JP2014088008A - Method of producing decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of producing a decorative sheet which enables production of a decorative sheet having stable appearance quality.SOLUTION: A method of producing a decorative sheet 10A comprises engaging a group of decorative rigid bodies 14, in a concavoconvex manner, in a group of particle receiving convex parts 26 formed in a molding surface 23M of a lower fixed die 23 to carry out positioning and, after adhering a hot melt 15 to the upper surface of the group of decorative rigid bodies 14, heat-pressing a non-molded sheet 10 between the lower fixed die 23 and an upper movable die 21. The heat pressing molds irregularities consisting of trough parts 10T and rectangular swollen parts 10U in the non-molded sheet 10 and simultaneously attaches the decorative rigid bodies 14, leading to stability of the positions of the decorative rigid bodies 14 with respect to the irregularities of the decorative sheet 10A and thereby enabling production of a decorative sheet 10A having stable appearance quality.

Description

  The present invention relates to a method for manufacturing a decorative sheet, in which an unmolded sheet including a foamed resin layer is heated and pressed with a molding die, and irregularities are formed on the front side surface of the unmolded sheet to form a decorative sheet.

  Conventionally, as a method for producing this type of decorative sheet, a method of performing a secondary process of attaching a decorative sheet to the molding surface after a primary process of molding irregularities on the front side of an unmolded sheet is known ( For example, see Patent Document 1).

JP2003-231235A (paragraph [0002])

  However, in the above-described conventional method for producing a decorative sheet, instead of the decorative sheet attached to the entire front surface of the unformed sheet, for example, a specific position on the unevenness of the front surface of the unshaped sheet (for example, in a recess, Or, when a decorative rigid body (for example, rhinestone, imitation jewelry, etc.) is attached to the tip of the protrusion, there is a problem that the attachment position of the decorative rigid body varies and the appearance quality of the decorative sheet is not stable. .

  This invention is made | formed in view of the said situation, and aims at provision of the manufacturing method of the decorating sheet which can manufacture the decorating sheet of the stable external appearance quality.

  In order to achieve the above object, a method for producing a decorative sheet according to the invention of claim 1 is characterized in that an unmolded sheet including a foamed resin layer is placed between an upper movable mold and a lower fixed mold of a molding die. In the method of manufacturing a decorative sheet that is heated and pressed to form a decorative sheet by forming irregularities on the front side surface of the unmolded sheet with the lower fixed mold, the decorative rigid body that is not deformed by heating with the molding die is Between the lower fixed mold and the upper movable mold after positioning with the concave and convex engagement with a part of the molding surface of the fixed mold and with the hot melt or other adhesive attached to the upper surface of the decorative rigid body It is characterized by heating and pressing an unformed sheet.

  According to a second aspect of the present invention, in the method for producing a decorative sheet according to the first aspect, a hot melt as an adhesive is adhered to a decorative rigid body, and the decorative rigid body is formed on the molding surface of the lower fixed mold. After the arrangement, the hot melt is melted by heating the molding die.

  Invention of Claim 3 is a manufacturing method of the decoration sheet | seat of Claim 1 or 2, A decoration rigid body is a rhinestone, imitation jewelry, an artificial diamond, a button, and another granule, Comprising: Lower fixed type The molding surface is characterized in that a granule receiving recess for receiving and positioning a granule which is a decorative rigid body is provided.

  The invention of claim 4 is characterized in that, in the method for producing a decorative sheet according to claim 3, the unformed sheet is hot-pressed in a state in which a part of the decorative rigid body protrudes from the granule receiving recess.

  The invention of claim 5 is the method for producing a decorative sheet according to claim 3, wherein the entire decorative rigid body is received in the particle receiving recess, and only the adhesive layer is protruded from the particle receiving recess. It is characterized in that an unformed sheet is heated and pressed.

  The invention of claim 6 is the method for producing a decorative sheet according to any one of claims 3 to 5, wherein the molding is performed for forming a recess in an unmolded sheet of the molding surface of the lower fixed mold. It is characterized in that a granule receiving recess is arranged at the tip of the protrusion.

