JP6976364B2 - How to manufacture a picture plate - Google Patents

Description

The present invention relates to a method for manufacturing a picture plate in which a figure or the like is added to the surface of a resin product.

In manufacturing a resin product, a figure or the like may be added to the surface of the resin product by drawing a figure, a character, a photograph, a pattern or the like (hereinafter referred to as "figure or the like") with a coloring material. A resin product having a figure or the like added to the surface is referred to as a "picture plate" in the present specification.

As a method for manufacturing such a picture plate, in Patent Document 1, a decorative paper having a desired color pattern such as thin leaf paper or kraft paper printed on the upper surface of a substrate such as plywood, particle board, or MDF is attached with an adhesive. After that, an unsaturated polyester resin solution containing an unsaturated polyester resin as a main component and a mixture of a polymerization initiator, a polymerization accelerator, a styrene monomer, etc. is applied to the surface thereof, and a film such as vinylon or cellophane is applied on the upper surface thereof. A method of producing a decorative board by placing an object on it, defoaming it, heating it at room temperature or using an infrared irradiation device or the like to cure the resin, and then peeling off the film-like material is described. There is.

Japanese Unexamined Patent Publication No. 6-31886

However, in the method described in Patent Document 1, after a decorative paper is attached to the upper surface of the substrate with an adhesive, an unsaturated polyester resin solution is applied, a film-like material is placed, and the unsaturated polyester resin is cured. Since the film-like material is peeled off, there is a problem that it takes time and effort to manufacture. In addition, a substrate on which a film-like material is placed is required separately, which causes a problem that it takes time and effort to manufacture.

Therefore, an object of the present invention is to provide a simple method for manufacturing a picture plate.

The inventor of the present application has examined the above-mentioned problems. Then, when manufacturing a resin product, a transfer medium on which a figure or the like is drawn by a coloring material is placed, the resin flows in, the resin is cured in a state where the resin has penetrated into the transfer medium, and the resin is drawn by the coloring material. It was found that the figures and the like were included in the resin. Then, they have found that they manufacture a resin product to which a figure or the like is transferred, and have invented the present invention.

The method for manufacturing a picture plate according to one aspect of the present invention includes a mounting step of mounting the transfer medium in the form of a sheet containing a coloring material on which the transfer body is fixed, on a part or all of the inner surface of the mold. An inflow step of flowing an uncured resin into the mold as a transfer destination of the transfer to allow a part of the resin to permeate into the transfer medium, and the resin and the resin in the mold. A curing step of curing a part of the resin permeated into the transfer medium as an integral resin, a demolding step of removing the mold from the integral resin, and removal of removing the transfer medium from the integral resin. The transfer medium is a backlight film having a step and a porous receiving layer and a dense light diffusion layer, and in the inflow step, the coloring material is encapsulated in a part of the resin permeated into the transfer medium. Then, in the curing step, the resin in the mold is cured to form the transferred body, and in the curing step, the integrated resin composed of the transferred body and the resin containing the coloring material is formed. Then, the transfer body containing the coloring material is transferred from the transfer medium to the transfer target body.

According to one aspect of the present invention, since the resin product can be manufactured and the figure or the like can be transferred at one time, the picture plate can be easily manufactured.

At this time, the transfer body containing the coloring material may be any one or more of figures, characters, photographs and patterns drawn by the coloring material.

At this time, the uncured resin and fibers may flow into the mold.

At this time, the fiber may be any one or more of glass fiber, carbon fiber, boron fiber, and aramid fiber.

This makes it possible to easily manufacture a picture plate made of fiber reinforced plastic.

At this time, the coloring material may be a pigment-based ink.

At this time, the coloring material may be used as toner.

At this time, the resin may contain 25 to 35% by weight of styrene.

At this time, the resin may be an unsaturated polyester resin.

At this time, after the removal step, a transparent layer may be formed on the surface of the picture plate on the side of the colored portion.

As a result, the picture plate has a clear finish, and the wear resistance of the picture plate is further improved.

According to the present invention, since the resin product can be manufactured and the figure or the like can be transferred at one time, the picture plate can be easily manufactured. Further, since the drawn figure or the like can be included in the resin, the figure or the like is not exposed and deteriorated, and a clear picture plate can be manufactured.

