JPH07148848A - Resin molding method - Google Patents

Abstract

PURPOSE:To easily and inexpensively form a resin molded product of high quality. CONSTITUTION:A thermoplastic resin molding material 7 is subjected to press molding in a press molding part 6 to form fine uneven patterns on the surface of the thermoplastic resin molding material 7. This resin molding material 7 is set to a vacuum mold 15 to be subjected to vacuum molding. By this method, the uneven patterns corresponding to the large uneven parts formed to the molding surface of the mold 15 are formed on the surface of the resin molding material 7 and fine patterns having a size corresponding to the fine patterns formed by press molding are formed on the surface of the resin molding material at least at the recessed parts of the uneven patterns.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in a resin molding method for molding a resin molded product having a pattern on its surface.

[0002]

2. Description of the Related Art Conventionally, as disclosed in, for example, Japanese Patent Laid-Open No. 63-3912, a molding resin material is injected into a heated molding die, and the resin material in contact with the molding surface of the molding die is gelled. A resin molded product such as an instrument panel having a shape corresponding to the molding surface has been molded by a slush molding method in which the resin is cured or cured.

Further, as disclosed in, for example, Japanese Patent Application Laid-Open No. 63-120608, a sheet-like material made of a thermoplastic resin material is set in a mold and is heated to soften the material while A resin molded product having a shape corresponding to the molding surface of the molding die is formed by a vacuum molding method in which a vacuum is applied between the molding die and the molding die to bring the material into close contact with the molding die.

[0004]

According to the above-mentioned slush molding method, a pattern corresponding to the irregularities formed on the molding surface of the molding die can be accurately formed on the surface of the resin molded product, and the resin molding having a precise pattern is formed. Although it has an advantage that a product can be formed, it has drawbacks that a work process is complicated, productivity is low, and manufacturing cost is high.

On the other hand, according to the above-mentioned vacuum forming method, there is an advantage that a resin molded product can be formed relatively easily and quickly, but it is difficult to form a complicated pattern on the surface of the molded product. Yes, especially when forming a pattern that combines fine irregularities and large irregularities, the material cannot be completely adhered to the molding surface of the molding die, and the fine irregular patterns are partially missing. It has the drawback of being easy.

In order to improve the formability of the pattern by the above vacuum forming method, it is possible to use a highly fluid material as the sheet material. There is a problem that the shape retention is lowered. Further, when a material having a high shape-retaining property is used as the sheet-shaped material, there is a problem that the formability of the pattern by the vacuum forming is further deteriorated.

The present invention has been made to solve the above problems, and an object of the present invention is to provide a resin molding method capable of easily and inexpensively forming a high quality resin molded article.

[0008]

The invention according to claim 1 is
A resin molding material made of a thermoplastic resin material is press-molded to form a fine pattern of fine irregularities on the surface of this resin molding material, and then the above resin molding material is set in a vacuum molding mold and vacuum molded. By doing so, a concavo-convex pattern corresponding to the large concavo-convex portion formed on the molding surface of the molding die is formed on the surface of the resin molding material, and at least the concavo-convex pattern of the concavo-convex pattern is formed by the fine pattern formed in the press molding. It is intended to form a fine pattern having unevenness of a size corresponding to the pattern.

According to a second aspect of the present invention, in the resin molding method according to the first aspect, a surface layer material made of a flexible material and a backing material made of a material having a higher shape retention property than the surface layer material are provided. A resin molding material is formed by polymerization.

[0010]

According to the invention described in claim 1, the resin molding material having a fine pattern formed of fine irregularities on the surface is
By being pressed into contact with the molding surface for vacuum molding, a pattern formed by combining a rough pattern and a fine pattern corresponding to the large irregularities and fine irregularities formed on this molding surface is vacuum molded on the surface of the resin molded product. Will be formed by.

According to the invention described in claim 2, the concavo-convex pattern and the fine pattern are formed on the surface of the surface layer material constituting the resin molding material in the vacuum molding part, and are joined to the back surface of the surface layer material. The backing material maintains the shape retention of the resin molded product.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows a schematic construction of a molding apparatus for carrying out a resin molding method according to the present invention. This forming apparatus includes a surface material supplying section 2 for supplying a surface material 1, and a backing material 3.
, A backing material supply section 4, a superposition section 5 for superimposing the surface layer material 1 and the backing material 3 and superposing them, and a press molding section for forming a fine pattern having fine irregularities on the surface of the surface layer material 1. 6, a cutting portion 8 for cutting the resin molding material 7 obtained by polymerizing the surface layer material 1 and the backing material 3 into a predetermined length.
And a heating part 9 for heating the resin molding material 7, and the resin molding material 1 obtained by processing the heated resin molding material 7 into a predetermined shape.
And a vacuum forming unit 11 for vacuum forming 0.

