JP4660515B2 - Decorative resin molded product - Google Patents

Description

The present invention relates to a decorated resin molded article, in particular, it relates to a design surface of a substrate made of a resin molded article, appearance of different types of metallic decorative comprising is performed decorated resin molded article It is.

  Conventionally, as a type of decorative resin molded product, for example, a coating film by metallic coating, a plating film by metal plating, or a metal thin film by vapor deposition, etc. is formed on the design surface of a substrate made of a resin molded product. By doing so, there is known a decorative resin molded product that is so-called metal-like decoration that artificially represents a metal surface (for example, see Patent Document 1 below). And this decorative resin molded product is lighter than real metal products, is excellent in moldability and workability, and does not require rust-proofing. For example, automotive interior parts, furniture, architecture, etc. It has been widely used as a skin material and parts of various products and articles such as materials, home appliances and portable electronic devices.

  By the way, in general, in products and articles that can be seen by the human eye, those with a structure in which a plurality of parts having different appearances are assembled to each other rather than a monotonous structure consisting of a single part. , Can give a higher-class impression to the viewer.

  Therefore, even in a decorative resin molded product that has been decorated with a metallic tone as described above, in order to obtain a more sufficient high-class feeling, it is composed of separate members that are independent from each other, and has an external appearance on the design surface. In some cases, a structure in which a plurality of types of base materials with different metallic decorations are integrally assembled is employed. For example, two types of base materials that are decorated with metal-like decoration by metal plating on a design surface are integrally joined and assembled to a part of an automotive interior part by welding or the like, Only the surface of the plating film on one of these two types of base material is formed with a textured surface consisting of fine recesses, so that it has a three-dimensional textured metal surface and a glossy mirror surface. Some of these metal surfaces are positioned next to each other.

  However, such a decorative resin molded product has some problems as follows. That is, generally, a plating film formed by metal plating has a relatively thick film thickness. Therefore, in a decorative resin molded product in which such a plating film is formed on the design surface, it is inevitable that the corners and edges are lacking in sharpness. Even if a three-dimensional texture is expressed on the design surface due to the embossing or the like on the plating film, it is extremely difficult to obtain a sufficient “real feel” of the metal. This problem similarly occurs in a decorative resin molded product in which a metallic surface decoration is applied to a design surface by a metallic coating film.

  In addition, when the decorative resin molded product is configured by integrally assembling a plurality of types of base materials, when vibration is applied to the decorative resin molded product, the base materials assembled with each other There is a risk that an abnormal noise such as a rubbing noise may be generated due to the contact of the head. In addition, the problem of the occurrence of this abnormal noise is, for example, that non-woven fabric or the like is attached as a cushion material to any one of the contact portions of the base materials that are in contact with each other when vibration is input, or the contact portions of the base materials are It can be prevented beforehand by fixing or screwing. However, if it does so, in the manufacture of a decorative resin molded product, the work man-hour will increase and the new problem that cost will raise will arise.

  Furthermore, in a decorative resin molded product made up of an integral assembly of a plurality of types of base materials, the base materials are usually assembled with a parting part made up of fine gaps in between, in consideration of appearance and the like. However, if the width of the parting portion is non-uniform, the sense of quality obtained by applying a plurality of types of metallic decorations with different appearances to the design surface is significantly impaired. It becomes. For this reason, there has been a problem that, when assembling the base materials, it is troublesome and requires extra work to make the parting width constant.

  However, even if there is a decorative resin molded product consisting of only one substrate without multiple types of base materials being assembled, different types of metallic materials can be applied to adjacent parts of the design surface of one base material. By applying paint using paint, or after applying one type of metal plating to the design surface, applying a matte or clear coating to only a part of the metal plating, etc. A structure in which different types of metallic decorations having different appearances relating to the texture and the like are applied can be realized. However, in such a structure, even if the type of paint applied to the design surface or metal plating is changed, the surface of each coating film is smooth, so that the design surface is shaded and deep. Therefore, it was impossible to apply a metallic decoration to express a metal surface with a three-dimensional texture.

JP 2002-262197 A

Here, the present invention has been made in the background of the circumstances as described above, and the problem to be solved is that it can express a sufficient real feeling, and the design of one base material. A structure that can give an even higher class impression can be realized easily and at low cost by applying multiple types of metallic decorations with different three-dimensional textures next to each other. Ru near providing a decorative resin molded article may be.

And, in the present invention, in order to solve the problems relating to the decorative resin molded product, the gist is that the design surface of the base material made of the resin molded product is decorated with a metallic tone. A decorative resin molded product having a pattern formed by a large number of fine concave portions and / or convex portions on the design surface of the base material, and a decorative pattern forming surface portion to be decorated, There are at least two types of decorated portions of the depth of the concave portion, the height of the convex portion, or a plurality of types different from each other in the pattern type, and the decorative smooth surface portion to be decorated, which is not uneven. , Provided next to each other, and at least two kinds of decorated parts by physical vapor deposition or chemical vapor deposition , gold, silver, platinum, copper, aluminum, zinc, nickel, chromium, tin, titanium Of nickel-chromium alloy, stainless steel, molybdenum Metallic material consisting of any one of Chi, or consist of any two or more alloying materials of which a metal thin film having a linear expansion coefficient of more than 6.0 × 10 ^-6 is the 0.001~1μm By being formed with a film thickness, the design surface is decorated with a plurality of types of metal-like decorations having different external appearances , and further, the at least two types of the design surfaces provided adjacent to each other on the design surface of the base material The decorative resin molded product is characterized in that a parting portion composed of a groove or a step is continuously provided over the entire length at a boundary portion between the decorated portions .

  Moreover, according to another preferable aspect of the decorated resin molded product according to the present invention, the parting portion is a V-groove extending along a boundary portion between the at least two types of decorated portions. Configured.

  Furthermore, according to another advantageous aspect of the decorative resin molded product according to the present invention, a coating for protecting the metal thin film on the surface of the metal thin film opposite to the design surface side of the base material is provided. A film layer is laminated and a corner portion is provided on the design surface of the substrate by the parting portion, and the corner portion is a curved corner portion having a radius of curvature of 0.1 to 1 mm. The

  Furthermore, according to one of the other suitable aspects of the decorated resin molded product according to the present invention, the decorated resin molded product is used as an automobile interior part.