FIG. 1 is a flow chart for explaining a method for manufacturing a picture plate according to an embodiment of the present invention. FIG. 2 is a diagram for explaining a method for manufacturing a picture plate (hereinafter, also referred to as “the present method”) according to the first embodiment of the present invention, and is a back light film on which a figure or the like is drawn (printed). It is sectional drawing of the formwork arranged on the bottom plate. FIG. 3 is a plan view of the formwork shown in FIG. FIG. 4 is a cross-sectional view illustrating the structure of the backlight film shown in FIGS. 2 and 3. FIG. 5 is a cross-sectional view of a picture plate manufactured by the method shown in FIGS. 2 and 3 to which an ink receiving layer (also simply referred to as “receptive layer”) is attached. FIG. 6 is a bottom view of the picture plate shown in FIG. FIG. 7 is a cross-sectional view of a picture plate manufactured by the present method described with reference to FIGS. 2 to 6 and further provided with a transparent layer. FIG. 8 is a diagram for explaining a method for manufacturing a picture plate according to a second embodiment of the present invention (also referred to as “the present method”), and a paper on which a figure or the like is drawn (printed) is arranged on a bottom plate. It is sectional drawing of the formwork. FIG. 9 is a diagram for explaining the manufacturing process by this method shown in FIG. 8, and is a cross-sectional view of a picture plate to which paper is attached. FIG. 10 is a cross-sectional view of a picture plate from which the paper other than the white background is removed from the state in the middle of manufacturing shown in FIG.

Here, the following terms will be defined and then explained. First, the "transferred body" refers to a black-and-white or color figure to be transferred, and a dye constituting the same. The "transfer body" here means a coloring material itself such as ink or paint, and a figure drawn by the coloring material itself. Further, the "transferred body" is a partner for transferring the transferred body and refers to a transfer destination. The "transferred body" referred to here is mainly a resin.

Further, the "transfer medium" refers to a sheet body used for the original plate and capable of maintaining a figure or the like to be transferred, or a thin plate member having an equivalent function. The "transfer medium" referred to here is mainly a backlight film, a general white paper as a sheet body, and includes a transfer sheet (not shown), a transfer sticker, an iron print paper and an iron transfer paper described later. Further, although the backlight film is mainly exemplified as the transfer medium here, the present invention is not limited to this, and any other material may be used as long as it functions as a transfer medium as defined above.

Hereinafter, an outline of a method for manufacturing a picture plate according to an embodiment of the present invention will be described.

[1. Outline of manufacturing method of picture plate]
First, an outline of a method for manufacturing a picture plate will be described using drawings. FIG. 1 is a flow chart for explaining a method for manufacturing a picture plate according to an embodiment of the present invention. As shown in FIG. 1, the method for manufacturing a picture plate according to an embodiment of the present invention includes a mounting step S1, an inflow step S2, a curing step S3, a demolding step S4, and a removing step S5.

[1-1. Placement process S1]
In the mounting step S1, a sheet-shaped transfer medium on which a transfer body containing a coloring material is fixed is placed on a part or all of the inner surface of the mold.

As described above, the "transfer body" means a coloring material itself such as ink or paint, and a figure drawn by the coloring material itself. Further, as described above, the "graphics and the like" refer to figures, characters, photographs, patterns and the like.

The material of the coloring material is not particularly limited as long as it does not adversely affect the curing of the resin. As such a coloring material, for example, a fluororesin-based oil-based coloring material, a urethane resin-based oil-based coloring material, an acrylic resin-based oil-based coloring material, a pigment-based ink, a dye-based ink, a toner for a printer, or the like is appropriately used. be able to. Graphite powder used for pencils and pigments used for crayons can also be used. Further, it is desirable that the coloring material easily adheres to the resin.

The material of the transfer medium is not particularly limited as long as it allows the resin to permeate, but it is preferable to use a porous layered body in which the resin easily permeates in the inflow step S2 described later. Further, it is preferable to use a backlight film having a porous receiving layer and a dense light diffusing layer, or paper which is an aggregate of fibers and has gaps between the fibers.

Further, the color of the transfer medium is not particularly limited, and a transparent color, white color, or the like can be appropriately used depending on the background of the figure or the like.

The shape of the formwork is appropriately determined according to the shape of the picture plate to be manufactured. The material of the formwork is not particularly limited, and those used for general resin formwork such as iron, wood, plastic, and paper are appropriately used. From the viewpoint of strength and the viewpoint that the resin does not penetrate, it is preferable to use a steel plate or a plastic plate.

The transfer body is fixed to the transfer medium by being drawn on the transfer medium, for example, with a coloring material. At this time, the colorant adheres to the surface or the inside of the transfer medium, so that the transfer body is fixed to the transfer medium.

[1-2. Inflow process S2]
In the inflow step S2, the uncured resin flows into the mold on which the transfer medium is placed. Then, a part of the resin that has flowed into the mold penetrates into the transfer medium. The resin that has flowed into the mold and the resin that has penetrated into the transfer medium are cured as an integral resin in the curing step S3 described later.

As described above, the colorant adheres to the surface and the inside of the transfer medium, so that the transfer body is fixed to the transfer medium. Then, in the inflow step S2, a part of the resin that has flowed into the mold permeates the transfer medium, and at this time, the coloring material fixed on the surface and inside of the transfer medium is included in the resin in a state of forming a figure or the like. Will be done.

