JP6844766B2 - Manufacturing method of decorative resin products - Google Patents

Manufacturing method of decorative resin products Download PDF

Info

Publication number
JP6844766B2
JP6844766B2 JP2016167259A JP2016167259A JP6844766B2 JP 6844766 B2 JP6844766 B2 JP 6844766B2 JP 2016167259 A JP2016167259 A JP 2016167259A JP 2016167259 A JP2016167259 A JP 2016167259A JP 6844766 B2 JP6844766 B2 JP 6844766B2
Authority
JP
Japan
Prior art keywords
decorative
decorative film
resin
manufacturing
film
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.)
Active
Application number
JP2016167259A
Other languages
Japanese (ja)
Other versions
JP2018034336A (en
Inventor
一晴 成瀬
一晴 成瀬
Original Assignee
株式会社丸三金属
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by 株式会社丸三金属 filed Critical 株式会社丸三金属
Priority to JP2016167259A priority Critical patent/JP6844766B2/en
Publication of JP2018034336A publication Critical patent/JP2018034336A/en
Application granted granted Critical
Publication of JP6844766B2 publication Critical patent/JP6844766B2/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Description

本発明は、凹凸形状をなす樹脂基材の表面に加飾フィルムが接合された加飾樹脂製品の製造方法に関する。 The present invention relates to a method for manufacturing a decorative resin product in which a decorative film is bonded to the surface of a resin base material having an uneven shape.

樹脂基材の表面を加飾フィルムで覆ってなる加飾樹脂製品は、自動車や電化製品など様々な分野で使用されている。こうした加飾樹脂製品の製造方法としては、フィルムインサート成形がよく用いられている(例えば、特許文献1)。フィルムインサート成形では、賦形した加飾フィルムを射出成形金型にセットして、加飾フィルムの裏面側に樹脂基材を射出成形することにより、樹脂基材の成形と同時に、樹脂基材の表面に加飾フィルムを一体的に接合する。かかる製造方法によれば、樹脂基材の成形後に加飾フィルムを接合する場合に比べて、樹脂基材と加飾フィルムの一体性が高くなるため、高品質の製品が得られる。 Decorative resin products in which the surface of a resin base material is covered with a decorative film are used in various fields such as automobiles and electric appliances. Film insert molding is often used as a method for producing such a decorative resin product (for example, Patent Document 1). In film insert molding, the shaped decorative film is set in an injection molding mold, and the resin base material is injection-molded on the back surface side of the decorative film. The decorative film is integrally bonded to the surface. According to such a manufacturing method, the integrity of the resin base material and the decorative film is higher than that in the case of joining the decorative film after molding the resin base material, so that a high quality product can be obtained.

特開2010−030053号公報(図8,9参照)Japanese Unexamined Patent Publication No. 2010-030053 (see FIGS. 8 and 9)

フィルムインサート成形で製造する加飾樹脂製品は、品質は良いものの、射出成形金型の製造コストが高いため、試作品やパーツ等の少量生産には適していない。 Decorative resin products manufactured by film insert molding are of good quality, but are not suitable for small-quantity production of prototypes and parts due to the high manufacturing cost of injection molding dies.

本発明は、かかる現状に鑑みて為されたものであり、少量生産の加飾樹脂製品を、品質を低下させることなく、低廉に製造可能な製造方法の提供を目的とする。 The present invention has been made in view of the present situation, and an object of the present invention is to provide a manufacturing method capable of manufacturing a decorative resin product produced in a small amount at a low cost without deteriorating the quality.

本発明は、凹凸形状をなす樹脂基材の表面に加飾フィルムが接合された加飾樹脂製品の製造方法であって、 加飾フィルムを凹凸形状に賦形する賦形工程と、該賦形工程の後に、積層造形法によって加飾フィルムの裏面側に樹脂層を積層することにより、加飾フィルムと一体的に接合された樹脂基材を造形する積層造形工程とを含むことを特徴とする加飾樹脂製品の製造方法である。 The present invention is a method for manufacturing a decorative resin product in which a decorative film is bonded to the surface of a resin base material having a concavo-convex shape. After the step, it is characterized by including a laminated molding step of molding a resin base material integrally bonded to the decorative film by laminating a resin layer on the back surface side of the decorative film by a laminated molding method. This is a method for manufacturing decorative resin products.

