JPH0549442B2 - - Google Patents

Description

[Detailed description of the invention]

[Industrial Field of Application] The present invention relates to a method for manufacturing products having a pseudo three-dimensional pattern, and more particularly to a method for manufacturing products such as ceramics and plastics having a colored pattern with a detailed three-dimensional effect. [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, first, place the
After forming a layer of a light-scattering material, such as wax, with a substantially uniform thickness, a desired portion of the wax layer is carved to form a concavo-convex image. At that time, the wax is carved while observing the model item 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 process, gypsum mixed with water is poured onto the wax layer, and after it hardens, the wax is peeled off.
A plaster mold is formed on which the uneven image is transferred. Using this plaster mold, a slurry of a ceramic raw material composition (clay) is cast and molded to produce a thin molded body with 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 images carved with wax layers are faithfully transferred to the ceramics, so when light shines through the back of the ceramics, a three-dimensional watermark pattern emerges. This is because the amount of light transmitted from the back of the ceramic to the front changes as the thickness of the ceramic changes, and the areas where the amount of light transmitted appears to be raised.
This is based on the result that the part with a small amount of transmission looks like a shadow. [Problem to be solved by the invention] The patterned portion of ceramics formed by the conventional method is
If you just look at it from behind without any light shining through it, the intricate unevenness gives it a cluttered appearance, and you don't get a sense of beauty or 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 may stick out and be difficult to perceive. Furthermore, the very 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 for which the three-dimensional patterns can be utilized. Furthermore, with the method using openwork, only ceramic products could be produced. Moreover, with openwork products, dust and other substances may adhere to the uneven patterns, spoiling the aesthetic appearance.
Since the pattern is delicate, it is difficult to remove dust etc. that enters the recess. The present invention solves the above-mentioned problems, and a pattern similar to an elaborate openwork pattern with a three-dimensional effect is exposed without irradiating light from the back side, and has a pseudo-three-dimensional pattern that can be used for various purposes. The purpose of the present invention is to provide a method for manufacturing a product that can prevent the adhesion of substances and maintain a clean surface. Another object of the present invention is to have a pseudo three-dimensional pattern,
The object of the present invention is to provide a manufacturing method that can manufacture products made of various materials. [Means for Solving the Problems] The above objects can be achieved by the following present invention.
That is, the present invention includes a step 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; A step of flowing a fluid raw material or filling a powder raw material or a plastic raw material into a mold in which the 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; and a step of forming a transparent colored layer in which a colored substance is dispersed to bury the unevenness of the uneven surface and substantially smooth the surface of the colored layer. , a step of forming on the uneven surface, and a method for manufacturing a product having a pseudo three-dimensional pattern. [Function] Since the surface of the product manufactured by this method is smooth, the adhesion of dust and the like is prevented and the product is kept clean. Moreover, like a watermark pattern, the pattern, which is detailed and full of three-dimensionality, can be perceived by the eye even without shining light from the back of the product. The reason why such a three-dimensional pattern appears is thought to be as follows. As shown in Fig. 1, the surface of the colored layer 1 is smooth, so the thickness of the colored layer 1 depends on the thickness change of the molded body 2 covered by the layer 1 (thickness change due to surface irregularities). Determined by correspondence (determined by almost exact opposite relationship). The thickness change of the colored layer 1 determined in this way is
It is almost proportional to the change in the thickness of the original layer, which faithfully reflects the three-dimensional effect of the model. In the colored layer 1 exhibiting such a thickness change, the thinner the part, the smaller the total amount of the colored substance, the greater the translucency, and the surface of the molded body 2 underneath 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. 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 translucency and light scattering is carved while irradiating light from below to form a prototype having a desired uneven image (step 1). Here, the disc that exhibits translucency and light scattering properties is:
These are so-called translucent discs, ie, discs made of materials other than those that are substantially completely transparent (eg, silica glass) and those that are substantially completely opaque (eg, iron).
Examples of the material for this disk include wax, synthetic wax, translucent resin such as vinyl chloride, and 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 step 1, the light is irradiated from the lower side of the board, that is, the opposite side of the board surface where the uneven image is to be drawn.
By carving the uneven image while perceiving the degree of light transmission from the board depending on its thickness using the eye or mechanical means such as a sensor, the three-dimensional effect of the model is created on the semi-transparent board. This is to reflect the image extremely faithfully. Next, inject fluid raw materials into the above-mentioned master mold, or
Alternatively, a powder raw material or a plastic raw material is filled (Step 2). The fluid raw material may be any material as long as it can be cured by appropriate treatment such as being left to stand or adding a heat curing agent after flowing into the master mold. Examples include fluid plastics (e.g., unsaturated polyesters, melamine resins, polyamide resins, silicone resins, epoxy resins, acrylic resins), fluid polymerizable low-molecular compounds (e.g., styrene, methacrylic acid esters). , fluid rubber (e.g. butyl rubber,
(nitrile rubber), molten glass, cement raw materials, molten metals, and slurry for ceramics. Examples of the powder raw material include various materials such as plastic powder, wood and paper powder, and starch. A binder or the like may be mixed with such powder raw material.
