Door and door manufacturing method

Abstract

To provide a door and a door manufacturing method which can three-dimensionally show a printed matter, even if a user approaches and observes it.SOLUTION: A door includes a plate-like door body 2 having a printed part, and a printing part 5 formed in the printed part, where the printing part includes printing layers 8 stacked on the printed part, and projections 51 and recesses 52 are formed on the surface of the printed part depending due to differences in the number of layers where the printing layers are laminated.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a door and a method for manufacturing the door. [Background technology]

[0002] A conventional door is described in Patent Document 1. The door includes a core material and a plate material joined to the core material, and an image of a nesting frame, an insert plate, and a shadow caused by the nesting frame and the insert plate is photographically printed on the surface of the plate material.

[0003] With the above door, it is possible to print the shadows of the nesting frame and the inlay, which gives the print a three-dimensional feel, and it is said that it is possible to provide a door that looks almost the same as a Chinese door. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Utility Model Application Publication No. 55-86890 Summary of the Invention [Problem to be solved by the invention]

[0005] In the door described in Patent Document 1, the shadows are formed by printing, so when approaching the door to open or close it, the three-dimensional effect is lost and it no longer appears flat.

[0006] SUMMARY OF THE PRESENT DISCLOSURE An object of the present invention is to provide a door and a method for manufacturing the door that enable printed matter to appear three-dimensional even when viewed up close. [Means for solving the problem]

[0007] The door of the present invention comprises a plate-shaped door body having a printed portion, and a printing portion formed on the printed portion, the printing portion having a plurality of printing layers stacked on the printed portion, and convex portions and concave portions are formed on the surface of the printed portion depending on the difference in the number of layers in which the printing layers are stacked.

[0008] According to this configuration, since the surface of the printing portion is uneven, the unevenness of the door surface can be recognized even when observed closely, and thus the loss of the three-dimensional effect of the printed matter can be suppressed.

[0009] The printing section may also be configured to include a protective layer that covers the surface of the printing section.

[0010] According to this configuration, the surface of the printed portion is covered with the protective layer, so that damage to the printed portion due to external impacts, etc. can be suppressed.

[0011] The printing device may also include an adhesive layer disposed between the printed portion and the protective layer to bond the printed portion and the protective layer.

[0012] According to this configuration, since an adhesive layer is provided between the printed portion and the protective layer, the protective layer can be reliably adhered to the printed portion.

[0013] The protective layer covering the recessed portion may be formed to be thicker than the protective layer covering the protruding portion.

[0014] According to this configuration, a thick protective layer is provided around the protruding portion in the surface direction of the printing portion, so that the periphery of the protruding portion can be protected by the protective layer, and therefore, damage to the protruding portion can be suppressed when an impact is applied to the protruding portion, for example.

[0015] In addition, the door manufacturing method of the present invention includes a print data creation process for creating printed layer data by processing 3D data composed of layer data formed by stacking layer data separated at multiple positions at a distance from a predetermined position for a printing object, and a printing process for forming a printed part having a printed layer formed by 3D printing on a printing target part of a plate-shaped door body based on the printed layer data, wherein the printed layer data is data that specifies the arrangement of the printed layers and is created so that the number of printed layers is smaller than the layer data.

[0016] According to this configuration, the printing part is formed by printing fewer printing layers than the layer data of the 3D data, thereby reducing printing costs, while the printing layer data is created based on 3D data having layer data with a greater number of layers than the number of printing layers, making it easier to express the three-dimensionality of the object.

[0017] In addition, the door manufacturing method of the present invention includes an attachment step of attaching a sheet body having a printed portion on its surface to a plate body having a plurality of faces adjacent to each other through corner portions, to form the door body, the sheet body having a printed layer laminated on the printed portion, and a printed portion having convex portions and concave portions formed on its surface depending on the number of layers in which the printed layer is laminated, and in the attachment step, the sheet body with the printed portion formed thereon is attached to the plate body so that the plurality of faces include the protrusions or concave portions and span the corner portions.

