JPS6394824A - Manufacture of decorative product with uneven surface - Google Patents

Abstract

PURPOSE:To obtain a decorative product with a vivid embossed pattern by a method wherein embossed pattern is produced onto a thermoplastic resin sheet, which can laminate to a body to be laminated with an uneven surface, and, after an embossing protective layer is provided on the surface of said sheet so as to prevent said embossed pattern from deforming the sheet and the body to be laminated with the uneven surface are made into an integral body. CONSTITUTION:Hardening resin 2 is applied onto a thermoplastic resin sheet 1, to which emboss is produced with an embossing plate or an embossing roll, in the thickness, which does not impair the embossed pattern, and, after that, it is hardened so as to produce a laminating sheet 3. Next, a body to be laminated 4 and the laminating sheet 3 are installed on a setting stand 6 in a vacuum chamber 5. An elastic air-unpermeable sheet 7 is installed in such a manner as to bisect the interior of the vacuum chamber above the body to be laminated and the laminating sheet. Next, the vacuum state is produced in the vacuum chamber by evacuating through suction ports 8 and a suction and delivery port 9. After that, the outside air is lead only through the suction and delivery port 9 so as to bring the air- unpermeable sheet 7 and the laminating sheet 3 into close contact with the surface of the body to be laminated 4 in order to obtain an integral product of the laminating sheet 3 and the body to be laminated 4.

Description

Detailed Description of the Invention (Industrial Application Field) The present invention relates to a decoration in which a picture pattern is formed on the entire surface of an article such as a plastic molded article that has a three-dimensional shape and partially has an opening. Regarding product manufacturing methods, it 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:
This is usually called the suminagashi method, and extrusion molding is performed using two to three colored pellets on resin pellets 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. ■ A method known as hydraulic transfer has been used in which a pattern is printed on a film such as vinyl and then transferred to a molded product using a dipstick in water.

(Problems to be Solved by the Invention) Although it is possible to form a pattern on the surface of a molded product having an uneven surface using the conventional method described above, it is possible to form a pattern on the surface of a molded product having an uneven surface. All I could do was add a groove-like shape.

In addition, by forming an uneven pattern on the inner surface of the mold and then injecting resin into the pattern, it is possible to form an uneven pattern on the surface of the molded product. It was not possible to form a realistic uneven pattern like the conduit grooves of the wood grain without using a carving method or the like.

(Means for Solving the Problems) The present invention faithfully reproduces the realistic calmness, texture, and texture of natural products, which cannot be achieved by the conventional methods as described above, and creates a pattern. We supply three-dimensional decorative products that match the pattern and have real windows that are indistinguishable from natural products.

That is, an uneven pattern is formed on a thermoplastic resin sheet that can be laminated on the uneven surface of a laminate having an uneven surface, and an uneven protective layer is provided to prevent the uneven pattern from deforming. This is a step in the direction of unifying technology.

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

First, as shown in Figure 2, irregularities are formed on the surface of the thermoplastic resin sheet (1). These irregularities may be formed directly on the thermoplastic resin sheet, or they can be formed on the surface of the thermoplastic resin sheet as necessary. It is also possible to form a printed pattern layer on the surface of the thermoplastic resin sheet, and then form a thermally softenable resin layer thereon to form irregularities on the resin layer.Of course, by forming the printed pattern layer on the surface of the thermoplastic resin sheet, You may form unevenness from above.

Means for forming unevenness include an embossed plate or an embossing roll in which unevenness is formed on the surface of a metal plate or metal roll by engraving or etching, and an emphos sheet in which a layered pattern is printed on the surface of a sheet-like object and wrapped around a plate 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, etc., it will have a more realistic appearance that is closer to that of a natural product. Irregularities 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 impair the uneven shape, and is cured to produce a lamination sheet (3).

Next, place the object to be laminated (4) on the mounting table (6) in the vacuum chamber (5).
) and a laminating sheet (3), and above it an elastic non-breathable sheet (7) so as to divide the vacuum chamber into two.
). Next, the suction hole (8) and the suction/air supply hole (9)
) to create a vacuum state in the vacuum chamber, then only the suction and air supply hole (9) is communicated with the outside air, air is sent in if necessary, and the non-breathable sheet (7) is opened as shown in Figure 3.
and the laminating sheet (3) are brought into close contact with the surface of the object to be laminated (4) to form an integrated product of the laminating sheets i to (3) and the object to be laminated (4) as shown in FIG. Soru.

