JPS6362379B2 - - Google Patents

Description

[Detailed Description of the Invention] A. Purpose of the Invention (1) Industrial Field of Application The present invention relates to a synthetic resin sheet wrinkler that transfers an uneven pattern onto the surface of a heated synthetic resin sheet by vacuum suction. Concerning type.

(2) Prior Art Conventionally, a grained type is known in which a patterned shell having an uneven pattern on the sheet overlapping surface is produced by electroforming, and numerous vacuum suction holes are formed in the patterned shell.

(3) Problems to be Solved by the Invention However, in the conventional method, the vacuum suction hole is formed by drilling, electric discharge machining, laser, etc., so the hole diameter of the vacuum suction hole is larger than necessary when it is formed. Therefore, there is a problem in that not only the uneven pattern but also the vacuum suction holes with large pore diameters are transferred onto the surface of the synthetic resin sheet, which impairs the commercial value of the product.

An object of the present invention is to provide the above-mentioned graining mold which can solve the above-mentioned conventional problems.

B. Structure of the Invention (1) Means for Solving the Problems The present invention is a grained type that transfers an uneven pattern to the surface of the sheet by vacuum suctioning a synthetic resin sheet heated to a high temperature. A back-up body having a patterned shell manufactured by electroforming so as to have a sheet overlapping surface and countless fine continuous pores uniformly distributed over the entire sheet overlapping surface, and continuous pores bonded to the back surface of the patterned shell. and a cooling pipe embedded in the back-up body, and the back-up body is made of thermosetting synthetic resin along the back surface of the patterned shell and between adjacent steel balls having excellent corrosion resistance. The cooling pipe is made up of a bonded first layer and a second layer in which adjacent ones of countless glass beads laminated on the first layer are partially bonded with a thermosetting synthetic resin, and the cooling pipe is It is characterized in that it is disposed on the first layer so as to cover the entire back surface of the patterned shell.

(2) Effect When a synthetic resin sheet heated to a high temperature is placed opposite the sheet polymerization surface of the pattern shell and vacuum is sucked from the back-up body side, the synthetic resin sheet is formed into a sheet through the continuous pores of the back-up body and the fine continuous pores of the pattern shell. It comes into close contact with the polymerized surface, and the uneven pattern of the sheet polymerized surface is transferred to the surface of the synthetic resin sheet. In this case, since the fine continuous pores of the patterned shell are extremely small, these continuous pores are not transferred to the surface of the synthetic resin sheet.

In addition, since the first layer of the back-up body is mainly made of steel balls, the first layer has good conformability to the back surface of the patterned shell, and the sliding properties of the steel balls ensure sufficient filling. The same can be said of the second layer, so that the reinforcing effect of the backup body can be reliably obtained.

Furthermore, since the cooling pipe is arranged in the first layer, which is mainly composed of steel balls, the pattern shell is efficiently cooled due to the high thermal conductivity of the first layer, and this allows the synthetic resin sheet to be immediately removed after the uneven pattern is transferred. By cooling, the uneven pattern can be prevented from collapsing. In this case, since the second layer is mainly made of glass beads, its heat insulating properties can prevent the temperature of the first layer from rising due to heat absorption from the second layer side.

Furthermore, the first layer is mainly composed of steel balls and has high strength, and the cooling pipes provide reinforcement, so it is possible to form the first layer thinly, and this, combined with the lightness of the second layer, makes it possible to reduce the thickness of the backup body. The weight can be reduced, thereby providing a lightweight grained type.

Furthermore, due to the corrosion resistance of the steel balls and glass beads, the back-up body has a rust-preventing function, thereby improving the durability of the grained type.

(3) Example Fig. 1 shows an apparatus for obtaining a grained laminate consisting of a synthetic resin sheet S and a core material _C. It consists of a second movable part ₁₂ that can be moved up and down.

The first movable part ₁₁ is configured as follows.