[0018] According to this configuration, the sheet body on which the printed portion is formed is positioned continuously on the surfaces of two adjacent sides with the corner portion interposed therebetween, so that it is possible to prevent the printed portion from being interrupted at the corner portion B. This prevents the occurrence of a sense of incongruity caused by interruptions in the print, so that the printed matter can be seen three-dimensionally even when viewed up close. Effect of the Invention

[0019] According to the present invention, it is possible to obtain a door and a method for manufacturing a door that allows a printed matter to appear three-dimensional even when observed up close. [Brief description of the drawings]

[0020] [Figure 1] FIG. 2 is a perspective view showing a door according to an embodiment of the present invention. [Diagram 2] FIG. 2 is an enlarged view of part II shown in FIG. [Diagram 3] FIG. 3 is a cross-sectional view taken along line III-III of FIG. [Figure 4] FIG. 4 is an enlarged view of part IV shown in FIG. [Diagram 5] FIG. 2 is a plan view showing a printing object in the present embodiment. [Figure 6] 6 is a cross-sectional view taken along the line VI-VI shown in FIG. 5. [Figure 7] FIG. 13 shows a door according to another embodiment of the present invention. [Figure 8] 10A to 10C are schematic diagrams illustrating a door and a method of manufacturing the door according to another embodiment of the present invention. [Figure 9] FIG. 13 is a diagram showing a door manufactured by the same manufacturing method. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] A door 1 and a manufacturing method for the door 1 according to one embodiment of the present invention will be described with reference to Figures 1 to 6. For the sake of convenience, the drawings are schematic and do not necessarily correspond to the dimensions of the actual door 1.

[0022] As shown in Fig. 1, the door 1 includes a door body 2, a handle portion 21 provided on the door body 2, and a laminated body 3. The door 1 of the present embodiment is a door 1 arranged at the entrance of a room in a building, and constitutes, for example, a sliding door.

[0023] The door body 2 is a plate-like body having a front surface and a back surface separated in the thickness direction, and is formed into a plate shape as a whole by, for example, a core material and a finishing material covering the core material. The door body 2 of this embodiment is a rectangular plate-like body with a substantially constant thickness and a substantially flat front and back surfaces. The door body 2 also has a printable portion 2a on which a print section 5, which will be described later, is formed. In this embodiment, the entire front and back surfaces of the door body 2 are configured as the printable portion 2a. The printable portion 2a has a substantially flat surface without any irregularities. Furthermore, the door body 2 is configured so as not to transmit light in the thickness direction.

[0024] The handle portion 21 is a portion where fingers are engaged to open and close the door 1, and is provided on both the front and back surfaces (surfaces on which the printed portion 2a is disposed) of the door main body 2. The handle portion 21 in this embodiment is provided so as to protrude outward from the front and back surfaces of the door main body 2. However, the present invention is not limited to this configuration, and the handle portion 21 may also be configured so as to be recessed inward from the front and back surfaces of the door main body 2.

[0025] A laminate 3 is placed on the printed portion 2a. As shown in Figs. 3 and 4, the laminate 3 includes a first adhesive layer 4, a printing portion 5, a second adhesive layer 6, and a protective layer 7, and is placed on the printed portion 2a so that each layer is stacked in a direction away from the printed portion 2a. In the printed portion 2a of this embodiment, two types of laminates 3 with different appearances are placed side by side. The two types of laminates 3 with different appearances have the same configuration, except that the printing object 9 that is the basis of the printing portion 5 is different, as described later. In the following description of the laminate 3, the up-down direction will be described based on the direction shown in Fig. 3 (the stacking direction of the laminate 3).

[0026] As shown in Figures 1 and 2, a pattern is formed on the door 1 by the laminate 3. As shown in Figure 2, the pattern is composed of, for example, two colors (for example, white and black). In this embodiment, the areas marked with dots in Figure 2 are black, and the areas without dots are white.

[0027] As shown in FIG. 3 and FIG. 4, the first adhesive layer 4 is a layer disposed on the upper surface of the printed portion 2a, and is a layer for bonding the door body 2 and the printed portion 5 (laminate 3). Specifically, the first adhesive layer 4 is a layer (coating) formed by applying a primer (undercoat agent) to the upper surface of the printed portion 2a. The primer applied to the printed portion 2a is appropriately selected according to the material of the door body 2. The first adhesive layer 4 covers almost the entire upper surface of the printed portion 2a, covers fine irregularities formed on the upper surface of the printed portion 2a, and forms a substantially flat upper surface that is a base on which the printed portion 5 is disposed. The first adhesive layer 4 in this embodiment is formed by applying a primer to the printed portion 2a by a printing device described later before forming the printed portion 5.

