JPS6394825A - Manufacture of decorative product with uneven surface - Google Patents

Abstract

PURPOSE:To obtain a decorative product with hand and as good as natural product by a method wherein embossed pattern is produced onto a thermoplatic resin sheet, which can be laminated with 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, on 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 s as to produce a laminating sheet 3. Next, a large number of fine vent holes 5 are formed over the whole surface of the laminating sheet 3. Next, the laminating sheet 3 is inserted into a sizing device 6 together with a molded item 4, which is just extruded from an extruder, so as to size the molded item in order to obtain an integral product of the laminating sheet 3 and the molded item 4. Further, adhesive such as heat-sensitive adhesive, pressure-sensitive adhesive or the like is applied to the bond area of the laminating sheet.

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:
Usually called the suminagashi method, extrusion molding is carried out using colored pellets of 2 to 3 colors as resin pellets for molding molded products. ■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. It was not possible to give such a shape.

Also, by forming an uneven pattern on the inner surface of the mold and injecting resin into it, 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 calmness, texture, and texture of natural materials, which cannot be obtained by the conventional methods as described above, and reproduces the pattern and match. The present invention provides three-dimensional decorative products having 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 being deformed, and then a layer that covers the uneven surface is formed. It is a technology that integrates with the body.

The present invention will be described in detail in accordance with the drawings.

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

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 a metal plate, or an embossed sheet printed in raised shapes on the surface of a sheet-like object is wrapped around a plate or roll. If you use a small embossing plate or embossing roll made from an embossed sheet made by molding the surface shape of a natural material such as wood using silicone resin, you can create a more realistic and natural product. It is possible to form unevenness with a similar appearance.

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;
It is cured to produce a lamination sheet (3).

Next, there are many fine ventilation holes (
5> is formed. The size of this ventilation hole is set to 20 to 80μ in consideration of deaeration effect and design, and its density is set to 1 to 9.
pcs/cnf. Next, as shown in Fig. 3, the lamination sheet (3) is inserted into a vacuum sizing device (6) together with the molded product (4) just extruded from the extruder, and the molded product is sized. An integrated product of the lamination sheet (3) and the molded article (4) as shown in FIG.

Examples of the thermoplastic resin sheet (1) include polyvinyl chloride sheet, polyethylene sheet, polypropylene sheet, polyester sheet, nylon sheet, ABS resin sheet, polyimide sheet, acrylic sheet, polyvinyl acetate sheet, vinylidene chloride sheet, fluororesin sheet, and polycarbonate. A sheet, a synthetic paper or nonwoven fabric using each of the above resins, a composite sheet made by arbitrarily combining each of the above sheets, etc. can be used. Further, as described above, a printed pattern layer can be formed and covered on the surface of the sheet, or a stone coloring material can be mixed into the sheet and then covered with a color-containing sheet.

The curable resin (2) includes photocurable resins such as acrylic resins and polynisder resins, acrylic urethane resins,
Thermosetting resins such as urethane-based, polyester-based, epoxy-based, and melamine-based resins can be used, and the appropriate thickness is about 2 to 30 μm without impairing the uneven shape.

Thermoplastic resin sheet (1) A retrieval material may be embedded into the irregularities formed on the surface by a wiping method or the like, and after a surface protective layer is formed thereon, a resin having mold releasability is applied. It's okay.

In addition, the adhesive surface of the lamination sheet should be coated with a thermosensor (↓adhesive,
Apply an adhesive such as pressure sensitive/L contact 6 adhesive.

(Function) Thermoplastic = i due to the heat of heating and softening when pasting to the molded product
'The resin sheet softens and becomes easily deformed, or the recesses 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 are not added during embossing. The realistic uneven shape 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, ventilation holes were formed on the entire surface of the laminated sheet using a roll in which a large number of needle-like objects having a diameter of 60 μm were inserted at the tip.

Next, a lamination sheet was continuously layered on top of the extruded vinyl chloride resin molded product, and both were then inserted into a vacuum sizing device for sizing to obtain a decorative 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) ...Molded product (5) ...Vent hole

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 forming a large number of fine ventilation holes on the entire surface of the lamination sheet. A fourth step of inserting the lamination sheet together with the extruded molded product into a vacuum sizing device and vacuum sizing the molded product to integrate the molded product and the lamination sheet. A method for manufacturing a decorative product having an uneven surface, characterized by comprising the above steps.