かかる製造方法によれば、射出成形金型を用いずに加飾樹脂製品を製造できるため、少量生産の場合であれば、フィルムインサート成形による製造方法に比べて加飾樹脂製品を低コストで製造できる。また、かかる製造方法では、樹脂基材を構成する樹脂層を、凹凸形状に賦形した加飾フィルムの裏面側に積層するため、積層造形工程で樹脂基材を造形した時点で、樹脂基材は加飾フィルムの裏面に密着して、加飾フィルムと一体化される。したがって、かかる製造方法によれば、フィルムインサート成形による製造方法と同等の品質の加飾樹脂製品を製造できる。 According to such a manufacturing method, a decorative resin product can be manufactured without using an injection molding die. Therefore, in the case of small-quantity production, a decorative resin product can be manufactured at a lower cost than a manufacturing method by film insert molding. it can. Further, in such a manufacturing method, since the resin layer constituting the resin base material is laminated on the back surface side of the decorative film shaped into an uneven shape, the resin base material is formed when the resin base material is formed in the laminating molding step. Is in close contact with the back surface of the decorative film and is integrated with the decorative film. Therefore, according to such a manufacturing method, a decorative resin product having the same quality as the manufacturing method by film insert molding can be manufactured.

積層造形工程の具体的方法として、裏面側を上向きにした状態で加飾フィルムを治具に保持し、加飾フィルムの裏面側にノズルから樹脂材料を射出して所要断面形状の樹脂層を形成する工程を繰り返すことが提案される。かかる積層造形工程は、3次元プリンタで実現可能である。一般的な3次元プリンタは、平坦な造形用のステージの上に樹脂層を積層して立体物を造形するものであるため、本発明の積層造形工程のように、加飾フィルムを治具に保持する場合には、3次元プリンタのステージ上に治具を固定するか、ステージに替えて治具を配設すればよい。また、かかる積層造形工程においては、先細形状のノズルを採用したり、ノズルと加飾フィルムの距離を長めにしたり、ノズルの軌跡を調整したりすることにより、ノズルが加飾フィルムと干渉しないようにすることが提案される。 As a specific method of the laminated molding process, the decorative film is held on a jig with the back surface side facing upward, and a resin material is injected from a nozzle onto the back surface side of the decorative film to form a resin layer having a required cross-sectional shape. It is proposed to repeat the process. Such a laminated molding process can be realized by a three-dimensional printer. In a general 3D printer, a resin layer is laminated on a flat modeling stage to form a three-dimensional object. Therefore, as in the laminated modeling process of the present invention, a decorative film is used as a jig. When holding the jig, the jig may be fixed on the stage of the three-dimensional printer, or the jig may be arranged in place of the stage. Further, in such a laminated molding process, by adopting a tapered nozzle, increasing the distance between the nozzle and the decorative film, and adjusting the trajectory of the nozzle, the nozzle does not interfere with the decorative film. It is suggested to.

また、積層造形法には、光造形法、熱溶解積層法、インクジェット法、石膏粉末法、粉末焼結法などの方式があるが、本発明の積層造形工程における積層造形法は、熱溶解積層法であることが望ましい。熱溶解積層法は、現時点で最も低廉な積層造形法であり、また、樹脂材料をノズルから射出する方式であるため、凹凸形状に賦形された加飾フィルムの裏面側に樹脂層を積層するのが容易であるためである。 Further, there are methods such as a stereolithography method, a fused deposition modeling method, an inkjet method, a plaster powder method, and a powder sintering method as the additive manufacturing method. The additive manufacturing method in the additive manufacturing process of the present invention is a fused deposition modeling method. It is desirable to be a law. The Fused Deposition Modeling method is the cheapest additive manufacturing method at the present time, and since it is a method of ejecting a resin material from a nozzle, a resin layer is laminated on the back surface side of a decorative film shaped into an uneven shape. This is because it is easy to do.

また、上記のように積層造形工程を熱溶解積層法で行う場合には、積層造形工程の前に、加飾フィルムの裏面に熱可塑性の接着層を形成する工程を含むことが提案される。接着層の形成方法としては、アクリル系インキ又はウレタン系インキの印刷や、ホットメルト接着剤の塗布などが挙げられる。かかる構成によれば、積層造形工程において加飾フィルムの裏面に樹脂材料を射出した際に、樹脂材料の熱で接着層を溶かすことで、加飾フィルムの裏面に樹脂基材を容易に接合させることが可能となる。 Further, when the laminated modeling step is performed by the fused deposition modeling method as described above, it is proposed to include a step of forming a thermoplastic adhesive layer on the back surface of the decorative film before the laminated modeling step. Examples of the method for forming the adhesive layer include printing of acrylic ink or urethane ink, application of hot melt adhesive, and the like. According to this configuration, when the resin material is injected onto the back surface of the decorative film in the laminated molding process, the adhesive layer is melted by the heat of the resin material, so that the resin base material is easily bonded to the back surface of the decorative film. It becomes possible.

