JPS63297006A - Molding process of uneven surface - Google Patents

Abstract

PURPOSE:To obtain the uneven surface molding process having good operability and moreover the high reproducibility of the uneven surface by carrying out the molding of the uneven surface of the front surface of a depression forming regulation layer regulating the depth of the depression formed on the surface to be worked corresponding to the change of the layer thickness by using a molding process. CONSTITUTION:The depression forming regulation layer 2 regulating the depth of the depression to be formed on the surface 1 to be worked according to the change of layer thickness, is molded on the surface 1 to be worked in such a state that said surface becomes an uneven surface, whereby the depression forming is achieved for the surface 1 to be worked through the depression forming regulation layer 2. This method is the molding process of an uneven surface. The uneven surface of the front surface of the depression forming regulation layer 2 is molded by molding process, and the depressions are formed by etching process. The operability is improved by making the uneven surface of the depression forming regulation layer at one time by the molding process, and moreover the pattern may be surely reproduced by modeling the mold for molding process from an actual pattern.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a resin molded product having an uneven pattern on its surface, such as a texture pattern, a wood grain pattern, a satin pattern, a leaf vein pattern, a scale pattern, a marble pattern, etc. The present invention relates to a method for forming an uneven surface for forming a mold surface of a resin molding mold used in manufacturing.

More specifically, a four-part formation adjustment fIff layer in which the depth of the recesses to be formed on the workpiece surface is adjusted by changing the layer thickness is formed on the workpiece surface in a state where the surface becomes an uneven surface, and the recesses are By forming recesses on the processed surface through the formation control layer, the difference in processing time caused by the difference in removal time due to dissolution or swelling of the recess formation control layer, and the difference in the passage time of the etchant through the recess formation control layer. This invention relates to a method of forming an uneven surface by etching, sandblasting, etc., which allows the depth of the recesses to be varied.

[Conventional technology]

In the method for forming an uneven surface described above, conventionally, the uneven surface on the surface of the recess formation control layer can be formed simultaneously with the formation of the recess formation control layer by applying a viscous recess formation control agent with a brush or a brush. (For example, the
1-20178).

[Problem that the invention seeks to solve]

However, the conventional method described above has the following problems.

First, the formation of the concave-convex surface on one surface of the layer, which is performed simultaneously with the formation of the concave portion formation control layer, is performed by means of coating, which requires repeated work, and is therefore time-consuming and inefficient.

Moreover, since the uneven surface is applied manually by means of coating, it is difficult to faithfully reproduce uneven patterns that exist in nature, such as wood grain patterns or leaf vein patterns, on the uneven surface.

SUMMARY OF THE INVENTION In view of the above circumstances, an object of the present invention is to provide a method for forming an uneven surface with good workability and high reproducibility of an uneven surface.

[Means for solving problems]

The characteristic structure of the method for forming an uneven surface according to the present invention is that the uneven surface is formed on the surface of the recess formation control layer, which adjusts the depth of the recess formed on the processed surface by changing the layer thickness, by molding. .

[For production]

That is, in the case of the present invention, for example, the recess formation regulator is piled up on the workpiece surface to a predetermined thickness, and then
By pressing a master on which an uneven surface has been formed in advance, the uneven surface can be formed on the surface of the recess formation control layer all at once.

In addition, when producing the above-mentioned master that serves as a mold for molding, the recesses formed using this master are formed by pressing the uncured master material against the surface of the actual tree skin or leaf and making a mold. The uneven surface of the adjustment layer can be made to faithfully reproduce the above-mentioned actual pattern.

〔Effect of the invention〕

As a result, the uneven surface of the recess formation control layer can be created all at once by molding, which improves workability, and by making the mold from the actual pattern, it is also possible to faithfully reproduce the pattern. We have developed an excellent method for forming uneven surfaces.

〔Example〕

Hereinafter, the present invention will be described in detail based on the drawings.

The method for forming an uneven surface according to the present invention is particularly applicable to a resin molding mold used when producing a resin molded product having various uneven patterns such as a wood grain pattern, a leaf vein pattern, or a satin finish pattern on its surface. A method suitable for forming the surface, for example, an etching method, consists of the following steps.

<1> Concave formation adjustment layer (2) on the surface to be processed (1) of metal etc.
) into a state in which its surface (2a) becomes an uneven surface corresponding to the uneven surface to be formed on the surface to be processed (1) (the state at the end of this process is shown in Fig. 1 (a)). ).