And in this invention, in order to manufacture the above-mentioned decorative resin molded product , the decorative resin molded product in which the metallic surface decoration is given to the design surface of the base material which consists of a resin molded product. A method of manufacturing, wherein (a) the design surface of the substrate has a pattern formed by a large number of fine recesses and / or protrusions, the decorative pattern forming surface portion to be decorated, At least two types of decorated portions of the smooth surface portion to be decorated, which are not concave and convex, and a plurality of types having different depths and heights of the concave portions, or the types of the patterns, (B) forming a metal thin film by physical vapor deposition or chemical vapor deposition on the at least two types of decorated portions provided on the design surface of the base material; And applying a plurality of types of metallic decorations with different appearances to the design surface Decorating method for producing a resin molded article which comprises a comes to be advantageously employed.

Note that according to one preferred embodiment of the method of manufacturing such a decorated resin molded article, the substrate made of the resin molded article has a cavity surface to provide a design surface of the substrate, and the The pattern is formed on the design surface simultaneously with the molding of the base material by molding using a molding die in which a large number of fine convex portions and / or concave portions are integrally provided on the cavity surface. The plurality of fine concave portions and / or convex portions that give the shape are formed to have a shape corresponding to the multiple fine convex portions and / or concave portions provided on the cavity surface, thereby forming the decorated pattern It is comprised so that a surface part may be provided.

Moreover, according to one of the desirable aspects of the manufacturing method of this decorative resin molded product, after shape | molding the said resin molded product which comprises the said base material, the said pattern is made with respect to the said design surface of this base material. The decoration pattern forming surface is configured to be provided by forming the numerous fine recesses and / or protrusions.

  That is, in the decorative resin molded product according to the present invention, the metal thin film is formed by physical vapor deposition or chemical vapor deposition on the design surface, so that the film thickness of the metal thin film is, for example, metallic coating Further, it can be made sufficiently thinner than a coating film or a plating film formed by metal plating. Therefore, the corners and edges become sharp, and the “real feeling” of the metal can be sufficiently expressed.

  Moreover, in such a decorative resin molded product, a plurality of types of decorated portions are provided adjacent to each other on the design surface. In addition, at least one of the plurality of types of decorated portions is a decorated pattern having a pattern formed by either one of a number of fine concave portions and convex portions, or both concave portions and convex portions. In the case where a plurality of decorated portions including two or more types of decorated pattern forming surface portions are provided on the design surface, at least two types of decorated pattern forming surface portions are provided on them. The depth of the recessed part provided, the height of a convex part, or the kind of pattern formed in these recessed part or convex part is comprised from mutually different. And the metal thin film with sufficient thin film thickness is formed with respect to all the to-be-decorated parts including such a to-be-decorated pattern formation surface part.

  Thus, in the decorative resin molded product according to the present invention, the metal thin film is formed at many locations adjacent to each other on the design surface. It is formed with a large number of fine protrusions on the surface corresponding to the many fine protrusions on the decorative pattern forming surface, thereby creating a three-dimensional texture on the design surface of one substrate. Different types of metal decorations are applied. Therefore, unlike conventional products in which a plurality of independent base materials, each of which is decorated with metallic tones with different three-dimensional textures, are combined, vibrations are applied. The generation of abnormal noise due to contact between the substrates assembled with each other can be effectively eliminated, and, as a result, extra noise during manufacturing can be provided to prevent such abnormal noise. It is possible to completely eliminate the burden of burdensome work and cost.

  Therefore, in the decorative resin molded product according to the present invention as described above, not only a sufficient real feeling can be effectively expressed, but also a structure capable of giving a higher-class impression can be easily and at low cost. It can be realized.

  Moreover, in the decorative resin molded product according to the present invention, the three-dimensional texture is different from each other with respect to a plurality of types of decorated portions provided adjacent to each other on the design surface of one base material. Since multiple types of metallic decorations are applied, for example, when molding a base material, a step or a groove is linearly fixed with a constant width between adjacent decorative parts of the design surface. By providing them with a straight line, etc., a parting portion having a straight and uniform width can be formed by these steps, concave grooves, and the like. As a result, it is possible to ensure a more sufficient luxury feeling.

  Hereinafter, in order to clarify the present invention more specifically, embodiments of the present invention will be described in detail with reference to the drawings.

  First, in FIG. 1 and FIG. 2, as an embodiment of a decorative resin molded product having a structure according to the present invention, a cover panel which is a part of an instrument panel of an automobile and which is a part of an automotive interior panel is a perspective view thereof. The form and the partial cross-sectional form are shown schematically. As is clear from these figures, the cover panel 10 of the present embodiment has a base material 12 made of a resin molded product, and the base material 12 is configured with a metallic decoration. Yes.

  More specifically, the substrate 12 of the cover panel 10 includes a rectangular frame portion 14 in which a long rectangular window portion 13 is provided in the center of a substantially thin long rectangular plate, and the longitudinal length of the frame portion 14. It has two attachment parts 16 and 16 integrally formed so as to extend to one side in the plate thickness direction with respect to both ends in the direction.

  Moreover, in this base material 12, the surface on the opposite side to the surface at the side of the attachment part 16 formation in the frame part 14, ie, the surface of the cover panel 10 (under the attachment state to an instrument panel, it exposes in a vehicle interior. A surface to be a surface) is a design surface 18. A very thin metal film 20 is formed on the design surface 18 so as to cover the entire surface of the design surface 18. Further, an undercoat layer 22 made of a predetermined coating film is formed between the metal film 20 and the design surface 18, and further, on the side opposite to the design surface 18 side (upper side) of the metal film 20, A top-coat layer 24 made of a transparent coating film is formed.