The material of the resin is not particularly limited, but a thermoplastic resin such as polyvinyl chloride and acrylic resin, a thermosetting resin such as polyester resin, epoxy resin, phenol resin and polyurethane resin can be appropriately used. Further, it is preferable to use an unsaturated polyester resin. Further, it is preferable that the resin contains 25 to 35% by weight of styrene as a reactive monomer that cures the resin by crosslinking.

In addition, the uncured resin and fibers can flow into the mold. As the fiber, glass fiber, carbon fiber, boron fiber, aramid fiber and the like can be appropriately used. When the resin containing these fibers is cured, a picture plate made of fiber reinforced plastic can be easily manufactured.

In addition, a coloring material for coloring the resin can flow in. This makes it possible to easily manufacture a colored picture plate. The material of the coloring material for coloring the resin is not particularly limited, but paint, coloring toner, or the like can be appropriately used.

[1-3. Curing step S3]
In the curing step S3, the resin in the mold and the resin permeated into the transfer medium are cured. The entire resin is cured in a state where a part of the resin that has flowed into the mold has penetrated into the transfer medium, so that the resin in the mold and the resin that has penetrated into the transfer medium are cured to form an integral resin.

Further, as described above, in the inflow step S2, the coloring material fixed on the surface and inside of the transfer medium is encapsulated in the resin, and in this state, the resin is cured in the curing step S3. Therefore, the figure or the like made of the coloring material is contained in the cured resin without being deformed, and the shape of the figure or the like drawn in the mounting step S1 is maintained even in the cured resin. As a result, the transfer body fixed on the transfer medium, for example, a figure drawn on the transfer medium with a coloring material, is transferred from the transfer medium to the resin.

As the transfer medium, the material is not particularly limited as long as the resin permeates as described above, but it is preferable to use a porous layered body in which the resin easily permeates. Since the resin can be more easily permeated into the porous layered body, the figure or the like can be more easily included in the resin. As a result, the figure or the like fixed on the transfer medium can be more easily transferred to the resin, so that the picture plate can be manufactured more easily. As the porous layered body, a backlight film having a porous receiving layer and a dense light diffusion layer can be used. Also, paper can be used instead of the porous layered body. By easily infiltrating the resin between the fibers of the paper, the picture plate can be manufactured more easily.

Further, as described above, the color of the transfer medium is not particularly limited, and the background of a figure or the like such as a transparent color or white can be transferred to the transfer by appropriately using a transparent color or white. Here, for example, a white or milky white backlight film or white paper can be used as the transfer medium. Since the white background of the backlight film or paper can be transferred to the resin instead of the white coloring material, the picture plate can be manufactured more easily. When a white or milky white backlight film is used, it is preferable that the receiving layer is white or milky white as described later.

Some coloring materials, such as dye ink, permeate the transfer medium as a whole and adhere to the transfer medium. In such a case, as described above, the coloring material binds to the resin in a state of being encapsulated in the resin that has permeated the transfer medium. Then, the figure or the like fixed on the transfer medium is transferred to the resin.

Further, some coloring materials, such as pigment ink, do not penetrate the transfer medium as a whole and adhere to the transfer medium. Although the details are unknown, it is conceivable that the coloring material adhered to the transfer medium binds to the resin due to the high viscosity of the resin. Then, the coloring material fixed on the transfer medium binds to the resin, so that the figure or the like fixed on the transfer medium is transferred to the resin. Further, since the pigment ink is excellent in heat resistance, water resistance, and light resistance, the graphic image transferred to the picture plate is not easily deteriorated, so that it is preferably used.

[1-4. Demolding step S4]
In the demolding step S4, the mold is demolded from the resin cured in the curing step S3. A sheet-shaped transfer medium adheres to the bottom surface and side surfaces of the resin after demolding. The transfer medium is removed from the resin in the removal step S5 described later.

[1-5. Removal step S5]
In the removal step S5, the sheet-shaped transfer medium adhering to the resin after demolding is removed to obtain a picture plate, which is a resin product having the above-mentioned figures, characters, photographs, patterns and the like added to the surface.

Although the details are unknown, it is considered that the resin permeates not the entire transfer medium but the surface layer in the inflow step S2. For example, when a backlight film is used as a transfer medium as described later, by removing the light diffusing layer of the backlight film, it adheres to the receiving layer of the backlight film, and a coloring material such as ink contained in the resin is removed. It is exposed on the surface and a picture plate is manufactured. In this way, the light diffusion layer of the backlight film can be easily removed because, as described above, the resin permeates not the entire backlight film but the porous receiving layer, and the dense light diffusion layer can be used. It is probable that it did not penetrate. Further, for example, when paper is used as a transfer medium as described later, by removing the paper adhering to the surface of the resin, the paper permeated with the resin and the coloring material such as ink contained in the resin are exposed on the surface. Then, the picture plate is manufactured. It is considered that the reason why the paper can be easily removed in this way is that the resin permeates the surface layer instead of the entire paper as described above.