[0028] The printed portion 5 is a portion having a three-dimensional shape formed on the portion to be printed 2a. The printed portion 5 has printed layers 8 stacked in the vertical direction. The printed portion 5 has an overall thickness smaller than that of the door body 2, and is preferably 1 / 5 or less of the thickness of the door body 2. The thickness of the printed portion 5 in this embodiment is 0.01 mm to 2.0 mm. Within this range, the door 1 itself does not become thicker due to the printed portion 5, which makes it difficult to open and close, while still forming an appropriate shadow as described above.

[0029] The printing layer 8 includes a height-improving layer 81 and a colored layer 82, and the height-improving layer 81 and the colored layer 82 are arranged so as to be stacked in the vertical direction. In this embodiment, the colored layer 82 is configured to be located in the uppermost layer. Also, the printing layer 8 is stacked in different numbers depending on the position in the surface direction of the upper surface of the printed portion 2a. The printing layer 8 of this embodiment is stacked in one to three layers depending on the position in the surface direction of the upper surface of the printed portion 2a. The printing layer 8 of this embodiment is made of a resin material, specifically, a photocurable resin. The printing layer 8 of this embodiment is arranged over the entire upper surface of the printed portion 2a. That is, in the printing portion 5 of this embodiment, the printing layer 8 is arranged without gaps in the surface direction of the upper surface of the printed portion 2a.

[0030] The thickness of each layer of the printed layer 8 is approximately uniform. The thickness of the printed layer 8 is such that when light is incident on the printed layer 8 with the door 1 installed (when light is incident on the printed layer 8 from an oblique direction intersecting with the lamination direction and surface direction), the printed layer 8 can form a visible shadow. Specifically, the thickness of each layer is 0.005 mm to 0.6 mm, and more preferably 0.01 to 0.1 mm.

[0031] The height enhancing layer 81 is a layer disposed above the first adhesive layer 4, and has an approximately flat upper and lower surface. The height enhancing layer 81 in this embodiment is colorless and transparent. The height enhancing layer 81 is disposed on a portion of the upper surface of the printed portion 2a, and even in the portion where the height enhancing layer 81 is disposed, the number of height enhancing layers 81 stacked varies. Specifically, 0 (no height enhancing layer 81 is disposed) to 2 height enhancing layers 81 are disposed on the upper surface of the printed portion 2a, depending on the position in the surface direction.

[0032] The colored layer 82 is a layer disposed above the first adhesive layer 4 or above the height-extending layer 81, and has an approximately flat upper and lower surface. Specifically, the colored layer 82 is disposed above the first adhesive layer 4 in the portion where the height-extending layer 81 is not disposed in the surface direction of the upper surface of the printed portion 2a, and is disposed above the height-extending layer 81 in the portion where the height-extending layer 81 is disposed. The colored layer 82 is a non-light-transmitting layer made of a colored resin. The colored layer 82 of this embodiment includes a black colored layer 82b made of a black resin and a white colored layer 82w made of a white resin. The colored layer 82 is disposed so as to cover the entire upper surface of the printed portion 2a, and layers of different colors (black or white) are formed corresponding to the positions in the surface direction of the upper surface of the printed portion 2a. In this way, since the colored layer 82 is disposed so as to cover the upper surface of the printed portion 2a, the colored layer 82 can form a pattern on the door 1.

[0033] In this way, the number of printed layers 8 stacked (specifically, the number of height-adjusting layers 81 located below the colored layers 82) varies depending on the position in the surface direction of the upper surface of the printed portion 2a, so that the upper surface of the printed portion 5 has the convex portions 51 and the concave portions 52 located around the convex portions 51. The upper surface of the concave portion 52 is located one or two layers of the printed layer 8 (height-adjusting layer 81) below the upper surface of the adjacent convex portion 51. In addition, since the colored layer 82 is disposed on the top layer of the printed layer 8, when light hits the printed portion 5 from an oblique direction, the light is blocked by the colored layer 82 of the convex portion 51 to form a shadow. Particularly in this embodiment, since the colored layer 82 is configured as a layer with no light transmittance, the colored layer 82 can clearly form a shadow.