また、上記のように加飾フィルムの裏面に熱可塑性の接着層を形成する場合は、加飾フィルムを治具に保持するとともに、該治具の温度を調節することで、前記加飾フィルムの温度を調節することが提案される。かかる場合には、加飾フィルムの温度を、雰囲気温度を介して調節するよりも精密に調整可能となるため、接着層の溶融度合いをより精密に制御して、加飾フィルムと樹脂基材をより適切に接合させることが可能となる。 Further, when the thermoplastic adhesive layer is formed on the back surface of the decorative film as described above, the decorative film is held in a jig and the temperature of the jig is adjusted to control the decorative film. It is suggested to regulate the temperature. In such a case, since the temperature of the decorative film can be adjusted more precisely than adjusting it via the ambient temperature, the degree of melting of the adhesive layer can be controlled more precisely to control the decorative film and the resin base material. It becomes possible to join more appropriately.

以上に述べたように、本発明によれば、少量生産の加飾樹脂製品を、品質を低下させることなく、低廉に製造可能となる。 As described above, according to the present invention, it is possible to inexpensively manufacture a decorative resin product produced in a small amount without deteriorating the quality.

加飾樹脂製品1の使用状態を示す説明図である。It is explanatory drawing which shows the use state of the decorative resin product 1. 加飾樹脂製品1の(a)表面図、(b)裏面図、(c)側面図、(d)中央縦断面図である。It is (a) front view, (b) back view, (c) side view, (d) central vertical sectional view of the decorative resin product 1. FIG. 加飾樹脂製品1の(a)正面図、(b)背面図、(c)図2中のA−A線断面図、(d)図2中のB−B線断面図である。It is (a) front view, (b) back view, (c) cross-sectional view of line AA in FIG. 2, and (d) the cross-sectional view of line BB in FIG. 2 of the decorative resin product 1. 加飾樹脂製品1の断面拡大図である。FIG. 3 is an enlarged cross-sectional view of the decorative resin product 1. 加飾樹脂製品1の製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of the decorative resin product 1. 図5から続く加飾樹脂製品1の製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of the decorative resin product 1 which continues from FIG.

本実施例の製造方法によって製造される加飾樹脂製品1は、図1に示すように、自動車のドアDの内側に配設されたアームレストRの上部に装着されるパネル状の上部カバーである。 As shown in FIG. 1, the decorative resin product 1 manufactured by the manufacturing method of this embodiment is a panel-shaped upper cover mounted on the upper part of the armrest R arranged inside the door D of the automobile. ..

図2,3に示すように、加飾樹脂製品1は、樹脂基材4の表面に加飾フィルム5を接合してなるものである。加飾樹脂製品1は、外周部が裏側に湾曲することにより、表側全体が凸形状、裏側全体が凹形状をなしている。加飾樹脂製品1の中央には、操作スイッチS(図1参照)を装着する矩形状の開口部6が設けられる。また、加飾樹脂製品1の裏側には、加飾樹脂製品1をアームレストRに係止する複数の係止突起7が複数箇所に配設される。なお、図2,3中の加飾樹脂製品1の形状は、実物を模式化したものであり、係止突起7を除いた加飾樹脂製品1の厚さは約5〜10mm、加飾フィルム5の厚さは約125〜475μm、加飾樹脂製品1の裏側の凹みの深さは約3〜5mm程度である。 As shown in FIGS. 2 and 3, the decorative resin product 1 is formed by bonding the decorative film 5 to the surface of the resin base material 4. The decorative resin product 1 has a convex shape on the entire front side and a concave shape on the entire back side because the outer peripheral portion is curved to the back side. A rectangular opening 6 for mounting the operation switch S (see FIG. 1) is provided in the center of the decorative resin product 1. Further, on the back side of the decorative resin product 1, a plurality of locking projections 7 for locking the decorative resin product 1 to the armrest R are arranged at a plurality of locations. The shape of the decorative resin product 1 in FIGS. 2 and 3 is a schematic representation of the actual product, and the thickness of the decorative resin product 1 excluding the locking projection 7 is about 5 to 10 mm, and the decorative film. The thickness of 5 is about 125 to 475 μm, and the depth of the dent on the back side of the decorative resin product 1 is about 3 to 5 mm.

樹脂基材4は、ABS樹脂からなるものである。図示は省略しているが、後述するように、樹脂基材4は3次元プリンタによって造形された、厚さ約100μmのABS樹脂層を多数積層してなる積層体である。なお、樹脂基材4の材料はABS樹脂に替えて、PC−ABS樹脂などを用いてもよい。 The resin base material 4 is made of ABS resin. Although not shown, the resin base material 4 is a laminated body formed by a three-dimensional printer and formed by laminating a large number of ABS resin layers having a thickness of about 100 μm, as will be described later. As the material of the resin base material 4, PC-ABS resin or the like may be used instead of ABS resin.