  That is, in this embodiment, the undercoat layer 22, the metal film 20, and the top-coat layer 24 are laminated in order from the lower side with respect to the design surface 18 of the substrate 12 made of a resin molded product. And the metal film 20 is formed in the whole surface of the design surface 18 of the base material 12, The metal surface decoration is given to this design surface 18, Therefore, The surface of the cover panel 10 (frame part 14) In this case, the color, luster, etc. peculiar to the metal are expressed, and the metal surface can be expressed in a pseudo manner.

  In the cover panel 10, the top-coat layer 24 functions as a protective layer for the metal film 20. Further, the undercoat layer 22 masks unnecessary irregularities and wrinkles caused by molding defects on the design surface 18 of the base material 12 in the frame portion 14, and smoothes the design surface 18. A role of preventing the metal film 20 from being eroded by the component of the base material 12 that oozes from 12, a role of preventing the design surface 18 from being eroded by the component of the top-coat layer 24 that has penetrated the metal film 20, The role of improving the adhesion of the metal film 20 to the design surface 18 is exhibited. The top coat layer 24 and the undercoat layer 22 are not essential in the present invention, and at least one of them may be omitted.

  By the way, the base material 12 is comprised with the resin molded product in order to ensure the outstanding moldability and workability of the cover panel 10 whole, and also the lightweight property. Therefore, the resin material used as the material for forming the base material 12 is particularly limited in terms of the type as long as an easy molding technique such as mold molding can be employed. Although it is not a thing, as a formation material of the base material 12, Preferably, it is a non-crystalline resin, such as ABS resin, AAS resin, AES resin, PC, PMMA, PS, or crystalline resin, and melting | fusing point here. Any one of so-called microcrystalline resins such as PET and PBT having a relatively large difference from the temperature-falling crystallization temperature is used alone, or two or more of them are mixed, used.

  This is because these exemplary resin materials have such characteristics that, in a molded product molded by mold molding, the molding shrinkage rate is relatively small, so that sink marks hardly occur or weld lines hardly occur. . Therefore, one of the exemplified resin materials is used alone, or two or more of them are mixed (in this case, it is preferable to mix a material that does not easily cause sink marks and a material that does not easily generate weld lines). In use, when the base material 12 is molded, it is possible to avoid as much as possible that unnecessary uneven portions due to sink marks or weld lines are formed on the design surface 18. As a result, useless uneven portions are formed on the extremely thin metal film 20 formed on the design surface 18, and further, the metal film 20 adds a metal tone to the useless uneven portions. This is because it can be prevented as much as possible that the designability of the decorated design surface 18 is impaired. The use of the exemplified resin material as the forming material of the base material 12 is particularly effective when the undercoat layer 22 having the role of smoothing the design surface 18 is omitted.

  In this embodiment, in particular, the metal film 20 is applied to the design surface 18 of the base material 12 by, for example, a physical vapor deposition method (PVD method) such as a vacuum vapor deposition method, a sputtering method, or an ion plating method, or heat. It is formed using a CVD method, a chemical vapor deposition method (CVD method) such as a plasma CVD method or a photo CVD method. As a result, the thickness of the metal film 20 is extremely thin compared to the thickness of a metal film made of, for example, a plating film or a coating film formed by applying metal plating or metallic coating to the design surface 18. Has been. And since the film thickness of the metal film 20 is made very thin in that way, unlike the case where the thick plating film and coating film are formed in the design surface 18 of the base material 12, the design surface The edges, corners, and the like of the outer peripheral edge 18 have a more angular shape, so that a sharp impression inherent to the metal can be given to the viewer.

  In addition, although the specific film thickness of the metal film 20 is not limited at all, it is set as the thickness of about 0.001-1 micrometer here. This is because when the thickness of the metal film 20 is less than 0.001 μm, the metal film 20 is too thin, so that a uniform film thickness cannot be obtained. This is because it becomes difficult to express gloss and the like, and it becomes difficult to express the metal surface in a pseudo manner by the metal film 20. Further, when the thickness of the metal film 20 exceeds 1 μm, the metal film 20 is now too thick, so that the edges and corners of the outer peripheral edge of the design surface 18 are rounded with R. This is because there is a risk that the edges and corners may lack sharpness. That is, the thickness of the metal film 20 is preferably set to a value within the range of 0.001 to 1 μm, so that a more realistic metal surface can be surely expressed on the design surface 18. It can be done. In order to obtain such an effect more effectively, it is more desirable that the thickness of the metal film 20 is set to a value within the range of 0.005 to 0.1 μm.

  In general, the linear expansion coefficient of the resin is about 1/10 of the linear expansion coefficient of the metal, but is large between the linear expansion coefficient of the base material 12 made of a resin molded product and the linear expansion coefficient of the metal film 20. If there is a difference, the metal film 20 may be thermally deformed following the substrate 12 when the substrate 12 is thermally expanded or contracted due to rapid heating or rapid cooling of the cover panel 10. Otherwise, the metal film 20 may be cracked or flawed, and conversely, the metal film 20 inhibits or prevents thermal deformation of the substrate 12 due to rapid heating or rapid cooling of the cover panel 10. Thus, there is a concern that the substrate 12 is distorted. Therefore, it is desirable that the difference between the linear expansion coefficient of the metal film 20 and the linear expansion coefficient of the base material 12 made of a resin molded body is made as small as possible.

Therefore, here, for example, a metal material having a linear expansion coefficient of 6.0 × 10 ⁻⁶ or more is used as the metal material for forming the metal film 20. Thereby, due to the difference in coefficient of linear expansion between the metal film 20 and the base material 12, when the cover panel 10 is thermally deformed, the metal film 20 is cracked or wrinkled, or the base material 12 is distorted. Occurrence and the like can be effectively prevented. That is, it is desirable that the linear expansion coefficient of the metal material forming the metal film 20 is 6.0 × 10 ⁻⁶ or more, thereby causing cracks, wrinkles, etc. of the metal film 20 as much as possible. Therefore, stable quality can be ensured over a long period of time.