Note that the word "corresponding" mentioned above refers to the recess formation control layer (
The uneven surface in 2) also includes cases where the uneven surface is formed exactly the same as the uneven surface of the surface to be processed (1), and cases where it is formed in anticipation of deterioration in the reproduction of the uneven surface during processing, as will be described later. It is something that

<n> After a predetermined period of time has elapsed after forming the recess formation control layer (2), depending on the material of the surface to be processed (1), for example, a corrosive agent such as ferric chloride for copper and nitric acid for zinc is applied. Step of flowing the liquid over the entire surface of the recess formation control layer (2) (see Fig. 1 (El
)reference).

In this step, the etchant uniformly dissolves the surface of the recess formation control layer (2). As a result, the recess formation adjustment layer (
Starting from the thin layer portion 2), the surface of the processed surface (1) is exposed one after another, and this exposed surface portion is corroded by the corrosive liquid to form a recess. As the surface of the surface to be processed (1) is exposed, the dissolution gradually spreads to the thick part of the recess formation control layer (2), and the exposed surface of the surface of the surface to be processed (1) becomes large. Become. At this time, corrosion progresses in the bare surface of the processed surface (1) that is first exposed, and the recesses become deeper.

Therefore, when the recess formation control layer (2) is completely dissolved, the etching depth of the recess formation control layer (2) is deep in the thin layer part and shallow in the thick layer part on the surface to be processed (1). This results in the formation of an uneven surface with variations (Fig. 1 (c))
reference).

The step <1> described above, that is, the formation of the recess formation control layer (2) is performed by molding. Next, some of the methods are listed.

<Ia> As shown in Fig. 2 (a), the recess formation adjustment material (2°) is placed on the surface to be processed (1) to a predetermined thickness, and the recess formation adjustment material (2°) is in a deformable state. When the master (3), which will become a mold, is pressed against the concave part formation adjusting material (2゛), the uneven surface of the master (3) is formed on the surface by using means such as heating as necessary. A recess formation adjustment layer (2) having an uneven surface with inverted projections and recesses is formed, and this recess formation adjustment layer (2) is applied to the processed surface (
1) Method of fixing.

<Ib) As shown in Fig. 2 (II), the recess formation adjusting material (2゛) is applied to a predetermined thickness on the uneven surface of the master (3) that will serve as the mold (at this time, the recess formation adjusting material The surface of (2') does not need to be smooth), press the master (3) against the workpiece surface (1) while this recess formation adjusting material (2') is unsolidified, and heat as necessary. By using means such as
) to form the recess formation control layer (2).

<Ic> As shown in FIG. 2 (c), similar to <Ib> above, a recess formation adjusting material (2'
), the surface is smoothed and solidified, and after solidification, the recess formation adjusting material (2') is peeled off from the mask (3), and then adhered to the surface to be processed using an adhesive to form recesses. Method of forming the adjustment layer (2).

The master (3) used in the above-mentioned method (Ia) or Ic) may be made of a hard material such as a synthetic resin or metal, or a flexible material such as a resin. .

The latter flexible master (3) is roughly divided into [1] those that deform elastically and [2] those that deform coplastically,
[1] Elastically deformable materials include [1-11 Rubbers such as silicone rubber, styrene-butadiene rubber, and nitrile rubber, [1-2] Elastomers such as polyurethane, [1-3]
] There are flexible resins such as vinyl chloride, and those that undergo plastic deformation in [2] include [2-1] those in the process of complete reaction and complete polymerization; [2-2] those that are in the process of complete reaction and complete polymerization; There are products in which a polymerized portion and an unreacted or unpolymerized portion coexist.

In addition, as a specific example of the above [2-11, [2-1-1
] A compound in which a polyester resin, a filler, a thickener, a coloring agent, and a curing agent are appropriately mixed, or a mold release agent is mixed therein, is thickened at 40 to 50°C for one day, [2-1- 2] Ethyl silicate, colloidal silica,
[2-1-3] Gypsum, a slurry prepared by mixing a binder made of silicate or the like with powdered or fibrous ceramics, is mixed with water, a setting rate regulator, an accelerator (such as magnesium oxide), and a retarder. There is a paste-like plaster material that has been adjusted with a chemical agent (soda carbonate, etc.).

Further, as a specific example of [2-2], there is one in which an epoxy resin and a filler are mixed with a curing agent in an amount smaller than the appropriate curing ratio.

When using a flexible master (3), even if the surface to be machined (1) has a complex shape such as a three-dimensional curved surface, it can be deformed by stretching or contracting to follow the complex shape. It can be made into something.

