JP7047827B2 - 造形物の製造方法 - Google Patents
造形物の製造方法 Download PDFInfo
- Publication number
- JP7047827B2 JP7047827B2 JP2019191853A JP2019191853A JP7047827B2 JP 7047827 B2 JP7047827 B2 JP 7047827B2 JP 2019191853 A JP2019191853 A JP 2019191853A JP 2019191853 A JP2019191853 A JP 2019191853A JP 7047827 B2 JP7047827 B2 JP 7047827B2
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- Prior art keywords
- layer
- base material
- thermal expansion
- resin molded
- molded sheet
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Description
基材の一方の面に熱膨張性材料を含む熱膨張層が形成された樹脂成形シートを用い、前記樹脂成形シートの一方の面に電磁波を熱に変換する熱変換層を形成する第1の形成工程と、
前記熱変換層が形成された側から前記電磁波を照射し、前記熱膨張層を膨張させて凸部を形成する第1の膨張工程と、
前記基材の一方の面と反対の面に、前記熱変換層を形成する第3の形成工程と、
前記反対の面に形成された前記熱変換層に対して前記電磁波を照射し、前記熱膨張層を膨張させて当該反対の面に凹部を形成する第2の膨張工程と、
を備え、
前記第2の膨張工程において、前記基材を前記熱膨張層の膨張に追従して変形させ、前記基材をエンボス状に変形させる、
ことを特徴とする。
(樹脂成形シート10)
樹脂成形シート10は、図1に示すように、基材11と、基材11の一方の面上に設けられた熱膨張層12と、を備える。詳細に後述するように、樹脂成形シート10では、熱膨張層12が膨張する力を利用し、熱膨張層12の膨張する方向に追従するように基材11を変形させ、変形後の形状を維持させる。このようにして、樹脂成形シート10を用いて造形物を形成する。
また、本実施形態の樹脂成形シート10は、以下に示すようにして製造される。
まず、図2(a)に示すように、基材11としてシート状の材料、例えばポリエチレンテレフタレート(PET)からなるシートを用意する。基材11は、ロール状であっても、予め裁断されていてもよい。
これにより、樹脂成形シート10が製造される。
次に、造形物20について図3を用いて説明する。
造形物20は、樹脂成形シート10を成形加工したシートである。具体的に図3に示すように、基材11は、上面に凸部11aを備え、下面に凸部11aに対応する形状を有する凹部11bを備える。熱膨張層12は、上面に凸部12aを備える。基材11の凸部11a及び熱膨張層12の凸部12aは、周囲の領域から突出している。また、基材11の凹部11bを覆って、熱膨張層12を膨張させるための熱変換層82が形成されている。
次に、本実施形態の造形物20を用いたスイッチ34と、スイッチ34を備える電子機器30について図面を用いて説明する。本実施形態のスイッチ34と電子機器30とは、造形物20を備える製品の一例である。後述するように、電子機器30は入力部33の化粧カバーとして造形物20を備えるため、電子機器30も造形物20を備える製品である。図5では、電子機器30として電卓を例に挙げ、本実施形態のスイッチ34を電卓のキートップとして使用する構成を例に挙げる。なお、電子機器30としては、電卓に限られず、プリンタ、リモコン等であってもよく、この他の電子機器であってもよい。また、本実施形態のスイッチ34は、その機能や目的は任意である。本実施形態のような、数字、文字等を入力する目的に限られるものではなく、単に電源をオンオフするためのスイッチであってもよく、その他の目的に使用されてもよい。
次に、樹脂成形シート10を成形することで、造形物を形成する造形物の製造方法(樹脂成形処理)の流れを説明する。以下の造形物の製造方法では、ロール状に巻かれた樹脂成形シート10を使用する場合(ロール式)を例に挙げて説明するが、枚葉式であってもよい。
