Method for producing resin molded article having leather texture

Abstract

A method for manufacturing a resin molded article having a leather texture using 3D modeling improves the reproducibility of the leather texture. The method includes a 3D modeling step of inputting modeling data into a 3D modeling device to mold a semi-finished product having a semi-finished texture that serves as the basis for the leather texture; and a post-processing step of post-processing the semi-finished product molded in the 3D modeling step to obtain the resin molded article as a finished product. Furthermore, the texture height in the input modeling data in the 3D modeling step is at least 120% of the interlayer pitch in the 3D modeling step.

Description

Technical Field

[0001] The present invention relates to a method for producing a resin molded product having a leather texture. Background Art

[0002] As a method for shaping the leather grain shape, a method using inkjet is known (see Patent Document 1).

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2017-104988. Summary of the Invention

[0006] Problems to be solved by the invention

[0007] However, in recent years, there has been a demand to use 3D modeling to create leather texture shapes.

[0008] The problem to be solved by the present invention is to improve the reproducibility of leather texture in a method for manufacturing a resin molded product having leather texture using 3D modeling.

[0009] Solutions for solving problems

[0010] The first aspect of the method for producing a resin molded article having a leather grain texture comprises:

[0011] The manufacturing method comprises:

[0012] a 3D modeling step of inputting modeling data into a 3D modeling device to model a semi-finished product having a semi-finished texture serving as a basis for the leather texture; and

[0013] a post-processing step of obtaining the resin molded product as a finished product by performing post-processing on the semi-finished product molded in the 3D molding step;

[0014] The texture height in the input data as the modeling data input in the 3D modeling step is 120% or more of the stacking pitch in the 3D modeling step.

[0015] Due to issues with the modeling accuracy of 3D modeling devices, the texture shape (including texture height) in the input data naturally does not match the texture shape in the 3D modeled object (semi-finished product), causing reproducibility issues. The inventors focused on the following as a major obstacle to improving the reproducibility of leather texture in 3D modeling methods using the MJF method. Specifically, the shape of the semi-finished product is affected by the interlayer spacing of the 3D modeling, and as the interlayer spacing increases, the accuracy decreases accordingly. Therefore, when the shape of the desired resin molded product is a fine shape like the leather texture, it is impossible to reproduce its shape with high precision.

[0016] Therefore, in this method, the texture height in the modeling data (input data) input to the 3D modeling device during the 3D modeling step is at least 120% of the layer pitch in the 3D modeling step. This allows the shape of the leather texture to be reproduced in the semi-finished texture with greater precision, compared to a case where the texture height in the input data is less than 120% of the layer pitch. Consequently, the reproducibility of the leather texture in the finished product can be improved.

[0017] The second aspect of the method for producing a resin molded article having a leather grain texture is as follows: in the first aspect,

[0018] The texture height in the input data is greater than or equal to 200% of the stacking pitch.

[0019] In this method, the texture height in the input data is at least 200% of the stacking pitch, so the shape of the leather texture can be reproduced with higher precision in the semi-finished texture, and as a result, the reproducibility of the leather texture in the finished product can be further improved.

[0020] The third aspect of the method for producing a resin molded article having a leather grain texture is as follows: in the first aspect,

[0021] The leather texture of the resin molded product as a finished product has a texture height of not less than 70% and not more than 130% of the interlayer spacing.

[0022] The texture height in the input data is less than 300% of the stacking pitch.

[0023] In this embodiment, the leather texture of the finished resin molded product has a texture height of 70% to 130% of the interlayer pitch. Here, the texture height in the input data is 300% or less of the interlayer pitch, making post-processing steps easier.

[0024] The fourth aspect of the method for producing a resin molded article having a leather grain texture is as follows: in the first aspect,

[0025] The leather texture of the resin molded product as a finished product has a texture height of not less than 70% and not more than 130% of the interlayer spacing.

[0026] The texture height in the input data is greater than or equal to 200% and less than or equal to 300% of the stacking pitch.

