JPS62277183A - Production of ornamental sheet - Google Patents

Abstract

PURPOSE:To easily produce an ornamental sheet by coating a liquid resin on the surface of an air permeable member, blowing gas to the air permeable member from the rear side thereof to cure the liquid resin while napping said resin and partially pressing the napped part thereby forming a pattern. CONSTITUTION:The liquid resin consisting of a polyester resin is coated onto the surface of the air permeable member 3 which is a non-woven fabric. The gas H is blown from a low part 14 on the rear or front side of the member 3 to cure the liquid resin while napping 6 the same and at the same time, the napped part 6 is partially pressed by a pressing member 16 to form the pattern 8. More specifically, the pattern of characters, pictures, etc., is formed on the surface and in addition, the ornamental sheet provided with a high-grade feeling by the excellent touch is easily and inexpensively produced.

Description

Detailed Description of the Invention 3. Detailed Description of the Invention Object of the Invention (Industrial Application Field) The present invention relates to a method for producing a decorative sheet having a raised decorative layer on its surface.

(Prior technology) In various synthetic resin molded products such as automobile interior parts and indoor equipment products, it is necessary to give an excellent appearance, hide defects such as scratches and uneven color on the resin surface, and give a sense of luxury. Therefore, it is useful to decorate the surface.

Furthermore, it is desirable to form a flocked layer on the surface of the resin molded product, not only to solve the problem of appearance but also to improve the feel to the touch.

As a method for forming this flocked layer, an electrostatic flocking method has been generally used.

In recent years, there has been a trend toward favoring bankskin-like flocked hair, which looks luxurious and has an excellent feel to the touch.

(Problem to be solved by the invention) However, in the electrostatic flocking method, the direction of flocking is always perpendicular to the molding surface in any part of the molded product, so the whole molded product is not uniform. As a result, it lacked an interesting appearance.

Furthermore, in this flocking method, since the pile is adhered to the surface of the molded article, an expensive pile and adhesive are separately required, and at least two steps, an adhesion step and an electrostatic flocking step, are required. Therefore, there are problems in that the material cost increases, as well as the manufacturing time and manufacturing cost.

In addition, in order to form products using the electrostatic flocking method, flocking work must be performed between each completed product.
In order to process a plurality of products at once, a large-scale device is required, and when this large-scale device is employed, there is a problem in that the manufacturing cost increases.

Therefore, an object of the present invention is to eliminate the need for the expensive piles and adhesives used in the above-mentioned flocking method, and to create a decorative layer that can be applied to a molded product to provide a richly varied appearance and an excellent feel to the touch. An object of the present invention is to provide a method for manufacturing a decorative sheet.

Structure of the Invention (Means for Solving the Problems) In order to solve the above-mentioned problems, the present invention applies liquid resin to the surface of a breathable member and sprays gas from the back or surface of the breathable member. A method is adopted in which the liquid resin is cured while being raised and the raised raised is partially pressed to form a pattern.

(Function) When liquid resin is applied to the surface of the breathable member and gas is blown from the back side of the breathable member, the gas passes through the breathable member. At this time, the gas passes through the space of the air-permeable member and is narrowed down, and its pressure further increases, so that the gas passes through the resin on the surface side of the air-permeable member. Due to the penetration of this gas, the resin in the vicinity stands up like fluff, forming an elongated pile-like raised portion. In parallel with this gas penetration, since the liquid resin starts to harden after being applied, the raised portion is hardened in an upright state.

Further, when a gas is sprayed from the surface of a breathable base material whose surface is coated with a liquid resin, the surface of the liquid resin is undulated by the pressure of the sprayed gas.

This ripple causes the resin surface to stand up like a hair, forming a raised part, and is cured in the upright state in the same manner as described above.

When the raised portion is formed and at least a portion of the raised portion is pressed, the raised portion of the raised portion is deformed into a flat shape and forms a concave portion when viewed from the raised portion. A pattern is formed by these recesses.

(Example) Hereinafter, an example in which the present invention is applied to a skin attached to the surface of a center pillar interior material of an automobile will be described with reference to FIGS. 1 to 4.

First, to explain the center pillar interior material formed by this method, as shown in Figure 2.3, AB
An adhesive is applied to the surface of a base material 1 made of S resin to form an adhesive layer 2.