[0034] The second adhesive layer 6 is a transparent layer disposed above the printed layer 8 (above the colored layer 82) and is a layer for bonding the printed portion 5 and the protective layer 7 described below. The second adhesive layer 6 is disposed so as to cover the entire upper surface of the printed portion 5. The second adhesive layer 6 is a layer of approximately constant thickness, has a shape corresponding to the recesses 52 and protrusions 51 formed on the upper surface of the printed portion 5, and is disposed along the upper surface of the printed portion 5. The second adhesive layer 6 in this embodiment is thinner than the printed portion 5, and is preferably thinner than the thickness of one layer of the printed layer 8.

[0035] The second adhesive layer 6 is a layer (coating) formed by applying paint to the upper surface of the printed part 5 (colored layer 82). The second adhesive layer 6 in this embodiment is formed by applying a water-based paint, specifically, a water-based cationic epoxy composite primer, to the upper surface of the printed part 5. That is, the second adhesive layer 6 is a coating (specifically, a film made of a cationic resin) formed by volatilization of water, which is a solvent for the water-based paint. The configuration of the coating as the second adhesive layer 6 may be the same as that of the first adhesive layer 4, or may be a different configuration.

[0036] The protective layer 7 is a transparent layer disposed above the second adhesive layer 6. The protective layer 7 covers the entire upper surface of the printed portion 5, and protects the printed portion 5 from scratches and dirt.

[0037] The protective layer 7 is a layer formed by applying a coating agent as a paint on the second adhesive layer 6. The protective layer 7 in this embodiment is formed by applying a liquid glass coating agent on the upper surface of the second adhesive layer 6. That is, the protective layer 7 is a coating film (specifically, a glass coating) formed by volatilization of a solvent (e.g., isopropyl alcohol) of the liquid glass coating agent. The protective layer 7 is a layer of a glass coating, and is a layer having a pencil hardness of 2H or more, preferably 9H, in accordance with JIS K5600-5-4. Note that, although the protective layer 7 is a single layer in this embodiment, it may be configured to have multiple layers.

[0038] As shown in FIG. 4, the thickness of the protective layer 7 in the stacking direction is not uniform. Specifically, the protective layer 7 is configured so that the thickness T1 of the portion covering the recessed portion 52 of the printed portion 5 is thicker than the thickness T2 of the portion covering the protruding portion 51 of the printed portion 5. That is, in the surface direction of the upper surface of the printed portion 2a, the thickness of the protective layer 7 arranged around the protruding portion 51 is thicker than the thickness of the portion covering the protruding portion 51. Moreover, the protective layer 7 of this embodiment is configured so that the difference between the thickness T1 and the thickness T2 is smaller than the thickness of the printed layer 8 (height extension layer 81). With this configuration, the upper surface of the protective layer 7 has irregularities formed in shapes corresponding to the recessed portion 52 and the protruding portion 51 of the printed portion 5.

[0039] As described above, in the laminate 3, each layer (second adhesive layer 6 and protective layer 7) arranged above the printed layer 8 is transparent, making the printed portion 5 visible, and furthermore, a shadow can be formed due to the difference in height of the colored layer 82.

[0040] Next, a description will be given of a manufacturing method for the door 1. The manufacturing method for the door 1 includes a 3D data creation step, a print data creation step, a printing step, and a protection step.

[0041] The 3D data creation process is a process of creating 3D data of the printing object 9. In the 3D data creation process of this embodiment, the 3D data is created by 3D scanning the object. The printing object 9 of this embodiment is a cloth body having a pattern and unevenness on its surface, as shown in FIG.

[0042] The 3D data is data configured by stacking layer data L1 to L7 formed by dividing the printing object 9 at multiple positions based on the distance from a predetermined position (for example, the bottom of the printing object 9). As shown in FIG. 6, the 3D data of this embodiment has layer data L1 to L7 formed by dividing the printing object 9 at, for example, six positions, and having seven layers. The 3D data includes color information and height information. The color information is information regarding the color arrangement of the printing object 9. In this embodiment, the color information is information indicating the arrangement of two colors, white (a portion where dots are not arranged in the enlarged view of FIG. 5) or black (a portion where dots are arranged in the enlarged view of FIG. 5). The height information is information indicating the height of the surface of the printing object 9, and in this embodiment, the height is indicated by the positions of the layer data L1 to L7 where the surface of the printing object 9 is located.