上述した実施形態1では、造形物20をスイッチ34の化粧カバーとして利用する構成を例に挙げて説明したがこれに限られない。例えば、上部シート38は省略することができる。
実施形態2に係るシール60につき、以下図面を用いて説明する。本実施形態では、造形物20を、シール60として利用する場合を例に挙げる。本実施形態のシール60は、造形物20を備える製品の一例である。実施形態1と共通する特徴については、同一の符号を付し、詳細な説明は省略する。
実施形態3に係る照明器具70について図を用いて説明する。本実施形態では、造形物20を照明器具70の部品であるランプシェード71として利用する点に特徴を有する。本実施形態の照明器具70及びランプシェード71は、造形物20を備える製品の一例である。また、実施形態3では、スタンド型の照明器具70を例に挙げる。
実施形態4に係る造形物22について、以下図面を用いて説明する。実施形態4に係る造形物22が、上述した実施形態1に係る造形物20と異なるのは、シート表面に表側変換層84を形成し、熱膨張層12の一部を更に膨張させる点にある。実施形態1と重複する部分については、同一の参照符号を使用し、詳細な説明を省略する。また、本実施形態のスイッチも実施形態1と同様に製品の一例である。
実施形態5に係る樹脂成形シート15を、図面を用いて説明する。実施形態5に係る樹脂成形シート15が、上述した実施形態と異なるのは、熱変換層82が形成される面である樹脂成形シート15の第2の面(裏面)を覆う第1のフィルム16を有する点にある。上述した実施形態と重複する部分は、同一の符号を付し、詳細な説明は省略する。
[付記1]
基材の一方の面上に熱膨張性材料を含む熱膨張層が形成された樹脂成形シートであって、
前記熱膨張層を膨張させた際、前記基材は前記熱膨張層の膨張に追従して変形し、前記基材がエンボス状に変形し、前記基材の変形量は前記熱膨張層の膨張高さより大きくなる、
ことを特徴とする樹脂成形シート。
前記基材の厚みは、前記熱膨張層の厚みと同じ、又は前記熱膨張層より厚い、
ことを特徴とする付記1に記載の樹脂成形シート。
前記基材は、熱可塑性樹脂から形成される、
ことを特徴とする付記1又は2に記載の樹脂成形シート。
前記熱膨張層と前記基材の他方の面との少なくともいずれか一方の少なくとも一部を覆うように設けられたフィルムを更に備える、
ことを特徴とする付記1乃至3のいずれか1つに記載の樹脂成形シート。
基材の一方の面上に熱膨張性材料を含む熱膨張層が形成された樹脂成形シートを用い、前記樹脂成形シートの少なくとも一方の面に電磁波を熱に変換する熱変換層を形成する工程と、
前記熱変換層に電磁波を照射し、前記熱膨張層を膨張させる工程と、を備え、
前記熱膨張層を膨張させる際、前記基材を前記熱膨張層の膨張に追従して変形させ、前記基材をエンボス状に変形させ、前記基材の変形量を前記熱膨張層の膨張高さより大きくする、
ことを特徴とする造形物の製造方法。
前記基材の厚みは、前記熱膨張層の厚みと同じ、又は前記熱膨張層より厚い、
ことを特徴とする付記5に記載の造形物の製造方法。
前記基材は、熱可塑性樹脂から形成される、
ことを特徴とする付記5又は6に記載の造形物の製造方法。
前記樹脂成形シートは、前記熱膨張層と前記基材の他方の面との少なくともいずれか一方の少なくとも一部を覆うように設けられたフィルムを更に備え、
前記熱変換層を形成する工程では、前記フィルム上に前記熱変換層を形成する、
ことを特徴とする付記5乃至7のいずれか1つに記載の造形物の製造方法。
基材の一方の面上に熱膨張性材料を含む熱膨張層を備え、
前記熱膨張層の少なくとも一部が膨張されており、
前記熱膨張層が膨張された領域において、前記基材はエンボス状に成形されており、該領域における前記基材の変形量は、前記熱膨張層の膨張高さより大きい、
ことを特徴とする造形物。
付記9に記載の造形物を備える、
ことを特徴とする製品。
前記製品はスイッチであって、
前記造形物と、
前記基材の他方の面において、前記エンボス状に成形された前記領域に対向して配置される下部コンタクト部と、
前記基材の他方の面上の前記領域に設けられた上部コンタクト部と、を備える、
ことを特徴とする付記10に記載の製品。
前記上部コンタクト部は、上部シートを介して前記基材の他方の面上に設けられる、
ことを特徴とする付記11に記載の製品。
前記領域上には、電磁波を熱に変換する熱変換層が設けられており、
