JP5554016B2 - Decorative panel and its manufacturing equipment - Google Patents

Description

  The present invention relates to an apparatus for manufacturing a decorative panel having a three-dimensional shape by molding using a decorative panel having a three-dimensional shape and a pair of male and female dies.

  For decorations composed mainly of plastic molded products, there is a technology for pasting and integrating decorative sheets on the decorations on the product surface, game equipment, automotive parts (interior and exterior), home appliances, decorative parts for building materials, and other decorations. It is applied to products in many fields as parts. A decorative sheet is manufactured by setting a sheet decorated by a method such as gravure printing, silk screen printing, or vapor deposition into an injection mold and injection molding using a resin that is compatible with the sheet material. There are one that peels off the product and transfers the ink to the molded product, and one that integrates the decorative sheet as it is with the molded product.

  When such a decorative sheet is applied to a molded product having a three-dimensional structure, the decorative sheet needs to be three-dimensionally formed according to the form. In order to manufacture a three-dimensional decorative sheet, it is necessary to process a flat sheet base material by some means or method. For example, when using a mold such as injection molding, all three-dimensional shapes are accurate. Can be shaped. In contrast, conventional decorative sheets are often created by a vacuum forming method. However, in the case of the vacuum forming method, in addition to the finished dimensions of the actual decorative sheet, a portion for fixing the decorative sheet is necessary, so it is considerably larger than the area (finished dimension) used for the actual decorative sheet. It is necessary to use a sheet substrate.

  JP-A-6-344377 discloses an in-mold molding method for producing a decorative molded product, and the reference drawing shows a state in which the decorative sheet is fixed by vacuum suction. The decorative sheet in FIG. 2 is meant to include an unformed sheet base material, and is different from the meaning in the present invention indicating a three-dimensional final product, but as is clear from FIG. On the other hand, it can be seen that only a part of the decorative sheet is used. Even if it is not appropriate to believe the above drawing as it is, the size of the decorative sheet relative to the size required for the sheet base material is less than half, and the rest is discarded, which is wasteful and expensive. It has become one of the causes. In the above example, only one piece is shown, but even in the case of several pieces, the spacing between the decorative parts is set so that adjacent sheet base materials do not cause mutual interference during molding. Therefore, the waste of the sheet base material does not change much as in the case of taking one sheet, and the productivity is not good.

  As described above, in a decoration composed of a plastic molded product, a decorative sheet to be inserted into an injection mold must be shaped in advance into a desired shape by means of a vacuum molding method or the like. The types of materials are limited and cannot be selected easily. This is because when a decorative sheet is formed by a vacuum forming method, it is necessary to select a material for the sheet base material suitable for the vacuum forming method. The material of this sheet base material, that is, the type of resin and the specifications and physical properties of the injection molded product. This is because the types of resins determined depending on conditions and the like need to be the same or have an affinity. Since the types of resin that can be selected as the sheet base material are limited, and the types of trees that are insert-molded are limited, the probability of being employed in various industries is also reduced due to cost and efficiency. Also, when creating a three-dimensional decorative panel shape by vacuum forming method, the entire decorative sheet is heated to a high temperature and softened, so it cannot be formed with dimensional accuracy on the design and placed as designed. It is unsuitable when you want to.

JP-A-6-344377

  The present invention was made paying attention to the above points, and the problem is that, unlike the vacuum forming method, in order to fix the sheet substrate, it is not necessary to waste many times the area of the conventional decorative sheet, It is to provide a decorative panel with high productivity and a manufacturing apparatus thereof. In addition, another object of the present invention is that an inexpensive or expensive decorative panel can be selected without restriction, and a sheet base material used for the decorative panel can be designed, It is to be able to select freely according to the purpose.