加飾フィルム5は、樹脂基材4の表側の凹凸形状に倣うように賦形され、樹脂基材4の表側全体を覆うようにして樹脂基材4と一体的に接合されている。図4に示すように、加飾フィルム5は、透明樹脂からなるフィルム基材8の裏面側に、意匠を形成する意匠層9を印刷し、さらに意匠層9の裏面側にホットメルト接着剤からなる接着層10を塗布してなるものであり、透明なフィルム基材8を透して意匠層9の形成する意匠を視認させることで、加飾樹脂製品1の表面に光沢感のある意匠面を形成している。なお、透明なフィルム基材8は、ポリカーボネートや、PET樹脂、アクリル樹脂、ABS樹脂などによって構成できる。また、意匠層9は、グラビア印刷やラミネート加工によって形成してもよい。また、接着層10は、ホットメルト接着剤の塗布に替えて、アクリル系インキ又はウレタン系インキの印刷によって形成してもよい。 The decorative film 5 is shaped so as to imitate the uneven shape on the front side of the resin base material 4, and is integrally bonded to the resin base material 4 so as to cover the entire front side of the resin base material 4. As shown in FIG. 4, the decorative film 5 has a design layer 9 for forming a design printed on the back surface side of a film base material 8 made of a transparent resin, and further, from a hot melt adhesive on the back surface side of the design layer 9. The adhesive layer 10 is coated, and the surface of the decorative resin product 1 has a glossy design surface by visually recognizing the design formed by the design layer 9 through the transparent film base material 8. Is forming. The transparent film base material 8 can be made of polycarbonate, PET resin, acrylic resin, ABS resin, or the like. Further, the design layer 9 may be formed by gravure printing or laminating. Further, the adhesive layer 10 may be formed by printing an acrylic ink or a urethane ink instead of applying the hot melt adhesive.

以下に、上記加飾樹脂製品1の製造方法を説明する。
上記加飾樹脂製品1の製造方法は、加飾フィルム5を作製して賦形する加飾フィルム製造工程と、加飾フィルム製造工程の後に、加飾フィルム5の裏面側に樹脂基材4を造形する樹脂基材製造工程とを備えている。
The manufacturing method of the decorative resin product 1 will be described below.
The method for manufacturing the decorative resin product 1 is as follows: a decorative film manufacturing step of producing and shaping the decorative film 5, and a resin base material 4 on the back surface side of the decorative film 5 after the decorative film manufacturing step. It is equipped with a resin base material manufacturing process for modeling.

加飾フィルム製造工程は、以下の(1)〜(3)の工程を順次行うことによって実現される。
(1)意匠層形成工程
透明樹脂からなる平坦なフィルム基材8の裏面側にインキからなる意匠層9を印刷する。
(2)接着層形成工程
意匠層9の裏面側にホットメルト接着剤からなる接着層10を印刷して、フィルム基材8、意匠層9及び接着層10からなる平坦な加飾フィルム5を得る。
(3)賦形工程
図5(a)→5(b)のように、圧空成形によって、平坦な加飾フィルム5を、樹脂基材4の表側の凹凸形状に倣う凹凸形状に賦形する。なお、本製造方法では、かかる賦形工程の後は加飾フィルム5を成形しないため、本工程において加飾フィルム5を高圧で成形することにより、加飾フィルム5を加飾樹脂製品1の表面形状に、精密に成形する。
The decorative film manufacturing process is realized by sequentially performing the following steps (1) to (3).
(1) Design layer forming step The design layer 9 made of ink is printed on the back surface side of a flat film base material 8 made of transparent resin.
(2) Adhesive layer forming step An adhesive layer 10 made of a hot melt adhesive is printed on the back surface side of the design layer 9 to obtain a flat decorative film 5 made of a film base material 8, a design layer 9 and an adhesive layer 10. ..
(3) Forming Step As shown in FIGS. 5 (a) to 5 (b), the flat decorative film 5 is shaped into a concavo-convex shape that follows the concavo-convex shape on the front side of the resin base material 4 by compressed air molding. In this manufacturing method, since the decorative film 5 is not molded after the shaping step, the decorative film 5 is formed on the surface of the decorative resin product 1 by molding the decorative film 5 at a high pressure in this step. Precisely mold into shape.