The surface layer material 1 has a plasticizer content of 25 to
It is made of a flexible material such as a soft vinyl chloride resin material set to 50%. The backing material 3 is
It is made of a hard vinyl chloride resin or the like in which the content of the plasticizer is set to 10% or less, and is made of a material having a higher shape retention property than the surface layer material 1.

The superposing section 5 is composed of a pair of upper and lower press-contact rollers, and the surface layer material 1 and the backing material 3 are adhered to each other with an adhesive, or are heated and fused to form a surface layer material 1. The backing material 3 is bonded to the back surface of the.

As shown in FIG. 2, the press-molding section 6 is composed of a marking roller 12 having a peripheral surface with fine irregularities of several μ units, and a supporting roller 13 disposed below the marking roller 12. There is. While the back surface of the backing material 3 is supported by the support roller 13, the peripheral surface of the marking roller 12 is brought into pressure contact with the surface of the surface layer material 1, so that the surface of the surface layer material 1 is finely divided. The fine pattern 14 corresponding to the unevenness is formed.

The cutting section 8 has a pair of upper and lower cutting blades, and is configured to shear the resin molding material 7 to a length suitable for molding the resin molding 10. Also,
The heating unit 9 is composed of a heater or the like that imparts appropriate fluidity to the resin molding material 7 by heating the sheared resin molding material 7 to a predetermined temperature to plasticize it.

As shown in FIG. 3, the vacuum molding section 11 has a molding die 15 having a molding surface for molding the resin molded product 10 into a predetermined shape. The molding die 15 has a suction (not shown). A communication hole 15a communicating with the means is formed. The suction means sucks the air in the communication hole 15a to bring it into a vacuum state so that the resin molding material 7 is sucked onto the molding surface of the molding die 15.

Further, the molding surface of the molding die 15 is formed with a concavo-convex portion 16 of a unit of several mm, which is larger and smaller than the fine pattern formed in the press molding section 6, and corresponds to the fine pattern. Unevenness of several microns in size is formed on the entire surface of the uneven portion 16. In addition, the fine unevenness formed on the concave surface of the uneven portion 16 is
As will be described later, when there is no influence on the molding of the fine pattern, the structure may be omitted.

In order to mold the resin molded product 10 with the molding apparatus configured as described above, the surface layer material 1 supplied from the surface layer material supply section 2 and the backing material 3 supplied from the backing material supply section 4 are described. The resin molding material 7 is formed by polymerizing and in the polymerization section 5. Next, the resin molding material 7 is supplied to the press molding section 6 to form a fine pattern 14 having fine irregularities on the surface of the surface layer material 1.

Then, the resin molding material 7 cut to a predetermined length in the cutting section 8 is heated to a predetermined temperature in the heating section 9 to impart fluidity to the surface layer material 1 and then the resin molding material. 7 is supplied to the vacuum forming unit 11 to be adsorbed on the forming surface of the forming die 15. As a result, the resin molding material 7 is deformed along the molding surface of the molding die 15 to form the resin molding 10 having a predetermined shape.

Further, an uneven pattern corresponding to the uneven portion 16 formed on the molding surface in units of several mm is provided with the resin molded product 10.
The fine pattern, which is formed on the surface of the resin molded article 7 and is formed on the uneven portion 16 is transferred to the surface of the resin molded product 7. That is, when the surface of the resin molded product 10 is pressed against the convex portion 16a of the molding surface, a fine pattern corresponding to the fine irregularities formed on the convex portion 16a is formed on the surface of the resin molded product 10. .

Since it is difficult to bring the resin molding material 7 into close contact with the molding surface by the suction means, a predetermined gap is formed between the concave portion 16b of the molding surface and the resin molded article 10 and is formed in the concave portion 16b. When a situation occurs in which it is not possible to transfer a fine pattern corresponding to the formed fine irregularities, the above-mentioned press molding is performed on the portion corresponding to the concave portion 16b of this molding surface, that is, the convex portion of the irregular pattern of the resin molded product 10. Since the fine pattern 14 is formed in the portion 6, this fine pattern 14 is exposed on the surface.