In order to solve the above-mentioned problem, the present invention uses a decorative sheet in which a positioning hole penetrating the sheet surface is formed, and is formed by a plastic pressing technique as a decorative panel having a decorative portion. A panel body made of a plastic sheet base material, and the sheet base material is formed into a three-dimensional shape by molding, and ink or paint provided on one or both of the front and back surfaces of the panel main body Alternatively, a means is provided that includes a decorative portion made of any one of fine particles.
Such a decorative panel is a device for manufacturing a decorative panel having a three-dimensional shape by using a pair of male and female molds by a plastic pressing technique. It has a plurality of mold parts composed of a female mold part as a lower mold and a male mold part as an upper mold for molding a panel, and the plurality of mold parts are closely packed with each other. A pair of male and female molds is placed between the female mold part and the male mold part in a state where the decorative sheet is placed between the pair of molds and clamped to perform mold forming. Keep the clearance for the thickness of the decorative sheet that will be the product, around each mold part so that it does not move by engaging with the decorative sheet inserted between a pair of male and female molds to have a sheet fixing means for fixing, to adjust the heating temperature of the decorative sheet Provided with a degree adjusting means to the male part and a female part, said temperature adjusting means of the decorative panel, characterized in that arranged on substantially the entire form surrounding heatable of the panel is a three-dimensional shape It can be manufactured by a manufacturing apparatus.

  Here, the terms used in the present invention will be described. The sheet base material means a sheet that is a raw material for producing the decorative sheet, and the decorative sheet is decorated on the sheet base material. It is an intermediate product at the stage of applying. Moreover, what formed the decorative sheet | seat in the three-dimensional shape by shaping | molding is a decorating panel. The decorative panel is a final product because it has all the conditions as the target product in the present invention, but if necessary, it is possible to add more steps. In addition, decoration is performed by means, such as printing, vapor deposition, and coating, and it is provided in any one surface or both surfaces of the surface of a panel main body, or a back surface.

  As described at the beginning of the prerequisites of the decorative panel manufacturing apparatus, the present invention is an apparatus for manufacturing a decorative panel having a three-dimensional shape by molding using a pair of male and female dies. Molding is performed by using plastic molding technology such as injection molding technology and related technology and adjacent technology, and these technologies include molding methods such as insert molding and in-mold molding. . In other words, the decorative panel of the present invention is formed by insert molding or the like on a sheet substrate having a three-dimensionally formed sheet base material (single decorative panel) and a sheet substrate having a three-dimensionally formed sheet. Including those formed with another plastic molded body (composite decorative panel).

  The pair of male and female molds has a plurality of mold parts composed of a female mold part and a male mold part for molding a decorative panel, and the plurality of mold parts are closest to each other. It is necessary to be arranged in. Conventionally, since the decoration panel is extremely small and the corresponding part is discarded to the extent that the size of the decorative panel is less than half the size of the sheet base material, the present invention is as wasteful as possible. The purpose is to make it smaller. Therefore, it is necessary to have a plurality of mold parts and to arrange the plurality of mold parts closely together. Closed is understood to mean that the mold parts are adjacent, but this means that there is no space between the adjacent mold parts, thus allowing a minimum amount of space between adjacent mold parts. What is done is the closest. A sheet fixing means to be described later is provided using the minimum space between the adjacent mold parts.

  In addition, the pair of male and female molds is a target product between the female mold part and the male mold part in a state where the decorative sheet is placed between the pair of molds and the mold is clamped to perform molding. It is necessary to maintain a clearance corresponding to the thickness of a certain decorative panel. This clearance is a part where the decorative sheet is arranged and molded. For example, in the case of injection molding, this clearance is a part corresponding to a cavity into which resin is injected. In the present invention, the clearance is provided so that no load is applied during molding. Yes.

  And it is indispensable in the present invention that there is a sheet fixing means for fixing so as not to move by engaging with a decorative sheet inserted between a pair of male and female molds around each mold part. It becomes the element of. The sheet fixing means fixes the decorative sheet in a predetermined positional relationship against the pulling force inward of the mold part, which acts on the decorative sheet as the mold is clamped in the mold forming process for the decorative sheet. Thus, it becomes possible to mold with the dimensional accuracy on the design, or to arrange as designed. The sheet fixing means penetrates the decorative sheet inserted between the pair of male and female molds, for example, a convex portion such as a pin, and a concave portion such as a pin hole into which the convex portion is fitted, for example, the pin is fitted. It is desirable that

