JPS62267116A - Manufacture of decorated molded item - Google Patents

Abstract

PURPOSE:To obtain a decorative product with high decorativeness in design by a method wherein embosses pattern is formed on a thermoplastic resin sheet, which can be laminated to the rugged surface of a laminate having the rugged surface, and, after being provided with an emboss protective layer in order to prevent the embossed pattern from deforming, made into an integral body with the laminate having the rugged surface. CONSTITUTION:Hardening type resin 2 is applied onto the embossed surface of a thermoplastic resin sheet 1 by thickness which does not impair embossed form, and then hardened in order to make a laminating sheet 3. Next, the laminating sheet 3 is preformed with a vacuum mold. Molding resin is injected in an injection mold, onto the inner surface of which the preformed laminating sheet is installed, so as to be vacuum formed. After the hardening of the resin, a molded item is removed from the mold in order to make a product of the molded item 4 having embossed surface integrated with the laminating sheet 3.

Description

Detailed Description of the Invention (Industrial Application Field) The present invention is directed to forming a pattern on the entire surface of an article such as a plastic deck molded article that has a three-dimensional shape and partially has the same opening. The present invention is particularly applicable to molded products used in radio, television, video and audio cabinets, automobile instrument panels, console boxes, furniture interior parts, stationery, toys, etc.

(Prior art) Conventionally, methods for forming patterns on three-dimensional articles include:
Usually called the suminagashi method, a molded product is extruded using two to three colored colored pellets on a resin pellet for molding. ■A method called hot stamping, in which a molded product is transferred to a releasable plastic film with a pattern applied to it under heating conditions. ■After vacuum-forming a film with a pattern close to the desired three-dimensional molded product, the vacuum-formed product is placed in the mold of the three-dimensional molded product, and injection molded to combine the molded product and the vacuum-formed film. How to bring it all together. Alternatively, the same method can be used to impart releasability to the vacuum-formed film and transfer only the design onto the molded product. ■Hydraulic transfer is a method in which a pattern is printed on a film such as vinylon, and the pattern is transferred onto a molded product using water pressure underwater.

(Problems to be Solved by the Invention) With the conventional methods described above, although it is possible to form a pattern on the surface of a molded product having an uneven surface, it is possible to form an uneven pattern on the patterned surface, such as a conduit groove in the wood grain. Make a shape like this.
I couldn't get to 5.

Also, if an uneven pattern is formed on the inner surface of the mold and resin is injected into the pattern, it is possible to form an uneven pattern on the surface of the molded product. It was necessary to use a carving method, etc., and it was not possible to form a realistic uneven pattern such as the conduit grooves of wood grain.

(Means for Solving the Problems) The present invention faithfully reproduces the realistic feel, feel, and texture of natural products, which cannot be obtained with the conventional methods described above, and which matches the pattern. We provide three-dimensional devices@products that are so authentic that they cannot be distinguished from natural products.

That is, in a laminate having an uneven surface, an uneven pattern is formed on a thermoplastic resin sheet that is not laminated on the uneven surface, and an uneven protective layer is provided to prevent the uneven pattern from being deformed. It is a technology that integrates with

The present invention will be described in detail below with reference to the drawings.

First, as shown in FIG. 2, irregularities are formed on the surface of a thermoplastic resin sheet (1). These irregularities may be formed directly on the thermoplastic resin sheet, or a printed pattern layer may be formed on the surface of the thermoplastic resin sheet as necessary, and a heat-softening resin layer may be formed on top of the printed pattern layer. It is also possible to form irregularities on the layer. Of course, a printed pattern layer may be formed on the surface of the thermoplastic resin sheet, and irregularities may be formed thereon.

Examples of means for forming unevenness include an embossing plate or an embossing roll in which unevenness is formed by engraving or etching on the surface of a metal plate or metal roll, and an embossed sheet printed in raised shapes on the surface of a sheet-like object and wrapped around a plate or roll. However, if you use an embossing plate or embossing roll made based on an embossed sheet made by molding the surface shape of a natural product such as wood using silicone resin, you can create an uneven surface that has a more realistic appearance that is closer to that of a natural product. can be formed.