Further, after the removal step S5, a transparent layer can be formed on the surface of the picture plate on the side where the transfer body is transferred. This results in a sharper finish. By forming the transparent layer on the transfer body, it is possible to prevent the coloring material from peeling off from the picture plate, so that the abrasion resistance is further improved. The material of the transparent layer is not particularly limited as long as it is transparent, but a coating material containing urethane resin as a main component, a lacquer containing a transparent acrylic resin as a main component, or the like is appropriately used. For example, by applying these materials to the surface of the picture plate, a transparent layer can be formed.

As described above, in the method for manufacturing a picture plate according to an embodiment of the present invention, when a resin product is manufactured, a transfer medium on which a figure or the like is drawn by a coloring material is placed and an uncured resin flows in. The resin is impregnated into the transfer medium containing the figures and the like. Then, by curing the resin with the figure or the like included, the figure or the like is transferred to the resin to manufacture a picture plate. In the method for manufacturing a picture plate according to an embodiment of the present invention, it is possible to manufacture a resin product and transfer a figure or the like at one time, so that the picture plate can be easily manufactured. Further, the picture plate can be easily manufactured only from the transfer medium and the resin without the need for a substrate for drawing a figure or the like. Further, since the coloring material constituting the figure or the like is encapsulated in the resin, it is possible to prevent the coloring material from peeling off from the picture plate.

Hereinafter, the details of the method for manufacturing the picture plate according to the embodiment of the present invention will be described.
The present invention is not limited to the following embodiments.

<First Embodiment>
First, a method for manufacturing a picture plate (the present method) according to the first embodiment of the present invention will be described with reference to FIGS. 2 to 7. Here, a case of manufacturing a rectangular plate-shaped picture plate will be described, but the present invention can be applied to a picture plate having any shape. Further, the terms "top surface" and "bottom surface" are used, but these are for convenience of explanation and do not necessarily match the "top surface" and "bottom surface" when the picture plate is used.

FIG. 2 is a diagram for explaining this method, and is a cross-sectional view of a formwork in which a backlight film on which a figure or the like is drawn is arranged on a bottom plate. That is, FIG. 2 is a cross-sectional view of the mold 1 used for manufacturing the picture plate. FIG. 3 is a plan view of the formwork shown in FIG. The formwork 1 includes a bottom plate 10 firmly formed of a steel plate or the like, and side frames 11, 12, 13, 14 formed of a steel plate or the like and erected on the bottom plate 10. Further, a backlight film 25 is arranged on the upper surface 10a of the bottom plate 10.

The side frames 11, 12, 13, and 14 shown in FIGS. 2 and 3 may be fixed to the bottom plate 10 by any method such as welding or bolting, but it is preferable that the positions can be adjusted. Such a structure of the mold 1 is not different from a general resin mold.

A figure or the like is drawn on the upper surface 25c of the backlight film 25 by the coloring materials 20a and 20b (hereinafter, collectively referred to as “coloring material 20”). Drawing can be performed by any method such as coating with a brush or the like, spraying, printing with a copier, an inkjet printer, a laser printer, or the like, or other printing. As shown in FIG. 2, the coloring material 20 is fixed to the backlight film 25 in a state of being partially permeated. The coloring material 20 also includes a function of drawing a monochrome figure, and may be a solid black color.

FIG. 4 is a cross-sectional view illustrating the structure of the backlight film 25 shown in FIGS. 2 and 3. As shown in FIG. 4, the backlight film 25 has a two-layer structure including a receiving layer 25a and a light diffusing layer 25b. The receiving layer 25a is an upper layer that is on the upper side when installed on the bottom plate 10 and is in contact with the resin. The light diffusion layer 25b is a lower layer that is on the lower side when installed on the bottom plate 10 and is in contact with the bottom plate 10. The receiving layer 25a is, for example, a layer made of a material on which the coloring material 20 is easily fixed, such as a swelling type made of a water-soluble binder such as polyvinylpyrrolidone or polyvinyl alcohol, or a void type having a fine void structure formed by fine particles and a binder. can do.

The backlight film 25 used in this method is preferably thick because it is less likely to be displaced or damaged when the resin flows in. The backlight film 25 is also called a backlight sheet or an illuminated film, and its original purpose is to illuminate from the back with a fluorescent lamp, an LED, or the like for an illuminated advertisement or the like, and to display an image drawn on the film. .. The light diffusing layer 25b has a light diffusing property by using a milky white translucent PET material or the like that eliminates uneven lighting so as to be suitable for the application.

However, the backlight film 25 used in this method has both a case where it is necessary to be milky white translucent and a case where it may be simply a transparent film. First, when the transferee to which the figure or the like is transferred is white or light-colored, if a transparent film is used as the transfer medium in the first method described later, the transparent portion of the film is not printed. After being transferred as a thin layer, the white background of the transferred object can be seen through and expressed in white. On the contrary, when the transferred body is a dark color or a color, in the second method described later, the heat-transferred milky white thin layer is visually recognized by blocking the dark color of the transferred body on the unprinted white background. By doing so, it can be expressed in white.