The problem of cracks and wrinkles occurring in the metal film 20 due to such a difference in linear expansion coefficient becomes more obvious as the metal film 20 becomes thicker. In particular, when the film thickness of the metal film 20 becomes 1 μm or more. Become prominent. Therefore, even when the metal film 20 is formed using a metal material having a linear expansion coefficient of 6.0 × 10 ⁻⁶ or more, it prevents the metal film 20 from being cracked or wrinkled. Therefore, it is desirable that the thickness of the metal film 20 be less than 1 μm.

The type of metal material for forming the metal film 20 is not particularly limited as long as the metal film 20 can be formed by the physical vapor deposition method or the chemical vapor deposition method as described above. In order to obtain the advantages as described above, the material for forming the metal film 20 has a linear expansion coefficient of 6.0 × 10 ⁻⁶ or more, for example, gold, silver, platinum, copper, aluminum, zinc, nickel, Any one metal material of chromium, tin, titanium, nickel-chromium alloy, stainless steel, and molybdenum, or an alloy material composed of any two or more of them is used.

  Thus, as apparent from FIGS. 1 and 2, in the cover panel 10 of this embodiment as described above, in particular, the outer peripheral portion of the design surface 18 of the base material 12 that becomes the surface of the frame portion 14 is uneven. The metal film 20 is formed so as to cover the entire surface of the smooth surface portion 26 to be decorated. As a result, the smooth mirror surface portion 28, which is provided with a metal-like decoration that is mirror-finished on the outer peripheral portion of the surface of the frame portion 14, extends in the circumferential direction over the entire circumference of the outer peripheral portion. Is formed.

  Further, on the inner side of the decorative portion smooth surface portion 26 on the design surface 18 of the base material 12, fine concave grooves 30 having nonuniform lengths and widths are formed on both side portions of the longitudinal rectangular window portion 12 in the longitudinal direction. However, the first decoration pattern formation which is a to-be-decorated part different from the to-be-decorated smooth surface part 26 in which many and densely provided and the hairline pattern was formed in these many fine concave grooves 30 is formed. A plurality of the surface portions 32 are provided at intervals. And the metal film 20 is formed so that those 1st decorating pattern formation surface parts 32 may also cover those whole surfaces. As a result, a plurality of hairline pattern portions 34 having a metallic decoration having a hairline pattern are formed on both sides of the window portion 12 on the surface of the frame portion 14 at intervals.

  Furthermore, in the design surface 18 of the base material 12, the concave portions are formed on all the portions of the portion located inside the decorated portion smooth surface portion 26 except for the plurality of first decorated pattern forming surface portions 32. The fine grain-like recesses 36 having a shape different from that of the groove 30 are provided in a large number and densely with non-uniform depths and sizes, and the many fine grain-like recesses 36 are provided. The portion to be decorated is a second decorative pattern forming surface portion 38 which is a different decorative portion from the decorative smooth surface portion 26 and the first decorative pattern forming surface portion 32 in which a wrinkle pattern is formed. ing. Also, the metal film 20 is formed on the second decorative pattern forming surface portion 38 so as to cover the entire surface thereof. As a result, a wrinkle pattern in which all the portions of the inner surface portion of the decorated portion smooth surface portion 26 on the surface of the frame portion 14 except for the plurality of hairline pattern portions 34 are decorated with a metallic tone having a wrinkle pattern. Part 40.

  In addition, the depth of the fine ditch | groove 30 provided in the 1st and 2nd decorating pattern formation surface parts 32 and 38 in the design surface 18 of the base material 12 or the embossed recessed part 36 is not specifically limited. However, the concave grooves 30 and the textured concave portions 36 are not filled with the undercoat layer 22 and the metal film 20 formed on the first and second decorative pattern forming surface portions 32 and 38. In addition, it is desirable that the dimension is larger than the total thickness of the undercoat layer 22 and the metal film 20. Of course, when no undercoat layer 22 is provided, the depth of the recessed groove 30 and the embossed recess 36 may be larger than the thickness of the metal film 20.

  Thus, in the cover panel 10 of the present embodiment, the wrinkle pattern portion 40, the hairline pattern portion 34, and the mirror surface portion 28 are mutually attached to the surface of the frame portion 14 (design surface 18 of the substrate 12) made of only one substrate 12. It is formed so as to be located next to each other. As a result, two kinds of metallic decorations that are different in appearance from each other due to the difference in the pattern are applied to the adjacent portions of the surface of the frame portion 14, and such two kinds of decorations are applied. By not having any pattern in a portion adjacent to the portion that has been made, another metallic decoration different in appearance from that is further applied. As a result, it is possible to give the viewer an impression that the frame portion 14 is configured by integrally assembling three types of metal members having surfaces with different three-dimensional textures. It has become.

  By the way, in this embodiment, the parting part 42 is provided between the to-be-decorated smooth surface part 26 and the 2nd to-be-decorated pattern formation surface part 38 which are located in the design surface 18 adjacently. This parting part 42 is comprised by the V-shaped groove | channel of the longitudinal cross-section V extended continuously along the boundary part of the to-be-decorated smooth surface part 26 and the 2nd to-be-decorated pattern formation surface part 38. As shown in FIG. Further, the V-groove constituting the parting part 42 has a groove width (width of the opening) that is constant over the entire length in the extending direction.

  Thus, in the cover panel 10 of the present embodiment, on the surface of the frame portion 14, the mirror surface portion 28 in which the metal film 20 is formed on the surface to be decorated 26 and the second decorative pattern forming surface portion. 38, a parting portion 42 is present between the embossed pattern portion 40 formed by forming the metal film 20 on the surface 38 so that the mirror surface portion 28 and the embossed pattern portion 40 can be clearly distinguished from each other in appearance. It has become. As a result, in the frame portion 14, it is possible to give a deeper impression to the viewer that the surface portion of the mirror surface portion 28 and the textured portion 40 are made of separate members. It is like that.

  In this parting part 42, when the depth of the V-groove constituting the parting part 42 is small, the parting part 42 becomes inconspicuous, and thereby, the mirror surface part 28 and the wrinkle pattern located on both sides with the parting part 42 interposed therebetween. It may be difficult to distinguish the portion 40 from the appearance. Therefore, it is preferable that the parting part 42 has a depth as large as possible, and specifically, it is desirable that the parting part 42 be 0.1 mm or more.