[0027] In this method, the texture height in the input data is between 200% and 300% of the interlayer pitch. This allows the shape of the leather grain to be reproduced with even greater precision in the semi-finished texture, further improving the reproducibility of the leather grain in the finished product. Furthermore, post-processing steps can be performed more easily.

[0028] A fifth aspect of the method for producing a resin molded article having a leather grain texture is, in any one of the first to fourth aspects,

[0029] The manufacturing method further comprises:

[0030] a data preparation step of preparing the input data,

[0031] In the data creation step, input data is created by stretching the object data in the texture height direction.

[0032] In this method, the input data is created by stretching the physical data in the grain height direction during the data creation step. Therefore, even when the grain height in the physical data is low, the grain shape can be prominently reflected in the semi-finished product, resulting in further improved reproducibility of the leather grain in the finished product.

[0033] Effects of the Invention

[0034] According to the present invention, in a method for manufacturing a resin molded product having a leather texture using 3D modeling, the reproducibility of the leather texture can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 1. A diagram showing the relationship between the stacking direction, the carriage movement direction, and the roller movement direction in a 3D modeling apparatus;

[0036] Figure 2 It is a diagram used to illustrate the direction of modeling;

[0037] Figure 3 This figure illustrates the effect of the stacking distance and texture height on reproducibility when the modeling direction is horizontal.

[0038] Figure 4 This figure illustrates the effect of the stacking distance and texture height on reproducibility when the molding direction is vertical.

[0039] Figure 5This figure illustrates the difference in reproducibility between a case where the molding direction is perpendicular and a case where the molding direction is perpendicular and parallel.

[0040] Figure 6 This is a diagram illustrating an example of a method for measuring texture height;

[0041] Figure 7 is a photograph showing a real object of Type 1;

[0042] Figure 8 This is a photograph showing a real object of Type 2;

[0043] Figure 9 This is a photograph showing a real object of Type 3;

[0044] Figure 10 This is an example of a comparison between the texture shape of a real object and the texture shape of a semi-finished product made by 3D modeling.

[0045] Figure 11 This is an example of a comparison between the texture of a real object and the texture of a semi-finished product created by 3D modeling. DETAILED DESCRIPTION

[0046] Hereinafter, a method for producing a resin molded article having a leather texture (hereinafter referred to as “production method”) according to an embodiment of the present invention will be described.

[0047] The manufacturing method of this embodiment roughly follows the following steps.

[0048] (1) Scan a physical object with leather texture and generate physical data.

[0049] (2) Measure the texture height of the physical data.

[0050] (3) Process the object data and create data with changed texture height (input data).

[0051] (4) Inputting the input data into a 3D modeling device to model a semi-finished product with a semi-finished texture.

[0052] (5) The semi-finished product is subjected to post-processing (surface removal treatment, etc.) to obtain the finished product.

[0053] Next, each step is described in detail.

[0054] (1: Creation of physical data)

[0055] In this step, a real object with a leather texture is scanned to create real object data.

[0056] The real object refers to an object having the leather texture that is to be reproduced by the shaping method of the present invention. The leather texture refers to a three-dimensional wrinkle pattern or a wrinkle pattern similar to it on the surface of the leather. Examples of real objects are shown in 7- Figure 9 shown.

[0057] (2: Measurement of texture height of real-world data)

[0058] In this step, the texture height of the object data is measured.

[0059] Texture height refers to the height of a texture peak, specifically, the height difference between the top and bottom of a texture peak. The texture height can be measured by any method, for example, the following method.

[0060] That is, Figure 6 As shown, the height distribution of multiple (3 in the figure) measurement positions is obtained, and the average value of the maximum height difference in each measurement position is taken as the texture height.

[0061] (3: Preparation of input data)

[0062] In this step, the physical object data is stretched in the texture height direction, thereby increasing the texture height of the texture possessed by the data to a predetermined input texture height.

[0063] From the viewpoint of texture shape reproducibility, the input texture height is 120% or more of the interlayer pitch in 3D modeling, more preferably 200% or more, and even more preferably 200% or more and 300% or less.

[0064] The input texture height is, for example, not less than 90 μm and not more than 330 μm.