[Inventions of Claims 1 and 3]
According to the method for manufacturing a decorative sheet according to claim 1, the decorative rigid body is unevenly engaged and positioned on a part of the molding surface of the lower fixed mold, and hot melt or other adhesive is attached to the upper surface of the decorative rigid body. Then, the unformed sheet is heated and pressed between the lower fixed mold and the upper movable mold. Thereby, since a decoration rigid body is attached simultaneously with shaping | molding an unevenness | corrugation to an unshaped sheet | seat with a lower side fixed mold, the position of the decoration rigid body with respect to the unevenness | corrugation of a decoration sheet is stabilized. That is, it is possible to manufacture a decorative sheet having a stable appearance quality.

  The decorative rigid body may be a plate or a rod, and may be a rhinestone, imitation jewel, artificial diamond, button, or other grain as in the third aspect of the invention. Further, when the decorative rigid body is a granule, a granule receiving recess for receiving and positioning the granule that is the decorative rigid body may be provided in the lower fixed mold.

[Invention of claim 2]
According to the method for manufacturing a decorative sheet according to claim 2, after the hot melt is adhered to the decorative rigid body and the decorative rigid body is disposed on the molding surface of the lower fixed mold, the molding die is heated. Since the hot melt is melted, the decorative rigid bodies do not adhere to each other before the decorative rigid bodies are arranged on the molding surface of the lower fixed mold, and the decorative rigid bodies do not adhere to the operator, so that the work efficiency is improved.

[Invention of claim 4]
According to the method for producing a decorative sheet of claim 4, since the unmolded sheet is heated and pressed in a state in which a part of the decorative rigid body protrudes from the granule receiving recess, a part of the decorative rigid body is applied to the decorative sheet. Can be attached to the embedded state.

[Invention of claim 5]
According to the method for manufacturing a decorative sheet according to claim 5, the whole decorative rigid body is received in the granule receiving recess, and only the adhesive layer is protruded from the granule receiving recess, and the unformed sheet is heated and pressed. Therefore, the decorative rigid body can be attached to the decorative sheet in a state where the entire decorative rigid body is exposed.

[Invention of claim 6]
According to the method for producing a decorative sheet according to claim 6, since the granule receiving recess is arranged at the tip of the molding protrusion for molding the recess in the unmolded sheet of the molding surface of the lower fixed mold. The decorative rigid body can be attached to a part of the bottom surface of the concave portion of the decorative sheet.

(A) Perspective view of an unformed sheet according to the first embodiment of the present invention, (B) Perspective view of a decorative sheet manufactured from the unformed sheet Side sectional view of the mold and the first robot hand Side sectional view of the mold and the second robot hand Side cross-sectional view of unmolded sheet and decorative rigid body set in molding die Side sectional view of a state where an unmolded sheet is molded with a molding die (A) Partial sectional view of unformed sheet and lower fixed mold, (B) Partial sectional view of decorative sheet (A) Partial sectional view of the unformed sheet and lower fixed mold of the second embodiment, (B) Partial sectional view of the decorative sheet (A) Partial cross-sectional view of unformed sheet and lower fixed mold of third embodiment, (B) Partial cross-sectional view of decorative sheet

[First Embodiment]
Hereinafter, an embodiment of the present invention will be described with reference to FIGS. In this embodiment, in order to manufacture the decorative sheet 10A shown in FIG. 1 (B) from the unformed sheet 10 shown in FIG. 1 (A), the “method for manufacturing a decorative sheet” according to the present invention is used. Has been.

As shown in FIG. 1 (A), the unmolded sheet 10 is formed by, for example, laminating a skin layer 12 on the front side of the foamed resin layer 11 and a backing layer 13 on the back side, and integrating them with an adhesive or frame lamination. It has a three-layer structure. The foamed resin layer 11 is made of, for example, a flexible polyurethane foam, and has a density of 20 to 60 [kg / m ³ ] and a hardness of 60 to 80 [N]. Moreover, the skin layer 12 is comprised with the nonwoven fabric, for example, and the constant load elongation is 2-50 [%]. The backing layer 13 is made of, for example, a nylon sheet formed by knitting nylon fibers with a tricot knitting machine.