The coloring material 20 does not adversely affect the curing of the resin, for example, a fluororesin-based oil-based coloring material, a urethane resin-based oil-based coloring material, an acrylic resin-based oil-based coloring material, a pigment-based ink, or a dye-based ink. , Toner for printers and the like can be used. Further, it is desirable that the coloring material 20 easily adheres to the resin. In this embodiment, a pigment-based ink for a printer is used to clearly transfer a complicated figure, and printing is performed on the backlight film 25 by an ink jet printer. The color of the coloring material 20a and the color of the coloring material 20b may be the same or different.

A rectangular parallelepiped cavity 30 is formed by the bottom plate 10 and the side frames 11, 12, 13, and 14, and the uncured resin flows into the cavity 30 up to a predetermined height H. The state of the coloring material 20 at this time may be a completely cured state or a so-called dry state in which the coloring material 20 is not completely cured.

It should be noted that the figure of the transfer body transferred to the resin includes not only the colored portion by the colored ink but also a white background to some extent. In general, this white background can express white color while remaining achromatic. For example, a pure white paper surface has a white background except for a colored portion colored with colored ink. Then, the saturation is also adjusted by adjusting the amount of the ink to be colored.

On the other hand, since the resin is usually colorless and transparent and is not always pure white, a white transfer body that functions like white ink is required in order to reproduce the white background of the figure to be transferred to the original white color. Become. When a figure or the like is transferred, it is difficult to express a white background of the figure or the like on a colorless and transparent resin without a white transfer body. Further, when the resin is colored, it may not be acceptable in terms of aesthetics or display function depending on the properties of the transferred figure or the like.

It has been confirmed that a part of the receiving layer 25a of the backlight film 25 plays a role as the white transfer material required here. That is, if the receiving layer 25a of the backlight film 25 is, for example, milky white, the milky white receiving layer 25a is transferred corresponding to a white background such as a figure. Therefore, it is possible to express a white background such as a transferred figure as a white color close to pure white with respect to a colorless transparent or colored resin.

Further, if the receiving layer 25a of the backlight film 25 is colorless and transparent, only the portion drawn on the receiving layer 25a by the coloring material 20 is transferred as a figure or the like. Therefore, for a colorless transparent or colored resin product, only the portion drawn by the coloring material 20 can be expressed as a figure or the like.

As the resin, a thermoplastic resin such as polyvinyl chloride and acrylic resin, and a thermosetting resin such as polyester resin, epoxy resin, phenol resin and polyurethane resin are used. In this embodiment, an unsaturated polyester resin (Showa Denko Co., Ltd.) is used. It is preferable to use a company-made Rigolac 3519BQS (“Rigolac” is a registered trademark). Rigolac 3519BQS contains 25-35% by weight of styrene. Further, as a curing agent, an organic peroxide-based one (manufactured by NOF CORPORATION, Permec N, "Permec" is a registered trademark) was added in an amount of 2% by weight of the resin. Further, when it is desired to bring the color of the resin closer to white, it is preferable to add paint or a coloring toner as a coloring material.

Further, it is also possible to mix fibers such as glass fiber, carbon fiber, boron fiber and aramid fiber together with the resin and cure the resin to obtain a fiber reinforced plastic.

FIG. 5 is a cross-sectional view of a picture plate manufactured by the method of FIGS. 2 and 3 to which an ink receiving layer is attached. FIG. 6 is a bottom view of the picture plate shown in FIG. That is, FIG. 5 is a cross-sectional view of the picture plate 40 immediately after the mold is removed after the resin is cured and the light diffusion layer is peeled off and removed, and FIG. 6 is a bottom view of the same state. On the bottom surface of the picture plate 40 formed by curing the resin 41, a colored portion 43 having a rectangular shape in a plan view and a colored portion 44 having a circular shape in a plan view are formed by the coloring material 20 in FIG. Further, the bottom surface of the picture plate 40 is flat, and the portion where the light diffusion layer is peeled off is recessed. Of the backlight film 25, the receiving layer 25a is in a state of being attached to the bottom surface 42 of the resin 41.

The colored portions 43 and 44 are fixed to the receiving layer 25a in a state where a part of the colored portions 43 and 44 has penetrated into the receiving layer 25a. Then, the resin 41 and the receiving layer 25a are bonded to each other on the bottom surface 42 of the resin 41. Further, the colored portions 43 and 44 are included in a state of being sandwiched between the resin 41 and the receiving layer 25a on the bottom surface 42 which is a boundary surface between the resin 41 and the receiving layer 25a.