樹脂基材製造工程では、3次元プリンタを用いて熱溶解積層法により、賦形した加飾フィルム5の裏面に樹脂基材4を造形する。3次元プリンタには、通常は立体物が直接造形されるステージ13の上に治具12を固定して、ステージ13の所定位置に加飾フィルム5を正確に保持し得るようにする。具体的には、治具12は上面に凹部を備え、加飾フィルム5の表側の凸形状を該凹部に嵌合させることにより、加飾フィルム5を保持するものである。また、3次元プリンタは、ステージ13の下方に温度調節装置(図示省略)を備えており、該温度調節装置によってステージ13及び治具12の温度を調節することにより、治具12に保持した加飾フィルム5を所定温度に加熱し得るよう構成される。なお、治具12は、温度調節を容易とするために、熱伝導率の高い金属で形成することが望ましい。 In the resin base material manufacturing process, the resin base material 4 is formed on the back surface of the shaped decorative film 5 by the fused deposition modeling method using a three-dimensional printer. In a three-dimensional printer, a jig 12 is usually fixed on a stage 13 on which a three-dimensional object is directly formed so that the decorative film 5 can be accurately held at a predetermined position on the stage 13. Specifically, the jig 12 is provided with a concave portion on the upper surface, and the decorative film 5 is held by fitting the convex shape on the front side of the decorative film 5 into the concave portion. Further, the three-dimensional printer is provided with a temperature control device (not shown) below the stage 13, and the temperature of the stage 13 and the jig 12 is adjusted by the temperature control device to hold the printer on the jig 12. The decorative film 5 is configured to be able to be heated to a predetermined temperature. The jig 12 is preferably made of a metal having high thermal conductivity in order to facilitate temperature control.

樹脂基材製造工程は、以下の(1)〜(3)の工程を順次行うことによって実現される。
(1)準備工程
図5(c)に示すように、加飾フィルム5の表面側の凸形状を治具12の凹部に嵌合させることにより、裏面側を上向きにした状態で加飾フィルム5を治具12の上に保持する。また、3次元プリンタは、温度調整装置によって治具12及びステージ13を所定温度に加熱することで、接着層10が溶融し易い温度に加飾フィルム5を温めておく。なお、加飾フィルム5の温度調整は、以下の積層造形工程が終了するまで継続する。
(2)積層造形工程
図5(d)→6(a)→6(b)に示すように、溶融したフィラメント状のABS樹脂を3次元プリンタのノズル14の先端から加飾フィルム5の裏面側に射出して、加飾フィルム5の裏面側に所要の断面形状の樹脂層を形成する工程を繰り返し、加飾フィルム5の裏面側に樹脂層を積層することによって樹脂基材4を造形する。樹脂層の厚さは特に限定されないが、100μm程度が好適である。本積層造形工程において、樹脂基材4と加飾フィルム5は、加飾フィルム5の裏面に溶融した樹脂材料を射出した際に、樹脂材料の熱で接着層10が一時的に溶融することで一体的に接合される。なお、本積層造形工程に際しては、ノズル14と加飾フィルム5が干渉することのないノズル14の動かし方を予め3次元プリンタにプログラムしておく。なお、かかる工程では、ノズル14を加飾フィルム5の裏面に対して3次元方向に相対移動させるが、ノズル14のかかる相対移動は、ステージ13とノズル14の一方又は双方を動かすことによって実現される。
(3)後処理工程
図6(c)に示すように、加飾樹脂製品1を治具12から取り外し、加飾フィルム5の余剰部分を裁断する。また、加飾フィルム5を裁断して開口部6の部分を開口させる。なお、加飾フィルム5の裁断や開口部6の開口は、加飾フィルム製造工程で行ってもかまわない。また、本工程では、必要に応じて樹脂基材4の研磨や、ネジ孔の形成、サポート材の除去等を行ってもよい。
The resin base material manufacturing process is realized by sequentially performing the following steps (1) to (3).
(1) Preparation Step As shown in FIG. 5C, the decorative film 5 is fitted with the convex shape on the front surface side of the decorative film 5 into the concave portion of the jig 12, so that the back surface side faces upward. Is held on the jig 12. Further, in the three-dimensional printer, the decorative film 5 is warmed to a temperature at which the adhesive layer 10 is easily melted by heating the jig 12 and the stage 13 to a predetermined temperature by a temperature adjusting device. The temperature adjustment of the decorative film 5 is continued until the following laminating molding step is completed.
(2) Laminated molding process As shown in FIGS. 5 (d) → 6 (a) → 6 (b), the molten filamentous ABS resin is applied from the tip of the nozzle 14 of the three-dimensional printer to the back surface side of the decorative film 5. The process of forming a resin layer having a required cross-sectional shape on the back surface side of the decorative film 5 is repeated, and the resin base material 4 is formed by laminating the resin layer on the back surface side of the decorative film 5. The thickness of the resin layer is not particularly limited, but is preferably about 100 μm. In this laminated molding step, when the molten resin material is injected onto the back surface of the decorative film 5, the resin base material 4 and the decorative film 5 are temporarily melted by the heat of the resin material. It is joined integrally. In this laminated molding step, the method of moving the nozzle 14 so that the nozzle 14 and the decorative film 5 do not interfere with each other is programmed in advance in the three-dimensional printer. In this step, the nozzle 14 is relatively moved in the three-dimensional direction with respect to the back surface of the decorative film 5, but the relative movement of the nozzle 14 is realized by moving one or both of the stage 13 and the nozzle 14. Nozzle.
(3) Post-treatment step As shown in FIG. 6 (c), the decorative resin product 1 is removed from the jig 12, and the excess portion of the decorative film 5 is cut. Further, the decorative film 5 is cut to open the opening 6. The decorative film 5 may be cut and the opening 6 may be opened in the decorative film manufacturing process. Further, in this step, the resin base material 4 may be polished, screw holes may be formed, the support material may be removed, and the like, if necessary.

