JPH03167000A - Production of product with inlaid pattern - Google Patents

Abstract

PURPOSE:To develop a detailed inlaid pattern on the surface of a final product by a method wherein the first mold plate having a groove pattern on the surface thereof is formed and a synthetic resin having good releasability is cast on the surface thereof to form the second mold plate having a reversal groove pattern and a base material is injected therein to be cured. CONSTITUTION:An original plate 2 and a cover film 3 are placed on the upper surface of a glass plate 1 to be coated with a liquid ultraviolet curable resin 4 and a base film 5 is bonded to the coating surface of the resin 4. Subsequently, a glass plate 6 is placed on the upper surface of the base film 5 to bake the pattern 8 of the original plate 2 to the resin 4 by an ultraviolet lamp group 7. The uncured resin 4 is washed off to develop a protruding groove pattern 8a on the under surface of the resin 4 and the resin 4 is again irradiated with ultraviolet rays to obtain the first mold plate M1. A synthetic resin having good releasibility is cast on the surface of the first mold plate M1 to be cured and subsequently released from the first mold plate M1 to form the second mold plate M2 having the reversal groove pattern 8b of the groove pattern 8a. The second mold plate M2 is placed on the inner bottom surface of a retaining mold 10 so as to turn the mold surface upwardly and a base material 11 is kneaded to be injected in the retaining mold 10 and subsequently cured to prepare a block 12.

Description

DETAILED DESCRIPTION OF THE INVENTION (a) Field of Industrial Application This invention relates to a method for manufacturing a product with an inlaid pattern. Note that the inlaid patterned products mentioned here include not only ordinary concrete products and resin concrete products, but also ALC concrete products, gypsum boards, fire-resistant covering materials, fire-resistant building materials, and the like. Part C) Conventional Technology Conventionally, in order to make I keyaki or characters appear on the surface of the above-mentioned products, etc., it has been done by using paint or other paint and manually copying them while referring to the original drawings. However, because the surface of the product is rough, it is difficult to create detailed patterns, and the durability is poor due to fading or peeling of the paint.Furthermore, it is time-consuming to draw the same pattern in large quantities. There was a drawback. Therefore, the applicant of this application filed Japanese Patent Application No. 62-109548 (
In the title of the invention, ``Method for producing products with inlaid patterns,'' a method for solving the above drawbacks was disclosed. That is, in this method, an original am is baked on an ultraviolet curable resin to create a storage mold, and the same mold is used to create a consumable mold of a plastic material that is soluble in water, solvent, or heat. A mold is made using a mold, a base material that hardens in the mold after pouring is injected into the mold, and the consumable mold is removed from the surface of the block generated by the hardening of the base material. Forming a pattern on the surface, filling the same pattern with a colored material different from the base material, and after curing the same colored material, an inlaid pattern is made to appear on the surface of the block by polishing. This is a characteristic feature. Moreover, by this method, it is possible to produce an inlaid patterned product having a relatively detailed pattern substantially similar to that of the original. (c) Problems to be Solved by the Invention However, the method for manufacturing products with inlaid patterns still has the following problems to be solved. That is, the above manufacturing method uses a storage mold and water in the manufacturing process. It is necessary to create a consumable mold of a plastic material that can be melted with either solvent or heat, and paraffin is used as such a consumable mold. However, paraffin has low mechanical strength such as tensile strength, and also has a low elastic modulus, that is, a low expansion/contraction ratio. When paraffin is removed, paraffin strips become trapped within the groove pattern in the concrete block. Therefore, after that, the decorative material cannot flow uniformly and evenly into all the groove patterns, and a vivid and detailed inlaid pattern cannot appear on the surface of the final product. It was losing value. Moreover, after using such paraffin as a consumable type,
It is necessary to melt it using boiling water, which is complicated to handle, and also needs to be done manually, making the entire manufacturing method complicated and time-consuming.