A skin 10 of this embodiment is adhered to the surface of the adhesive layer 2, and this skin 10 will be described below.

This skin 10 is composed of a -r, yIa cloth 3 as a breathable member bonded to an adhesive layer 2, and a decorative portion 4 made of polyester resin integrally formed on the surface thereof.

The decorative portion 4 includes a base portion 5 integrally joined to the nonwoven fabric 3, and a raised portion 6 that stands up three-dimensionally from the base portion 5. Each of the raised portions 6 is formed to protrude in the form of a pile, and each has a moist feel and flexibility, so that the whole has a buckskin-like feel to the touch.

Further, the skin 10 is partially provided with a portion where the raised portion 6 is not formed, and this portion forms a recess when viewed from the raised portion 6, and this recess forms the letter 8 of the alphabet as a pattern. are doing.

The center pillar interior material 7 configured as described above has approximately the same feel to the touch as a conventional center pillar interior material to which buckskin is pasted, due to the raised portion 6 of the skin 10 pasted on the surface. Furthermore, since the letters 8 consisting of concave portions are formed on the surface of the skin 10, the overall appearance is excellent and luxurious.

Next, a method for manufacturing the center pillar interior material constructed as above will be explained with reference to FIG. 1.3.4.

First, among the devices used in this method, the device for forming the skin 10 will be explained. In front of the delivery shaft 11 (shown on the right side in FIG. 1), which is equipped with a delivery mechanism for delivering the roll-shaped nonwoven fabric 3, there is a liquid A nozzle 12 of a coating mechanism for coating the nonwoven fabric 3 with resin is provided. A plurality of infrared lamps 13 are provided in front of the nozzle 12 to spray a certain amount of the liquid resin solvent. In front of the infrared lamp 13, there is provided an air outlet 14 of an air blowing mechanism that blows hot air H from below the nonwoven fabric 3 to form a raised portion 6 on the surface. Accelerates resin curing. By pressing the raised portion 6 from above, the raised portion 6 is formed at a portion of the air outlet 14 that is substantially opposite to the surface of the air outlet 14 with the skin 10 in between.
A pressing member 16 that deforms into a flat shape to form a character 8 is provided so as to be movable up and down.

Next, a method for forming the center pillar interior material 7 of this embodiment using this apparatus will be explained.

First, the nonwoven fabric 3 is wound into a roll and the delivery shaft 1 is
1, and the tip thereof is guided to the nozzle 12 portion by rotation of the delivery shaft 11.

When the nonwoven fabric 3 is placed in the nozzle 12 by this operation, liquid polyester resin is flowed from the nozzle 12 to form a liquid resin layer 15.

Thereafter, the solvent in the liquid resin layer 15 is blown off to some extent by the infrared lamp 13, and pressurized hot air H is blown from the blower outlet 14 toward the nonwoven fabric 3 from the lower side, which is the back surface of the nonwoven fabric 3.

Then, the hot air H passes through the fine meshes of the nonwoven fabric 3 and is blown onto the liquid resin, and the pressure of the hot air H causes the portions of the resin that are hit by the air to bulge. However, since the hot air H passes between the fine meshes of the nonwoven fabric 3, the blowing pressure increases further, and the hot air H passes through the resin layer 15 at the raised portion.Therefore, as shown in FIG. Then, that part of the liquid resin layer 15 stands up like a tuft to form an elongated pile-like raised part 6. Therefore, the resin 1ii
15 is formed by hot air H into 2N of the raised raised portion 6 and the unraised base portion 5. Note that the curing of the liquid resin is promoted by the blowing of the hot air H.

Furthermore, at the same time as forming the raised portion 6, the pressing member 1
6 is lowered and pressed against the raised part 6. Then, the raised portion 6 is deformed into a planar shape and becomes a concave portion when viewed from the raised portion 6, forming the character 8.

Since each pile of the raised part 6 has a moist feel and flexibility, the decorative part 4 as a whole not only has a buckskin-like texture, but also a part of it has a texture similar to that of buckskin. The character 8 is also formed.

Finally, the skin 10 thus formed is trimmed to be larger than the base material 1, and is adhered to the ABS resin base material 1, which is formed by injection molding or the like and whose surface is coated with an adhesive. If the outer periphery is wrapped around the back surface of the base material 1, it is possible to form the center pillar interior material 7 in which the entire surface has a buckskin texture and the letter 8 is applied.

