JPH03290300A - Preparation of product having false three-dimensional pattern - Google Patents

Abstract

PURPOSE:To obtain a product having a false three-dimensional pattern rich in a three- dimensional feeling by forming a master having a desired uneven image and molding a body having the uneven surface corresponding to the uneven image and forming a transparent layer to the uneven surface and forming a light permeable colored layer on the transparent layer. CONSTITUTION:A plate showing light permeability and light scattering properties is engraved while irradiated with light from below to form a master having a desired uneven image. A flowable raw material is allowed to flow in this master or the master is filled with a powder raw material or a plastic raw material. When the flowable raw material is used, the raw material is cured by allowing the same to stand, heating the same or adding a curing agent thereto. When the powder raw material or the plastic raw material is used, a mold becoming a pair with respect to the master is utilized to press the raw material. By this method, a molded body having the uneven surface corresponding to the uneven image of the master is molded. A transparent layer 3 is formed to the uneven surface of the molded body 2 using a vitreous solid having light permeability or transparent plastic. A light previous colored layer 1 having a coloring substance dispersed therein is formed on the transparent layer 3 and the surface thereof is made smooth.

Description

[Detailed Description of the Invention] [Industrial Field of Application] The present invention relates to a method for manufacturing a product having a pseudo three-dimensional pattern, and more specifically, to a method for manufacturing a product having a pseudo three-dimensional pattern.
Concerning manufacturing methods for products such as plastics.

[Prior Art] Conventionally, as a method for manufacturing products with three-dimensional patterns, there is a method for manufacturing ceramics using a method called openwork carving.

In this method, a layer of light-scattering material such as wax is first formed on a transparent plate to have a substantially uniform thickness, and then a desired portion of the wax layer is carved to form an uneven image. that time,
The wax is carved while observing the model while shining light from the transparent substrate side. By doing this, when carving the uneven image into the wax, the degree of light transmission that changes depending on the layer thickness of the wax can be perceived as a reflection of the three-dimensional effect of the model. As a result, the three-dimensional effect of the model can be reflected extremely faithfully on the wax layer.

In the next step, plaster mixed with water is poured onto the wax layer, allowed to solidify, and then the wax is peeled off to form a plaster mold with the textured image transferred onto it. Using this plaster mold, a slurry of a ceramic raw material composition (clay) is cast and molded to produce a thin molded body having an uneven surface corresponding to the uneven image. Thereafter, the dried molded body is fired to produce patterned ceramics. When the molded body is fired, a transparent thin glaze having an uneven surface reflecting the uneven surface of the fired body may be formed.

The uneven image carved by the wax layer is almost faithfully transferred to the ceramic, so when light shines through the back of the ceramic, a three-dimensional watermark pattern emerges. This is based on the fact that as the thickness of the ceramic changes, the amount of light transmitted from the back side of the ceramic to the front surface changes, and areas with a large amount of light transmission appear to be raised, while areas with a low amount of transmission appear like shadows. It is.

[Problems to be Solved by the Invention] When looking at the patterned portion of ceramics formed by such a conventional method without light passing through it, the unevenness is so precise that it appears to be cluttered, and the aesthetic appearance is poor. There is no sense of three-dimensionality. However, there are many cases where the ceramics are left in such conditions. In order to avoid this problem, it is necessary to arrange lighting etc. so that the light will definitely fall on the ceramic.

Furthermore, in a place where the entire surrounding area is bright, the watermark pattern =3 may not be clearly perceived. Furthermore, the existence of a three-dimensional pattern on the ceramic may go unnoticed.

In addition, although ceramics with openwork patterns have been used in practical applications such as fluorescent lampshades, there have not been many uses in which the three-dimensional patterns can be utilized.

Furthermore, with the method using openwork, only ceramic products could be produced.The present invention solves the above problems, and allows a pattern similar to a detailed openwork pattern with a three-dimensional effect to be produced without irradiating light from the back side. The purpose of the present invention is to provide a method for producing a product having a pseudo three-dimensional pattern that can be used for various purposes.

Another object of the present invention is to provide a manufacturing method capable of manufacturing products having a pseudo three-dimensional pattern and made of various materials.

[Means to solve the problem] The above objects can be achieved by the present invention as described below.