Furthermore, the consumable type made of paraffin cannot be reused at all, which poses a problem from an economic standpoint. An object of the present invention is to provide a method for manufacturing a product with an inlaid pattern that can solve the above problems. (2) Means for Solving the Problems The present invention provides a method of: a) irradiating an ultraviolet curable resin with ultraviolet rays and removing the uncured portions of the ultraviolet rays corresponding to the pattern to be inlaid;
A first template having a groove pattern on the surface is created, b) a synthetic resin with good mold release properties is poured onto the surface of the first template, and the surface is
A second template having a groove pattern that is an inversion of the groove pattern of the first template described above is created, and C) the same second template is installed in the mold, and a base material is injected into the same. c) curing the base material, d) peeling off the second template from the surface of the block produced by curing the base material, and forming a groove pattern on the same surface that is an inversion of the groove pattern of the second template; e) In the same groove pattern,
Filled with a decorative material that has a different color from the base material,
f) A method for manufacturing a product with an inlaid pattern, characterized by comprising the above-mentioned steps of polishing the decorative material (13) to make an inlaid pattern appear on the surface of the block (12) after hardening. It is. (E) Functions and Effects According to the present invention, a synthetic resin with good mold releasability such as silicone resin or urethane resin added with fluororesin is poured onto the surface of the first template as the second template. You can use the template you created. Since the second template has sufficient elasticity and mechanical strength such as tensile strength, it has extremely good releasability and can be easily peeled off from the concrete block after hardening. Therefore, even if the groove pattern formed on the surface of the concrete block is extremely fine, it is possible to reliably prevent the pieces of the second template from entering and remaining in the groove pattern during the peeling operation. Therefore, the decorative material can subsequently flow uniformly and evenly into all the groove patterns, and an extremely fine inlay pattern can appear on the surface of the final product. The product value can be significantly improved. In addition, the second template made by pouring a resin with good mold releasability, such as silicone resin or urethane resin containing fluororesin, can be easily peeled off from the concrete block and can be reused. Since this is possible, economic efficiency can also be significantly improved. It is also conceivable to form the second mold plate from a material other than the above-mentioned Hewei resin with good mold release properties, and to apply a mold release agent to the surface of the second mold plate in order to improve the mold release properties. However, in blocks made of basic materials such as concrete produced using such a second template, the mold release agent is transferred into the groove pattern, so decorative materials are filled into the groove pattern. However, the decorative material cannot be integrated with the block, making it impossible to manufacture products with inlaid patterns. From this point of view as well, the effectiveness or significance of forming the second template from a resin with good mold release properties such as a silicone resin or a urethane resin added with a fluororesin can be found. (f) Examples Hereinafter, a method for manufacturing an inlaid patterned product according to the present invention will be explained in detail with reference to examples shown in the attached drawings. First, the original plate 2 used for manufacturing the inlaid patterned product of the present invention.
I will explain about it. As shown in FIG. 1, the original plate 2 is a raw film F for the original plate in which a transparent base layer T is laminated with a light-shielding surface layer R in a peelable manner. It can be formed by the method shown below. That is, the design concept of the pattern 8, such as the inlaid painting or letters, is determined (50). Next, while displaying the image of the pattern (5l), draw it on the computer using a keyboard or mouse (52),
Or, edit the original picture (53) and scan it with a scanner (
54), input the image data into the computer. The image data input in this way can be easily changed to positive negatives, the position or part of the pattern, enlarged or reduced, and in the case of text, changed fonts such as plain or italic, so you can easily create the original image. There is no need for experienced personnel to do this, and the effort and time required to create the original plate can be greatly reduced. Next, the original drawing means P such as an XY blotter is driven using the above image data, and the cuff C of the original drawing means P makes incisions based on the image data only on the light-shielding surface layer R of the original 2. The part with the incision is peeled off from the surface layer R, and an original plate 2 is created in which the pattern 8 to be inlaid is exposed (55
), Another method of creating an original plate is a hand-drawn original (
53), and the raw film F for the original plate is used as the original plate 2.
(56). Next, the production of an inlaid patterned product using the original plate 2 will be explained with reference to the flowchart of FIG. 2 and the schematic diagrams of the production situation shown in FIGS. 3 to 10. 3 to 6 show the manufacturing process of the first template H1. Original plate 2. Cover film 3 is placed in this order, and liquid ultraviolet curable resin 4 is placed on the top surface of the film 3.
and adhere base film 5 to the same coated surface. (
Figure 3). Here, to explain the ultraviolet curable resin 4, the resin 4 is a urethane or polyester photopolymer, the cover film 3 is a polypropylene film with a thickness of 30 μm, and the paste finolem 5 is a polypropylene film with a thickness of 10 μm.
0 μm polyester film. Next, a glass plate 6 is placed on the top surface of the base film 5, and the pattern 8 of the original plate 2 is printed on the same ultraviolet curable resin 4 using 7 groups of ultraviolet lamps arranged with the upper and lower glass plates 6.1 in between. wear. Therefore, the transparent portion from which the light-shielding surface layer R has been removed and the ultraviolet curable resin 4 between the transparent portion and the base film 5 are cured (FIG. 4). Wash away the uncured resin 4 with a washout liquid 9 such as a solution containing a surfactant, etc.
A protruding groove pattern 8a is made to appear on the lower surface of the resin 4 (Fig. 5). The remaining ultraviolet curable resin 4 is irradiated with ultraviolet rays again to after-cure and form the first template. MI (57) (Figure 6). Next, the production of an inlaid patterned product using the original plate 2 will be explained with reference to the flowchart of FIG. 2 and the schematic diagrams of the production situation shown in FIGS. 7 to 11. As shown in Figure 7, a synthetic resin with good mold releasability such as urethane resin containing silicone resin or fluorine resin is poured onto the surface of the first type tffln+ created as described above (58) ( Figure 7〉.As such urethane resin, DEPENSA?l from Dainippon Ink & Chemicals ■
A urethane resin containing a fluorine surface modifier added in CFC can be used. When such a surface modifier is added internally to a urethane resin, it is quickly oriented on the surface and can modify the surface. That is, it has high water and oil repellency, non-stick properties, and good mold release properties. After the above-described resin with good mold release properties is cured, the resin is peeled off from the first mold plate M, and the groove pattern formed on the surface of the above-described first mold plate is applied to the surface. A second template M7 having a groove pattern 8b which is an inversion of 8a is formed (59). A second mold plate M is placed on the inner bottom surface of the mold 10 with the mold surface facing upward (60), and 1 l of base material is kneaded (61).
Inject into the formwork 10 (62) (Fig. 8). after that,
Curing for a certain period of time to harden the base material l1 (63);
Block 12 is produced (FIG. 9).