Next, a curable resin (2) is applied to the uneven surface of the thermoplastic resin sheet (1) to a thickness that does not damage the uneven shape,
A cured-IC lamination sheet (3) is produced.

Next, the lamination sheets i to (3) are preformed using a vacuum mold, the preformed lamination sheet is attached to the inner surface of the injection mold, and the molding resin is injected to form the vacuum mold. After the resin has hardened, the molded product is taken out of the mold, and as shown in FIG. 1, an integrated product of the lamination sheet (3) and the molded product (4) having an uneven surface is produced.

Thermoplastic resin sheets (1) include polyvinyl chloride sheets, polyethylene sheets, polyp L1 pyrene sheets,
Polyester sheet, nylon sheet, ABS resin sheet, polyimide sheet, acrylic sheet, polyvinyl acetate sheet, vinylidene chloride sheet, fluororesin sheet 1~, polycarbonate sheet 1~, using each of the above resins (synthetic paper, nonwoven fabric, A composite sheet can be used by arbitrarily combining each of the above sheets 1 to 1.Also, a printed pattern layer can be formed on the surface of the sheet as in -5= above, or a coloring material can be mixed into the sheet. It can also be used as a colored sheet.

The curable resin (2) includes photocurable resins such as acrylic resins and polyester resins, acrylic urethane resins,
Thermosetting resins such as urethane-based, polyester-based, epoxy-based, and melamine-based resins can be used, and a thickness of about 2 to 30 μm that does not impair the uneven shape is appropriate.

The irregularities formed on the surface of the thermoplastic resin sheet (1) include
Coloring materials can also be embedded using the wiping method, etc.
Furthermore, after forming a surface protective layer thereon, a resin having mold releasability may be applied.

(Function) The thermoplastic resin sheet is softened by the heat of heating and softening when pasting it to the object to be laminated, and the heat applied when molding the resin.
However, the concave parts on the surface of the thermoplastic resin sheet are completely retained in shape by the hardening resin applied to the surface, so they do not deform, and the realistic concave and convex shape given during embossing remains the decoration. reproduced on the surface of the product.

(Effects of the Invention) A decorative product with a high design quality can be obtained by laminating sheets with a realistic uneven pattern formed on the surface.

■Since the irregularities are formed in advance on the sheets before lamination, it is possible to use electroforming plates with high reproducibility and the use of low-cost high-frequency molding methods. W
I can make A.

(Example) A straight-grain oak pattern was applied to a six-color Δ133 resin sheet with a thickness of 0.4 mm using a gravure printing method, and an uneven pattern was formed on the surface using an embossing roll.

The embossing roll used was a Den Q+i roll molded from natural wood with an A-ri straight grain pattern.

Next, a coloring material was embedded in the concave portions of the uneven pattern using a wiping method, and an acrylic photocurable resin was applied to a thickness of 5μ by a gravure printing method on the entire surface at 80W/cm. The resin was cured by irradiation with a photopolymerization lamp for 6 seconds to obtain lamination sheets 1 to 1.

Next, a τ lamination sheet is preformed using a vacuum forming mold of the same shape as the cutting mold for molding the roll box of an automobile, and then the preformed sheet 1 is subjected to the injection molding. The mold was placed in a mold, and ABS resin was injected at a resin temperature of 230° C. and a discharge pressure of 1,500 KI/cnf to obtain a decorative product.

[Brief explanation of drawings]

The drawings explain the present invention in detail, and FIG. 2 is a sectional view showing the structure of the lamination sheet, and FIG. 1 is a cross-sectional view showing the state in which the molded product and the lamination sheet are integrated.

Claims (1)

[Claims] The first step is to form irregularities on the surface of the thermoplastic resin sheet. A second step of applying a curable resin to the uneven surface to a thickness that does not impair the uneven shape and curing it to produce a lamination sheet. A third step of preforming the lamination sheet. A fourth step of mounting the preformed lamination sheet in an injection mold and injecting a molding resin into the mold to produce a molded product integrated with the preformed lamination sheet. A method for producing a decorated molded article, characterized by comprising the above steps.