In this way, the resin molding material 7 having the surface layer material 1 made of a thermoplastic resin material is press-molded to form a fine pattern 14 having fine irregularities on the surface thereof, and then the resin molding material 7 is vacuum molded. By setting in a molding die 15 for vacuum molding and performing vacuum molding, a concavo-convex pattern corresponding to the large concavo-convex portion 16 formed on the molding surface of the molding die 15 is formed on the surface of the resin molded article 10, and Since the fine pattern corresponding to the fine unevenness formed on the surface of the portion 16 is formed on at least the convex portion of the uneven pattern,
A pattern having the same precision as that of slush molding can be easily and precisely formed on the entire surface of the resin molded product 10.

That is, a molding defect that is likely to occur when a pattern formed by combining a concavo-convex pattern having large concavities and a fine pattern having fine concavities and convexes is formed on the surface of the resin molding material 7 in advance. Since it is configured so as to be supplemented by press molding, the resin molding 10 having the appearance similar to the natural skin material having the uneven pattern and the fine pattern can be quickly molded by the flow work by the molding device.

Further, the uneven portion 16 formed on the molding surface of the molding die 15 has a limited directionality as in the case where it is formed by the marking roller 12 of the press molding portion 6 or the like. Never be done. Therefore, it is possible to easily form a pattern close to a natural leather material by forming the uneven pattern in any direction.

Further, a resin molding material 7 obtained by polymerizing the surface layer material 1 made of a material having flexibility as described above and the backing material 3 made of a material having a higher shape retention property than the surface layer material 1 are used. When configured to do so, when the above-mentioned pattern is formed on the surface of the resin molded article 10 in the vacuum forming part 11, sufficient moldability can be given to the forming part to improve formability, and The shape retention of the resin molded product 10 after molding can be ensured by the backing material 3.

The resin molded article 10 may be molded by a single layer resin molding material made of a thermoplastic resin material. Further, by configuring the resin molding material 7 to be heated in the vacuum molding section 11,
The heating unit 9 may be omitted. Further, in the above-mentioned embodiment, the fine pattern of several μ unit is formed on the surface of the resin molded product 10 and the concavo-convex pattern of several mm unit is formed. However, various modifications are possible without being limited to the above-mentioned embodiment.

[0028]

As described above, according to the present invention, a resin molding material having a surface layer material made of a thermoplastic resin material is press-molded to form a fine pattern having fine irregularities on the surface thereof, and then the resin By setting the forming material in the forming mold for vacuum forming and vacuum forming, a concavo-convex pattern corresponding to the large concavo-convex portion formed on the molding surface of this molding die is formed, and it is formed on the surface of this concavo-convex portion. Since a fine pattern corresponding to the fine irregularities is formed on the surface of the resin molded product, there is an advantage that a resin molded product having a high-quality and dense appearance can be easily and quickly formed.

Further, the above resin molded article is molded by using a resin molding material obtained by polymerizing a surface layer material made of a flexible material and a backing material made of a material having a higher shape retention property than the surface layer material. In such a case, when the above pattern is formed on the surface of the resin molded product in the vacuum forming part, sufficient moldability can be imparted to the forming part to improve the formability, and after the forming, The shape retention of the resin molded product can be secured by the backing material. Therefore, while preventing the occurrence of a situation in which the overall strength of the resin-molded product is reduced as in the case where the resin-molded product is composed of only a flexible material, the fine pattern and the uneven pattern can be easily formed by vacuum molding. There is an advantage that it can be formed.

[Brief description of drawings]

FIG. 1 is an explanatory view showing an example of a molding apparatus for carrying out a resin molding method according to the present invention.

FIG. 2 is an explanatory diagram showing a configuration of a press molding unit.

FIG. 3 is a cross-sectional view showing a configuration of a vacuum forming unit.

[Explanation of symbols]

 1 Surface Layer Material 3 Backing Material 5 Overlapping Area 6 Press Molding Area 7 Resin Molding Material 9 Heating Area 10 Resin Molded Product 11 Vacuum Molding Area 14 Fine Pattern 16 Concavo-convex Area

Claims (2)

[Claims] 1. A resin molding material made of a thermoplastic resin material is press-molded to form a fine pattern having fine irregularities on the surface of the resin molding material, and then the resin molding material is used as a mold for vacuum molding. By setting and vacuum forming,
An uneven pattern corresponding to the large uneven portion formed on the molding surface of this mold is formed on the surface of the resin molding material, and at least the concave portion of the uneven pattern corresponds to the fine pattern formed in the press molding. A resin molding method, characterized in that a fine pattern having unevenness of a size is formed. 2. A surface layer material made of a material having flexibility,
The resin molding method according to claim 1, wherein the resin molding material is formed by polymerizing with a backing material made of a material having a shape-retaining property higher than that of the surface layer material.