[0065] (4: Semi-finished product modeling)

[0066] In this step, the input data is input into a 3D modeling device to model a semi-finished product with a semi-finished texture.

[0067] As an example, the 3D modeling device is a 3D modeling device of the MJF method.

[0068] The MJF method is an abbreviation of a multi jet fusion method, and is roughly as follows.

[0069] (a) Powder materials are arranged into thin layers.

[0070] (b) Ink is sprayed on the part of the powder material that needs to be shaped in a layered manner.

[0071] (c) The portion where the ink is sprayed is solidified by adding melting energy.

[0072] (d) Repeat the above steps (a) to (c).

[0073] 3D modeling is performed in the specified modeling direction.

[0074] The modeling direction represents the concept of what kind of texture to model relative to the structure of the 3D device. Modeling direction is not particularly limited, and examples include Figure 2 The horizontal positive direction, horizontal reverse direction, vertical perpendicular direction, vertical parallel direction, 45 degree positive direction, and 45 degree reverse direction are shown. Figure 1 The +Z direction is the stacking direction, the Y direction is the roller movement direction, and the X direction is the carriage movement direction. The roller is used to arrange the powder material into a thin layer, and the carriage is used to spray the ink.

[0075] like Figure 2 As shown,

[0076] ·Horizontal positive refers to the shaping direction where the grain height direction is toward the lamination direction.

[0077] Horizontal back refers to the shaping direction in which the grain height direction faces the opposite direction of the lamination direction.

[0078] Perpendicular refers to the shaping direction where the height of the grain is towards the direction of the bracket movement.

[0079] Vertical parallel means that the height of the grain is in the direction of the roller movement.

[0080] 45-degree positive direction means that the height direction of the grain is 45 degrees to the lamination direction.

[0081] 45-degree back refers to the direction of the grain height facing the shaping direction at 135 degrees relative to the lamination direction.

[0082] The 3D modeling apparatus is not particularly limited, and for example, MJF 5200 (manufactured by Hewlett-Packard) is used.

[0083] The stacking pitch in 3D modeling is determined by the performance and settings of the 3D modeling apparatus and is not particularly limited, but is, for example, 60 to 100 μm.

[0084] The powder material is not particularly limited, and for example, PA12 is used.

[0085] The average particle size of the powder material is not particularly limited, but is, for example, 50% to 80% of the interlaminar distance, for example, 40 to 60 μm.

[0086] (5: Post-processing)

[0087] In the post-processing step, the semi-finished product is post-processed to obtain the finished product. There are no specific restrictions on the type of post-processing performed, and chemical polishing, for example, may be performed. Due to post-processing, the grain height of the finished resin molded article may be lower than that of the semi-finished product. For example, the grain height of the finished resin molded article is 80 to 120 μm.

[0088] Effects

[0089] Next, the effects of this embodiment will be described.

[0090] In this embodiment, the texture height in the modeling data (input data) input to the 3D modeling device in the 3D modeling step is 120% or more (more preferably 200% or more) of the stacking pitch in the 3D modeling step.

[0091] This allows the shape of the leather grain to be reproduced with high precision in the semi-finished texture, compared to a case where the texture height in the input data is less than 120% of the stacking pitch. As a result, the reproducibility of the leather grain in the finished product can be improved.

[0092] Figure 3 This figure illustrates the effect of the stacking distance and texture height on reproducibility when the molding direction is horizontal (horizontal forward or horizontal reverse).

[0093] Figure 3 (a) shows the case where the stacking distance is small. Figure 3 (b) shows the case where the stacking distance is large. As can be seen from these figures, the texture reproducibility is high when the stacking distance is small, while the reproducibility becomes low when the stacking distance is large. Figure 3 As shown in (c), by increasing the texture height, the desired texture shape can be easily reflected on the object. As a result, the adverse effect of the stacking pitch on reproducibility can be reduced.

[0094] Figure 4 This figure explains the influence of the stacking distance and texture height on reproducibility when the molding direction is vertical (perpendicular orthogonal or vertically parallel).