[0043] The printing data creation process is a process of processing the 3D data to create printing layer data that specifies the arrangement of the printing layer 8. In the printing data creation process, the 3D data is processed (for example, processed by a computer) to create printing layer data for forming a printing layer 8 that is fewer in number than the layer data L1 to L7. As a method for processing the 3D data, various methods are considered that can three-dimensionally express the printing object 9 with the printing part 5 formed based on the printing layer data. For example, the arrangement of the top layer of the printing layer 8 is made to correspond to the layer data L7 of the top layer, and the layer data L1 to L6 adjacent to the layer data L1 to L6 below the layer data L7 of the top layer are appropriately integrated to express the most protruding part. In addition, the layer data L1 to L7 can be integrated so that the difference in the area where each layer of the printing layer 8 is exposed is minimized. In such a case, the undulations of the printing part 5 are clear overall, so that a three-dimensional effect can be firmly created. Furthermore, the printing layer data can be configured by extracting specific layer data L1-L7 from the adjacent layer data L1-L7, such that the part corresponding to the bottom layer part (layer data L1) of the layer data L1-L7 is the first printing layer 8, the part corresponding to the middle part (layer data L4) of the layer data L1-L7 is the second printing layer 8, and the part corresponding to the top layer of the layer data L1-L7 (layer data L7) is the third printing layer 8. With such a configuration, it is possible to easily reproduce a concave-convex shape that matches the printing object 9. In addition, it is also possible to create printing layer data from the remaining part (L3-L7 in FIG. 6) after processing to remove the part where the layer data L1-L7 are located in the entire area (lower layer, layer data L1, L2 in FIG. 6). When such a configuration is adopted, the concave-convex shape of the printing object 9 can be made more prominent.

[0044] Furthermore, in the print data creation process, the print layer data is created so that the colored layer 82 is located on the uppermost surface of the print layer 8. Specifically, for the print layer data created based on the layer data L1 to L7 in the above procedure, print layer data is generated in which the layer located on the uppermost surface is designated as the colored layer 82 and the other layers are designated as the height-extending layers 81. Here, the position of the colored layer 82 is determined so as to correspond to the color information.

[0045] The printing step is a step of printing and forming the printing layer 8 on the printed portion 2a using a printing device. The printing device is a device capable of 3D printing based on printing layer data, and in this embodiment, is configured to deposit a thick layer of photocurable resin (specifically, ultraviolet curable resin) on the printed portion 2a and cure the photocurable resin in this state. The printing device is also capable of applying a primer to the printed portion 2a, and in the printing step of this embodiment, the printing device applies a primer to the printed portion 2a to form the first adhesive layer 4 before forming the printing layer 8.

[0046] In the printing process, a printed layer 8 is formed on the first adhesive layer 4 based on the printed layer data. Specifically, ink is printed and cured on the upper surface of the first adhesive layer 4 to form a colored layer 82 and a height-adjusting layer 81, which are the first printed layer 8, and ink is further printed and cured on the first height-adjusting layer 81 to form the second and third printed layers 8. In this way, the printed layer 8 is printed on top of the printed layer 8, thereby forming a printed portion 5 in which the printed layers 8 are stacked.

[0047] The protection step is a step of forming a second adhesive layer 6 and a protective layer 7 on the upper surface of the printed part 5. When forming the second adhesive layer 6, paint is applied to the entire upper surface of the printed part 5, and the solvent is volatilized. Then, after the solvent has volatilized and the second adhesive layer 6 has been formed, the protective layer 7 is formed.