Note that the grain size of the base material 11 is selected depending on the fineness of the inlaid pattern 8d of the inlaid pattern product B, which is the final product to be described later, and the inlay pattern I! The finer the i8d, the finer the grain size is used. In addition, as the material for the fine-grained base material l1, cement. There are those that solidify through the Eiwa reaction, such as mortar and plaster, and those that are mixed with silica fume, fly ash, limestone, etc. that have been crushed to a particle size of 1 μm or less. Further, as the base material 11, a mixture of thermosetting resin such as unsaturated polyester resin and powdery fine aggregate can also be used. Further, in order to prevent air bubbles from entering the base material 11 poured into the formwork 10 and damaging the groove pattern 8c, the kneaded base material 11 may be subjected to vacuum defoaming treatment before casting. ．． It is also possible to attach the formwork 10 to a centrifugal machine and cast the base material 11 in a compacted state using centrifugal force. Then, the block 12 is taken out from the formwork IO together with the second template M2, and the second template M2 is mechanically peeled off (64).
(FIG. 9), after the second template M2 is removed, the concave portion formed on the surface of the block 12, that is, the second template M2 is removed. The groove pattern 8c, which is an inversion of the groove pattern 8b, is filled with a decorative material 13 having a different texture and color from the base material 1l forming the block 12 (65) (FIG. 10),
Wait for curing and complete hardening of the decorative material 13 (66
), the surface of the block 12 is polished using a whetstone 14 or the like to remove the inlaid pattern 8d, thereby producing an inlaid pattern product B.
(67) (Figures 11 and 12). However, without waiting for the decorative material l3 to cure and completely harden,
You can also puff it while pouring water on it while it is in a semi-hardened state. In this case, a shadow can be formed on the surface of the inlaid patterned product B to improve the aesthetic effect, and when used as a block for forming a road surface, it can also provide an anti-slip effect.

Furthermore, it is also possible to shot-peen the surface of product B with an inlaid pattern using 11 steel balls to give it a unique aesthetic appearance. Further, the fabric of the decorative material 13 is made of the same texture and grain size as the base material 11, and by mixing pigments etc. into the fabric, the color can be freely selected. Of course, the decorative material f413 can not only change its color with respect to the base material 1l, but also its strength.

For example, for the purpose of improving the aesthetic effect, decorative materials l3
Alternatively, an unsaturated polyester resin or epoxy resin may contain an ultraviolet light-emitting substance that develops a vivid color when irradiated with ultraviolet light. As the ultraviolet light-emitting substance, for example, manganese-activated, arsenic-activated zinc silicate green-emitting phosphor, manganese-activated magnesium silicate red-emitting phosphor, manganese-activated zinc orthophosphate red-emitting phosphor, etc. can be used.

As explained above, this embodiment has the following effects.