[0095] Figure 4 (a) shows the case where the stacking distance is small. Figure 4 (b) shows the case where the stacking distance is large. As can be seen from these figures, the texture reproducibility is high when the stacking distance is small, while the reproducibility becomes low when the stacking distance is large. Figure 4 As shown in (c), by increasing the texture height, the desired texture shape can be easily reflected on the object. As a result, the adverse effect of the stacking pitch on reproducibility can be reduced.

[0096] Figure 5This is a diagram explaining the difference in reproducibility between the case where the molding direction is perpendicular and perpendicular and the case where the molding direction is parallel.

[0097] Since the carriage applies ink while moving, if there is an error in the ink application timing, an error will occur in the application area in the direction of carriage movement.

[0098] Here, when the shaping direction is perpendicular and parallel, errors in the ink application area can cause valleys in the applied texture to be filled. Therefore, errors in the application area significantly impact texture reproducibility. In contrast, when the shaping direction is perpendicular and orthogonal, the texture height direction aligns with the carriage's movement direction. Therefore, even if errors in the ink application area occur, their impact on texture reproducibility is minimal.

[0099] However, if the texture height of the semi-finished texture is low (for example, less than 110% of the texture height of the leather texture possessed by the finished resin molded product), the following problem will arise: it is difficult to achieve the texture height of the leather texture possessed by the finished resin molded product through the post-processing step.

[0100] Therefore, the texture height of the semi-finished texture is preferably 110% or more of the texture height of the leather texture of the finished resin molded article.

[0101] [Example]

[0102] Next, the production method of the present invention will be described using examples.

[0103] The powder material and 3D modeling device (including settings) are as follows.

[0104] Powder material: PA12 (average particle size 50 μm.)

[0105] Device: MJF5200 (Mode: Advance) (Layer pitch: 80 μm.)

[0106] Regarding the objects, three different types of objects were used (Type 1 to Type 3, see Figures 7 to 9 ).

[0107] Three types of input data were used: texture heights of 100 μm, 200 μm, and 300 μm.

[0108] Regarding the modeling direction, six forms are adopted: horizontal forward, horizontal back, vertical orthogonal, vertical parallel, 45-degree forward, and 45-degree back.

[0109] That is, the test was performed in a total of 54 patterns (3×3×6). In addition, input data was newly created for each pattern and the test was performed multiple times, and the average value was used as the result.

[0110] As an example, in Figure 10 The results of type 1, 200 μm, 45 degrees back are shown in Figure 11 The results of type 2, 200 μm, and vertical parallel are shown in FIG. The format of each figure shows the results of recreating the input data and performing the test 6 times.

[0111] In addition, all the results are summarized in Table 1.

[0112] [Table 1]

[0113] Table 1

[0114]

[0115] The “texture height” in Table 1 is the texture height of the semi-finished product obtained through 3D modeling.

[0116] The "reproducibility" in Table 1 is evaluated from the perspective of whether the texture shape of the real object can be reproduced. A, B, and C all indicate reproducibility that can withstand use, but B is better than C, and A is even better than B.

[0117] As shown in Table 1, reproducibility was consistently high for all 100μm, 200μm, and 300μm diameters. However, the 200μm and 300μm diameters produced more favorable results than the 100μm diameter, with the 200μm diameter producing more excellent results. Furthermore, the examples in which the molding directions were perpendicular and parallel produced more favorable reproducibility than those in which the molding directions were perpendicular and orthogonal.

[0118] Regarding texture height, in the example with an input texture height of 100 μm, there were many instances where the texture did not reach the desired semi-finished texture height (approximately 100 μm or greater). In contrast, in the examples with input texture heights of 200 μm and 300 μm, sufficient height was achieved in both cases. Furthermore, since the texture height of the finished product after post-processing is preferably approximately 80 to 120 μm, the required semi-finished texture height is approximately 100 μm, as described above.

[0119] As mentioned above, although the manufacturing method of this invention was demonstrated using an Example, this invention is not limited to these.

