KR102557896B1 - molding material and manufacturing method the molding material - Google Patents

Abstract

Unlike conventional molding materials, the molding material and method of manufacturing the same of the present invention are made by omitting the protective film attached to the upper surface of the film unit for laminating, and in particular, a UV curing layer is formed on the film, and irregularities are formed on the surface of the UV curing layer. In this way, the inconvenience of removal caused by the protective film or the problem of bad judgment can be solved.

Description

Molding material and manufacturing method the molding material}

The present invention relates to a new type of molding material that can be smoothly manufactured without using a protective film provided for manufacturing the molding material provided for the exterior of a product and a manufacturing method thereof.

In general, exteriors of various home appliances used in the home are made of metal or synthetic resin.

In particular, in the case of various components (eg, handles) forming the exterior of home appliances, they are formed of a molding material made of synthetic resin. As a result, the components have the advantage of being easy to manufacture and can be molded into various shapes.

On the other hand, the molding material is usually made by applying a deposition layer for expressing various colors or textures on the surface of a molding made of ABS resin, or by attaching a film for laminating.

In particular, in the case of the molding and the film for laminating (eg, film), they are molded so as to be integrated through a mold operation, and through this, a surface layer having better wear resistance than the printing method can be obtained. Regarding the mold process of the molding and the film for laminating, it is as provided in Patent Registration No. 10-1041987, Patent Registration No. 10-1250221, and the like.

However, in the case of the film, since the surface (friction surface with the mold) is formed smoothly, there was a problem that the mold for laminating (lamination mold) did not pass smoothly due to excessive frictional force when passing through the mold.

Accordingly, conventionally, by additionally attaching a separate protective film coated with a wax-based mold release agent on the surface of the laminating film, the frictional force with the mold can be reduced.

However, since the protective film is a configuration provided to assist extrusion molding, there is an inconvenience that it must be peeled off after extrusion molding between the laminating film and the molding is completed.

Of course, the protective film is also used to protect the surface of the product until the product is delivered to the buyer.

In this case, the protective film must remain precisely attached to the surface of the laminating film until delivery is completed. That is, if the protective film is peeled off or lifted from the laminating film before delivery is completed, the consumer recognized it as a product defect.

However, in the case of a product having a bent portion, a phenomenon in which the protective film is often lifted from the film for laminating at the bent portion, and accordingly, there is a problem of being ignored by consumers.

As a result, in order to prevent the above-described problem from occurring, the protective film had to be firmly attached to the laminating film so as not to peel or lift, so the overall manufacturing cost was inevitably increased.

Of course, even in this case, there was an inconvenience that an operation for peeling off the protective film had to be additionally performed after the delivery of the product was completed.

Registered Patent No. 10-1041987 Registered Patent No. 10-1250221

The present invention has been made to solve various problems according to the prior art described above, and an object of the present invention is to provide a new molding material having a film portion for laminating that does not require a protective film and a manufacturing method thereof.

That is, by omitting the protective film, the manufacturing cost can be reduced and the inconvenience of work can be eliminated, while the work for extrusion can be performed smoothly.

According to the molding material of the present invention for achieving the above object, a film for laminating, a UV curing layer formed on the upper surface of the laminating film, and irregularities formed on the surface of the UV curing layer are included.

In addition, according to the molding material of the present invention, the irregularities formed on the UV curing layer may be formed in a shape in which peaks and valleys are repeated.

Further, according to the molding material of the present invention, the film unit for laminating may include an aluminum layer formed on the lower surface of the film for laminating.

In addition, according to the molding material of the present invention, a primer layer formed on the lower surface of the aluminum layer may be included.

According to the molding material manufacturing method of the present invention for achieving the above object, the base molding and the film for laminating prepared in the film preparation step are drawn from different directions or different positions of the laminating mold, respectively, and the laminating step of passing the laminating mold in the same direction is included.

According to the molding material manufacturing method of the present invention, the film preparation step may include a first process of applying a UV resin to the upper surface of the film for laminating.

According to the molding material manufacturing method of the present invention, the film preparation step guides the film for laminating to which the liquid UV resin is applied to pass through the upper concave-convex roller and the lower guide roller to form concavo-convex patterns on the upper surface of the UV resin. It may include a second process.

According to the molding material manufacturing method of the present invention, the film preparation step is a third process of forming a UV cured layer having concavo-convex molded on the upper surface by curing the UV resin while passing the concavo-convex film through the curing part to which UV is irradiated. It may be included.