As described above, according to this embodiment, since the letters 8 are formed on the surface of the skin 10, the appearance is excellent, and the decorative portion 4 has a buckskin-like feel to the touch.
The entire center pillar interior material 7 can have a sense of luxury.

Furthermore, according to the above method, decoration can be applied without using the electrostatic flocking method that requires expensive piles and adhesives, and it is also possible to easily create a buckskin-like texture that is difficult to achieve with the electrostatic flocking method. Not only can it be printed out, but characters such as the letter 8 can also be easily added to the front side. Further, this buckskin-like decorative portion 4 can be manufactured at a much lower cost than when actual buckskin is used.

Furthermore, since the process of forming the skin 10 is performed in a series of continuous steps, it can be manufactured in a very short manufacturing time.

Furthermore, since this skin 10 is formed in a sheet state,
Parts other than the center pillar interior material 7 of this embodiment can be easily modified and implemented.

Furthermore, since the nonwoven fabric 3 is used, the decorative sheet as a whole can be made soft and snug.

In addition, since the liquid resin has entered between the meshes of the nonwoven fabric 3, a mechanical anchor effect occurs, and the nonwoven fabric 3 and the base 5
It is strongly bonded to.

Note that the present invention is not limited to the above embodiments,
For example, it is also possible to implement the following modifications.

(1) In addition to the nonwoven fabric of the above embodiment, the breathable member may be made of a plain woven fabric, a twill woven fabric, a satin woven fabric, or a knitted fabric. In this way, the raised portion 6 becomes three-dimensional due to the three-dimensional configuration of the stitches, making the appearance more interesting. Alternatively, a resin sheet having an open cell structure may be used.

(2) The liquid resin may be a liquid resin such as polyurethane in addition to the polyester resin of the above embodiment, and furthermore, the following resin may be used. However, in this case, it is necessary to add the solvent shown in parentheses. In this way, the hardness, thickness, and length of the raised portion 6 can be changed arbitrarily.

■Polyamide resin (alcohol) ■Polyvinyl chloride resin (tetrahydrofuran) ■Paste PVC (plasticizer) It may also be viewed from the surface side. In this case, another gas may be blown onto the surface side of the nonwoven fabric 3 to change the direction in which the raised portions 6 stand.

(4) The part pressed by the pressing member 16 does not need to be in a completely flat state as in the embodiment, and the raised part 6
It may be deformed to about half the height of . By doing this, the pattern is formed and the pressed portion can also maintain its raised state, so that the appearance can be further improved.

(5) The pressure and temperature of the hot air H can also be arbitrarily changed depending on the length and diameter of the raised part 6 to be formed, and the viscosity of the liquid resin can also be changed depending on the length and diameter of the raised part 6. It can be changed arbitrarily by

(6) In addition to the center pillar interior material of the above-mentioned embodiment, the present invention is applicable to automobile interior products such as automobile door linings, ceiling materials, instrument panels, steering wheel covers, furniture,
It is also possible to embody it as a decorative sheet attached to various resin molded products such as fittings and wall materials.

Effects of the Invention As detailed above, the method of the present invention not only makes it possible to apply patterns such as letters and pictures on the surface, but also makes it possible to easily and inexpensively produce decorative sheets with a luxurious feel due to their excellent texture. It has the excellent effect of being able to be manufactured in a number of ways.

[Brief explanation of drawings]

FIG. 1 is a schematic diagram showing the manufacturing process of the present invention, FIG. 2 is a front view showing a center pillar interior material for an automobile molded by the manufacturing method of the present invention, and FIG. 3 is A-A in FIG. A line sectional view and FIG. 4 are partially enlarged sectional views showing the state in which raised portions are formed on the surface of the epidermis.

Claims (1)

[Claims] 1. Applying a liquid resin to the surface of the breathable member (3), and raising the liquid resin by blowing gas (H) from the back or surface of the breathable member (3) (6) A method for producing a decorative sheet, which comprises curing the decorative sheet while partially pressing the nap (6) to form a pattern (8). 2. The method for manufacturing a decorative sheet according to claim 1, wherein the breathable member (3) is a nonwoven fabric. 3. The method for manufacturing a decorative sheet according to claim 1, wherein the liquid resin is a polyester resin.