  On the other hand, if the depth of the parting portion 42 is too large, the protrusion height for forming the parting portion 42 formed of the V groove is excessive in the mold used when the cover panel 10 is molded. Therefore, there is a concern that the productivity of the mold and the releasability of the cover panel 10 from the mold are lowered. Therefore, it is desirable that the parting part 42 has a depth or height of 1 mm or less.

  Moreover, since the parting part 42 provided in the cover panel 10 of this embodiment consists of V-groove which has two side parts, in the design surface 18 of the base material 12, it is formed between these two side parts. Although it has two corners formed between a corner (bottom of the V-groove), each side surface, and the first and second decorative pattern forming surface portions 32 and 38, here Each of these three corners is a curved corner with R applied thereto. And each radius of curvature of these three curved corners is preferably set to a value in the range of 0.1 to 1 mm.

  This is because when the radius of curvature of each of the three corners formed on the design surface 18 of the base material 12 by the parting portion 42 is less than 0.1 mm, the metal film 20 provided on the design surface 18 is formed. When the thick topcoat layer 24 is formed by painting, a liquid pool of the paint forming the topcoat layer 24 is likely to occur at each corner, and such a liquid pool is cured as it is. This is because the sharpness on the design surface 18 expressed by the extremely thin metal film 20 is impaired. In addition, when the radius of curvature of each corner exceeds 1 mm, the sharpness at each corner is significantly impaired regardless of the presence or absence of the topcoat layer 24 on the metal film 20. It is. That is, here, the curvature radius of each corner formed on the design surface 18 of the base material 12 by the parting portion 42 is set to a value within the range of 0.1 to 1 mm, so that the sharpness inherent to the metal is reduced. Can be advantageously secured.

  By the way, the cover panel 10 of this embodiment having such a structure is manufactured, for example, according to the following work procedure.

  That is, first, the base material 12 integrally including the frame portion 14 provided with the window portion 13 and the two attachment portions 16 and 16 is molded by, for example, injection molding using the resin material exemplified above. Is performed. At this time, as the mold for injection molding, a large number of fine protrusions corresponding to the fine concave grooves 30 provided in the first decorative pattern forming surface portion 32 of the substrate 12 are provided densely on the molding cavity surface. Corresponding to the decorated smooth surface portion 26, the portion provided with a large number and fine projections corresponding to the fine embossed recesses 36 provided on the second decorated pattern forming surface portion 38, and the decorated smooth surface portion 26. The mirror-polished part is provided so as to be adjacent to each other, and a V-groove is formed at the boundary part between the part where these fine projections are provided in large numbers and the mirror-polished part. What is provided with a protrusion having a V-shaped longitudinal section corresponding to the parting part 42 is used. Thereby, at the same time as the base material 12 is molded, the first decorative pattern forming surface portion 32, the second decorative pattern forming surface portion 38, and the decorative smoothness are formed on the design surface 18 of the base material 12. The surface portion 26 is formed so as to be adjacent to each other, and a parting portion 42 is formed between the second decorated pattern forming surface portion 38 and the decorated smooth surface portion 26.

  In addition, as a method of forming fine protrusions corresponding to the fine concave grooves 30 and fine protrusions corresponding to the fine embossed concave portions 36 on the molding cavity surface of the mold used in this step, for example, shot Any known method generally used for forming a predetermined concavo-convex portion on the mold cavity surface of the mold, such as blasting, etching, polishing, etc., can be adopted, but among them, shot blasting, A technique that makes the shape, size, depth, and the like of the concave and convex portions formed on the molding cavity surface non-uniform, such as polishing, can be suitably employed. As a result, a hairline pattern, a texture pattern, or the like including a groove or a recess formed on the surface of the target cover panel 10 (the surface of the frame portion 14) having a shape corresponding to the protrusion formed on the surface of the molding cavity. However, there is a variation, so that a metal-like decoration is applied, and a more sufficient real feeling can be obtained in the finally obtained cover panel 10.

  In addition, in the finally obtained cover panel 10, the decorated smooth surface portion 26 provided on the design surface 18 of the base material 12 has higher smoothness in order to obtain a sufficient real feeling. It is desirable that Therefore, here, the mold cavity surface of the mold is provided with a mirror-polished portion corresponding to the surface to be decorated 26 with a mirror surface polished with, for example, No. 3000 or more. A pre-hardened material or a material that does not easily cause pinholes is preferably used.

  Next, for example, a predetermined paint is applied to the entire design surface 18 (the surface of the frame portion 14) of the base material 12 thus formed, and an undercoat layer 22 made of a paint film of the paint is applied to the design surface. It is formed so as to cover the entire surface of 18. In addition, the kind of coating material which provides this undercoat layer 22 is not specifically limited, When providing a metal film on the surface of a resin molding, it is used for forming the coating film as the base layer. Any known various paints such as a two-component urethane paint, an ultraviolet curing type, or a thermosetting type can be used.

  Thereafter, the metal film 20 is formed with a sufficiently thin film thickness on the undercoat layer 22 formed on the design surface 18 of the base material 12 by physical vapor deposition or chemical vapor deposition so as to cover the entire surface. The As a material for forming the metal film 20, for example, a material having a desired metal color, metallic luster, or the like is appropriately selected from the several types of metal materials exemplified above.

  In addition, although the physical vapor deposition method and the chemical vapor deposition method performed to form the metal film 20 are not particularly limited, the metal film 20 has a film thickness of 0.001 for the reasons described above. Since it is desirable that the thickness of the metal film 20 to be formed is about 0.001 to 1 μm, it is preferable that the physical vapor deposition method and the chemical vapor deposition method be performed in this step. Conditions that can be considered to be the thickness are adopted. When the undercoat layer 22 is omitted, a component that erodes the base material 12 as a part of the components contained in the topcoat layer 24 formed on the metal film 20 penetrates the metal film 20. In order to prevent this as much as possible, it is preferable that the metal film 20 be formed at a high density (for example, when a sputtering method is used, a relatively low pressure, for example, about 0.1 Pa). Are carried out under an atmosphere of a certain pressure).