  In addition to the flexible polyurethane foam, foamed polyethylene or the like may be used as the foamed resin layer 11. In addition to the nonwoven fabric, for example, woven fabric, natural leather, synthetic leather or the like may be used as the skin layer 12. Moreover, it is good also as a structure which does not equip the unshaped sheet | seat 10 with the backing layer 13. FIG.

  As shown in FIG. 1 (B), the decorative sheet 10A forms a lattice-shaped valley 10T on the above-described unformed sheet 10, and a portion other than the valley 10T is a plurality of rectangular bulges 10U. Furthermore, the decoration rigid body 14 is attached to the part used as the intersection of the grid | lattice valley 10T, respectively.

  The decorative rigid body 14 is made of a heat-resistant resin or glass that does not melt when heated by a molding die 20 described later. Further, as shown in FIG. 6B, the decorative rigid body 14 has a structure in which one end of a cylindrical body is provided with a hemispherical surface 14K, and the other end is provided with a flat mounting surface 14H, and the mounting surface 14H is hot. It is fixed to the decorative sheet 10A by melt.

  Note that the decorative sheet 10A is sewn in a bag shape and attached to a sheet, a headrest, an armrest or the like. In addition, the decorative sheet 10A may be cut into a predetermined shape and used for decoration such as decoration of a floor mat of a vehicle or a house, a ceiling surface, and an inner wall. Further, if the decorative sheet 10A does not include the lining layer 13, the foamed resin layer 11 is frictionally engaged with the core material such as the sheet and the headrest when the sheet is sewn in a bag shape and covered with the core material such as the sheet and the headrest. And it will take time to work. However, the decorative sheet 10A of the present embodiment is provided with a nylon sheet knitted from nylon fibers as the backing layer 13, so that the decorative sheet 10A becomes slippery with respect to a core material such as a sheet or a headrest, and the decorative sheet 10A is sewn. Can be smoothly covered with a core material such as a headrest.

  FIG. 2 shows a decorative sheet manufacturing apparatus 100. The decorative sheet manufacturing apparatus 100 includes a molding die 20 composed of an upper movable die 21 and a lower fixed die 23 as a main part. The lower fixed mold 23 is provided with, for example, a sheet receiving recess 28 that can be received in a state where the unformed sheet 10 is spread horizontally. A plurality of molding recesses 24 are arranged in a matrix on the molding surface 23M located at the bottom of the sheet receiving recess 28. A grid-like region other than the molding recess 24 group in the molding surface 23 </ b> M is a molding protrusion 25 that protrudes upward with respect to the bottom surface of the molding recess 24.

  In addition, a granule receiving concave portion 26 is formed in a concave portion at the intersection of the lattice-shaped forming protrusions 25. As shown in FIG. 6A, the granule receiving recess 26 is located slightly inside the outer edge of the flat upper surface 25A of the molding protrusion 25, and the inside is a cylindrical space. The granule receiving recess 26 has a depth such that when the decorative rigid body 14 is received from the hemispherical surface 14K side, the mounting surface 14H of the decorative rigid body 14 and the upper surface 25A of the molding protrusion 25 are flush with each other. .

  As shown in FIG. 2, the upper movable die 21 is provided with a pressure protrusion 22 protruding from the lower surface. Then, as shown in FIG. 5, the pressing projection 22 enters the sheet receiving recess 28, and the outer edge flat portion 21 </ b> K around the pressing projection 22 is around the sheet receiving recess 28 in the lower fixed mold 23. In contact with the upper surface of the surrounding wall 27, the molding die 20 is closed.