前記熱変換層が、前記上部コンタクト部として機能する、
ことを特徴とする付記11に記載の製品。
前記領域上には、電磁波を熱に変換する熱変換層が設けられており、
前記上部コンタクト部は、前記熱変換層の上に設けられる、
ことを特徴とする付記11に記載の製品。
付記11乃至14のいずれか1つに記載のスイッチを備える電子機器である、
ことを特徴とする製品。
前記製品はシールであって、
前記造形物を備え、
前記造形物の他方の面上に、接着層を更に備える、
ことを特徴とする付記10に記載の製品。
前記製品は照明器具であって、
前記造形物をランプシェードとして備える、
ことを特徴とする付記10に記載の製品。
前記造形物は、前記熱膨張層が膨張された領域における透光性が、前記熱膨張層が膨張されていない領域と比較して高い、
ことを特徴とする付記17に記載の製品。
Claims (12)
- 基材の一方の面に熱膨張性材料を含む熱膨張層が形成された樹脂成形シートを用い、前記樹脂成形シートの一方の面に電磁波を熱に変換する熱変換層を形成する第1の形成工程と、
前記熱変換層が形成された側から前記電磁波を照射し、前記熱膨張層を膨張させて凸部を形成する第1の膨張工程と、
前記基材の一方の面と反対の面に、前記熱変換層を形成する第3の形成工程と、
前記反対の面に形成された前記熱変換層に対して前記電磁波を照射し、前記熱膨張層を膨張させて当該反対の面に凹部を形成する第2の膨張工程と、
を備え、
前記第2の膨張工程において、前記基材を前記熱膨張層の膨張に追従して変形させ、前記基材をエンボス状に変形させる、
ことを特徴とする造形物の製造方法。 - 前記基材は、前記第2の膨張工程において前記反対の面に前記凹部を形成する際、前記熱膨張層の追従に伴って、当該基材の変形量を前記熱膨張層の膨張高さより大きくなる、
ことを特徴とする請求項1に記載の造形物の製造方法。 - 前記基材の厚みは、前記熱膨張層の厚みと同じ、又は前記熱膨張層より厚い、
ことを特徴とする請求項1又は2に記載の造形物の製造方法。 - 前記基材は、熱可塑性樹脂から形成される、
ことを特徴とする請求項1乃至3のいずれか1項に記載の造形物の製造方法。 - 前記第3の形成工程で形成される前記熱変換層の面積は、前記第1の形成工程で形成される前記熱変換層の面積より大きい、
ことを特徴とする請求項1乃至4のいずれか1項に記載の造形物の製造方法。 - 前記第1の膨張工程の後であって、前記第3の形成工程の前に、前記凸部にカラーインク層を形成する第2の形成工程をさらに備える、
ことを特徴とする請求項1乃至5のいずれか1項に記載の造形物の製造方法。 - 前記第2の形成工程において、前記第1の形成工程で形成される前記熱変換層の形成領域に重なるように、前記カラーインク層を形成する、
ことを特徴とする請求項6に記載の造形物の製造方法。 - 前記第2の形成工程において、前記第2の膨張工程で形成される前記凹部の形成領域に少なくとも重なるように、前記カラーインク層を形成する、
ことを特徴とする請求項7に記載の造形物の製造方法。 - 前記第2の形成工程において、前記第3の形成工程で形成される前記熱変換層の形成領域に少なくとも重なるように、前記カラーインク層を形成する、
ことを特徴とする請求項6乃至8のいずれか1項に記載の造形物の製造方法。 - 前記樹脂成形シートは、前記一方の面にフィルムが設けられていて、
前記第1の形成工程において、前記樹脂成形シートに設けられた前記フィルム上に前記熱変換層を形成し、
前記第1の膨張工程の後に、前記フィルムを除去する工程をさらに備える、
ことを特徴とする請求項1乃至9のいずれか1項に記載の造形物の製造方法。 - 前記第1の膨張工程の後であって、前記第2の形成工程の前に、前記フィルムを除去する工程をさらに備える、
ことを特徴とする少なくとも請求項6乃至9のいずれか1項を引用する請求項10に記載の造形物の製造方法。 - 前記樹脂成形シートは、前記反対の面にフィルムが設けられていて、
前記第3の形成工程において、前記樹脂成形シートに設けられた前記フィルム上に前記熱変換層を形成し、
前記第2の膨張工程の後に、前記フィルムを除去する工程をさらに備える、
ことを特徴とする請求項1乃至11のいずれか1項に記載の造形物の製造方法。
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