A plurality of mold parts composed of a female mold part and a male mold part for molding a decorative panel are arranged such that the female mold part side is disposed in the lower position, while the male mold part side is disposed in the upper position, and the decorative sheet. It is desirable to provide temperature adjusting means for adjusting the heating temperature of the male mold part and the female mold part. By disposing the male mold portion on the upper side, the decorative sheet approaches the male mold portion, and the male mold portion takes the lead to perform mold forming. In addition, in order for the decorative sheet to be molded as a decorative panel as intended by the designer, it is necessary for the decorative sheet as a whole to have a uniform or predetermined temperature distribution condition. In order to improve the temperature condition, a temperature adjusting means is installed in the entire mold part. In this case, the temperature adjusting means is arranged in the male part that approaches the decorative sheet first, and the temperature adjusting means is also installed in the female part that receives the decorative sheet, so that the heating action is applied to the inside and outside of the decorative sheet. Therefore, the structure will be more accurate and effective.
The manufacturing apparatus of the present invention can also have a press machine configuration, but it must be able to operate slowly and be stopped in the middle of mold clamping. Unlike other die-cut presses, the specifications are similar to hot stamping machines. As described above, the upper mold (male mold part) and the lower mold (female mold part) are each adjusted in temperature, and the heating temperature varies depending on the base material of the decorated sheet, but is approximately 100 to 300 degrees. It is sufficient to expect the adjustment range of the above, but specifically, it is changed according to the tree species.

  Since the present invention is configured and operates as described above, the decorative panel is used to fix the sheet base material as in the vacuum forming method by the plurality of mold parts arranged in close proximity. It is possible to provide a highly productive decorative panel manufacturing apparatus that does not waste many times as much area. In addition, according to the present invention, it is possible to select an inexpensive decorative or decorative panel as a decorative panel without restriction. Thus, it is possible to select freely.

  Hereinafter, the present invention will be described in more detail with reference to the illustrated embodiments. FIG. 1 shows a decorative panel 10 having a three-dimensional shape according to the present invention. In the illustrated example, the decorative panel 10 has a flat square dish shape that can be used as an inscription with illumination. The illustrated decorative panel 10 is made of a plastic sheet base material, and the sheet main body is formed into a three-dimensional shape by molding, and the ink attached to the back surface of the panel main body 11; And a decorating part 12 made of either paint or fine particles. In this example, the back surface of the panel main body 11 is provided with a decorative portion 12, and the back surface decorative portion 12 is seen through from the front of the panel main body 11, and the resin constituting the panel main body includes Usually, transparent plastic is selected.

As the material of the sheet base material 11, any type of resin can be used depending on the application. That is, for example, when designing as a sheet base material for a decorative panel used in the amusement industry such as a game machine, a design and a high degree of freedom of expression are heat resistance, impact resistance, wear resistance, etc. Therefore, if a resin substrate made of polyethylene terephthalate (PET) resin, acrylonitrile butadiene styrene (ABS) resin or the like is used, cost merit is great. For example, when the decorative panel of the present invention is used for automobile interior parts, polycarbonate (PC) is used as a sheet base material of the decorative panel in order to cope with heat resistance, impact resistance, wear resistance, and the like. It is necessary to use a sheet base material made of a resin made of resin, acrylic resin, or the like. Polycarbonate resins are expensive and have a high melting point among thermoplastic resins, and are difficult to handle. It is very difficult to make this resin into a three-dimensional shape by a vacuum molding method. By using an apparatus for manufacturing a decorative panel, it can be molded without any problems.

  The decorative portion 12 provided on the back surface of the decorative panel 10 is formed on a sheet base material made of the above-described polyethylene terephthalate (PET) resin, acrylonitrile butadiene styrene (ABS) resin, polycarbonate (PC) resin, acrylic resin, or the like. It is provided by means such as printing. As a decoration method, methods such as printing, vapor deposition, and painting can be applied, and among them, printing can be properly used according to the type and specification of the substrate such as gravure printing, offset printing, silk screen printing, and various conditions. Naturally, it is possible to properly use the methods such as vapor deposition and coating according to the application conditions. The decorative panel 10 of the present invention is configured as described above, and has a feature that fine molding and expression that cannot be expected from conventional products formed by a vacuum forming method are possible.