The downward opening 4 of the box body 3 having the top wall 2 is closed by a patterned shell 5 having a shape that matches the shape of the molded product to be formed, and the outer peripheral edge of the shell 5 is connected to the box body through a patch plate 6. A plurality of bolts 8 on the flange 7 of 3
and is fixed by a nut 9. A support plate 10 is suspended from the top wall 2 of the box body 3, and the intermediate portions of a plurality of angle members 11 are attached to the lower edge of the support plate 10 at predetermined intervals in a plane orthogonal to FIG. Both ends of each angle member 11 are welded to the inner surface of the box body 3. The pattern shell 5 is attached to each angle member 11, and the pattern shell 5 is attached to each angle member 11 by passing through the angle member 11.
It is suspended by a plurality of bolts 13 screwed into a threaded cylinder 12. A vacuum sealing material 14 is interposed between the inner peripheral edge of the flange 7 and the pattern shell 5.

As shown in FIGS. 2 and 3, the patterned shell 5 is made of nickel electroformed material, and a concavo-convex pattern 15 faithful to cowhide is formed on the sheet overlapping surface 5a. In addition, numerous fine continuous pores 16 are formed in the pattern shell 5 so as to be uniformly distributed throughout the thickness thereof, and these fine continuous pores 16 are used as vacuum suction holes. The openings 16a of the fine continuous pores 16 on the sheet overlapping surface 5a are arranged in the vertical and horizontal directions at a pitch of about 0.2 mm, and their diameters are 0.03 to 0.05 mm. As described above, since the openings 16a of the fine continuous pores 16 have an extremely small diameter, the uneven pattern 15 is not damaged in any way.

The manufacturing of the pattern shell 5 includes the steps of creating a precision model from cowhide, forming a conductive layer on the cowhide pattern surface of the precision model, laminating four layers of polystyrene beads with a diameter of 0.2 mm on the surface of the conductive layer, and then forming a conductive layer on the surface of the conductive layer. The process of placing a floating prevention body containing glass beads in a net and placing the precision model in the plating liquid layer, forming the plating layer to a thickness that exposes the upper circumferential surface of the top layer of polystyrene beads. This is carried out through an electroforming step in which the spaces between adjacent polystyrene beads are filled with nickel, and a step in which the polystyrene beads are eluted from the nickel electroformed body.

As a result of this elution of the polystyrene beads, an opening 16a is formed at the contact point between the polystyrene beads in the lowermost layer and the conductive layer on the precision model, and a cavity 16 corresponding to the size of the polystyrene beads is formed in the nickel electroformed body.
A communication hole 16c of the cavity 16b adjacent to the contact point between the polystyrene beads of the outermost layer is formed at the contact point between the polystyrene beads of the outermost layer, and an opening 16d is formed at the position where the upper peripheral surface of the outermost polystyrene bead was exposed. Continuous pores 16 are obtained.

Inside the box body 3, a back-up body 17 having continuous pores is integrally joined to the back side of the patterned shell 5 to reinforce the patterned shell 5. The backup body 1
7 is a thin first layer 17 ₁ along the back surface of the patterned shell 5, in which numerous adjacent steel balls made of stainless steel or the like with excellent corrosion resistance are partially bonded with thermosetting synthetic resin such as epoxy resin; , a second layer 172 is laminated on the first layer ₁₇₁ , and a plurality of adjacent glass beads are partially bonded to each other by _the same thermosetting synthetic resin as described above.

When forming the first layer 17 ₁ , a thin resin layer made of the thermosetting synthetic resin is placed on the surface of the box body 3 on the back side of the patterned shell 5 as shown in FIG.
A predetermined amount of steel balls 18 of 70 to 150μ with R ₁ are injected,
Thereafter, the steel balls 18 and the resin layer R ₁ are heated to 70 to 80°C to join the parts of the resin layer R ₁ located at the contact points between adjacent steel balls 18, and the air space surrounded by each joint point is
It forms V ₁ . Continuous pores are formed in the first layer 17 ₁ by this void V ₁ . This steel ball 1
8, the first layer ₁₇₁ and the patterned shell 5 are also bonded by the resin layer _R1 .