Examples of the plastic raw material include clay. Next, when a fluid raw material is used in the above step, the raw material is cured by treatments such as standing, 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. thus,
A molded body having an uneven surface corresponding to the uneven image of the original model is shaped (step 3). The molded body may be subjected to heat treatment, sintering treatment, etc. as necessary. If you try to use it in steps 1, 2, and 3 above, depending on the combination of the material of the master mold and the raw material for the molded body, the master mold may be damaged if they come into contact, or even if a release agent is used, the molded body may separate from the master mold. It may be difficult to mold a molded product because it becomes difficult to release from the mold. In addition, the prototype itself is easily damaged and may not be able to be used repeatedly. If such inconvenience occurs, a mold (hereinafter referred to as a reproduction mold) is produced 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 concavo-convex image is created by molding using the master mold, and then the first mold is It can be easily obtained as a molded article. 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 raw materials for the first mold and reproduction mold, materials within the same range as the raw materials for the molded object described above can be used, but from among them, the material of the original mold, the material of the molded object to be molded by the reproduction mold, etc. It may be selected appropriately in consideration so that the above-mentioned inconvenience does not occur. Examples of combinations of materials for the master mold, first mold, transfer mold, and molded body that are preferable for preventing the above-mentioned disadvantages are listed below.

[Table] In Example 3, to form a metal mold from a plaster mold, layer sand, wax, and sand in that order to a uniform thickness on the uneven surface of the plaster mold, and then layer the sand toward the wax. All you have to do is flow molten metal. 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 light-transmitting colored layer in which a coloring substance is dispersed is formed on the uneven surface of the molded body formed by the original mold or reproduction mold by substantially smoothing the surface (step 4). The colored substances referred to in the present invention may be colored molecules or colored particles having a diameter of about 0.1 to 0.001 μm, that is, colloid colored particles (e.g., pigment particles).
It may be. The colored layer is formed by dispersing the above-mentioned adhesive particles in a light-transmitting solid (vitreous solid, transparent fixed plastic, etc.) or a light-transmitting fluid (water, transparent fluid plastic, etc.). When the colored layer is mainly composed of a solid, it is preferably glass because it gives a glossy product, and it is preferably plastic because the colored layer can be easily formed. It is desirable if the dispersion system of the colored layer is uniform because the three-dimensional image of the original formed in step 1 can be faithfully reproduced. In order to form the colored layer, the colored layer material may be applied, introduced, placed, etc. in an amount that will bury the unevenness of the molded body, and then, if necessary, treatments such as heating and baking may be performed. Through the above 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. The thinner the colored layer is, the smaller the total amount of colored substances dispersed, the more translucent the colored layer is, and the surface of the product appears to be transparent, and the thicker the colored layer is, the more transparent the colored layer is. There is no light property, and the color of the colored substance appears dark and looks like a shadow. Therefore, the product has a three-dimensional pattern that appears even if it is not transparent to light. Products having such pseudo-three-dimensional patterns can be used for a variety of purposes, such as tableware, ashtrays, vases, ornaments, interior tiles, cosmetic containers, ceramic plates, and frames. As is clear from the above explanation, unlike the conventional openwork manufacturing method, the manufacturing method of the product with the pseudo three-dimensional pattern of the present invention allows the manufacturing of products made of various materials, 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 to a substantially uniform thickness (usually about 2 to 4 mm) on a transparent substrate such as a glass plate (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 metal brush, etc., to create a precise shape. A concavo-convex image is formed (step 1-2). The reason why wax is used in this process is that wax is translucent and can easily form precise images.
Therefore, instead of wax, wax-like substances having such characteristics, such as glue and machinable synthetic resin, 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 wax onto which the image has been 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) with the image transferred thereon 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, the molded body with the uneven surface is fired, and a transparent colored layer containing a coloring substance dispersed therein is formed on the uneven surface by burying the unevenness and making the surface substantially smooth, and then fired. Obtaining a body (Step 4)
-1). The firing in this step and the shape of the colored layer may or may not be done at the same time. This step 4-1 can take various forms depending on the type of colored layer. The colored layer consists of colored particles suspended in a glassy phase.
A typical procedure of this step 4-1a in the case of a glaze layer that does not lose its translucency will be explained. First, the maximum temperature is applied to the molded body formed in step 3-1.