According to the molding material manufacturing method of the present invention, the film preparation step may include a fourth process of attaching a protective film to the upper surface of the UV curing layer.

According to the molding material manufacturing method of the present invention, the protective film attached to the upper surface of the UV curing layer may be removed before passing through the mold for paper during the extrusion step.

As described above, in the molding material and the manufacturing method of the present invention, the UV curing layer having irregularities replaces the protective film separately provided on the outer surface of the film unit for laminating. Accordingly, inconvenience such as a delivery driver for product installation removing the protective film after product installation or a user removing the protective film can be prevented.

In particular, since the irregularities formed on the surface of the UV curing layer reduce surface friction of the UV curing layer, smooth extrusion molding is possible without applying wax or attaching the wax-coated protective film. This can prevent molding defects caused by the protective film during extrusion molding.

In addition, since the molding material and the manufacturing method of the present invention do not provide a protective film on the surface of the molding material, the problem of the product being treated as defective due to bubbles or lifting generated when the protective film is attached can be solved.

1 is a schematic state diagram of a molding material according to an embodiment of the present invention
Figure 2 is a perspective view of the main part of the molding material according to an embodiment of the present invention
3 is a cross-sectional view of a molding material according to an embodiment of the present invention
Figure 4 is a perspective view of the main part of the conventional molding material
Figure 5 is a schematic state diagram of a conventional molding material
6 is a state diagram for explaining a process of forming a film part for laminating of a molding material according to an embodiment of the present invention.
7 is a state diagram for explaining a process of forming a molding material according to an embodiment of the present invention.
8 is a block diagram schematically illustrating a process of molding a molding material according to an embodiment of the present invention.
9 is a flowchart illustrating a molding material manufacturing process according to an embodiment of the present invention.
10 is a flowchart of a process of forming a film portion for laminating of a molding material according to an embodiment of the present invention.

Hereinafter, a preferred embodiment of a molding material and a method for manufacturing a molding material according to the present invention will be described with reference to FIGS. 1 to 10.

1 is a schematic state diagram of a molding material according to an embodiment of the present invention, FIG. 2 is a perspective view of main parts of a molding material according to an embodiment of the present invention, and FIG. 3 is a cross-sectional view of a molding material according to an embodiment of the present invention.

As shown in this figure, unlike the conventional molding material, the molding material according to the embodiment of the present invention is made by omitting the protective film 10 (see FIGS. 4 and 5) attached to the upper surface of the film unit 200 for laminating (see FIGS. .

The detailed structure of the molding material according to the embodiment of the present invention will be described in more detail as follows.

First, a molding material according to an embodiment of the present invention includes the base molding 100.

The basic molding 100 is a part that forms the basic shape of a substantial molding material while being made of synthetic resin (eg, ABS). That is, the basic shape of the molding material to be manufactured is molded into the base molding 100.

After the base molding 100 is made into a finished product, it passes through the laminating mold 400 to be integrated with the laminating film part 200, or the base molding 100 is melted or molded into a semi-finished product in an unhardened state. Then, it can be integrated with the laminating film part 200 while passing through the laminating mold 400.

Next, the molding material according to the embodiment of the present invention includes a film unit 200 for laminating.

The film unit 200 for laminating is a component provided to protect the surface of the base molding 100 and impart a specific texture. That is, it is possible to express the texture of metal while preventing scratches of the base molding 100 by using the film unit 200 for laminating.

The film unit 200 for laminating includes a film 230 for laminating made of a PET (Poly Ethlene Terephthalate) material.

In addition, the film unit 200 for laminating includes a UV curing layer 210.

The UV curing layer 210 serves to prevent damage such as scratching or tearing of the surface of the laminating film 230 while being formed on the upper surface of the laminating film 230 . The UV curing layer 210 may be formed by applying a liquid UV resin 211 to the upper surface of the laminating film 230 and then curing with UV.

In addition, the film unit 200 for laminating includes concavo-convex 220.

The unevenness 220 is a structure for reducing surface friction of the film part 200 for laminating, and the unevenness 220 causes the film part 200 for laminating to pass through the mold 400 for laminating. Molding defects caused by excessive friction can be prevented.