That is, the present invention includes a process of carving a disc exhibiting translucency and light scattering properties while irradiating light from the lower side to form a prototype having a desired uneven image of -4=; A process of injecting a fluid raw material or filling a powder raw material or a plastic raw material into a mold that reproduces the uneven image of the original mold through its transfer, and solidifying the fluid raw material or compressing the powder raw material or the plastic raw material. , a step of molding a molded body having an uneven surface corresponding to the uneven image; a step of forming a transparent layer on the uneven surface; and forming the transparent layer on the transparent layer.

[Function] In the product produced by this method (FIG. 2), the pattern, which is as precise and full of three-dimensionality as the watermark pattern, can be perceived by the eye without irradiating light from the back side of the product. The reason why such a three-dimensional pattern appears is thought to be as follows.

As shown in Figure 1, the surface of the colored layer is smooth, so
The thickness of the colored layer] is determined in accordance with the thickness change (thickness change based on surface irregularities) of the molded body 2 covered by the colored layer (determined in an almost opposite relationship). The thickness change of the colored layer 1 determined in this way is approximately proportional to the thickness change of the layer of the original model, which faithfully reflects the three-dimensional effect of the model.

In the colored layer 1 exhibiting such a thickness change, since the total amount of the colored substance is small in the thinner portion, the light transmittance is large, and the surface of the molded body 2 below the thinner portion appears to stand out. On the other hand, the thick portion of the colored layer 1 has a large total amount of colored substances and therefore has low translucency, so that the surface of the molded body 2 is difficult to see through and looks like a shadow due to the colored substance. As a result, it is thought that a three-dimensional pattern appears in the product manufactured by the method of the present invention. In particular, in the present invention, the transparent layer 3 consists of the molded body 2 and the colored layer 1.
is set between. Therefore, the transparent layer 3 soaks into the colored layer 1, and as a result, the colored layer 3 bleeds (blurs), resulting in an interesting aesthetic sensation.

Hereinafter, typical embodiments of the method for producing a product having a pseudo three-dimensional pattern of the present invention will be described.

First, a disk exhibiting light-transmitting and light-scattering properties is carved while irradiating light from below to form a prototype having a desired uneven image (step 1).

Here, the disc exhibiting translucency and light scattering properties refers to so-called translucent discs, that is, discs made of materials other than those that are substantially completely transparent (e.g., silica glass) and those that are substantially completely opaque (e.g., iron). This is a board made up of.

Examples of the material of this disc include wax, synthetic wax; translucent resin such as vinyl chloride; translucent ceramics made of small particle size and high density alumina, magnesia, etc.

To engrave a board made of such materials, there are several methods that can be used, including manual methods using an iron pen, methods using physical means such as a laser, and mechanical methods. It is sufficient to select an appropriate method according to ease of use, etc.

In this process, light is irradiated from the bottom of the board (i.e., the opposite side of the board surface on which the uneven image is to be drawn), and the degree of light transmission from the board depending on its thickness is measured by the eye or sensor. This is because the three-dimensional effect of the model is reflected extremely faithfully on the translucent board by carving the uneven image while perceiving it using mechanical means.

Next, a fluid raw material is introduced into the above-mentioned master mold, or a powder raw material or a plastic raw material is filled (Step 2).

After the fluid raw material flows into the master mold, it is left to heat.

Any material that can be cured by appropriate treatment such as addition of a curing agent may be used. Examples include flowable plastics (e.g. unsaturated polyesters, melamine resins, polyamide resins, silicone resins, epoxy resins, acrylic resins),
Polymerizable low-molecular compounds with fluidity (e.g. styrene, methacrylic acid ester), fluid rubbers (e.g. butyl rubber).

trill rubber), molten glass, cement raw materials, molten metal,
Examples include slurry for ceramics.

Powder raw materials include plastic powder, wood and paper car powder,
Examples include starch and calm. A binder or the like may be mixed with such powder raw material.

Examples of the plastic raw material include clay.

− Next, if fluid raw materials are used in the above process, leave them
The raw material is hardened through treatments such as heating and addition of a hardening agent. Further, when a powder raw material or a plastic raw material is used, the raw material is compressed using a mold or the like that pairs with the master mold. In this way, a molded body having an uneven surface corresponding to the uneven image of the original mold is formed (Step 3).