[0048] When forming the protective layer 7, a liquid coating agent (glass coating agent in this embodiment) is applied to the entire upper surface of the second adhesive layer 6. Here, the coating agent is applied so that more of the coating agent is located in the portion covering the recessed portion 52 than in the portion covering the protruding portion 51 of the printed portion 5 in the surface direction of the printed portion 2a. For example, by applying the coating agent to the upper surface of the printed portion 5 with the printed portion 5 (door body 2) laid down, a part of the coating agent covering the protruding portion 51 can flow to the recessed portion 52, so that more of the coating agent can be located in the portion covering the recessed portion 52 than in the portion covering the protruding portion 51. Then, when the solvent of the applied coating agent evaporates, the protective layer 7 is formed, and since more of the coating agent is located in the portion covering the recessed portion 52 than in the portion covering the protruding portion 51 as described above, the thickness of the protective layer 7 becomes thicker in the portion covering the recessed portion 52 than in the portion covering the protruding portion 51.

[0049] The door 1 is manufactured through the above-mentioned process.

[0050] According to the door 1 configured as above, the surface of the printed portion 2a is uneven, so that the unevenness of the surface of the door 1 can be recognized even when observed closely. In addition, since the unevenness actually forms a shadow, it is possible to prevent the shadow from losing the three-dimensional effect, which would otherwise be unnatural, compared to a case where the shadow is printed. Therefore, the printed matter can be made to look three-dimensional.

[0051] In addition, since the surface of the printed part 5 is covered with the protective layer 7, damage to the printed part 5 due to external impacts can be suppressed. Furthermore, since the protective layer 7 is a glass coating, it is easy to clean the surface when dirt or the like adheres to it.

[0052] Furthermore, since an adhesive layer (second adhesive layer 6) is provided between the printed portion 5 and the protective layer 7, the protective layer 7 can be reliably adhered to the printed portion 5.

[0053] In addition, since the protective layer 7 is provided thickly around the protruding portion 51 in the surface direction of the printing portion 2a, the periphery of the protruding portion 51 can be protected by the protective layer 7. Therefore, when the protruding portion 51 is subjected to an impact, damage to the protruding portion 51 can be suppressed.

[0054] Furthermore, since the surface of the protective layer 7 has projections and recesses corresponding to the recesses 52 and projections 51 of the printed portion 5, the user can sense that the printed matter has a three-dimensional shape even when touching the surface of the protective layer 7. Therefore, when the protective layer 7 is shaken, the printed matter can be sensed as being three-dimensional.

[0055] The second adhesive layer 6 is formed of a water-based paint. Therefore, compared to when the second adhesive layer 6 is formed of an oil-based paint, it is possible to suppress dissolution of the printed layer 8 (particularly the colored layer 82) by a solvent. On the other hand, when the second adhesive layer 6 is formed of an oil-based paint, the solvent volatilizes faster than when the second adhesive layer 6 is formed of a water-based paint, so the time required for the paint to dry can be shortened.

[0056] Furthermore, since the colored layer 82 is a non-translucent layer, the upper surface of the printing portion 2a is visible through the colored layer 82, and this prevents the design from being impaired.

[0057] According to the manufacturing method of the door 1, the printed portion 5 is formed by printing fewer printed layers 8 than the layer data L1 to L7 of the 3D data, so that the printing costs are kept to a minimum, while a greater number of layer data L1 to L7 is obtained than the number of printed layers 8 printed in the 3D data creation process, making it easier to express the three-dimensionality of the object.

[0058] In addition, the printing object 9 is 3D scanned to obtain 3D data, and the layer data L1 to L7 contained in the 3D data is processed to reduce the number of layers to create the printing layer data. This makes it easier to create data for printing compared to creating a three-dimensional effect by adding shading to a 2D photograph, etc., and printing the photograph with the shading added.

[0059] Although an embodiment of the present invention has been described above by way of example, the present invention is not limited to the above embodiment, and various modifications can be made without departing from the spirit of the present invention.

[0060] For example, the door 1 has been described as a door 1 for use as a building material, but it is not limited to this configuration and can be configured as various doors 1, such as a furniture door 1. Even when configured as a building material, the door 1 is not limited to a sliding door, but can also be configured as a hinged door or a folding door.

[0061] In addition, the printing portion 2a is located on the entire surface of the door body 2 in the above description, but it is not limited to this configuration and can be located only on a part (for example, the center) of the surface of the door body 2. In addition, the printing portion 2a is approximately flat in the above description, but it is not limited to this configuration and can be curved.

[0062] Furthermore, the protective layer 7 has been described as being made of paint (glass coating agent), but is not limited to this configuration and may be made of a sheet attached to the surface of the printed part 5. In such a configuration, the second adhesive layer 6 functions as an adhesive for attaching the protective sheet.