■ As the second template M2, use a template created by pouring a resin with good mold release properties, such as silicone resin or urethane resin added with fluororesin, onto the surface of the first template H. Can be done. Unlike paraffin or the like, the second mold plate M2 has sufficient elasticity and mechanical strength such as tensile strength, so it has extremely good mold releasability and can be easily peeled off from the block 12 after hardening. ．． In particular, when a urethane resin to which a fluororesin is added is used, the fluororesin precipitates on the surface of the second mold plate M2 and modifies the surface, resulting in extremely good mold releasability. Therefore, the groove pattern il8c formed on the surface of the block 12
Even if the surface is extremely fine, the second mold 1 inch is used during peeling work.
It is possible to reliably prevent the small pieces of t from entering into the groove pattern 8c and remaining in the same groove pattern 8c. Therefore, after that, the decorative material l3 is applied to all the groove patterns 8.
c, and an extremely fine inlaid pattern 8d can be produced on the surface of the final product, thereby significantly improving the product value of the inlaid patterned product B. ．． In addition, the second template Mt made by pouring a silicone resin or a resin with good mold release properties such as urethane resin added with a fluororesin can be easily peeled off from the block 12 and can be reused. Since it can also be used, economic efficiency can be significantly improved. ■Furthermore, a second mold plate M made of such silicone, etc.
In the block 12 made of the basic material l1 such as concrete produced using , the decorative material l3 can be reliably integrated with the block 12 and an inlaid patterned product can be produced which can be used permanently.

Note that depending on the type of silicone, etc., oil and fat components may be slightly exposed on the surface of the second template M2, but in this case, before filling the decorative material 13, jet air is applied to the It can be easily removed by spraying, etc. Further, other embodiments of the method for manufacturing an inlaid patterned product will be described with reference to FIGS. 13 to 16.

First, the second template M2 is placed on the inner bottom surface of the mold 10O with the mold surface facing upward, and the first decorative material 13a is placed on the second template M2. ! ．． 1 l of base material is kneaded and injected into the formwork 10 while filling the inside of the groove pattern 8b (13th
figure). Thereafter, the substrate material 11 and the first decorative material 13a are cured for a certain period of time to harden, thereby producing the block 12 (Fig. 14). Note that as the base material 11, a material having the same &Il strength as in the above-mentioned embodiments can be used.

Then, the block 12 is taken out from the formwork 10 together with the second template M2, and the second template M2 is mechanically peeled off (the 14th
After that, the block 12 is shaped into a recess formed on the surface of the block 12 after the second mold board 2 is removed, that is, into a groove pattern 8c that is an inversion of the groove pattern 8b of the second mold plate n2. Filled with a second decorative material 13b having a different texture and color from a certain base material l1 and the first decorative material 13a (
15), wait for curing and complete hardening of the decorative material 13, and then polish the surface of the block 12 using a grindstone 14 or the like to polish the inlaid pattern 8d.
(Figure 16).

[Brief explanation of the drawing]

Fig. 1 is a partial perspective view of an original plate used in the method for manufacturing an inlaid patterned product according to the present invention, Fig. 2 is a flowchart of the manufacturing process, and Figs. 3 to 6 are explanatory diagrams of the first template manufacturing process. , Fig. 7 is an explanatory diagram of the manufacturing process of the second template, Fig. 8 is an explanatory diagram of the base material casting process, Fig. 9 is an explanatory diagram of the peeling process of the second template, and Fig. 10 is an illustration of the decorative material. FIG. 11 is an explanatory diagram of the polishing process, FIG. 12 is a perspective view of the inlaid patterned product manufactured by the above manufacturing process, and FIG. 13 is casting of the base material in another example. An explanatory diagram of the process, FIG. 14 is an explanatory diagram of the peeling process of the second template in the same example,
Figure 5 is an explanatory diagram of the filling process for decorative materials, and Figure 16 is an explanatory diagram of the sanding process. In the figure, (F): Raw film for original plate (1: 1st template (M2): 2nd template (8): 1 style (8a): Groove pattern (8b): Groove g4 style (8c): Groove Pattern (8d): Inlay pattern (10): Formwork (11): Base material (12): Blossom (13): Decorative material

Claims (1)

[Claims] 1. a) A first template (M_1) having a groove pattern on the surface is obtained by irradiating an ultraviolet curable resin with ultraviolet rays and removing an uncured portion of the ultraviolet rays corresponding to the pattern to be inlaid. b) Pour a synthetic resin with good mold release properties onto the surface of the first template (M_1) to form a groove pattern on the surface that is an inversion of the groove pattern of the first template (M_1). Create a second template (M_2), and c) Place the second template (M_2) in the formwork (10) and inject the base material (11) into it. d) Peeling the second template (M_2) from the surface of the block (12) generated by curing the base material (11), and forming the groove pattern of the second template (M_2) on the same surface. forming an inverted groove pattern; e) filling the same groove pattern with a decorative material (13) having a different color from the base material (11);
13) After curing, a method for manufacturing a product with an inlaid pattern is characterized by comprising the above-mentioned steps of polishing to reveal an inlaid pattern on the surface of the block (12). 2. The method for manufacturing an inlaid patterned product according to claim 1, wherein the second template (M_2) is made of silicone resin. 3. The method for manufacturing an inlaid patterned product according to claim 1, wherein the second template (M_2) is made of urethane resin to which a fluororesin is added.