The molded body may be subjected to heat treatment, sintering treatment, etc. as necessary.

Above step 1. 2. Depending on the combination of the material of the mold to be used in step 3 and the raw material for the molded body, the mold may be damaged if the two come into contact, or the molded body may be difficult to release from the mold even if a release agent is used. For this reason, it may be difficult to mold a molded article. In addition, the prototype itself is easily damaged and may not be able to be used repeatedly. If such an inconvenience occurs, a mold (hereinafter referred to as a reproduction mold) is created by reproducing the uneven image of the original mold by transfer, and this is used to create a molded object having an uneven surface corresponding to the uneven image of the original mold. Just make it.

There are no particular restrictions on the method of obtaining the reproduction mold, but for example, a first mold having a concavo-convex image that is the inverse of the concave-convex image is produced by molding using the master mold, and then that first mold is used. ) can be easily obtained as a molded product. Furthermore, the reproduction mold can be obtained by a method in which the uneven image of the original mold is analyzed by a computer and the image is reproduced on an appropriately selected material using mechanical means.

As the raw materials for the first mold and reproduction mold, materials within the same range as the raw materials for the molded body described above can be used, but from among them, the material of the original mold, the material of the molded body to be molded by the reproduction mold, etc. It is only necessary to take this into account and select it appropriately so that the above-mentioned inconvenience does not occur.

Examples of combinations of materials for the original mold, first mold, transfer mold, and molded body that are preferable for preventing the above-mentioned disadvantages are listed below.

In Example 3, to form a metal mold from a plaster mold, sand, wax, and sand are each layered in that order to a uniform thickness on the uneven surface of the plaster mold, and molten metal is poured on the same day. Just let it flow.

This causes the molten metal to melt the wax and fill in between the sand instead of the wax.

The filling becomes a metal mold.

Next, a transparent layer is formed on the uneven surface of the molded body formed by the master mold or reproduction mold (step 4).

Here, the transparent layer may be a translucent glassy solid, a transparent plastic, or the like.

Next, a transparent colored layer in which a colored substance is dispersed is formed on the transparent layer by substantially smoothing the surface thereof (Step 5).

The colored substance referred to in the present invention may be a colored molecule,
Colored particles having a diameter of about 0.1 to 0.001 μm, that is, colloidal colored particles (for example, pigment particles) may be used. In the colored layer, the colored particles are made of a translucent solid (vitreous solid, transparent solid plastic, etc.) or a translucent fluid (
Higashi Transparent Fluid Plastic, etc.).

When the main body constituting the colored layer 1 is solid, it is preferable that it is vitreous because it gives a predetermined quality to the product, and it is preferable that it is plastic because the colored layer can be easily formed. It is desirable if the dispersion system of the colored layer is uniform, since the three-dimensional image of the original mold formed in step 1 can be faithfully reproduced.

In order to form the colored layer, the colored layer material may be applied onto the molded body, poured into the molded body, stored, etc., and then heated, fired, etc. may be performed as necessary.

Through the following steps, a product with a smooth surface and a colored layer in which a colored substance is dispersed can be manufactured. In that product, the change in thickness of the product body (molded body) corresponds to almost the exact opposite of the change in thickness of the master mold that formed the uneven image. Therefore, the change in thickness of the colored layer that covers the product body and has a smooth surface is almost proportional to the change in the thickness of the original model. In the thinner parts of this colored layer, the total amount of coloring substances dispersed is small and the colored layer is translucent, so the surface of the product body can be seen through, and in the thicker parts, the colored layer is transparent. The layer is not translucent and the color of the colored substance is so dark that it appears as a shadow. Therefore, the product has a three-dimensional pattern that appears even if it is not transparent to light.

Products with such pseudo three-dimensional patterns are used for tableware,
Ashtrays, vases, figurines, interior tiles, cosmetics tender ceramic plates, frames are listed.

As is clear from the above explanation, unlike the conventional openwork manufacturing method, the method for manufacturing products with pseudo-three-dimensional patterns of the present invention allows products made of various materials to be manufactured, but it is also possible to manufacture products with particularly good durability. An example in which the present invention is applied to the production of a ceramic product will be described in more detail below.