  Next, for example, a transparent paint is applied to the entire surface of the metal film 20 on the design surface 18 of the base material 12 so that the top coat layer 24 made of the paint film covers the entire surface of the metal film 20. ,It is formed. Thus, the target cover panel 10 is obtained.

  Note that the thickness of the top coat layer 24 is sufficiently thicker than the metal film 20 so that the metal film 20 can be reliably protected. Moreover, the kind of coating material which gives the topcoat layer 24 is not particularly limited, and is used to form a coating film as a protective layer when a metal film is provided on the surface of the resin molded body. For example, any of the two-component urethane paint, the ultraviolet curable type, or the thermosetting type of known various paints can be employed. Furthermore, the top coat layer 24 does not necessarily need to be colorless as long as it is transparent. For example, the top coat layer 24 may have the same or different color from the color of the metal film 20.

  Thus, in the cover panel 10 of this embodiment, the metal film 20 is formed with a sufficiently thin film thickness on the design surface 18 of the base material 12 by physical vapor deposition or chemical vapor deposition, and is decorated with a metallic tone. By being applied, the metal surface can be expressed more advantageously with a more real feeling so that the metal surface can give a sharp impression on the surface of the frame portion 14.

  Moreover, in this cover panel 10, the 1st and 2nd to-be-decorated pattern formation surface parts 32 and 38 provided in the mutually adjacent location of the design surface 18 of the base material 12, and the to-be-decorated smooth surface part 26 each whole surface Since the metal film 20 is formed on the design surface 18 of the base material 12, three kinds of metallic decorations with different appearances of hairline, embossing, and mirror surface are given. Three kinds of metal members having different textures from each other are integrally assembled to give the viewer an impression that the frame portion 14 is configured. And thereby, a sufficient high-class feeling can be exhibited advantageously.

  Moreover, since the cover panel 10 of the present embodiment is formed by decorating the design surface 18 of one base material 12 with three kinds of metallic decorations having different external appearances, for example, actually Unlike the case where three types of metal members are assembled together, the problem of abnormal noise due to contact between the metal members can be effectively eliminated. As a countermeasure against such abnormal noise, it is possible to completely eliminate the burden of extra work and cost during manufacturing.

  Therefore, in the cover panel 10 of the present embodiment as described above, a sufficient genuine feeling and a higher quality feeling can be effectively provided in a simple and low-cost structure.

  Moreover, in this cover panel 10, the parting part 42 is provided in the boundary part of the to-be-decorated smooth surface part 26 in the design surface 18 of the base material 12, and the 2nd to-be-decorated pattern formation surface part 38, and the frame part 14 is provided. Among these, it is possible to give the viewer a deeper impression that the surface is composed of the mirror surface portion 28 and the portion composed of the embossed pattern portion 40 is composed of separate members. Moreover, since such a parting part 42 is configured by a V-groove, for example, the parting part 42 is different from a case where the parting part 42 is configured by a rectangular groove or U-groove having a rectangular shape or a U-shaped cross section. Thus, it is difficult for the bottom portion of the parting portion 42 to be visually recognized from the outside. And thereby, the mirror surface part 28 and the embossed pattern part 40 on the surface of the frame part 14 can give the viewer a deeper impression that they are made of separate members. As a result, a sufficiently high quality feeling can be provided more reliably.

  Moreover, in this embodiment, since the V groove which comprises the parting part 42 has a fixed width | variety over the full length of the extension direction, the width | variety of the parting part 42 becomes non-uniform | heterogenous. Such a loss of feeling can be advantageously avoided.

Furthermore, in the cover panel 10 of the present embodiment, the metal film 20 has a thickness within a range of 0.001 to 1 μm, so that the design surface 18 has a more realistic feeling. The surface can be expressed reliably, and the metal film 20 is formed by using a metal material having a linear expansion coefficient of 6.0 × 10 ⁻⁶ or more. The occurrence of cracks and wrinkles in the metal film 20 is prevented as much as possible, and stable quality can be advantageously ensured.

  Furthermore, when manufacturing the cover panel 10 of the present embodiment, the first and second decorative pattern forming surface portions 32 and 38 on the design surface 18 of the substrate 12 and the decorative smooth surface are formed on the molding cavity surface. The molding pattern provided with the part which forms the surface part 26 and the parting part 42 is used, the base material 12 is shape | molded, and the 1st decorating pattern is performed with respect to the design surface 18 of the base material 12 simultaneously. The forming surface portion 32, the second decorative pattern forming surface portion 38, and the decorative smooth surface portion 26 are formed so as to be adjacent to each other, and further, the second decorative pattern forming surface portion 38 and the applied decorative surface portion are added. A parting part 42 is formed between the decorative smooth surface part 26. Therefore, for example, a plurality of the cover panels 10 can be easily manufactured by the same processing process efficiently, with good manufacturability, and with uniform quality.

  Here, the test conducted by the present inventors in order to examine the relationship between the linear expansion coefficient of the metal film 20 and the film thickness with respect to the quality of the cover panel 10 having the structure as described above will be described in detail.

  That is, first, 16 plate-like substrates made of a flat plate made of ABS resin having dimensions of length × width × thickness = 150 mm × 150 mm × 3 mm were prepared and prepared. In addition, four types of metal materials of molybdenum, chromium, nickel-chromium alloy (Ni: Cr = 80: 20), and SUS316 stainless steel having linear expansion coefficients shown in Table 1 below were prepared.

  Then, using four of the prepared 16 plate-like base materials and molybdenum, a metal film made of molybdenum is formed on each surface of the four plate-like base materials by a known sputtering method. Four types of decorative resin molded products that are formed in different thicknesses (0.001 μm, 0.04 μm, 1 μm, and 1.2 μm) and have a metallic decoration on the surface with a molybdenum metal film Got. Similarly, metal films made of chromium are formed on the surfaces of the four plate-like base materials with different thicknesses, while nickel- Metal films made of chromium alloy (Ni: Cr = 80: 20) are formed with different thicknesses, and further, metal films made of SUS316 stainless steel are made different on the surfaces of the remaining four plate-like substrates. Formed in thickness. As a result, by forming metal films having different kinds of metal materials or different film thicknesses, 12 types of decorated resin molded products having metal-like decorations on the surfaces were obtained.