以上の製造方法によれば、射出成形金型を用いずに加飾樹脂製品1を製造できるため、少量生産の場合であれば、フィルムインサート成形で製造する場合に比べて低廉に製造可能となる。上述のように、本実施例に係る加飾樹脂製品1は、自動車の内装品(アームレストRの上部カバー)であるため、生産数の少ないカスタムパーツの製造に際しては、本実施例の製造方法が、フィルムインサート成形による製造する場合に比べて有効となる。 According to the above manufacturing method, since the decorative resin product 1 can be manufactured without using an injection molding die, it can be manufactured at a lower cost in the case of small-quantity production than in the case of manufacturing by film insert molding. .. As described above, since the decorative resin product 1 according to this embodiment is an interior part of an automobile (upper cover of armrest R), the manufacturing method of this embodiment is used when manufacturing custom parts with a small number of production. , It is more effective than the case of manufacturing by film insert molding.

また、上記製造方法によれば、積層造形工程で樹脂基材4を造形した時点で、樹脂基材4が加飾フィルム5の裏面に接合して、加飾フィルム5と一体化されるため、かかる製造方法によれば、フィルムインサート成形で製造したものと同等品質の加飾樹脂製品1を製造できる。なお、3次元プリンタで造形した樹脂基材4であれば、自動車の内装品に必要な強度は十分に確保できる。 Further, according to the above manufacturing method, when the resin base material 4 is formed in the laminated molding step, the resin base material 4 is bonded to the back surface of the decorative film 5 and integrated with the decorative film 5. According to such a manufacturing method, a decorative resin product 1 having the same quality as that manufactured by film insert molding can be manufactured. If the resin base material 4 is formed by a three-dimensional printer, sufficient strength required for the interior parts of an automobile can be secured.

なお、本発明は、上記実施例の形態に限定されるものではなく、本発明の要旨を逸脱しない範囲内で適宜変更可能である。例えば、上記実施例の加飾樹脂製品1は、自動車のドアのアームレストの上部カバーであるが、本発明は様々な加飾樹脂製品の製造に適用可能であり、特に、少量生産品の製造に有効である。例えば、自動車の他の内装品であれば、カスタムパーツのドアトリムやシフトパネルの製造に適用することが挙げられる。 The present invention is not limited to the above-described embodiment, and can be appropriately modified without departing from the gist of the present invention. For example, the decorative resin product 1 of the above embodiment is an upper cover of an armrest of an automobile door, but the present invention is applicable to the production of various decorative resin products, and particularly for the production of small-quantity products. It is valid. For example, for other interior parts of automobiles, it can be applied to the manufacture of door trims and shift panels for custom parts.