First, a layer of wax is laminated on a transparent substrate such as a glass plate to an approximately uniform thickness (usually 2 to 4 mm) (Step 1-1
).

Next, light is irradiated from the transparent substrate side, and while the three-dimensional effect of the wax surface is perceived by the degree of light transmission from the wax, the unevenness corresponding to the model is carved into the wax layer with a pencil or the like.
A precise uneven image is formed (step 1-2).

The reason why wax is used in this process is because wax is translucent and can easily form precise images.Therefore, instead of wax, glue, machinable Wax-like substances having such properties, such as synthetic resins, can also be preferably used.

Next, surround the wax layer with a frame, etc., pour plaster mixed with water onto the layer, let the plaster harden, remove the wax after hardening, and remove the first plaster with the image transferred. A mold is formed (Step 2-1).

Note that other materials, such as resin, may be used instead of the first plaster mold.

Furthermore, plaster mixed with water is poured onto the first plaster mold, the plaster is solidified, and a second plaster mold (one of the transfer molds) in which the image is transferred is again formed (Step 2- 2).

Next, using the second plaster mold, a slurry of porcelain clay is cast and molded (step 3-1).

By casting, a molded body having an uneven surface corresponding to the uneven image on the wax layer is formed.

Then, while firing the molded body with the uneven surface,
A transparent layer is formed (step 4-1). More specifically, a transparent layer is formed by coating and pouring a glassy solid or transparent plastic.

Normally, conventional glazes without added pigments can be used as is as a transparent layer.

Next, a light-transmitting colored layer in which a colored substance is dispersed is formed on the uneven surface so that the surface thereof is substantially smooth to obtain a fired body (step 5-1). The firing and the formation of the colored layer in this step may or may not be simultaneous.

This step 5-1 can take various forms depending on the type of colored layer.

A typical procedure of this step 5-1a will be explained when the colored layer is a glaze layer in which colored particles are suspended in a glassy phase and does not lose its translucency.

First, the molded body formed in step 3-1 is heated to a maximum temperature of 600~
Bisque firing is carried out at about 900 degrees. After the unglazed body is glazed, it is fired. When applying the glaze, it is necessary to use enough glaze to make the surface smooth and not reflect the unevenness of the ceramic itself, since the glaze will be thick after firing. As for the material of the glaze, it is necessary to use one that does not cause defects such as cracks even when the glaze is thick (approximately 3 mm or more) as shown in 5- above.

Examples of combinations of glaze materials and ceramic clay for this purpose are shown below.

Porcelain clay component Feldspar silica pottery clay (kaolin) Alumina Talc Glaze component Feldspar silica Dolomite Lime Zinc Barium carbonate Weight parts 20-25 ] O 0 0 0-5 0-5 Weight parts 0 0 5 ] 6- Oxidation Cobalt 0. 2 The firing conditions for final firing must be determined by considering the above combinations, but for example, in the case of feldspathic porcelain clay with a large amount of feldspar, firing in an oxidizing atmosphere may cause the firing to be heated to 900°C.
Raise the temperature to around 1,200 degrees, then increase the temperature to around 1,200 degrees by firing in a reducing atmosphere, and then increase the temperature to around 1,200 degrees by firing in a near-neutral atmosphere.
After raising the temperature to 00 degrees, cooling begins.

Through the above steps, ceramics with a smooth surface and a translucent colored glaze can be manufactured.

In this ceramic, where the glaze is thin, the total amount of dispersed colored substances is small and the glaze is transparent, making the surface of the ceramic body visible and visible, and where the glaze is thick, the glaze is transparent. It has no color and the color of the colored substance appears dark and looks like a shadow. As a result, ceramic products exhibit three-dimensional patterns even if they are not transparent to light. In addition, the transparent substance constituting the transparent layer soaks into the colored layer, and as a result, the boundary between the colored layer and the transparent layer becomes unclear, resulting in a smeared or blurred feeling, which is more aesthetically pleasing.

When the colored layer is a layer in which colored molecules or colored particles are dispersed in transparent plastic, this step 5-1 is performed by the following procedure (5-1b).