  Next, a total of 16 types of decorative resin molded articles thus obtained were used, and these were allowed to stand for 240 hours in an environment of 50 ° C. and 95% humidity, and then left at 80 ° C. for 15.5 hours while maintaining the humidity → Leave at 20 ° C. for 0.5 hours → Leave at 30 ° C. for 7.5 hours → Leave at 20 ° C. for 0.5 hours → Leave at 49 ° C. for 15.5 hours → Leave at 20 ° C. for 0.5 hours → At 30 ° C. 4 cycles of standing for 5 hours → 20 ° C. for 0.5 hour. Then, an appearance inspection was performed to visually confirm the presence or absence of cracks in each metal film provided in 16 types of decorative resin molded products. The results are shown in Table 1 below. In addition to such appearance inspection, a cross-cut tape peeling test was conducted in accordance with JIS K5400 for each of 16 types of decorative resin molded products, and the presence or absence of peeling of the metal film at that time I investigated. The results are also shown in Table 1 below. In Table 1 below, it was confirmed that there were no cracks in the appearance test, and no peeling of the metal film was observed in the cross-cut tape peeling test, and a crack was found in each test or metal The case where peeling of the film occurred was indicated by x.

As is apparent from the results of Table 1, a decorative resin molding in which a metal film is formed using a metal material having a linear expansion coefficient of 6.0 × 10 ⁻⁶ or more and a metal-like decoration is applied. In general, there is a tendency that a thinner film is preferable, but in general, the metal film cracks due to changes in ambient temperature, that is, the thermal deformation of the substrate, and the adhesion of the metal film to the substrate. It can be seen that it can be advantageously prevented that the sag decreases. Further, it can be recognized that the thinner the metal film is, the more the metal film can be prevented from cracking due to thermal deformation of the base material due to the surrounding temperature change and the adhesion of the metal film to the base material can be reduced. . In order to more advantageously prevent cracking of the metal film due to thermal deformation of the base material due to a change in ambient temperature and deterioration of the adhesion of the metal film to the base material, the metal film is 6.0 × 10 ^−6. It is recognized that it is desirable that the metal material having the above linear expansion coefficient is formed and that the thickness of the metal film has a value within the range of 0.001 μm or more and less than 1 μm. .

  The specific configuration of the present invention has been described in detail above. However, this is merely an example, and the present invention is not limited by the above description.

  For example, in the said embodiment, the design surface 18 of the base material 12 does not have an uneven | corrugated | grooved part, the decorating smooth surface part 26 which does not have any pattern, and the 1st and 2nd 2nd coverings from which the kind of pattern differs mutually. Although the three types of decorated portions of the decorative pattern forming surface portions 32 and 38 are provided, the decorated portions provided on the design surface 18 of the base material 12 are two or more types that are not the same. If there are, the combination is not particularly limited.

  That is, for example, the decorated part provided on the design surface 18 of the base material 12 has only two kinds or three or more kinds of patterns different from each other, or has no pattern and has a pattern. One or more types of things can be combined. Further, in the case where a plurality of types of decorated parts having patterns are provided on the design surface 18 of the substrate 12, the patterns of the decorated parts are the same shape as each other, Different depths, heights, widths, lengths, and the like of the recesses and protrusions forming the pattern can be combined with each other.

  Furthermore, the pattern provided on the decorated portion is not only formed by only a large number of fine concave portions, but also formed by only a large number of fine convex portions, or a large number of fine concave portions and a large number of fine concave portions. You may form combining a convex part.

  In addition, the pattern provided in the decorated part in this way is not limited to the hairline pattern or the wrinkle pattern exemplified in the above embodiment, but also a geometric pattern, an indefinite shape pattern, or various characters. Various known patterns such as patterns made up of symbols and symbols can be employed. The geometric pattern includes, for example, one of the same size of a circle, an ellipse, an ellipse, a polygon, and a line segment (including straight lines, bent lines, curved lines, wavy lines, etc.) Patterns formed with different sizes and patterns formed by combining two or more of them are included. In addition, in geometric patterns formed including circles, ellipses, ellipses, and polygons, only the outlines of those shapes are composed of concave grooves or ridges, The whole or a part thereof is also recessed or protruded.

  Furthermore, it is not always necessary that one decorated portion is provided with only one type of pattern, even if a plurality of types of patterns are provided on one decorated portion (decorated pattern forming surface portion). There is no problem.

  Furthermore, the depth and height of the recesses and projections that give the pattern provided on one decorated part do not necessarily have to be constant, so that there is variation as a whole, or a part thereof is another part. In addition, it may be non-uniform only in a part.

  Moreover, in the said embodiment, although the to-be-decorated smooth surface part 26 in the design surface 18 of the base material 12 and the 2nd to-be-decorated pattern formation surface part 38 were provided, the parting part 42 which consists of V-grooves was provided. As long as this parting part 42 is provided between the decoration parts adjacent to each other, the type of the decoration parts is not limited at all.

  Furthermore, the structure of the parting part 42 is not particularly limited to that of the illustrated V groove, and various structures can be adopted. For example, as shown in FIG. 3 and FIG. 4, the parting portion 42 can be configured by a rectangular groove having a rectangular longitudinal section, a U groove having a U-shaped longitudinal section, or the like. Further, as shown in FIG. 5, between the two decorated parts (here, the decorated smooth surface part 26 and the second decorated pattern forming surface part 38) adjacent to each other, A step which makes one of the decorative portions one step lower than the other may be provided, and the parting portion 42 may be formed by this step (here, the second decorative pattern forming surface portion 38 is decorated). It is one step lower than the smooth surface portion 26, but the reverse may also be possible). Furthermore, as shown in FIG. 6 to FIG. 8, between the two decorated portions adjacent to each other, a step is provided to make one of the two decorated portions one step lower than the other, and this Provide a V-groove, rectangular groove, U-groove, etc. with a part of the step as a part of the side surface, and the parting part 42 is constituted by these stepped V-groove, stepped rectangular groove, stepped U-groove, etc. You can also.