Further, the above-mentioned master (3) can be produced by various methods, but in particular, when the master is produced using a material that hardens by means such as heating or pressure, it can be made using wood skin, leaves, or By pressing the material against the surface of an actually existing object such as natural stone and making a mold, the concave-convex surface of the concave-concave control layer (2) obtained from the master (3) is faithful to the actual concavo-convex pattern. Similarly, the uneven surface of the processed surface after corrosion processing can be faithfully reproduced to the actual uneven pattern.

The recess formation regulating material (2゛) constituting the recess formation feather layer (2) obtained in the above-mentioned step <H is, for example, made by mixing [a] American flour or asphalt powder and precipitated calcium carbonate in a predetermined ratio. A clay-like material made by mixing with water, adding a certain amount of water, stirring, adding a water-soluble adhesive such as vinyl acetate resin adhesive, and kneading to give it an appropriate viscosity; [b] Thermosetting [C] Various metals, [d] Various ceramics, [8] Natural polymers such as gum arabic, glue, or polypebutite, dextrin, carboxymethyl cellulose, etc. Semi-synthetic polymers, synthetic polymers such as polyvinyl alcohol and polyacrylic acid, water-soluble resins or water-absorbing resins (as a base material or binder), [f] 2 or 3 of the above [bl to [8]] Seed mixture, [g] Resin, metal, or ceramic powder or particles, fibers, or whiskers, soluble or insoluble epoxy, urethane, acrylic, polyester,
There are also those dispersed in a binder made of resin such as PVC or water glass.

Any of the above-mentioned recess formation adjusting materials [a] to [g] (
2"), the recess formation adjusting material (2") is configured to be etched at approximately the same speed as the etching speed of the surface to be processed (1), or at a slightly slower speed. It is desirable to do so.

By mixing powder and granules into the etching liquid used in the above-mentioned step <n> and spraying this etching liquid in the etching direction, the directionality of etching by this g etchant is enhanced, and the processed surface after etching is improved. It is also preferable to prevent the uneven surface of (1) from becoming rougher than the uneven surface of the surface of the recess formation control layer (2). Further, in the recess formation adjustment layer (2),
For the same reason, it is also preferable to improve the directionality of etching by including particles, particles, fibers, etc. soluble in the etching solution with orientation in the etching direction.

In addition, in anticipation of the deterioration in reproduction of the uneven surface described above due to etching performed in the same direction, a recess formation adjustment layer (2
) After forming an uneven surface on the surface, it is also preferable to process the edges so as to make the unevenness of the uneven surface stand out. Furthermore, in the master (3), an uneven surface may be formed by performing correction in advance in consideration of deterioration in reproduction of the uneven surface.

Recess formation adjustment material (2') forming the recess formation adjustment layer (2)
) may be removed by being dissolved by a corrosive solution as described above, or may be removed by crushing or swelling.

In addition, the recess formation control layer (2) is formed from a recess formation control material (2'') that has permeability to the corrosive liquid, and the difference in passage time of the corrosive liquid is adjusted according to the thickness of the recess formation control layer (2). , the etching depth on the surface to be processed (1) may be made different.

Further, the method for forming an uneven surface according to the present invention can be applied to methods for forming an uneven surface by various processes such as sandblasting, polishing, etc. in addition to the etching process described above.

Incidentally, although reference numerals are written in the claims section for convenient comparison with the drawings, the present invention is not limited to the structure shown in the accompanying drawings.

[Brief explanation of drawings]

The drawings show an embodiment of the uneven surface forming method according to the present invention, and FIG. 1 (a) to c) are cross-sectional views showing the steps, and FIG.
A) to C) are cross-sectional views showing a method of forming a recess formation control layer. (1)... Processed surface, (2)... Concavity formation control layer.

Claims (1)

[Scope of Claims] 1. A recess formation control layer (2) for adjusting the depth of recesses to be formed on the surface to be processed (1) by changing the layer thickness is applied to the surface of the surface to be processed (1), with the surface thereof becoming an uneven surface. A method for forming an uneven surface in which depressions and depressions are formed on the surface (1), and depressions and depressions are formed on the processed surface (1) through the depression formation adjustment layer (2), the unevenness of the surface of the depression formation adjustment layer (2) being An uneven surface forming method in which the surface is formed by molding. 2. The method for forming an uneven surface according to claim 1, wherein the formation of the recesses is performed by etching.