First, a fired body is formed in substantially the same manner as step 5-1a above, but without glazing. Next, a plastic fluid in which an appropriately selected coloring substance (dye, pigment, etc.) is dispersed is poured onto the uneven surface of the fired body whose sides are surrounded by a frame, etc., and solidified while the surface is smoothed. In this way, ceramic products with three-dimensional patterns similar to the ceramics described above are produced.

Note that the plastic material may be any material as long as it has translucency and exhibits adhesiveness to the fired body upon solidification. For example, epoxy resin etc. can be mentioned.

Further, as another embodiment of step 5-1, an embodiment may be mentioned in which colored suspended particles or colored molecules are dispersed in water and filled into a transparent container containing the fired body.

Ceramic products having a pseudo three-dimensional pattern manufactured in this manner are used for various purposes as described above.

[Example] In order to further clarify the present invention described above, specific examples of the method for manufacturing a product having a pseudo three-dimensional pattern of the present invention will be described below.

Example] First, molten wax was poured onto transparent glass and solidified, and a layer of wax with a thickness of about 3 mm was laminated. Next, while shining light from the glass plate side, an image of a ship was carved into the wax with an iron brush. Gypsum mixed with water (100 parts by weight of gypsum to 1 part of water)
00 parts) was poured onto the framed layer of wax and solidified to form a first plaster mold with the image transferred thereon. In addition, the first
The plaster mold was shaped like a rectangular plate, and the peripheral part was raised in the shape of the part where the image was formed.The plaster mixed with water similar to the one above was poured into this mold, and then it solidified. , a second plaster mold was formed.

Using the second plaster mold, the following porcelain clay was cast and molded.Commercially available porcelain clay Ingredients Weight feldspar 23 Pottery stone ]O Silica stone ]0 Clay (kaolin) 40 Alumina 3 Talc 3 The slurry for casting is 100 parts by weight of porcelain clay, 3 parts by weight of water.
A rectangular plate shape with a maximum thickness of about 5 mm on the uneven surface corresponding to the image was formed by mixing 0 parts of water glass and 2/1000 weight of water glass as a dispersant, and casting for 40 minutes. A molded body was molded.

After drying this molded body, it was bisque fired.In the bisque firing process, the temperature was gradually raised to 500 degrees over about 4 hours, mainly to remove moisture, and then the temperature was raised to 800 degrees over another 2.5 hours. As a result, a plate-shaped bisque with a raised peripheral area was formed, measuring 15 x 13 cm square, having an uneven surface of about 0.3 cm thick, and weighing 290 grams. The ingredients were mixed.

Ingredients Weight: feldspar 50 quartzite 20 dolomite 5 lime 15 zinc white 9 barium carbonate 1 100 parts by weight of water was mixed with this 100 parts by weight, and the mixture was mixed with an electric mill.This was applied to the unglazed surface.

On the other hand, 100 parts by weight of water was mixed with 100 parts by weight of this 100 parts by weight, and the mixture was mixed with 100 parts by weight of water, and mixed with 100 parts by weight of water. After rubbing it for about 22 hours, and then drying it, I put 45 grams of this glaze on the center of the uneven surface of the unglazed body.
Asahi for Honyaki In this honyaki, the temperature is raised to 900°C over 9 hours through oxidation firing, and then the temperature is raised to 1200°C over 7 hours through reduction firing.
After that, by firing in a near-neutral atmosphere, 1
After raising the temperature to 250 degrees over 3 hours, cooling (1
0 hours).

In this way, the glaze layer spreads over the entire uneven surface of the ceramic body, creating a ceramic plate with a smooth horizontal surface and a three-dimensional ship pattern. It was about 3 mm, and there were no cracks on its surface.

Although products in which powdered glass is fused to bone china at about 1,000 degrees are known, the product manufactured in this example is a high-temperature fired porcelain that has great strength and tongue wear resistance when fired at 1,200 degrees or higher. What's more, the glaze is thick (the glaze of conventional high-temperature fired porcelain is about 1.5 mm), there are no cracks, and in addition, the glaze has a special effect (the ability to bring out three-dimensional patterns). It can be thought of as a combination product of glaze and glaze), and this is an unprecedented product.

Example 2 First, molten wax was flowed and solidified onto a transparent glass, and a layer of wax having a thickness of about 3 mm was laminated thereon. Next, while shining light from the glass plate side, the statue of Mona Lisa was carved into the wax with an iron brush.Then, gypsum mixed with water (100 parts of water to 100 parts of gypsum) was added to the wax, surrounded by a frame. The first plaster mold was poured on top of the layer and solidified to form a first plaster mold with the image transferred thereon. It has a raised shape.