[0063] In addition, although a case has been described in which concaves and convexes corresponding to the concaves 52 and convexities 51 of the printed portion 5 are formed on the surface of the protective layer 7, the present invention is not limited to this configuration, and the surface of the protective layer 7 may be configured to be substantially flat. In such a configuration, since the surface of the protective layer 7 is substantially flat, it is easy to clean when dirt or the like adheres to it.

[0064] Also, although the height-extending layer 81 has been described as being a transparent layer, it is not limited to this configuration, and may be, for example, a layer of the same color as the colored layer 82 laminated above the height-extending layer 81. In this configuration, even if the colored layer 82 is scratched or chipped, the height-extending layer 81 of the same color as the colored layer 82 is exposed, so that loss of design can be suppressed. In particular, since the convex portion 51 is more susceptible to external impacts and the like than the concave portion 52, it is preferable that the height-extending layer 81 located below the colored layer 82 be configured with the same color.

[0065] Furthermore, as shown in FIG. 7, the printing portion 5 can also be configured to include a base layer 83 disposed below the height-adjusting layer 81 and the colored layer 82. The base layer 83 can be, for example, a layer formed of a resin of a color corresponding to the position in the surface direction of the upper surface of the printed portion 2a, similar to the colored layer 82. In this configuration, even if the colored layer 82 is damaged or chipped, the base layer 83 of the same color as the colored layer 82 can be visible through the transparent height-adjusting layer 81, so that the design can be prevented from being impaired. The base layer 83 can also be configured of the most commonly used colored ink among the colored inks that constitute the colored layer 82. Even in this configuration, even if the colored layer 82 is damaged or chipped, the base layer 83 can be visible through the transparent height-adjusting layer 81, so that the design can be prevented from being impaired. In particular, when the colored layer 82 is configured of two colors, the design is less likely to be impaired even if the base portion becomes visible.

[0066] In addition, the printing section 5 has been described as being configured so that the printing layer 8 is arranged over the entire surface of the printed section 2a, but this configuration is not limited to this, and it is also possible to form areas in which the printing layer 8 is not arranged.

[0067] Furthermore, although the height-extending layer 81 and the colored layer 82 have been described as being stacked directly one on top of the other, this configuration is not limited to this, and other layers, such as an adhesive layer formed from a primer or the like, can also be placed between the height-extending layer 81 and the colored layer 82.

[0068] Also, a configuration may be adopted in which the second adhesive layer 6 and the protective layer 7 are not provided. In such a configuration, the printed portion 5 is exposed, and therefore it is possible to prevent the color of the printed portion 5 from being impaired due to the influence of light refraction, light reflection at the protective layer 7, and the like.

[0069] Furthermore, the colored layer 82 can be formed again on the surface of the printed portion 5. With this configuration, the newly formed colored layer 82 can also be made into a three-dimensional shape by utilizing the unevenness of the already formed printed portion 5.

[0070] In addition, since the protective layer 7 is formed by applying paint to the upper surface of the printed portion 5, for example, if a part of the protective layer 7 is damaged, the damaged part can be re-applied with paint to form an adhesive layer and the protective layer 7. Therefore, repairs are easier than when the protective layer 7 is formed by printing.

[0071] In addition, the door body 2 has been described as having a structure in which the laminate 3 is directly formed on the plate-like body, but the structure is not limited to this. For example, as shown in Fig. 8 and Fig. 9, the door body 2 can be formed by attaching a sheet body 22 on which the laminate 3 is formed to the plate body.

[0072] As shown in Fig. 8, the plate-like body constituting the door main body 2 has a front surface A1 and a side surface A2 adjacent to the front surface A1 via a corner portion B. The corner portion B is a portion that connects two surfaces extending in different directions, and is, for example, a chamfered corner. The side surface A2 is formed with a curved portion 211 that is concave on the inside. The curved portion 211 is, for example, a depression large enough to hook a finger, and functions as a handle portion 21.