The receiving layer 25a has a porous structure so that the coloring material can easily permeate and adhere to the receiving layer 25a. A part of the resin 41 permeates the porous receiving layer 25a, and the resin 41 is cured in a state where a part of the resin 41 permeates the surface layer of the receiving layer 25a. Therefore, the resin 41 and the receiving layer 25a are firmly adhered to each other. Then, since the resin 41 is cured in a state of being infiltrated into the surface layer of the receiving layer 25a in which the colored portions 43 and 44 are infiltrated, the resin 41, the receiving layer 25a and the colored portions 43 and 44 are firmly adhered to each other. Further, the colored portions 43 and 44 contained in the resin 41 side of the bottom surface 42 are firmly adhered to the resin 41. Further, the colored portions 43 and 44 are included in the resin 41 and the receiving layer 25a, and the coloring material constituting the colored portions 43 and 44 is difficult to peel off.

The figure or the like drawn by the coloring material on the upper surface 25c of the backlight film 25 before being placed on the mold is not deformed before and after the curing of the resin 41, and the resin 41 is used as the coloring portions 43 and 44 in FIG. It is contained in the receiving layer 25a. In this way, the figures and the like drawn on the backlight film 25 are transferred to the picture plate 40.

Next, a more high-class oriented picture plate will be described with reference to FIG. 7. FIG. 7 is a cross-sectional view of a picture plate manufactured by the present method described with reference to FIGS. 2 to 6 and further provided with a transparent layer. Although the colored portions 43 and 44 can be visually recognized even in the state of FIG. 5, the finish may be slightly cloudy due to the influence of the receiving layer 25a. Therefore, in the present embodiment, a transparent layer 26 (FIG. 7) made of a material transparent to visible light is formed on the outside of the receiving layer 25a. By providing the transparent layer 26, cloudiness is eliminated and gloss and color as shown in a photograph can be obtained. The transparent layer 26 can be formed, for example, by applying a coating material containing urethane resin as a main component, a lacquer containing a transparent acrylic resin as a main component, or the like.

In FIG. 6, a simple figure is shown as an example of the colored portions 43 and 44, but the colored portion having any shape can be formed by the above-mentioned method. For example, characters, complicated patterns, human figures, etc. can be formed as colored portions. In particular, by using the backlight film 25, a precise photographic image can be clearly transferred.

In the description so far, the backlight film 25 is arranged in the entire area of the upper surface 10a of the bottom plate 10 as shown in FIG. 2, but it may be arranged only in a part of the upper surface 10a. Further, in FIG. 3, the backlight film 25 is arranged on the bottom plate 10, but in addition to or instead of this, the backlight film 25 is arranged on the inner surface of one or more of the side frames 11 to 14. May be.

According to the above method, a backlight film 25 on which a figure or the like is drawn with a coloring material is placed on the bottom plate, the resin 41 flows in, and the resin 41 is cured and then demolded. The picture plate 40 having the 44 can be easily manufactured. Further, the resin 41 is also cured in a state of being infiltrated into the surface layer of the receiving layer 25a in which the colored portions 43 and 44 are infiltrated, and the resin 41, the receiving layer 25a and the colored portions 43 and 44 are firmly adhered to the surface layer. Since the colored portions 43 and 44 are included in the resin 41 and the receiving layer 25a, the coloring materials constituting the colored portions 43 and 44 are difficult to peel off.

In the picture plate 40, the colored portions 43 and 44 are contained in the resin 41 and the receiving layer 25a, and the receiving layer 25a remains on the bottom surface 42 and the colored portions 43 and 44 are not exposed. Therefore, the colored portions 43 and 44 are less likely to deteriorate due to friction or the like. Further, by providing the transparent layer 26 on the receiving layer 25a, the colored portions 43 and 44 have a clear finish and further enhance the abrasion resistance.

In addition, although the formwork is usually used repeatedly, when the figure to be transferred is drawn directly on the formwork, especially when it is drawn on the bottom plate which is usually strongly configured and not easy to replace, the picture plate is manufactured. Drawing is required every time. In addition, when drawing directly on the formwork, the coloring material is basically transferred to the picture plate, but a small amount may remain on the formwork after demolding. In such a case, the next drawing It is necessary to remove the coloring material before. However, according to the present embodiment, it is possible to complete the preparation for the next production simply by preparing a pre-drawn backlight film and a paper to be described later as needed and replacing them after demolding.

As described above, in this method, the backlight film 25, which is a sheet-shaped transfer medium on which the transfer body made of the coloring material 20 containing monochrome is fixed, is placed on a part or all of the inner surface of the mold 1. The uncured resin 41 flows into the mold as the transfer destination of the transfer body, a part of the resin 41 is impregnated into the backlight film 25, and then a part of the permeated resin 41 and the mold are used. The resin 41 inside is cured to form an integral resin containing the coloring material 20. Then, after the resin 41 is cured, the mold 1 is removed from the mold 1.

As a result, according to the present invention, it is possible to provide a method for manufacturing a picture plate 40 which can easily draw a figure or the like on the surface of a resin product with a coloring material and the coloring material 20 is difficult to peel off from the resin 41. can.