In addition, when forming the second layer 17 ₂ , a member (not shown) having the same shape as the recess 17 a is suspended in the box 3 to form the recess 17 a to reduce weight.
As shown in FIG _{. 5} , a predetermined amount of glass beads 19 of 400 to 600 μm having the thin resin layer R ₂ on the surface are injected onto the surface of the glass beads 19, and then the glass beads 19 and the resin layer R ₂ are heated to 70 to 80°C The parts of the resin layer R ₂ located at the contact points between adjacent glass beads 19 are bonded by heating to form a void V ₂ surrounded by each bond point. Continuous pores are formed in the second layer 17 ₂ by this void V ₂ . When bonding the glass beads 19, the resin is also applied between the first layer ₁₇₁ and the second layer ₁₇₂ .
Each is joined by R ₂ .

A plurality of through holes 20 are formed in the support plate 10 so that the flow of the glass beads 19 is not obstructed by the support plate 10 when the glass beads 19 are injected.

A cooling pipe 21 is embedded in the first layer 17 ₁ in a meandering manner so as to cover the entire back surface of the patterned shell 5 . In this case, the first layer 17 ₁ is mainly composed of steel balls 18 and has good thermal conductivity, so that the patterned shell 5 can be efficiently cooled over its entire area. Furthermore, the first layer 17 ₁ is reinforced by embedding the cooling pipe 21 in a meandering manner.

A vacuum pump 23 is connected to the inside of the box body 3 via a switching valve 22.
₁ and the blower 24.

The second movable part ₁₂ is configured as follows.

Upward opening 27 of box body 26 having bottom wall 25
A pressing die 28 having a shape matching the pattern shell 5 is fixed to the holder. A recess 29 for fitting the core material C is formed on the upper surface of the pressing mold 28, and a plurality of vacuum suction holes 30 are formed in the pressing mold 28 so as to be distributed substantially uniformly throughout the mold. is formed. The box body 26 is connected to a vacuum pump 23 ₂ .
The synthetic resin sheet S may be a single sheet made of polyvinyl chloride or the like, or a laminated sheet in which the sheet is used as a skin layer and a polypropylene foam sheet is laminated thereon as a cloth layer.

The core material C is made of a plate made of ABS resin or the like, with a plurality of small-diameter vacuum suction holes 31 formed therein, and this plate is molded to fit into the recesses 29 of the pressing die 28.

Next, manufacturing of the grained laminate will be explained.

A hot melt adhesive is applied as an adhesive to the surface of the core material C, and the adhesive is softened by heating.

As shown in FIG. 1, raise the first movable part ₁₁ ,
Further, the second movable part 1 ₂ is lowered to open the pattern shell 5 and the pressing mold 28, and the core material C is fitted and installed in the recess 29 of the pressing mold 28 with its adhesive coated surface facing outward. Each vacuum suction hole 31 is pressed into the mold 28.
to each vacuum suction hole 30 of.

A synthetic resin sheet S consisting of a skin layer a and a cushion layer b is heated to approximately 180°C to soften it,
The synthetic resin sheet S is placed first with its skin layer a facing up.
and disposed between the second movable parts 1 ₁ and 1 ₂ .

As shown in FIG. 6, lower the first movable part ₁₁ ,
Further, the second movable part ₁₂ is raised to sandwich the synthetic resin sheet S between the pattern shell 5 and the pressing die 28. Since the synthetic resin sheet S is pressed against the sheet overlapping surface 5a of the pattern shell 5 by the pressing die 28, it has good conformability to the surface 5a.

The inside of the box 3 of the first movable part 1 ₁ is connected to the vacuum pump 23 ₁ via the switching valve 22, and the vacuum pump 2
3 Vacuum the synthetic resin sheet S according to _{step 1} .
The patterned shell 5 has countless fine continuous pores 16 throughout, and since the synthetic resin sheet S is sufficiently blended with the sheet polymerization surface 5a by the pressing mold 28, the sheet S is not easily polymerized. It strongly adheres to the entire surface 5a, so that the concavo-convex pattern 15 is accurately and clearly transferred to the surface of the sheet S, and at the same time, the sheet S is formed into the shape of the pattern shell 5. Since the pattern shell 5 is cooled by the cooling pipe 21,
The sheet S is immediately cooled, and the uneven pattern 15 and shape collapse are prevented.

The vacuum pump 23 ₂ on the second movable part 1 ₂ side is operated to press the molded body formed from the sheet S into the press mold 2.
8 and the surface of the core material C, and the first
The inside of the box 3 of the movable part ₁₁ is switched to the blower 24 side via the switching valve 22 to apply blow pressure to the molded article.