These irregularities 220 may be formed on the surface of the UV curing layer 210 . That is, since the UV curing layer 210 has sufficient rigidity, irregularities 220 are formed on the surface of the UV curing layer 210 so that the irregularities 220 can also have sufficient rigidity. As a result, deformation such as crushing of corners during storage of the laminating film unit 200 can be prevented, and sufficient frictional force can be reduced while the laminating film unit 200 passes through the laminating mold 400.

The irregularities 220 may be formed in a shape in which peaks and valleys are repeated. At this time, the peaks and valleys of the unevenness 220 may be formed in various ways, such as a round (eg, semicircular) cross section, a triangle, or other polygons.

The irregularities 220 may be formed in a shape in which peaks and valleys repeat along the longitudinal direction of the film unit 200 for laminating. That is, by forming the irregularities 220 in a shape in which the frictional area is minimized in the direction in which the film unit 200 for laminating passes through the mold 400 for laminating, defects in extrusion due to friction can be further reduced.

Meanwhile, the irregularities 220 may be formed together with the UV curing layer 210 during the molding process of the UV curing layer 210 .

That is, since the UV curing layer 210 has a high hardness, it is difficult to form irregularities 220 on the surface after curing of the UV curing layer 210 . Considering this, in a state where the UV resin 211 is applied to the surface (surface of the film) of the film unit 200 for laminating, the unevenness 220 is formed before the corresponding UV resin 211 is cured, and the unevenness 220 is formed. After the UV resin 211 is irradiated with UV, the UV curing layer 210 and the unevenness 220 can be cured.

The irregularities 220 may be formed by using a molding tool 330, and the molding tool 330 may be formed in a roller shape (gear shape) with peaks and valleys formed on a surface thereof. Of course, the forming tool 330 may be formed as a tool for knurling.

Although not shown, the irregularities 220 may be formed in various shapes of hairline or embossed structures.

The UV curing layer 210 is preferably formed to have a thickness of about 5 μm to 15 μm. That is, if the UV curing layer 210 is formed to a thickness lower than 5 μm, damage due to abrasion can be easily achieved. On the other hand, if the UV curing layer 210 is formed to a thickness higher than 15 μm, it may take a long time to cure the UV curing layer 210, and as a result, the peaks and valleys of the irregularities formed on the UV curing layer 210 may not be accurately formed. A phenomenon may occur. Considering this, it is most preferable that the UV curing layer 210 is formed to have a thickness of about 10 μm. That is, since the protective film 10 (see FIGS. 4 and 5) is omitted, it is possible to form the UV curing layer 210 as much as the thickness of the protective film 10 or to form the UV curing layer 210 to a thickness of about 10 μm.

On the other hand, the film unit 200 for laminating may include a component for imparting texture. For example, an aluminum layer 240 may be formed on the lower surface of the laminating film 230 for laminating.

The aluminum layer 120 allows the molding material to have a metallic texture. That is, as the aluminum layer 240 is formed to surround the surface of the base molding 100 made of synthetic resin (eg, ABS), the corresponding molding material can produce a metallic texture or feeling. Of course, if you want to give other textures (eg, stone or wood) other than metal textures, instead of the aluminum layer 240, a thin plate or film that makes you feel other textures is attached to the bottom of the laminating film 230.

The aluminum layer 120 may be attached and fixed to the lower surface of the laminating film 230 using an adhesive (not shown). Of course, the aluminum layer 120 may be formed by depositing liquid aluminum on the lower surface of the film 230 for laminating.

In addition, a primer layer 250 may be further formed on the opposite surface to the base molding 100, which is the bottom surface of the film unit 200 for laminating. The primer layer 250 serves as an adhesive to firmly attach the base molding 100 and the film unit 200 for laminating.

In particular, the primer layer 250 may be formed to be fused to the upper surface of the base molding 100 when high-temperature heat of a certain temperature or higher is applied.

Hereinafter, the manufacturing process of the molding material according to the embodiment of the present invention will be described in more detail with reference to the flow charts of FIGS. 9 and 10 and the state diagrams of FIGS. 6 to 8.

The method for manufacturing a molding material according to an embodiment of the present invention includes a film preparation step (S100) of preparing the film unit 200 for laminating.

The film preparation step (S100) is a process of forming a UV curing layer 210 and irregularities 220 on the surface of the film 230 for laminating. At this time, the laminating film 230 may be a transparent film, semi-transparent film, or a film having a specific color.