  In the decorative panel 10, a pair of male and female dies 13, 14 has a plurality of mold parts 17 including a female part 15 and a male part 16 for molding the decorative panel 10. In addition, the plurality of molding die portions 17 are arranged closest to each other, and the pair of male and female molds 13 and 14 is molded by placing a decorative sheet 18 between the pair of molds. In order to perform, in the clamped state, a clearance 31 corresponding to the thickness of the decorative sheet 18 as the target product is held between the female mold part 15 and the male mold part 16 (see FIG. 5). Around each mold part 17, a convex part 19 that penetrates a decorative sheet 18 inserted between a pair of male and female dies 13, 14 and a concave part 21 into which the convex part 19 is fitted, A manufacturing apparatus that has a sheet fixing means 20 for fixing in a predetermined positional relationship. It is molded by. That is, the flat decorative sheet 18 has a three-dimensional shape by the present manufacturing apparatus.

  FIG. 2 shows the manufacturing apparatus of the present invention having three rows of female mold portions 15 and male mold portions 16, wherein the lower mold (14) is placed on the stationary mold plate, and the upper mold (13) It is installed on the movable template. The mold part 17 composed of the female mold part 15 and the male mold part 16 is installed in a close-packed arrangement in which only a minimum space exists between adjacent mold parts as shown in FIG. In the minimum space between adjacent mold parts, a convex part 19 shown as a pin and a concave part 21 in which the pin can be fitted are provided (see FIG. 4). In addition, the decorative sheet 18 positioned by the convex portion 19 is preliminarily provided with a through hole through which a pin can pass. Although it is a rough comparison, when the size of the convex part (16) in the mold part 17 shown in FIG. 3 reflects the actual situation, the conventional vacuum molding system apparatus has four mold parts. However, in the manufacturing apparatus of the present invention, 15 mold parts can be provided, and it can be seen that the production efficiency can be increased to nearly four times.

  A plurality of mold parts 17 comprising a female mold part 15 and a male mold part 16 for molding the decorative sheet are arranged with the female mold part on the lower side, while the male mold part side is arranged on the upper side. In addition, the male mold portion 15 and the female mold portion 16 are provided with temperature adjusting means 22 and 23 for adjusting the heating temperature of the decorative sheet. The temperature adjusting means 22 on the male part side can heat almost the entire inside of the three-dimensional panel main body 11, and the temperature adjusting means 23 on the female part side is almost on the outside of the three-dimensional shaped panel main body 11. It is provided in an arrangement form that surrounds the whole so that it can be heated (see FIGS. 2 and 5). This arrangement form is only an example, but is shown as an example in which the entire three-dimensional panel body 11 can be heated uniformly. In addition, although not shown in figure, the manufacturing apparatus of this invention shall be equipped with all the mechanisms required for implementation of the manufacturing process of a series of decorating panels ranging from opening and closing of a mold, mold forming, and taking out of a molded article.

  The operation of the present invention configured as described above will be described below. FIG. 7 shows a mold open state in which the male mold part 16 is lifted with respect to the female mold part 15 by a mold opening / closing mechanism (not shown) and a space 24 is formed between both mold parts. In this state, the decorating sheet 18 is arranged in the space 24 between both mold parts (FIG. 8). The decorative sheet 18 is a stage in which the decorative portion 12 is printed on one surface of a plastic sheet base material by printing means. As a printing method, a known printing method such as gravure printing, offset printing, silk screen printing, or the like can be used properly depending on the type, specifications, and various conditions of the sheet base material.

  A plurality of printing patterns are printed on the decorative sheet 18 as decorative portions 18a in accordance with the positions of the plurality of mold portions 17, so that the decorative portions 18a face upward, that is, a male mold. Arranged so as to face the part 16. At the stage where the decorative sheet 18 is placed in the mold part 17 composed of a pair of male and female dies 13, 14, a positioning hole 25 penetrating the sheet surface is formed in the decorative sheet 18, and the positioning hole 25 is a convex part 19. And the decorative sheet 18 is positioned and fixed. As a result of the decorative sheet 18 being held and fixed by fitting the convex portion 19 and the concave portion 21, an accurate decorative panel 10 that retains design dimensional accuracy can be formed, and Even when a plurality of decorative panels 10 are combined, arrangement as designed is possible.

