B32B2262/062—Cellulose fibres, e.g. cotton
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2451/00—Decorative or ornamental articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Textile Engineering (AREA)
- Forests & Forestry (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
Description
11:リアルウッド層
12:接着層
13:繊維層
20:離型フィルム
30:IMDフィルム
40:成形品
41:射出層
42:コーティング層
100:ベースフレーム
110:移動フレーム
120:固定フレーム
210:下部金型
211:キャビティ
212:密着部
213:吸入ホール
220:上部金型
221:挿入ホール
222:加圧部
230:真空ポンプ
310:IMDフィルム供給ローラ
320:IMDフィルム回収ローラ
400:射出手段
500:取出部
Claims (13)
- 離型フィルムにリアルウッド積層体が備えられたIMDフィルムを準備するIMDフィルム準備ステップと、
前記リアルウッド積層体が射出地点に位置するように、IMDフィルムを供給するIMDフィルム供給ステップと、
真空吸着により下部金型のキャビティにIMDフィルムを密着させて、リアルウッド積層体が前記キャビティの形状に対応して変形密着するIMDフィルム固定ステップと、
上部金型と前記下部金型とが型合わせされ、前記上部金型を介して前記キャビティに溶融した射出材料を注入した後、硬化して射出層を形成する射出層形成ステップと、
前記下部金型と前記上部金型とを分離して、リアルウッド積層体から離型フィルムが分離された成形品を取り出す成形品取出ステップと、を含み、
前記IMDフィルム準備ステップは、
天然木材を切断して所定の厚さを有する薄膜状のリアルウッド層を形成するリアルウッド層形成ステップと、
前記リアルウッド層の下面に繊維層を付着させる繊維層形成ステップと、
前記リアルウッド層の変色を防止するように、前記リアルウッド層に前記繊維層が積層されたリアルウッド積層体を前処理する前処理ステップと、
前処理された複数のリアルウッド積層体を離型フィルムに一定間隔離隔して付着させかつ、前記リアルウッド層を前記離型フィルムに付着させてIMDフィルムを製造するIMDフィルム製造ステップと、を含み、
前記前処理ステップは、
前記リアルウッド積層体を脱色剤を用いて脱色する脱色ステップと、
脱色が完了した前記リアルウッド積層体を洗浄する洗浄ステップと、
洗浄された前記リアルウッド積層体を乾燥する乾燥ステップと、を含み、
前記脱色ステップは、前記繊維層形成ステップが完了した後に進行することを特徴とする成形品の製造方法。 - 前記リアルウッド層形成ステップは、
前記リアルウッド層を、厚さが0.1mm以上1.0mm以下の薄膜に切断して製造することを特徴とする請求項1に記載の成形品の製造方法。 - 前記繊維層形成ステップは、
前記リアルウッド層に前記繊維層を接着剤で付着するか、熱圧着で付着させることを特徴とする請求項1に記載の成形品の製造方法。 - 前記脱色ステップは、
過酸化水素希釈液またはアンモニアが添加された過酸化水素希釈液で設けられる脱色剤を用いて脱色することを特徴とする請求項1に記載の成形品の製造方法。 - 前記過酸化水素希釈液は、
純水と過酸化水素とを8:2〜5:5の重量%で混合して設けられることを特徴とする請求項4に記載の成形品の製造方法。 - 前記アンモニアが添加された過酸化水素希釈液は、
純水と過酸化水素とを8:2〜5:5の重量%で混合して設けられた過酸化水素希釈液に、アンモニアを過酸化水素の重量の5〜20%で混合して設けられることを特徴とする請求項4に記載の成形品の製造方法。 - 前記離型フィルムは、
PET、PE、PP、CPPフィルムのいずれか1つで設けられ、厚さは0.1mm以上1.0mm以下に設けられることを特徴とする請求項1に記載の成形品の製造方法。 - 前記IMDフィルム製造ステップは、
前記下部金型に前記リアルウッド積層体を連続的に供給できるように、前記IMDフィルムをロール状に製造することを特徴とする請求項1に記載の成形品の製造方法。 - 前記リアルウッド層を保護するために、前記リアルウッド層をカバーするコーティング層を形成するコーティング層形成ステップと、をさらに含むことを特徴とする請求項1に記載の成形品の製造方法。
- 前記コーティング層形成ステップは、
前記前処理ステップの後に、フィルム状の樹脂を前記リアルウッド層に付着させてコーティング層を形成するか、液体状態の樹脂を前記リアルウッド層に塗布してコーティング層を形成することを特徴とする請求項9に記載の成形品の製造方法。 - 前記コーティング層形成ステップは、
前記成形品取出ステップの後に、前記成形品を金型内部に配置した後、前記リアルウッド層にインサート射出成形でコーティング層を形成するか、液体状態の樹脂を前記成形品のリアルウッド層に塗布してコーティング層を形成することを特徴とする請求項9に記載の成形品の製造方法。 - 前記IMDフィルム固定ステップは、
前記下部金型における前記キャビティの外側に備えられた密着部が動作して、前記下部金型の上側に配置されたIMDフィルムの離型フィルムの部分を前記下部金型の上側面に密着させるIMDフィルム位置固定ステップと、
前記下部金型に形成された吸入ホールを介して真空排気を行って、IMDフィルムにおける前記リアルウッド積層体が備えられた部分を前記キャビティの内側面に密着させる真空吸着ステップと、を含むことを特徴とする請求項1に記載の成形品の製造方法。 - 前記成形品取出ステップは、
前記リアルウッド積層体と前記離型フィルムとの間の接着力より、前記上部金型と前記射出層との間の接着力がさらに強くて、前記下部金型から前記上部金型の分離時、前記リアルウッド積層体から前記離型フィルムは分離され、前記上部金型に付着して共に移動した前記成形品を離脱させた後に取り出すことを特徴とする請求項1に記載の成形品の製造方法。
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