また、加飾フィルムについても、上記実施例の装飾や、材料、層構造、厚さに限らず適宜変更可能である。例えば、加飾フィルムは金属調装飾のフィルムであってもかまわない。また、上記実施例の加飾フィルムは、裏面側全体が凹形状となっていたが、本発明に係る加飾フィルムは、裏面側に部分的な凸形状が形成されていてもよいし、裏面側全体に凸形状が形成されていてもよい。また、加飾樹脂製品は、複数種類の加飾フィルムで覆われていてもよい。なお、一部の規格では、厚さ250μm未満のものを「フィルム」、厚さ250μm以上のものを「シート」と分類しているが、本発明に係る加飾フィルムは、厚さ250μm未満のものに限られず、厚さ250μm以上のものを含む。ただし、加飾フィルムが厚すぎると、賦形の難易度が高くなるため、加飾フィルムの厚みは500μm以下とすることが望ましい。 Further, the decorative film can be appropriately changed regardless of the decoration, material, layer structure, and thickness of the above embodiment. For example, the decorative film may be a metallic decorative film. Further, the decorative film of the above embodiment has a concave shape on the entire back surface side, but the decorative film according to the present invention may have a partially convex shape on the back surface side, or the back surface side. A convex shape may be formed on the entire side. Further, the decorative resin product may be covered with a plurality of types of decorative films. In some standards, a film having a thickness of less than 250 μm is classified as a “film” and a film having a thickness of 250 μm or more is classified as a “sheet”, but the decorative film according to the present invention has a thickness of less than 250 μm. It is not limited to the one, and includes the one having a thickness of 250 μm or more. However, if the decorative film is too thick, the difficulty of shaping becomes high, so it is desirable that the thickness of the decorative film is 500 μm or less.

また、上記樹脂基材の積層造形方法としては、上記実施例の熱溶解積層法に限らず、他の積層造形方法を適宜採用可能であり、積層造形方法に応じて樹脂基材の材料も適宜変更可能である。また、樹脂基材は一種類の樹脂で造形するものに限られず、多種類の樹脂で造形してもよい。 Further, the laminated modeling method of the resin base material is not limited to the Fused Deposition Modeling method of the above embodiment, and other laminated modeling methods can be appropriately adopted, and the material of the resin base material is also appropriately used depending on the laminated modeling method. It can be changed. Further, the resin base material is not limited to the one formed by one kind of resin, and may be formed by many kinds of resins.

1 加飾樹脂製品
4 樹脂基材
5 加飾フィルム
6 開口部
7 係止突起
8 フィルム基材
9 意匠層
10 接着層
12 治具
13 ステージ
14 ノズル
D ドア
R アームレスト
S 操作スイッチ
1 Decorative resin product 4 Resin base material 5 Decorative film 6 Opening 7 Locking protrusion 8 Film base material 9 Design layer 10 Adhesive layer 12 Jig 13 Stage 14 Nozzle D Door R Armrest S Operation switch

Claims (3)

凹凸形状をなす樹脂基材の表面に加飾フィルムが接合された加飾樹脂製品の製造方法であって、
加飾フィルムを凹凸形状に賦形する賦形工程と、
該賦形工程の後に、積層造形法によって加飾フィルムの裏面側に樹脂層を積層することにより、加飾フィルムと一体的に接合された樹脂基材を造形する積層造形工程と
を含むことを特徴とする加飾樹脂製品の製造方法。
A method for manufacturing a decorative resin product in which a decorative film is bonded to the surface of a resin base material having an uneven shape.
The shaping process of shaping the decorative film into an uneven shape,
After the shaping step, a laminating molding step of forming a resin base material integrally bonded to the decorative film by laminating a resin layer on the back surface side of the decorative film by a layered manufacturing method is included. A characteristic method for manufacturing decorative resin products.
積層造形工程では、裏面側を上向きにした状態で加飾フィルムを治具に保持し、加飾フィルムの裏面側にノズルから樹脂材料を射出して所要断面形状の樹脂層を形成する工程を繰り返すことを特徴とする請求項1に記載の加飾樹脂製品の製造方法。 In the laminating molding process, the decorative film is held in a jig with the back surface side facing upward, and a resin material is injected from a nozzle onto the back surface side of the decorative film to form a resin layer having a required cross-sectional shape. The method for producing a decorative resin product according to claim 1, wherein the decorative resin product is produced. 前記積層造形法は、熱溶解積層法であって、
積層造形工程の前に、加飾フィルムの裏面に熱可塑性の接着層を形成する工程を含み、
積層造形工程では、加飾フィルムを金属製の治具に保持するとともに、該治具の温度を調節することで、前記加飾フィルムの温度を調節することを特徴とする請求項1又は請求項2に記載の加飾樹脂製品の製造方法。
The layered manufacturing method, it fused deposition modeling der,
Prior to lamination shaping step, seen including the step of forming a thermoplastic adhesive layer on the back surface of the decorative film,
The first or claim in the laminating molding step is characterized in that the decorative film is held in a metal jig and the temperature of the decorative film is adjusted by adjusting the temperature of the jig. 2. The method for manufacturing a decorative resin product according to 2.
JP2016167259A 2016-08-29 2016-08-29 Manufacturing method of decorative resin products Active JP6844766B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP2016167259A JP6844766B2 (en) 2016-08-29 2016-08-29 Manufacturing method of decorative resin products

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2016167259A JP6844766B2 (en) 2016-08-29 2016-08-29 Manufacturing method of decorative resin products