<Second embodiment>
A method for manufacturing the picture plate 49 according to the second embodiment of the present invention will be described with reference to FIGS. 8 to 10. The same components as those in the first embodiment are designated by the same reference numerals as those in FIGS. 2 to 7 and the description thereof will be omitted. FIG. 8 is a diagram for explaining this method, and is a cross-sectional view of a formwork in which a paper on which a figure or the like is drawn (printed) is arranged on a bottom plate.

The second embodiment is the same as the first embodiment in that the thin plate member on which the figure or the like is drawn is arranged on the bottom plate, but in the formwork 2 shown in FIG. 8, paper 27 is used as the thin plate member. The point is different. When paper 27 is used, it is preferable to use any of pigment ink, dye ink, and toner as the coloring material 20 and draw with an inkjet printer or a laser printer.

As the paper 27, any type and thickness can be used, but a paper having a basis weight of ^{about 70 g / m 2,} which is commercially available as plain paper for printers or copiers, can be preferably used. In addition, commercially available paper under the names of photo paper, art paper, matte paper, etc. can also be used. A thick paper 27 is preferable because it is less likely to be misaligned or damaged during casting.

As described above, when paper 27, which is a general blank paper, is used as the transfer medium instead of the backlight film 25, it has been confirmed that the surface layer of the paper 27 functions as a white transfer body. That is, the surface layer of the paper 27 constituting the white background portion (hereinafter, also simply referred to as “white background”) such as a figure is partially peeled off and transferred to a colorless transparent or colored resin. As a result, it becomes possible to express a white background such as a figure as a white color close to pure white.

In addition, there are transfer media commercially available under the names such as "iron print paper" and "iron transfer paper". In this iron transfer paper, it is common to select a cloth such as a shirt as the transfer destination as the transfer destination of the pattern to be the transfer body. Also in this case, as the pattern to be the transfer body, a pattern printed on iron transfer paper by a printer can be used.

A method of expressing white color at the transfer destination of such an iron transfer paper will be described. Here, since the printer does not use white ink, white cannot be printed, but white is expressed by the first and second methods shown below.

As a first method, when the transferred object is a white or light-colored fabric, a transfer paper having a property of becoming transparent when heated with an iron, that is, an iron transfer paper for white fabric, is used to see through the white background after thermal transfer. Let it express white color.

As a second method, when the transferred object is a dark-colored or colored cloth, when heated with an iron, the unprinted white portion is thermally transferred to the transferred object as it is and fixed, that is, a transfer paper having a property of fixing. By using the iron transfer paper for dark-colored fabrics, the white part after thermal transfer is visually recognized as it is to express white color.

However, the above-mentioned iron transfer paper is merely an example for facilitating explanation. Therefore, the picture plate manufactured by this method can express white color at the transfer destination even if the iron transfer paper is replaced with paper 27, which is a general blank paper.

FIG. 9 is a diagram for explaining the manufacturing process by this method shown in FIG. 8, and is a cross-sectional view of a picture plate to which paper is attached. As shown in FIG. 9, immediately after demolding, a part or all of the paper 27 is attached to the bottom surface 42 of the resin 41. The attached paper 27 is removed by infiltrating the picture plate 49 with water to dissolve the paper 27 or by spraying high-pressure water. When the resin 41 of the transferred body is dark or colored, the white portion of the transfer medium is thermally transferred and fixed to the transferred body as it is by the above-mentioned second method, so that it can be visually recognized as a white background. do. In the above-mentioned backlight film, the resin permeates the porous receiving layer and is cured, so that the resin, the receiving layer and the colored portion are firmly adhered to each other. The resin permeates and hardens, so that the resin, paper, and colored parts are firmly attached. Then, the white color is expressed by the paper permeated with the resin. Since the resin has not penetrated to the entire paper, it is considered that the paper 27 adhering to the bottom surface 42 can be removed.

FIG. 10 is a cross-sectional view of the picture plate 49 from which the paper 27 other than the white background portion 27a is removed from the state in the middle of manufacturing shown in FIG. As shown in FIG. 10, when the white background portion 27a is left and the other paper 27 is removed, the picture plate 49 having the colored portions 43 and 44 embedded in the resin 41 and having a substantially flat bottom surface is completed. As described above, the resin permeates between the fibers of the paper in the surface layer and hardens, so that the surface layer of the paper firmly adhered to the resin forms a white background portion 27a, so that the resin 41 has a hue and brightness other than pure white. Even so, it is possible to express pure white by the white background. When the paper 27 is used, the transparent layer 26 may be provided as in the case where the backlight film 25 is used.

According to the second embodiment, a clear colored portion can be formed and a picture plate can be manufactured at low cost.