23- Pour silicone resin (TSE350RTY (product name), manufactured by Toshiba Silicone) into the second plaster mold and leave it for several hours to solidify to form a silicone mold that reproduces the Mona Lisa statue carved in wax. , the silicone mold could be easily released from the plaster.

Next, the following composition was prepared.

Composition commercially available components Parts by weight/Calcium carbonate]000/Unsaturated polyester resin 700 (Nister 3115PA (
Product name), manufactured by Mitsui Toatsu Chemical Co., Ltd.) / Hardening agent
3.5 (Kayamek (trade name), manufactured by Kayaku Akzo Co., Ltd.) This composition was stirred to give about 170%
3.5 g was poured onto the silicone mold surrounded by a frame.
If it is left to stand, the composition will harden and
After standing for a minute, the composition was cured and the rectangular plate-shaped molded product was released from the mold.This release was also very easy.

After standing for 30 hours, the same transparent component 4 as in Example 1 was prepared and applied to the desired areas of the molded body. I didn't apply it to areas where I didn't need blurring, such as around Mona Lisa's eyes, and where I wanted a strong outline.

737.8 g of the following composition was mixed, stirred, and poured onto the molded body. After that, when left for 2 hours, the following composition hardens and a brown transparent colored layer is formed on the molded product.Ingredients: Parts by weight: Unsaturated polyester resin 700 (Nister 3
115PA (trade name)) - Aluminum hydroxide] O aqueous solution 25 - Hardening agent (Kayamec (trade name)) 12.5 - Coloring substance iron oxide 0. Chromium monoxide 0. 2 In this way, the colored layer
A rectangular plate-shaped plastic product (Figure 2) with a Mona Lisa pattern with a three-dimensional effect, which spreads over the entire uneven surface of the molded body and has a smooth horizontal surface, has been created.The area near the eyes is clearly visible. I got the line.

Although the embodiments of the present invention have been described above, the present invention is not limited to these embodiments, and it goes without saying that the present invention can be implemented in various forms without departing from the gist of the present invention.

"Effects of the Invention" According to the method of manufacturing a product having a pseudo-three-dimensional pattern of the present invention as explained above, a pattern with a detailed three-dimensional effect can be displayed in the same way as a conventional watermark pattern without irradiating light from the back side of the product. The product has a more natural feel than the smudging of the colored parts.As a result, anyone can perceive the three-dimensional pattern drawn on the product at any time and in any place without any effort. Furthermore, the material of the product can be made of various materials other than ceramics.

With the above effects, the applications of products with three-dimensional patterns can be widely expanded.

[Brief explanation of drawings]

FIG. 1 is a schematic sectional view of a product manufactured according to a typical example of the present invention, and FIG. 2 is a plan view of the same side. 1... Colored layer 3... Transparent layer 2... Molded object

Claims (1)

[Scope of Claims] 1. A step of carving a disk exhibiting translucency and light scattering properties while irradiating light from the lower side to form a prototype having a desired uneven image; A process of flowing a fluid raw material or filling a powder raw material or a plastic raw material into a mold in which the uneven image has been reproduced through the transfer, and solidifying the fluid raw material or compressing the powder raw material or the plastic raw material. , a step of molding a molded body having an uneven surface corresponding to the uneven image; a step of forming a transparent layer on the uneven surface; and forming a pseudo three-dimensional pattern on the transparent layer. 2 A process of stacking wax on a transparent plate, a process of carving a desired part of the wax layer while irradiating light from below the transparent plate to form an image, and a process of forming an image on the wax layer with a mold. a step of transferring the image of the mold to a plaster mold, and using the plaster mold, a slurry for manufacturing ceramics is cast and molded to form a molded body having an uneven surface corresponding to the image. a step of forming a transparent layer on the uneven surface, firing the molded body,
A pseudo three-dimensional pattern comprising the steps of forming a fired body and forming a transparent colored layer in which a colored substance is dispersed on the transparent layer with a substantially smooth surface to obtain the fired body. A manufacturing method for ceramic products with