As shown in the state diagram of FIG. 6 and the flowchart shown in FIG. 10, the film preparation step (S100) is a liquid state on the upper surface of the prepared laminating film 230 after preparing the laminating film 230 (S110). A first step (S120) of applying UV resin 211 in a gel state may be included. At this time, the laminating film 230 may be provided in a state wound around the supply roller 310, and the UV resin 211 may be applied to the surface of the laminating film 230 using the coating roller 320.

In addition, the film preparation step (S100) may include a second process (S130) of guiding the UV resin 211-coated film 230 to pass through the upper molding tool (convex-convex roller) 330 and the lower guide roller 340. At this time, the forming tool 330 is a roller having irregularities along the circumferential surface, and the laminating film 230 is in close contact with at least a part of the forming tool 320, and the forming tool 330 and the guide roller 340 It can be installed to pass between. The guide roller 340 serves to pressurize a part of the laminating film 230 so that it adheres to the forming tool 330. Through this second process, irregularities 220 may be formed on the upper surface of the UV resin 211 .

In addition, the film preparation step (S100) may include a third process (S140) of forming a UV cured layer 210 by curing the UV resin 211. The third process is a process of curing while passing the UV resin 211 on which the irregularities 220 are formed by the second process through the curing unit 350 to which UV is irradiated. That is, as the UV resin 211 is cured by UV irradiation, the UV curing layer 210 having the irregularities 220 is formed.

In particular, since the UV curing layer 210 can be additionally formed to be as thick as the thickness of the conventional protective film 10 (see FIGS. 4 and 5) to which the release agent is applied, it can provide more rigidity. Due to the irregularities 220 formed on the surface, fine scratches and the like are difficult to visually check.

Meanwhile, in the film preparation step (S100), a fourth process of attaching a protective film 361 to the upper surface of the UV curing layer 210 may be further included. This protective film 361 is a film provided to protect the film unit 200 for laminating on which the UV curing layer 210 is formed from the external environment until extrusion molding. That is, since the protective film 361 is removed and discarded during the extrusion operation of the film unit 200 for laminating, precise attachment is not required. Of course, the protective film 361 may be additionally attached to the lower surface of the film unit 200 for laminating.

If, after the film preparation step (S100), the lamination step (S300) to be described later is performed immediately or continuously, the attachment of the protective film 361 is not required.

In addition, in the film preparation step (S100), a process (S151) of forming an aluminum layer 240 on the bottom surface of the film 230 for laminating may be further included. That is, through the formation of the aluminum layer 240, the film unit 200 for laminating can have a metallic texture.

This aluminum layer 240 may be formed by attaching a thin aluminum plate to the lower surface of the film 230 for laminating.

Of course, the aluminum layer 240 may be formed by depositing an aluminum solution on the lower surface of the film 230 for laminating. However, when the aluminum layer 240 is formed using the thin aluminum plate, it is more preferable than forming the aluminum layer 240 by depositing aluminum because shape deformation during the extrusion process can be minimized.

In addition, various patterns or patterns may be formed on the surface (upper surface) of the thin aluminum plate for forming the aluminum layer 240 . For example, a hairline may be formed on the upper surface of the aluminum layer 240 . As a result, the hairline can be seen through the film 230 for laminating.

In addition, in the film preparation step (S100), a step of forming a primer layer 250 on the lower surface of the aluminum layer 240 (S152) may be further included. The primer layer 250 is an adhesive provided to ensure that the film unit 200 for laminating is stably attached to the base molding 100.

The primer layer 250 may be formed by applying or attaching a primer to the lower surface of the aluminum layer 240 .

Next, the method for manufacturing a molding material according to an embodiment of the present invention includes an extrusion molding step (S200) for molding the base molding 100.

This base molding 100 may be made through an extruder 500. That is, the base molding 100 may be made by melting the synthetic resin (eg, ABS, PC, PVC, etc.) powder while passing through the extruder 500. At this time, the base molding 100 that has passed through the extruder 500 may be provided to the post process (mold for laminating) as a finished product in a completely hardened state, may be provided to the post process in a completely unhardened state, or a simple liquid It may be provided to the post process.

Next, the method for manufacturing a molding material according to an embodiment of the present invention includes a laminating step (S300) of laminating the base molding 100 and the film unit 200 for laminating with each other.

As shown in the state diagrams of FIGS. 7 and 8, the base molding 100 used in the lamination step (S300) is supplied to the lamination mold 400 in a molten or non-melted state after passing through the extruder 500, and the lamination film unit 200 is provided by being wound around a supply roll 310 with a UV curing layer 210 and irregularities 220 formed on the surface.