As a result, the molded body is released from the patterned shell 5 and is brought into close contact with the core material C and integrally joined thereto. Since the molded body is strongly adhered to the patterned shell 5, the combination of the vacuum suction action and the blow pressure is an extremely effective means for promoting release of the molded body.

The blower 24 is stopped, and the inside of the box 26 of the second movable part 1 ₂ is switched to the atmosphere, and then the first movable part 1 ₁ is switched to the atmosphere.
is raised, and the second movable part ₁₂ is lowered to remove the laminate L from the pressing mold 28.

On the surface of this laminate L, an uneven pattern 15 identical to the skin pattern of cowhide is clearly applied without running,
Further, the bonding strength between the molded body made of the synthetic resin sheet S and the core material C is high, and the durability is excellent. This type of grained laminate L is suitable for automobile instrument panels, interior materials, etc.

C. Effects of the Invention According to the present invention, the pattern shell is manufactured by electroforming so as to have a sheet overlapping surface having an uneven pattern and fine continuous pores uniformly distributed over the entire sheet overlapping surface. The continuous pores are not transferred to the surface of the synthetic resin sheet, and a product with high commercial value can be obtained.

In addition, the patterned shell is reinforced with a back-up body, so the mold as a whole has great strength.
Excellent durability. In this case, since the first layer of the back-up body is mainly composed of steel balls, the first layer has good conformability to the back surface of the patterned shell, and the sliding properties of the steel balls ensure sufficient filling. The same can be said about the second layer of subjects,
It is possible to reliably obtain the reinforcing effect of the backup body.

In addition, since the cooling pipe is arranged in the first layer, which is mainly composed of steel balls, the pattern shell is efficiently cooled due to the high thermal conductivity of the first layer, which allows the synthetic resin sheet to be immediately cooled after the uneven pattern is transferred. This can prevent the uneven pattern from collapsing. In this case, since the second layer is mainly made of glass beads, its heat insulating properties can prevent the temperature of the first layer from rising due to heat absorption from the second layer side.

Furthermore, the first layer is mainly composed of steel balls and has high strength, and can be reinforced with cooling pipes, so it is possible to form the first layer thinly, and this, combined with the lightness of the second layer, makes it possible to make a backup body. The weight can be reduced, thereby providing a lightweight grained type.

Furthermore, due to the corrosion resistance of the steel balls and glass beads, the back-up body has a rust-preventing function, thereby improving the durability of the grained type.

[Brief explanation of drawings]

FIG. 1 is a sectional view of an apparatus for obtaining a grained laminate to which an embodiment of the present invention is applied, FIG. 2 is a partial plan view of a patterned shell, and FIG. 3 is a sectional view taken along the line of FIG.
FIG. 4 is a sectional view of a portion of the first layer in the backup body, FIG. 5 is a sectional view of a portion of the second layer in the backup body, and FIG. 6 is a sectional view of the device showing the graining and forming steps. It is. S...synthetic resin sheet, _R1 , _R2 ...resin layer,
5... Pattern shell, 5a... Sheet polymerization surface, 15...
Uneven pattern, 16... fine continuous pores, 17... back up body, 17 ₁ , 17 ₂ ... first and second layers, 1
8...Steel ball, 19...Glass beads, 21...Cooling tube.

Claims (1)

[Claims] 1. A grained type that transfers an uneven pattern to the surface of the sheet by vacuum suction on a synthetic resin sheet heated to a high temperature, and includes a sheet polymerization surface having an uneven pattern and countless particles uniformly distributed over the entire sheet polymerization surface. A patterned shell manufactured by electroforming to have continuous fine pores, a backup body having continuous pores bonded to the back surface of the patterned shell, and a cooling pipe embedded in the backup body, A first layer in which numerous adjacent steel balls with excellent corrosion resistance are partially joined together by a thermosetting synthetic resin along the back surface of the patterned shell, and numerous glasses laminated on the first layer. A second piece in which adjacent beads are partially joined with thermosetting synthetic resin.
What is claimed is: 1. A grained mold for synthetic resin, comprising layers, and characterized in that the cooling pipe is disposed in the first layer so as to cover the entire back surface of the patterned shell.