  The decorating sheet manufacturing apparatus 100 includes, for example, a first robot hand 35 for setting the decorative rigid body 14 in each granule receiving recess 26 of the lower fixed mold 23. The first robot hand 35 includes, for example, a lattice frame portion 36 formed by joining square members of iron or aluminum in a lattice shape, and an extension arm 36 </ b> A extending from the upper surface of the lattice frame portion 36 is not illustrated. It is attached to the tip of the arm. Further, on the lower surface of the lattice frame portion 36, a particle suction recess 37A is formed to be depressed corresponding to the particle receiving recess 26 of the lower fixed mold 23, while on the upper surface of the lattice frame portion 36, a particle suction recess is formed. A screw hole 37B is recessed and formed at a position directly behind 37A, and these are communicated with each other through a small-diameter communication hole 37C. A hose 39 is connected to a hose joint 38 screwed into each screw hole 37B. The hose 39 group is connected to a suction pump (not shown) via a switching valve, and the decorative rigid body 14 can be sucked into the granule suction recess 37A by opening the switching valve. Yes.

  As shown in FIG. 3, the decorative sheet manufacturing apparatus 100 is provided with a second robot hand 40 for setting the unformed sheet 10 in the sheet receiving recess 28 of the lower fixed mold 23. The second robot hand 40 includes a suction base 41, which is a metal plate having substantially the same size as the unformed sheet 10, and an extension arm 41A extending from the suction base 41 is attached to the tip of a robot arm (not shown). Yes. In addition, a plurality of hose joints 38 similar to those of the first robot hand 35 are distributed and attached to a plurality of positions on the upper surface of the suction base 41. Further, an extremely large suction recess 37D, which is larger than the granule suction recess 37A of the first robot hand 35, is formed on the back side of the hose joint 38. And the hose 39 group extended from each hose joint 38 is connected to a suction pump via a switching valve, and the unformed sheet 10 can be sucked to the lower surface of the suction base 41 by opening the switching valve. It is like that.

  Although not shown, the decorative sheet manufacturing apparatus 100 includes a temporary placement table having a plurality of granule receiving recess groups in the same arrangement as the granule receiving recess groups 26 of the lower fixed mold 23, and an unformed sheet 10. And a plurality of sheet placement portions for positioning and stacking.

  The description regarding the configuration of the decorative sheet manufacturing apparatus 100 is as described above. In order to manufacture the decorative sheet 10A with this decorative sheet manufacturing apparatus 100, as shown in FIG. 6 (A), a plurality of decorative rigid bodies 14 adhered to the mounting surface 14H in a state where the hot melt 15 is solidified are previously provided. Have it ready. Then, a plurality of unformed sheets 10 are stacked on the sheet placement portion (not shown) with the skin layer 12 facing down, and the decorative rigid body 14 is inserted into each granule receiving recess of the temporary placement table (not shown) from the hemispherical surface 14K side. The mounting surface 14H to which the hot melt 15 is attached is directed upward. The work of inserting the decorative rigid body 14 into each granule receiving recess of the temporary table may be performed manually by a worker or by a robot.

  When the decorative sheet manufacturing apparatus 100 is activated, the decorative sheet 10A is manufactured as follows. That is, when the decorative sheet manufacturing apparatus 100 is started, heat is generated by the heater built in the molding die 20 and the heat is opened when a predetermined temperature is reached. Then, the robot is actuated so that the particle suction recesses 37A group of the first robot hand 35 overlaps the particle receiving recess groups of the temporary table, and the decorative rigid bodies 14 of the temporary table are placed in the particle suction recesses 37A. Suction.

  Next, as shown in FIG. 2, the first robot hand 35 enters between the upper movable mold 21 and the lower fixed mold 23 of the molding die 20. Then, the suction is stopped with the group of particle suction recesses 37 </ b> A overlapped with the particle receiving recess 26 of the lower fixed mold 23. As a result, as shown in FIG. 6A, each decorative rigid body 14 is received in the granule receiving recess 26, and only the hot melt 15 protrudes upward from the upper surface 25 </ b> A of the molding protrusion 25. In such a state, the first robot hand 35 is retracted from between the upper movable mold 21 and the lower fixed mold 23.