Bisque firing is carried out at a temperature of about 600 to 900 degrees. After the unglazed body is glazed, it is fired. When applying the glaze,
The glaze becomes thick after firing, and it is necessary to use enough glaze to cover the unevenness of the ceramic body and make it smooth without reflecting the unevenness. Even if the glaze is made thicker (approximately 3
mm or more), and must be free from defects such as cracks. Examples of combinations of glaze materials and ceramic clay for this purpose are shown below. Porcelain clay Ingredients by weight : Stone 20-25 Silica stone 10 Pottery stone 10 Clay (kaolin) 40 Alumina 0-5 Talc 0-5 Glaze Medicinal ingredients Weight: Stone 50 Silica stone 20 Dolomite 5 Lime 15 Zinc oxide 9 Barium carbonate 1 Cobalt oxide 0.2 The firing conditions for final firing must be determined taking into account the above combinations, but for example, in the case of feldspathic porcelain clay with a large amount of feldspar, firing in an oxidizing atmosphere is recommended. The temperature is raised to around 900 degrees Celsius, then the temperature is raised to around 1200 degrees by firing in a reducing atmosphere, and then the temperature is raised to 1250 to 1300 degrees by firing in a near-neutral atmosphere. After that, start cooling. Through the above steps, ceramics with a smooth surface and a translucent colored glaze can be manufactured. In this ceramic, the thinner the glaze, the lower the total amount of dispersed colored substances, and the more translucent the glaze is, making the surface of the ceramic body appear transparent, and the darker the glaze, the more translucent the glaze is. Instead, the color of the colored substance appears darker and looks like a shadow. As a result, ceramic products exhibit three-dimensional patterns even if they are not transparent to light. If the colored layer is a layer in which colored molecules or colored particles are dispersed in transparent plastic, this step 4-
1 is done by the following procedure (4-1b). First, a fired body is formed in substantially the same manner as step 4-1a above, but without glazing. Next, a plastic fluid in which an appropriately selected colored substance (dye, pigment, etc.) was dispersed was poured onto the uneven surface of the fired body whose sides were surrounded by a frame, etc., to bury the unevenness and smooth the surface. solidify in the state. In this way, ceramic products with three-dimensional patterns similar to the ceramics described above are produced. In addition, the plastic material has translucency,
Any material may be used as long as it exhibits adhesiveness to the fired body upon solidification. For example, epoxy resin etc. can be mentioned. Further, as another embodiment of step 4-1, there may be mentioned an embodiment in which colored suspended particles or colored molecules are dispersed in water, and the dispersed particles are 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 1 First, molten wax was poured and solidified onto a transparent glass, and a layer of wax with a thickness of about 3 mm was laminated. Next, while shining light from the glass plate side, a ship image was carved into wax with an iron brush.Next, plaster mixed with water (100 parts of gypsum by weight to 100 parts of water) was surrounded by a frame. It was poured onto a layer of wax and allowed to harden to form a first plaster mold with the image transferred thereon. Note that the first plaster mold has a rectangular plate shape,
The peripheral portion was shaped to be raised relative to the portion where the image was formed. Plaster mixed with water similar to that described above was poured into this plaster mold and solidified to form a second plaster mold. Using the second plaster mold, the following porcelain clay was cast. Porcelain clay commercially available ingredients Ingredients by weight: Stone 23 Pottery stone 10 Silica stone 10 Clay (kaolin) 40 Alumina 3 Talc 3 The slurry for casting is based on 100 parts by weight of porcelain clay.
30 parts of water was mixed, and 2/1000 of the amount of water by weight of water glass was further mixed in as a dispersant to prepare the mixture. Casting time is 40 minutes, the uneven surface corresponds to the image and the maximum thickness is approximately 5.
