JPS6394826A - Manufacture of decorative product with uneven surface - Google Patents

Abstract

PURPOSE:To obtain a three-dimensional decorative product with hand and texture as good as natural product by a method wherein embosses pattern is produced onto a thermoplastic resin sheet, which can be laminated onto 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:Resin 2 with releasability is applied onto a thermoplastic resin sheet 1, to which emboss is produced with an embossing plate or an embossing roll is such a manner as to completely fill recesses in order 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 vacuum 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 body to be laminated and the laminating sheet. Finally, the resin 2 is removed.

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 feel, feel, and texture of natural products, which cannot be obtained by the conventional methods described above, and matches the pattern. The purpose is to provide three-dimensional decorative products that have a sense of authenticity that is 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 FIG. 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 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 from that layer.

Means for forming unevenness include an embossed plate or embossing roll in which unevenness is formed on the surface of a metal plate or metal roll by engraving or etching, and an embossed plate or embossed roll in which unevenness is formed on the surface of a sheet-like object. However, if you use an embossing plate or an embossing roll made based on T-Boss Sea-1, which is a mold of the surface shape of a natural material such as wood using silicone resin, you can create a more realistic look. It is possible to form irregularities that have an appearance similar to natural products.

Next, a resin (2) having releasability with respect to the thermoplastic resin sheet (1) is applied to the uneven surface of the thermoplastic resin sheet (1), and the resin (2) having releasability is applied to the thermoplastic resin sheet (1). A lamination sheet (3) is produced by completely filling the recesses.

Next, there are many fine ventilation holes (
5) Form. Considering the deaeration effect and design, the size of this ventilation hole is set to 20 to 80μ, and its density is 1 to 9.
pieces/ci. Next, as shown in Figure 3, the laminating sheet (
3) is inserted into a vacuum sizing device (6) and the molded product is sized to produce an integrated product of the object to be laminated and the sheet for lamination.

Finally, as shown in Figure 1, a resin (2) with mold release properties is added.
By removing this, a decorative product with a realistic uneven pattern on the surface can be obtained.

Thermoplastic resin sheets (1) include polychloride = 5-vinyl sheet, polyethylene sheet, polypropylene sheet, polyester sheet, nylon sheet, BS resin sheet, polyimide sheet, acrylic sheet, polyvinyl acetate sheet, vinylidene chloride sheet, fluorine Resin sheets, polycarbonate sheets, synthetic papers and nonwoven fabrics using each of the above resins, composite sheets made by arbitrarily combining each of the following sheets, etc. can be used.Also, as mentioned above, printing on the surface of the sheet can be used. A pattern layer can be formed, or a colored sheet can be obtained by mixing a coloring material into the sheet.

The resin (2) having mold releasability has mold releasability with respect to the thermoplastic resin sheet used and has high heat resistance,
Moreover, it must have enough fluidity to completely fill the recesses on the surface of the thermoplastic resin sheet. Specifically, the thermoplastic resin sheet must be made of polypropylene resin, polyester resin, polyethylene resin, polyvinyl chloride resin, etc. Select and use a resin that is suitable for the resin used.

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.

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

(Function) The thermoplastic resin sheet becomes soft and easily deformed by the heat of heating and softening when it is attached to a molded product, but the recesses on the surface of the thermoplastic resin sheet are completely filled with the resin that has mold releasability. Because of this, it does not deform, and the realistic uneven shape added during embossing is reproduced 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 electroformed plates with high reproducibility and the low-cost high-frequency forming method, 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 enphos roll.

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

Next, a coloring material is embedded in the concave portions of the uneven pattern by a wiping method, and then a urethane resin is applied to the entire surface of the sheet using a gravure coater, and after drying, polyvinyl alcohol resin is applied to the entire surface of the sheet so that the thickness of the convex surface is 100 mm.
The adhesive was coated in an amount of μ to completely fill the recesses, dried, and then a hot-melt 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 is continuously layered on top of the extruded PVC resin molded product, and both are then inserted into a vacuum sizing device for sizing, and the lamination sheet is attached to the surface of the molded product. After that, the polyvinyl alcohol resin layer was removed 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 releasability of the lamination sheet. FIG. 3 is a cross-sectional view showing each state in which resin is removed. (1)...Thermoplastic resin sheet (2)...
・・Curing resin

Claims (1)

[Claims] The first step is to form irregularities on the surface of the thermoplastic resin sheet. A second step of applying a resin having mold releasability to the thermoplastic resin sheet on the uneven surface to completely fill the recesses 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 sizing the molded product to integrate the molded product and the lamination sheet. A fifth step of removing resin having mold releasability from the sheet surface. A method for manufacturing a decorative product having an uneven surface, characterized by comprising the above steps.