  Next, the second robot hand 40 sucks the unformed sheet 10 of the sheet placement portion, and stops the suction after entering between the upper movable mold 21 and the lower fixed mold 23 as shown in FIG. To do. As a result, as shown in FIG. 4, the unformed sheet 10 is placed in the sheet receiving recess 28 of the lower fixed mold 23. In such a state, the second robot hand 40 is retracted from between the upper movable mold 21 and the lower fixed mold 23.

  Next, the upper movable die 21 is lowered, and the molding die 20 is closed as shown in FIG. And it maintains for 1 to 4 minutes in the state by which the inside of the shaping die 20 was 180-200 [degreeC]. Thereby, the unmolded sheet 10 is molded into a shape corresponding to the molding die 20, and the hot melt 15 of the decorative rigid body 14 is melted by the heat of the molding die 20.

  Next, the inside of the molding die 20 is lowered to a temperature at which the hot melt 15 is solidified and maintained for a predetermined time. Thereby, the decoration rigid body 14 adheres to the molded product of the unshaped sheet 10, and the decorative sheet 10A is completed. Then, the molding die 20 is opened, and the decorative sheet 10 </ b> A is taken out from the molding die 20 with the second robot hand 40 described above. In addition, the decorative sheet 10 </ b> A can be sequentially manufactured by the decorative sheet manufacturing apparatus 100 by repeating the above operation.

  Thus, in the manufacturing method of the decorative sheet 10A of the present embodiment, the decorative rigid body 14 is attached to the unformed sheet 10 at the same time as the concave and convex portions including the valley portion 10T and the rectangular bulging portion 10U are formed. The position of the decorative rigid body 14 with respect to the unevenness is stabilized. That is, it is possible to manufacture a decorative sheet 10A having a stable appearance quality. In addition, since the hot melt 15 is adhered to the decorative rigid body 14 and the decorative rigid body 14 is disposed on the molding surface 23M of the lower fixed mold 23, the hot melt 15 is melted by heating the molding die 20. Before the decorative rigid body 14 is placed on the molding surface 23M of the lower fixed mold 23, the decorative rigid bodies 14 do not adhere to each other and the decorative rigid body 14 does not adhere to the operator, and the working efficiency is improved. Further, since the entire decorative rigid body 14 is received in the particle receiving recess 26 and only the hot melt 15 is protruded from the particle receiving recess 26, the unmolded sheet 10 is heated and pressed. As shown in FIG. 5, the decorative rigid body 14 can be attached to the decorative sheet 10A with the entire structure exposed.

[Second Embodiment]
This embodiment is shown in FIG. 7 and differs from the first embodiment only in the shape of the granule receiving recess 26V provided in the lower fixed mold 23V. That is, as shown in FIG. 7A, the particle receiving recess 26V of the lower fixed mold 23V of this embodiment receives the end of the decorative rigid body 14 on the hemispherical surface 14K side, and the axis of the decorative rigid body 14 is received. The mounting surface 14H side is held in a state of protruding from the upper surface 25A of the molding protrusion 25 from the middle position in the direction. Thereby, if this lower fixed mold 23V is used, as shown in FIG. 7 (B), the concave portion 10X is formed in the unformed sheet 10 by the decorative rigid body 14 protruding from the upper surface 25A of the forming protrusion 25, A decorative sheet 10B having a configuration in which a part of the decorative rigid body 14 is embedded in the recess 10X can be manufactured.

[Third Embodiment]
This embodiment is shown in FIG. 8, and the configuration of the lower fixed mold 23W is different from that of the first embodiment. That is, as shown in FIG. 8A, in the lower fixed mold 23W of this embodiment, a plurality of the granule receiving recesses 26V described in the second embodiment are formed in the flat molding surface 23M. In addition, a plurality of receiving bases 29 are formed to protrude. The cradle 29 has a cylindrical shape with the same diameter as that of the decorative rigid body 14 and has a granule receiving recess 29A for receiving the hemispherical surface 14K at the tip.