  As described above, even when the parting part 42 is configured with a structure other than a simple V groove, the depth and height of the parting part 42 (when the parting part 42 is formed of a U groove or a rectangular groove) When the parting portion 42 has a step, the depth of the groove, or the parting height 42, or the parting portion 42 is a stepped V groove, a stepped U groove, a stepped rectangular groove, or the like. In this case, it is desirable that the total height of the height of the step and the depth of each groove is about 0.1 to 1 mm, and is formed on the design surface 18 of the substrate 12 by the parting portion 42. The corner is preferably composed of a curved corner having a radius of curvature of 0.1 to 1 mm.

  Furthermore, each of the plurality of surfaces of the base material may be a design surface.

  Further, in the above embodiment, a molding die having a molding cavity surface portion provided with a plurality of fine convex portions and concave and convex portions corresponding to concave portions formed in a plurality of types of decorated portions is used. At the same time that the substrate was molded with the mold, multiple types of decorated parts (decorated pattern forming surface part) were formed on the design surface of the substrate, but there were any uneven parts After forming a base material using a molding die having no molding cavity surface, a decorative pattern forming surface portion is formed by forming a large number of fine convex portions and concave portions on the design surface of the base material. May be provided. Thereby, a plurality of decorative resin molded products can be advantageously manufactured with high originality and having different textures and textures. In addition, as a method for forming a large number of fine convex portions and concave portions on the design surface of the substrate, for example, predetermined concavo-convex portions are formed on the surface of the resin molded product such as shot blasting such as sand blasting, etching, polishing, etc. Any known technique that is generally implemented can be employed.

  In addition, in the said embodiment, although the specific example of what applied this invention to the cover panel attached to the instrument panel which is a kind of interior component for motor vehicles, and its manufacturing method was shown, this invention is other than this cover panel. Of course, the present invention is advantageously applied to any of the automotive interior parts and the manufacturing method thereof, or the decorative resin molded products other than the automotive interior parts and the manufacturing method thereof.

  The specific configuration of the present invention has been described in detail above. However, this is merely an example, and the present invention can be implemented in various forms. Accordingly, various embodiments relating to various changes, modifications, and improvements of the present invention adopted based on the knowledge of those skilled in the art are all within the scope of the present invention without departing from the spirit of the present invention. It should be understood that it belongs.

It is a perspective explanatory view showing one embodiment of a decorative resin molded product having a structure according to the present invention. It is the elements on larger scale in the II-II cross section of FIG. It is a figure corresponding to FIG. 2 which shows an example different from what is shown by FIG. 1 of the decorative resin molded product which has a structure according to this invention. It is a figure corresponding to FIG. 2 which shows an example different from what is shown by FIG.1 and FIG.3 of the decorative resin molded product which has a structure according to this invention. It is a figure corresponding to FIG. 2 which shows an example different from what is shown by FIG.1, FIG.3 and FIG.4 of the decorative resin molded product which has a structure according to this invention. It is a figure corresponding to FIG. 2 which shows an example different from what is shown by FIG. 1, FIG. 3 thru | or FIG. 5 of the decorative resin molded product which has a structure according to this invention. It is a figure corresponding to FIG. 2 which shows an example different from what is shown by FIG. 1, FIG. 3 thru | or FIG. 6 of the decorative resin molded product which has a structure according to this invention. It is a figure corresponding to FIG. 2 which shows an example different from what is shown by FIG. 1, FIG. 3 thru | or FIG. 7 of the decorative resin molded product which has a structure according to this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Cover panel 12 Base material 18 Design surface 20 Metal film 22 Undercoat layer 24 Topcoat layer 26 Decorated smooth surface part 28 Mirror surface part 30 Ditch | groove 32 First decorating pattern formation surface part 34 Hairline pattern part 36 Wrinkle-shaped recessed part 38 Second decorative pattern forming surface part 40 Wrinkle pattern part 42 Parting part

Claims (5)

A decorative resin molded product in which a metallic decoration is applied to the design surface of a base material made of a resin molded product,
The depth of the concave portion and the height of the convex portion of the decorative pattern forming surface portion to be decorated having a pattern formed by a large number of fine concave portions and / or convex portions on the design surface of the substrate. Or, at least two types of decorative portions to be decorated, which are different from each other and a plurality of different types of the patterns, and to be decorated, are provided adjacent to each other, and at least Two kinds of decorated parts are made of gold, silver, platinum, copper, aluminum, zinc, nickel, chromium, tin, titanium, nickel-chromium alloy, stainless steel, molybdenum by physical vapor deposition or chemical vapor deposition . A metal thin film having a linear expansion coefficient of 6.0 × 10 ⁻⁶ or more, which is made of any one of these metal materials, or any two or more alloy materials thereof is 0.001 to 1 μm . Formed with a film thickness of By this, the design surface is decorated with a plurality of types of metallic tones that differ in appearance from each other ,
Furthermore, a parting part consisting of a groove part or a step is continuously provided over the entire length at the boundary part between the at least two kinds of decorated parts provided adjacent to each other on the design surface of the base material. Decorative resin molded product characterized by being made. The decorated part is composed of the decorated pattern forming surface part and the decorated smooth surface part, and the parting line extends over the entire length of the boundary portion between the decorated pattern forming surface part and the decorated smooth surface part. The decorative resin molded product according to claim 1, wherein a portion is formed . The decorative resin molded product according to claim 1 , wherein the parting portion is a V-groove extending along a boundary portion between the at least two types of decorated portions. A coating layer for protecting the metal thin film is formed on the surface of the metal thin film opposite to the design surface side of the base material, and corners are formed on the design surface of the base material by the parting portion. The decorative resin molded product according to any one of claims 1 to 3, wherein the decorative resin molded article is provided with a curved corner having a radius of curvature of 0.1 to 1 mm. . The decorative resin molded product according to any one of claims 1 to 4 , wherein the decorative resin molded product is an automotive interior part.

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