The base molding 100 and the film unit 200 for laminating are introduced from different directions or different positions of the laminating mold 400 and supplied to pass through the laminating mold 400 in the same direction. It can be performed. That is, the lower surface of the film unit 200 for laminating is gradually contacted and pressed to the upper surface of the base molding 100 introduced from different positions and integrated with each other.

In this extrusion step (S300), heat may be applied to the mold 400 for laminating. Therefore, while the primer layer 250 formed on the bottom surface of the laminating film part 200 is melted, the laminating film part 200 is more firmly fused to the base molding 100.

On the other hand, when the protective film 361 is present on the surface of the film unit 200 for laminating, the protective film 361 is removed before passing through the mold 400 for laminating when performing the laminating step (S300). If a protective film (not shown) is present in the base molding 100, it is removed before passing through the laminating mold 400.

In particular, the laminating film part 200 may not smoothly pass through the laminating mold 400 due to surface frictional force while passing through the laminating mold 400 while being gradually compressed on the surface of the base molding 100. However, since the UV curing layer 210 is formed on the surface of the laminating film part 200, and the irregularities 220 are formed on the surface of the UV curing layer 210, the frictional area between the laminating film part (or UV curing layer) 200 and the laminating mold 400 is minimized.

Therefore, even without attaching a separate protective film 10 coated with a release agent on the surface of the film unit 200 for laminating, it can be pressed to the base molding 100 while smoothly passing through the laminating mold 400. Accordingly, an operation for removing the protective film 10 coated with the release agent is not required after manufacturing, and defects caused by bubbles or lifting in the protective film 10 coated with the release agent can be prevented.

In particular, since the UV curing layer 210 can be additionally formed as thick as the thickness of the protective film 10 to which the release agent is applied (e.g., formed to a thickness of about 10 μm), it can have sufficient hardness, and the unevenness 220 can also be formed.

And, in the post process of the above-described laminating step (S300), a cutting step (S500) of cutting the molding material drawn out from the laminating mold 400 to a predetermined length (set length) may be performed.

Of course, after the lamination step (S300) and before the cutting step (S500) is performed, a cooling process (S400) of cooling the molding material heated by the extrusion process may be further included. At this time, the cooling process (S400) may be performed by either air cooling or water cooling.

After all, in the molding material of the present invention, since the UV curing layer 210 having irregularities 220 replaces the conventional protective film that is separately provided on the outer surface of the film member 200 for laminating, the product (product having the molding material) is installed. Inconvenience such as removal of the protective film by a delivery driver or removal of the protective film by the user can be prevented.

In particular, since the irregularities 220 formed on the surface of the UV curing layer 210 reduce surface friction of the UV curing layer 210, smooth extrusion molding is possible without applying wax or attaching a protective film coated with wax.

100. Basic molding 200. Film part for laminating
210. UV curing layer 211. UV resin
220. Concavo-convex 230. Film
240. Aluminum layer 250. Primer layer
310. Feed roller 320. Forming tool
330. guide roller 350. hardened part
361. Protective film 400. Mold for laminating
500. Extruder

Claims (5)

delete delete delete In order to reduce friction between the laminating mold and the UV curing layer in the process of passing through the laminating mold for integration with the basic molding, a UV curing layer formed with irregularities having a shape in which hills and valleys are repeated along the length direction of the laminating film, a film preparation step of preparing a film unit for laminating including an aluminum layer formed on the bottom surface of the laminating film and having a pattern or pattern formed on the upper surface thereof, and a primer layer formed on the bottom surface of the aluminum layer;
An extrusion molding step of molding a base molding using a synthetic resin;
A lamination step in which the base molding and the film portion for laminating are drawn into the laminating mold from different directions or different positions, and then supplied to pass through the laminating mold in the same direction;
A cutting step of cutting the molding material discharged through the laminating mold to a set length; included,
The film preparation step,
A first step of applying UV resin to the upper surface of the laminating film;
A second process of forming irregularities on the upper surface of the UV resin by guiding the laminating film coated with the liquid UV resin to pass through the upper uneven roller and the lower guide roller;
After the second process is performed, a third process of forming a UV cured layer having concavo-convex molded on the upper surface by curing the UV resin while passing the concave-convex film through a curing part to which UV is irradiated. Molding material manufacturing method characterized in that it proceeds. delete