  As shown in FIG. 8B, the decorative sheet 10C manufactured using the lower fixed mold 23V has a plurality of first recesses 10Z formed by the decorative rigid body 14 held in the particle receiving recesses 26V. Then, a part of the decorative rigid body 14 is embedded in the first recesses 10Z, and the plurality of second recesses 10Y deeper than the first recess 10Z by the decorative rigid bodies 14 held in the granule receiving recesses 29A of the cradle 29. Is formed so that the entire decorative rigid body 14 is embedded in the second recesses 10Y.

[Other Embodiments]
The present invention is not limited to the above-described embodiment. For example, the embodiments described below are also included in the technical scope of the present invention, and various other than the following can be made without departing from the scope of the invention. It can be changed and implemented.

  (1) In addition to the decorative rigid body 14 of each of the above embodiments, for example, rhinestones in which a resin or glass having translucency is faceted (for example, brilliant cut, step cut, etc.) and metal is deposited on a part thereof, Imitation jewelry, artificial diamonds, and buttons may be used as decorative rigid bodies.

  (2) Moreover, the decorative rigid body of this invention may not be a granule, but may be a plate or a rod. Specifically, for example, it may be a plate with the name of a car or an emblem of a car.

  (3) In the said 1st Embodiment, although the granule receiving recessed part 26 was provided in the shaping | molding protrusion 25, the granule receiving recessed part 26 was provided in the bottom face of the shaping | molding recessed part 24, and the rectangular swelling of the decorating sheet 10A The decorative rigid body 14 may be attached to the part 10U.

  (4) In the first embodiment, the hot melt 15 is adhered to the decorative rigid body 14 in advance in a solidified state. However, the decorative rigid body 14 group is not attached to the granular material receiving recess 26 group of the lower fixed mold 23. Then, an adhesive (including melted hot melt) may be applied to these decorative rigid bodies 14 by a robot hand.

10 Unmolded sheet 10A, 10B, 10C Decorative sheet 10T Valley (unevenness)
10U rectangular bulge (unevenness)
10X Concave (Uneven)
10Y 2nd recess (unevenness)
10Z 1st recess (unevenness)
11 Foamed resin layer 14 Decorative rigid body (Decorative rigid body)
15 hot melt 20 molding die 21 upper movable mold 23, 23V, 23W lower fixed mold 23M molding surface 25 molding projection 26, 26V, 29A granule receiving recess

Claims (6)

The unmolded sheet containing the foamed resin layer is heated and pressed between the upper movable mold and the lower fixed mold of the molding die, and irregularities are formed on the front side surface of the unmolded sheet with the lower fixed mold. In the method of manufacturing a decorative sheet to be used as a decorative sheet,
A decorative rigid body that is not deformed by heating with the molding die is positioned by engaging with a part of the molding surface of the lower fixed mold in advance, and hot melt or other adhesive is attached to the upper surface of the decorative rigid body. After making into a state, the said non-shaped sheet | seat is heat-pressed between the lower side fixed mold | type and the said upper side movable mold | type, The manufacturing method of the decorating sheet characterized by the above-mentioned.   The hot melt as the adhesive is attached to the decorative rigid body in a solidified state, the decorative rigid body is disposed on the molding surface of the lower fixed mold, and then the hot melt is heated by heating the molding die. It melts, The manufacturing method of the decorating sheet of Claim 1 characterized by the above-mentioned.   The decorative rigid body is a rhinestone, imitation jewel, artificial diamond, button, or other granular material for receiving and positioning the granular material that is the decorative rigid body on the molding surface of the lower fixed mold. The method for producing a decorative sheet according to claim 1, wherein a body receiving recess is provided.   The method for producing a decorative sheet according to claim 3, wherein the unformed sheet is heated and pressed in a state in which a part of the decorative rigid body is protruded from the granule receiving recess.   4. The unmolded sheet is heated and pressed in a state in which the entire decorative rigid body is received in the granule receiving recess and only the adhesive layer is protruded from the granule receiving recess. The manufacturing method of the decorating sheet of description.   6. The granule receiving recess is arranged at the tip of a molding protrusion for molding a recess in the unformed sheet of the molding surface of the lower fixed mold. The manufacturing method of the decorating sheet of Claim 1.

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