A rectangular plate-like molded product of millimeter size 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 a period of about 4 hours, mainly to remove moisture, and then the temperature was raised to 800 degrees over a further 2.5 hours, and then cooled. As a result, 15×
It was a plate-shaped bisque ceramic body measuring 30 cm square, with an uneven surface about 0.3 cm thick, and weighing 290 grams, with raised edges. Meanwhile, a glaze with the following ingredients was prepared. Ingredient weight manager Stone 50 Silica stone 20 Dolomite 5 Lime 15 Zinc white 9 Barium carbonate 1 Cobalt oxide 0.2 Mix 100 parts by weight of water with this 100 parts by weight, rub it with an electric mill for about 22 hours, and then dry. It was prepared by 45 grams of this glaze was placed on the center of the uneven surface of the unglazed body and fired. In this firing, the temperature is raised to 900℃ over 9 hours through oxidation firing, followed by reduction firing to 1200℃ over 7 hours, followed by firing in a near-neutral atmosphere ( The temperature was raised to 1250 degrees over 3 hours by heating, and then cooled (10 hours). In this way, the glaze layer spread over the entire uneven surface of the ceramic body, creating a ceramic plate with a smooth horizontal surface and a three-dimensional ship pattern. The glaze was blue and transparent, had a maximum thickness of about 3 mm, and had 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 fired at a temperature of 1,200 degrees or more, making it a high-temperature fired porcelain with high wear resistance and strength. 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). (can be considered as a combination product), and this is an unprecedented product. Example 2 First, molten wax was poured and solidified onto a transparent glass, and a layer of wax with a thickness of about 3 mm was laminated. Next, while shining light from the glass plate side, the statue of Mona Lisa was carved into the wax with an iron brush. Next, gypsum mixed with water (100 parts by weight of gypsum to 100 parts of water) was poured onto the wax layer surrounded by the frame and solidified, forming a first plaster mold with the image transferred thereto. . Note that the first plaster mold has a rectangular plate shape,
The peripheral part was shaped to swell up relative to the part where the image was formed. Silicone resin (TSE350RTY (trade name), manufactured by Toshiba Silicone) was poured into this plaster mold and left to solidify for several hours, creating a silicone mold that reproduced the Mona Lisa statue carved in wax. In addition,
The silicone mold could be easily released from the plaster. Next, the following composition was prepared. Composition Commercial product Ingredients Parts by weight ● Calcium carbonate 1000 ● Unsaturated polyester resin (Estar 3115PA (product name), manufactured by Mitsui Toatsu Chemical Co., Ltd.) 700 ● Hardening agent 3.5 (Kayametsuku (product name), Kayaku Akzo (product name) (manufactured by Co., Ltd.) This composition was stirred and about 1703.5 g of it was poured onto the silicone mold surrounded by a frame. When left to stand, the composition hardened. After standing for 40 minutes, the rectangular plate-shaped molded product obtained by curing the composition was released from the mold. This mold release was also very easy to perform. After standing for 30 hours, 73.8 g of the following composition was mixed and stirred and poured onto the molded body. Thereafter, when the composition was left for 2 hours, it was cured, and a brown transparent colored layer was formed on the molded article. Ingredients Parts by weight ●Unsaturated polyester resin (Estar 3115PA (trade name)) 700 ●Aluminum hydroxide 10 aqueous solution 25 ●Curing agent (Kayametsuku (trade name)) 12.5 ●Coloring substances Iron oxide 0.1 Chromium oxide 0.2 In this way, the colored layer We were able to produce a rectangular plate-shaped plastic product with a Mona Lisa pattern that spreads over the entire uneven surface of the molded body, has a smooth horizontal surface, and has a three-dimensional effect. Although the embodiments of the present invention have been described above, the present invention is not limited to these embodiments in any way, and within the scope of the gist of the present invention,
Of course, it can be implemented in various ways. [Effects of the Invention] According to the method of manufacturing a product having a pseudo-three-dimensional pattern of the present invention as described above, a pattern with a detailed three-dimensional effect similar to a conventional watermark pattern can be displayed even without irradiating light from the back side of the product. The product to be released can be formed. As a result, anyone can perceive the three-dimensional pattern drawn on the product anytime, anywhere, without any effort. Furthermore, the material of the product is not limited to ceramics, and can be made of various materials. Moreover, since the surface of the product is smooth, there is very little dust, etc. adhering to it, and even if dust, etc. adheres to the surface, it can be easily removed, so the surface is kept clean and does not spoil its aesthetic appearance.

[Brief explanation of the drawing]

FIG. 1 is a schematic cross-sectional view of a product manufactured according to a representative example of the present invention. 1... Colored 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 step 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; and a step of forming a light-transmitting colored layer in which a colored substance is dispersed to bury the unevenness of the uneven surface and substantially smooth the surface of the colored layer. A method for producing a product having a pseudo three-dimensional pattern, comprising: forming the pattern on the uneven surface. 2. A process of stacking wax on a transparent plate, a process of carving a desired part of the wax layer to form an image while irradiating light from below the transparent plate, and molding the image on the wax layer. a step of transferring the image of the mold to a plaster mold; using the plaster mold to cast and mold a slurry for manufacturing ceramics to form a molded body having an uneven surface corresponding to the image. a step of firing the molded body to form a fired body;
forming a light-transmitting colored layer in which a colored substance is dispersed on the uneven surface by burying the unevenness of the uneven surface and substantially smoothing the surface of the colored layer to obtain a fired body; A method for manufacturing a ceramic product having a pseudo three-dimensional pattern.