[Example 1]
By the method of the first embodiment, the prototype of the picture plate was made under the following conditions.
<Manufacturing condition 1>
Resin type: Showa Denko KK, Rigolac 3519BQS (main component unsaturated polyester resin, styrene monomer)
Type of coloring material: Toner for laser printer Drawing: Portrait of a person Picture Plate shape: Plate-shaped backlight film: EPSON backlight film MJA3SP4
Printer used for drawing: Laser printer bizhub C284e manufactured by Konica Minolta
Material of transparent layer: Transparent resin for FRP surf manufactured by Nippon Special Paint Co., Ltd. (main component unsaturated polyester resin, styrene monomer)

After the resin was cured, the mold was removed, and the light scattering layer of the backlight film was peeled off to remove it. As a result, although the receiving layer of the backlight film remained and some white turbidity was observed, it was possible to transfer clearly. Furthermore, when a transparent layer was formed, a glossy finish as shown in the photograph was obtained.

When the printer was a Canon inkjet printer "MG6530" and the prototype was made under the same conditions as the above manufacturing condition 1 except that the coloring material was a pigment-based ink, it was as good as when the figures drawn by the laser printer were transferred. The result was obtained.

[Example 2]
By the method of the second embodiment, the prototype of the picture plate was made under the following conditions.
<Manufacturing condition 2>
Resin type: Showa Denko KK, Rigolac 3519BQS (main component unsaturated polyester resin, styrene monomer)
Type of coloring material: Toner for laser printer Drawing figure: Portrait of a person Picture Plate shape: Type of plate paper: ^{Printer used for drawing plain paper with a weighing of 70 g / m 2} : Laser printer bizhub C284e manufactured by Konica Minolta

After the resin was cured, the mold was removed and the paper adhering to the bottom surface was removed, and the transfer was clear.

When the printer was a Canon inkjet printer "MG6530" and the prototype was made under the same conditions as the above manufacturing condition 2 except that the coloring material was a pigment-based ink, it was as good as when the figures drawn by the laser printer were transferred. The result was obtained.

Although one embodiment of the present invention and each embodiment have been described in detail as described above, those skilled in the art will be aware that many modifications that do not substantially deviate from the new matters and effects of the present invention are possible. , Will be easy to understand. Therefore, all such modifications are included in the scope of the present invention.

For example, in a specification or drawing, a term described at least once with a different term having a broader meaning or a synonym may be replaced with the different term in any part of the specification or the drawing. Further, the configuration of the method for manufacturing the picture plate is not limited to that described in one embodiment of the present invention and each embodiment, and various modifications can be carried out.

1, 2 formwork, 10 bottom plate, 10a top surface (of bottom plate 10), 11-14 side frame, 20, 20a, 20b colorant, 25 backlight film, 25a receiving layer, 25c top surface (of backlight film 25), 26 Transparent layer, 27 paper, 27a (white background) paper, 27 paper, 30 cavities, 40, 49 picture plates, 41 resin, 42 bottom, 43, 44 colored parts, H height

Claims (9)

A method for manufacturing a picture plate that transfers a transfer body fixed on a transfer medium from a transfer medium to a transfer target.
A mounting step of placing the sheet-shaped transfer medium containing the colorant on which the transfer body is fixed is placed on a part or all of the inner surface of the mold.
An inflow step of inflowing an uncured resin into the mold as a transfer destination of the transfer body and infiltrating a part of the resin into the transfer medium.
A curing step of curing the resin in the mold and a part of the resin permeated into the transfer medium as an integral resin.
A demolding step of demolding the mold from the one-piece resin,
It has a removal step of removing the transfer medium from the one-piece resin.
The transfer medium is a backlight film having a porous receiving layer and a dense light diffusing layer.
In the inflow step, the coloring material is encapsulated in a part of the resin that has penetrated into the transfer medium.
In the curing step, the resin in the mold is cured to form the transferred body.
In the curing step, a picture plate is formed by forming the integrated resin composed of the transferred body and the resin containing the coloring material, and transferring the transfer body containing the coloring material from the transfer medium to the transferred body. Manufacturing method. The method for manufacturing a picture plate according to claim 1, wherein the transfer body containing the coloring material is at least one of a graphic, a character, a photograph, and a pattern drawn by the coloring material. The method for manufacturing a picture plate according to claim 1 or 2, wherein the uncured resin and fibers flow into the mold. The method for manufacturing a picture plate according to claim 3, wherein the fiber is one or more of glass fiber, carbon fiber, boron fiber, and aramid fiber. The method for manufacturing a picture plate according to any one of claims 1 to 4 , wherein the coloring material is a pigment-based ink. The method for manufacturing a picture plate according to any one of claims 1 to 4 , wherein the coloring material is toner. The method for producing a picture plate according to any one of claims 1 to 6 , wherein the resin contains 25 to 35% by weight of styrene. The method for manufacturing a picture plate according to any one of claims 1 to 7 , wherein the resin is an unsaturated polyester resin. The method for manufacturing a picture plate according to any one of claims 1 to 8 , wherein a transparent layer is formed on the surface of the picture plate on the side where the transfer body is transferred after the removal step.

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