= 5- As the thermoplastic resin sheet (1), polyvinyl chloride sheet, polyethylene sheet, polypropylene sheet, polyester sheet, nylon sheet, ABS @ resin sheet imide sheet, acrylic sheet, polyvinyl acetate sheet, vinyl chloride sheet ~, a fluororesin sheet, a polycarbonate sheet, a synthetic paper or nonwoven fabric using each of the above resins, a sheet formed by arbitrarily combining and bonding each of the above sheets, etc. can be used. Additionally, a printed pattern layer can be formed on the surface of the sheet as described above,
It is also possible to prepare the colored sheet 1 by mixing a coloring material into the sheet.

As the curable resin (2), photocurable resins such as acrylic resins and polyester resins, and thermosetting resins such as acrylic 1-cretanes, urethanes, polyesters, epoxys, and melamines can be used. The thickness that does not impair the uneven shape is approximately 2 to 30 μm.

For the laminated body (4), index molding, extrusion molding (he!
4 or the like can be used, but of course, it is also possible to use a material like an essential material formed into an uneven shape by cutting or the like.

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.

As the air-impermeable sheet (7), a silicone rubber sheet, a synthetic rubber sheet, etc. can be used.

Note that an adhesive such as a heat-sensitive adhesive is applied to the adhesive surface of the lamination sheet.

(Function) The thermoplastic resin sheet is softened by the heat of heating and softening when it is attached to the object to be laminated, and becomes easily deformed, but the recesses on the surface of the thermoplastic resin sheet are completely cured by the hardening resin applied to the surface. Because it is kept in shape, it will not deform,
The realistic uneven shape imparted during embossing is reproduced directly on the surface of the decorative product.

(Effects of the Invention) Since the sheets having realistic uneven patterns formed on their surfaces are laminated, a highly designed decorative product can be obtained.

■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, making it possible to manufacture products that more closely resemble natural products at low cost. can.

(Example) A straight-grain oak pattern was applied to a colored ABS resin sheet with a thickness of 0.4 # by gravure printing, and an uneven pattern was formed on the surface using an embossing roll.

The embossing roll used was an electroformed roll molded from natural wood with a straight-grained oak pattern.

Next, a coloring material was embedded in the concave portions of the uneven pattern by a wiping method, and an acrylic photocurable resin was applied to a thickness of 5 μm on the entire surface of the sheet by a gravure printing method.
The resin was cured by irradiation with a photopolymerization lamp of 80 W/cm for 6 seconds, and then a hot melt type adhesive was applied to the back side to obtain a lamination sheet.

Next, the ABS resin automobile control box molded product is placed on a mounting table inside the vacuum chamber, a lamination sheet is placed on top of it, and a silicone rubber sheet is placed on top of that, and the ends are placed outside the vacuum chamber. The entire vacuum chamber is then vacuum-suctioned to create a vacuum inside the chamber, and then only the top side of the silicone rubber sheet is communicated with the outside air to bring the silicone rubber sheet and lamination sheet into close contact with the surface of the molded product for decoration. Got the product.

[Brief explanation of the drawing]

The drawings are for explaining the present invention in detail, and Fig. 2 shows the structure of the lamination sheet, Fig. 3 shows the process of laminating the lamination sheet on the surface of the object to be laminated, and Fig. 1 shows the molded product and the lamination sheet. FIG. 3 is a cross-sectional view showing a state in which the sheets are integrated. (1)...Thermoplastic resin sheet (2)...
...Curing resin (3) ...Lamination sheet (4) ...Lamination object (5) ...Vacuum chamber (6) ...Mounting Placement stand (7)...Non-breathable sheet (8)...Suction hole

Claims (1)

[Claims] A first step of forming irregularities on the surface of a 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, in which the object to be laminated and the lamination sheet are installed in a vacuum chamber so that the lamination sheet is on top, and an elastic non-porous sheet is installed above the lamination sheet so as to divide the vacuum chamber into two. Process. After vacuum suction is applied to both the upper and lower sides of the non-porous sheet to remove the air around the laminated object, only the upper side of the non-porous sheet is brought to a normal pressure or pressurized state, and the non-porous sheet and the lamination sheet are separated. A fourth step of producing an integrated product of the laminating sheet and the laminated body in close contact with the surface of the laminated body. A method for manufacturing a decorative product having an uneven surface, characterized by comprising the above steps.