  When a particularly thick sheet base material is used as the decorative sheet 18, the processing time can be shortened by heating in advance, and uniform molding can be performed over the entire surface. In addition, care should be taken when the decorative portion 18a is expressed by various types of printing. When the mold of the decorated sheet base material 18 (decoration part 18a) and the upper mold male part 16 is at a high temperature (100 degrees to 300 degrees), the lower mold with the female mold section 15 There is a risk of being pressed and closely attached to the mold surface in the mold forming performed between them, and therefore, when the decorative portion 18a is expressed by various printing in this way, Desirably, a film 18b of about 10 to 20 microns is disposed in advance between the surfaces of the decorative sheet 18 where the decorative portion 18a is provided (FIG. 6). As a result, the printing ink of the decorating part 18 is not transferred to the mold of the male part 16 which is the upper mold. When insert molding is performed by injection molding, it is necessary to apply (print) an adhesive that is compatible with the plastic resin, so when the temperature of the male mold portion 16 that is the upper mold is higher than the melting point of the adhesive. Particularly suitable heating is effective. In addition, when the decorating part 12 is provided not on the back side of the decorating sheet 18 but on the front side, the front side on which the female mold part 15 in the molding die part 17 and the decorating part 18a of the decorating sheet 18 are provided. The above-described film 18b is arranged in advance.

  Under the molding conditions as described above, the male mold part 16 is lowered with respect to the female mold part 15 by a mold opening / closing mechanism (not shown), and a mold molding process for the decorative sheet 18 is started (FIG. 9). When the male mold part 16 is lowered to the position where the convex part 19 is fitted or not in the concave part 21, the male mold part 16 is temporarily stopped immediately before the mold surface of the male mold part 16 touches the decorative sheet 18, and almost the whole of the male mold part 16 is stopped. The decorative sheet 18 is heated by the temperature adjusting means 22 and 23 arranged so as to surround it. After receiving the necessary heating, or while receiving the heating, the male mold part 16 starts to descend again to be in a clamped state, and the decorative sheet 18 is sandwiched between the male mold part 16 and the female mold part 15. Moreover, it stops once and the male mold | type part 16 raises and mold-opens after that. The setting of the temporarily stopped time, the heating temperature, and the descending speed differs depending on the type and thickness of the base material of the decorated sheet. After mold opening, the molded product (decorative panel 10) is taken out from the mold part 17, and the obtained decorative panel 10 has a three-dimensional shape as shown in FIG. 18a having high transparency as intended.

  In the case where the uneven shape provided as the decorative portion 18a on the decorative sheet 18 is complicated or a sharp shape, the shape of the lower portion of the female mold portion 15 is changed to a complicated shape or a sharp shape portion. A suction hole 26 having a corresponding hole diameter (for example, less than 1 mm to several millimeters) is opened in several places so as to communicate from the inside of the mold to the outside of the mold (see FIG. 10), and the decorative sheet 18 and the female mold as the lower mold A method is adopted in which the space between the portions 15 is evacuated to prevent the decorative sheet 18 from being broken or split. At that time, the same injection hole 27 is formed in the male mold portion 16 which is the upper mold at the same time or alone, and the same effect is obtained by injecting air into a compressed air state, or air suction and injection are performed in parallel. It is also possible to carry out the process, which is complicated, but more effective for precise molding.

  Further, by providing a cutting blade 28 and its receiving portion 29 on the outer peripheral portion of the upper die male portion 16 and the lower die female portion 15, respectively, the decorative sheet 18 is simultaneously formed with the completion of the mold clamping. It is possible to provide a configuration for cutting off the excess ear 18c (see FIG. 11). In the figure, reference numeral 30 denotes a cutting line. In addition, as shown in FIG. 6, when the film 18b is arrange | positioned between the male mold part 16 and the one surface in which the said decoration part 18a of the decorating sheet 18 is provided, the film 18b may be removed afterwards. Since the film is the back surface of the decorative panel 10, it may not be necessary to remove it.