Publications (2)

Publication Number Publication Date
JP2018034336A JP2018034336A (en) 2018-03-08
JP6844766B2 true JP6844766B2 (en) 2021-03-17

Family

ID=61566818

Family Applications (1)

Application Number Title Priority Date Filing Date
JP2016167259A Active JP6844766B2 (en) 2016-08-29 2016-08-29 Manufacturing method of decorative resin products

Country Status (1)

Country Link
JP (1) JP6844766B2 (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10967576B2 (en) 2017-11-10 2021-04-06 Local Motors IP, LLC Additive manufactured structure having a plurality of layers in a stacking direction and method for making the same
JP2019162826A (en) * 2018-03-20 2019-09-26 学校法人慶應義塾 Three-dimensional object manufacturing apparatus, three-dimensional object manufacturing method and program
EP3650529A1 (en) * 2018-11-09 2020-05-13 Sartorius Stedim FMT SAS Single-use container with 3d printed functional element, printing method therefor and assembly
US11813790B2 (en) 2019-08-12 2023-11-14 Rapidflight Holdings, Llc Additively manufactured structure and method for making the same

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IN2014DN09076A (en) * 2012-04-10 2015-05-22 Raymond A & Cie
JP6453088B2 (en) * 2015-01-30 2019-01-16 名古屋油化株式会社 Masking material
DE102015114604B4 (en) * 2015-09-01 2020-11-19 Universität Stuttgart Method for manufacturing a component from plastic

Also Published As

Publication number Publication date
JP2018034336A (en) 2018-03-08

Similar Documents

Publication Publication Date Title
JP6844766B2 (en) Manufacturing method of decorative resin products
US11072296B2 (en) Method and tool for manufacturing a vehicle interior trim part, as well as a vehicle interior trim part
JP6752857B2 (en) Cover for automotive radar sensors
EP2869981B1 (en) A method for the manufacture of a plastics product and a product made by the method
JP5928713B2 (en) In-mold decoration method and apparatus
JP4633181B2 (en) Injection mold and method of manufacturing composite product
US8291593B2 (en) Method of manufacturing multicolored interior trim components
US20210237323A1 (en) Method and apparatus for nonwoven trim panels
JP5756473B2 (en) Method and apparatus for manufacturing molded trim parts
US7875339B2 (en) Thermoplastic resin casing and method for fabricating the same
US10377068B2 (en) Method and apparatus for non-woven trim panels
KR20180061599A (en) Car interior material manufacturing apparatus
JP2010521333A (en) Component parts, especially interior parts for automobiles and manufacturing methods
CN203472158U (en) 3D (Three-Dimensional) printing realizing device based on fused deposition modeling
WO1994026500A1 (en) Method and apparatus for manufacturing multiple colored pliable soft trim components
JP2017094702A (en) Injection molding method
US11642820B2 (en) Tool for plastic injection molding and method for manufacturing the tool
CN111136859A (en) Injection molding apparatus, resin molded article, and method for manufacturing the same
JP2007301932A (en) Manufacturing method of interior material for vehicle
JP2018052093A (en) Method for producing resin molding
US20110315665A1 (en) Battery casing manufacturing method
JPH10180798A (en) Injection molding simultaneous foil-decorating apparatus and method therefor
JP6192095B2 (en) Skin material bonding structure for automotive interior parts
KR20160123663A (en) Apparatus for manufacturing internal parts of vehicles and method for manufacturing the same
JP2021074956A (en) Manufacturing method of resin molded product

Legal Events

Date Code Title Description
A621 Written request for application examination

Free format text: JAPANESE INTERMEDIATE CODE: A621

Effective date: 20190605

A977 Report on retrieval

Free format text: JAPANESE INTERMEDIATE CODE: A971007

Effective date: 20200427

A131 Notification of reasons for refusal

Free format text: JAPANESE INTERMEDIATE CODE: A131

Effective date: 20200616

A521 Request for written amendment filed

Free format text: JAPANESE INTERMEDIATE CODE: A523

Effective date: 20200812

TRDD Decision of grant or rejection written
A01 Written decision to grant a patent or to grant a registration (utility model)

Free format text: JAPANESE INTERMEDIATE CODE: A01

Effective date: 20210202

A61 First payment of annual fees (during grant procedure)

Free format text: JAPANESE INTERMEDIATE CODE: A61

Effective date: 20210209

R150 Certificate of patent or registration of utility model

Ref document number: 6844766

Country of ref document: JP

Free format text: JAPANESE INTERMEDIATE CODE: R150

R250 Receipt of annual fees

Free format text: JAPANESE INTERMEDIATE CODE: R250