[0120] (Description of Modifications)

[0121] In the above description, a method using an MJF-based 3D modeling apparatus as the 3D modeling apparatus has been described, but the present invention is not limited thereto. For example, a 3D modeling apparatus of the following method can be used as the 3D modeling apparatus.

[0122] SLS (Selective Laser Sintering) method

[0123] Binder jetting

[0124] SLA (Stereo Lithography Apparatus) method

[0125] The SLS method is roughly as follows.

[0126] (a) Powder materials are arranged into thin layers.

[0127] (b) In a layered powder material, the portion to be shaped is irradiated with laser light, adding melting energy to solidify it.

[0128] (c) Repeat the above steps (a) to (b).

[0129] The adhesive spraying method is roughly as follows.

[0130] (a) Powder materials are arranged into thin layers.

[0131] (b) In the layered powder material, a binder is sprayed on the portion to be shaped and solidified.

[0132] (c) Repeat the above steps (a) to (b).

[0133] The SLA method is roughly as follows.

[0134] (a) Immerse the platform for making the model in a pool filled with liquid material.

[0135] (b) The platform is positioned so as to be lowered from the liquid surface by a thin layer height.

[0136] (c) The laser is used to illuminate only the portion of the liquid surface that needs to be shaped, causing it to solidify.

[0137] (d) The platform is lowered from the position in (c) by a thin layer height, and the platform is arranged at the lowered height.

[0138] (e) Repeat the above steps (c) to (d).

[0139] The MJF method, SLS method, binder injection method and SLA method are all 3D modeling methods that use resin materials. In addition, modeling is performed layer by layer, and there is a concept of layer spacing (referring to the thickness of each layer). In addition, the layer spacing in the 3D modeling of each method is determined by the performance and settings of the 3D modeling device, and is not particularly limited, for example, 60 to 100 μm. Therefore, in any of the above methods, the method of the present invention is effective. For example, in any of the above methods, by making the texture height in the input data more than 120% of the layer spacing (preferably more than 200%, more preferably more than 200% and less than 300%), the reproducibility of the leather texture can be improved.

[0140] In particular, both the MJF method and the SLS method involve resin powder bed fusion bonding. Resin powder bed fusion bonding refers to a method that uses a resin powder material in a powder bed fusion process. While the MJF method uses ink and melting energy to solidify the powder material, the SLS method uses a laser to solidify the powder material. While this difference is considered minimal, it is believed that this difference has a minimal impact on the effectiveness of the present invention. Therefore, the results of the examples implemented using the MJF method are also particularly applicable to the SLS method.

Claims

1. A method for producing a resin molded product having a leather texture, The manufacturing method comprises: a 3D modeling step of inputting modeling data into a 3D modeling device to model a semi-finished product having a semi-finished texture serving as a basis for the leather texture; as well as a post-processing step of obtaining the resin molded product as a finished product by performing post-processing on the semi-finished product molded in the 3D molding step; The texture height in the input data as the modeling data input in the 3D modeling step is 120% or more of the stacking pitch in the 3D modeling step.

2. The method for producing a resin molded article having a leather texture according to claim 1, wherein: The texture height in the input data is greater than or equal to 200% of the stacking pitch.

3. The method for producing a resin molded article having a leather texture according to claim 1, wherein: The leather texture of the resin molded product as a finished product has a texture height of not less than 70% and not more than 130% of the interlayer spacing. The texture height in the input data is less than 300% of the stacking pitch.

4. The method for producing a resin molded article having a leather texture according to claim 1, wherein: The leather texture of the resin molded product as a finished product has a texture height of not less than 70% and not more than 130% of the interlayer spacing. The texture height in the input data is greater than or equal to 200% and less than or equal to 300% of the stacking pitch.

5. The method for producing a resin molded article having a leather texture according to any one of claims 1 to 4, wherein The manufacturing method further comprises: a data preparation step of preparing the input data, In the data creation step, input data is created by stretching the object data in the texture height direction.

6. The method for producing a resin molded article having a leather texture according to any one of claims 1 to 4, wherein: The 3D modeling device is an MJF 3D modeling device.

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