  The decorative panel 10 of the present invention is formed in this way, and has the possibility of being applied to products in many fields as game equipment, automobile parts (interior and exterior), home appliances, decorative parts for building materials, and other decorative parts. have. The example of the decorative panel of the present invention described here is a panel (single decorative panel) made of a sheet base material that is three-dimensionally formed. However, as described above, the sheet base material includes a three-dimensionally formed sheet base material added with another plastic molded body formed by insert molding or the like (composite decorative panel). In order to manufacture the composite decorative panel, insert molding or in-mold molding may be performed using the single decorative panel 10 of the present invention, and a specific method thereof is obvious to those skilled in the art.

  The above-described embodiment is an embodiment in which the present invention is an example of what is commonly referred to as a lighting panel having a decoration portion illuminated by illumination. Therefore, the decoration portion 12 on the back side of the panel body 11 is the front side. Therefore, the material of the panel body 11 needs to be transparent. However, providing the decorative portion 12 on the front side of the panel body 11 is naturally possible within the scope of the present invention, and the application can be applied to any other decorative panel as well as a lighting panel. Needless to say, the material of the panel body 11 is not limited to the transparent material.

An example of the decorating panel which concerns on this invention is shown, A is a front view and B is IB-IB sectional view taken on the line of FIG. 1A. It is explanatory drawing which shows an example of the manufacturing apparatus of the decorating panel which concerns on this invention. It is plane explanatory drawing of the male type | mold part in an apparatus same as the above. FIG. 4 is an enlarged explanatory view of the IV portion of FIG. 3. It is a fragmentary sectional view of the device of the present invention similarly. It is explanatory drawing of the modification of the apparatus of this invention similarly. FIG. 3 is a diagram illustrating an operation of the apparatus of the present invention and is an explanatory diagram of a mold open state. It is explanatory drawing of the state which has arrange | positioned the decoration sheet in the space of a shaping | molding die part from FIG. It is explanatory drawing which similarly shows a mold clamping state. It is sectional explanatory drawing which shows the example which provided the suction means etc. in the apparatus of this invention. It is sectional explanatory drawing which shows the example which provided the cutting-off means in the apparatus of this invention.

DESCRIPTION OF SYMBOLS 10 Decorating panel 11 Panel main body 12 Decorating part 13, 14 Mold 15 Female mold part 16 Male mold part 17 Molding part 18 Decorating sheet 19 Convex part 20 Sheet fixing means 21 Concave part 22, 23 Temperature adjusting means 24 Space 25 Positioning hole 26 Suction hole 27 Injection hole 28 Cutting blade 29 Receiving part 30 Cutting line

Claims (4)

Using a decorative sheet in which a positioning hole penetrating the sheet surface is formed , a decorative panel formed by a plastic pressing technique and having a decorative part,
A panel body made of a plastic sheet base material, and the sheet base material is formed into a three-dimensional shape by molding, and ink or paint provided on one or both of the front and back surfaces of the panel main body Or the decoration panel comprised including the decoration part which consists of either of microparticles | fine-particles. An apparatus for manufacturing a decorative panel having a three-dimensional shape using a pair of male and female molds by a plastic pressing technique,
The pair of male and female molds has a plurality of mold parts composed of a female mold part serving as a lower mold and a male mold part serving as an upper mold for molding a decorative panel, and the plurality of mold parts. The mold parts are arranged close together,
A pair of male and female molds is a decorative product that is a target product between a female mold part and a male mold part when a decorative sheet is placed between the pair of molds and the mold is clamped. Hold clearance for the thickness of the sheet,
Around each mold part, it has a sheet fixing means for fixing so as not to move by engaging with a decorative sheet inserted between a pair of male and female molds ,
The temperature adjusting means for adjusting the heating temperature of the decorative sheet is provided in the male mold portion and the female mold portion, and the temperature adjusting means is arranged in a form surrounding the entire panel body which is a three-dimensional shape so as to be heatable. An apparatus for producing a decorative panel characterized by that. A plurality of mold portions consisting of the female part and the male part for molding the decorative sheet will have a configuration where one placed the male part side to the upper placing the female portion to the lower The apparatus for manufacturing a decorative panel according to claim 2. The apparatus for manufacturing a decorative panel according to claim 2, wherein the sheet fixing means includes a convex portion penetrating the decorative sheet and a concave portion into which the convex portion is fitted.

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