[0073] The sheet body 22 is a sheet made of, for example, a synthetic resin, which has flexibility to such an extent that it can be deformed along the surface of the plate body. As shown in FIG. 8, the upper surface of the sheet body 22 is configured as the printed portion 2a. That is, as shown in FIG. 9, the laminated body 3 is formed on the upper surface of the sheet body 22. The lower surface of the sheet body 22 is disposed so as to face the upper surface of the plate body via an adhesive layer (not shown). The configuration of the laminated body 3 is the same as that of the embodiment shown in FIG. 7. Specifically, the laminated body 3 includes a first adhesive layer 4 disposed on the upper surface of the sheet body 22, a printed portion 5 located above the first adhesive layer 4, a second adhesive layer 6 disposed on the upper surface of the printed portion 5, and a protective layer 7 disposed on the upper surface of the second adhesive layer 6 and covering the upper portion of the printed portion 5. The printed portion 5 of this embodiment includes, as the printed layer 8, a base layer 83, and a height-extending layer 81 and a colored layer 82 disposed above the base layer 83. Note that the configuration is not limited to this, and a configuration without the first adhesive layer 4 or without the base layer 83 may also be used.

[0074] The door body 2 having the above-mentioned configuration is formed by attaching the sheet body 22 on which the laminated body 3 is formed to the plate body. Specifically, the sheet body 22 is aligned along the surface of the plate body so as to span the front A1 and the side A2, and the air between the plate body and the sheet body 22 is removed, so that the sheet body 22 is attached so as to extend along the surface of the plate body. With this configuration, the sheet body 22 on which the printed part 5 is formed is continuously positioned on the surfaces of two adjacent sides via the corner part B, so that the printed part 5 is prevented from being interrupted at the corner part B. Therefore, since it is possible to prevent a sense of incongruity caused by the interruption of the printing, the printed matter can be made to look three-dimensional even when observed up close. In addition, for example, even if a printing device (specifically, a head part) cannot approach the curved part 211 and it is difficult to directly form the printed part 5 on the curved part 211, the sheet body 22 on which the laminated body 3 is formed in advance is attached to the plate body, so that the printed part 5 can be formed on the curved part 211 as well.

[0075] This is not limited to the case where the plate body has the curved portion 211, but is similar even when the plate body has a protruding portion. That is, although the printing device may not be able to approach the side surface of the protruding portion (the surface intersecting the protruding direction), even in such a case, the printed portion 5 can be formed on the protruding portion by attaching the sheet body 22 to the side surface. Therefore, the printed portion 5 can be provided on the protruding portion or the recessed portion of the door 1 having the plate body with the protruding portion or the recessed portion formed on the surface. [Explanation of symbols]

[0076] 1...door, 2...door body, 2a...printed portion, 21...handle portion, 211...curved portion, 22...sheet body, 3...laminated body, 4...first adhesive layer, 5...printed portion, 51...projecting portion, 52...recessed portion, 6...second adhesive layer, 7...protective layer, 8...printed layer, 81...heightening layer, 82...colored layer, 82b...black colored layer, 82w...white colored layer, 83...base layer, 9...printed object

Claims

1. The door includes a plate-shaped door body having a printed portion and a printing portion formed on the printed portion. A door, wherein the printing unit includes a printing layer laminated on the printed portion, and protrusions and recesses are formed on the surface of the printed portion depending on the difference in the number of layers in which the printing layer is laminated.

2. The door according to claim 1 , further comprising a protective layer covering a surface of the printing portion.

3. The door according to claim 2 , further comprising an adhesive layer disposed between the printed portion and the protective layer, for adhering the printed portion and the protective layer.

4. The door according to claim 2 or 3, wherein the protective layer covering the recessed portion is formed to be thicker than the protective layer covering the protruding portion.

5. The method includes a print data creation process for creating print layer data by processing 3D data composed of layer data formed by stacking layer data separated at a plurality of positions at a distance from a predetermined position on a print object, and a printing process for forming a print part having a print layer formed by 3D printing on a print target part of a plate-shaped door body based on the print layer data. The printed layer data is data that specifies the arrangement of the printed layers, and the method for manufacturing a door is such that the number of printed layers is fewer than the layer data.

6. The method includes a bonding step of bonding a sheet body having a printed portion on a surface of a plate body having a plurality of surfaces adjacent to each other via corner portions to form a door body, The sheet body includes a printing layer laminated on a printed portion, and a printing portion having a convex portion and a concave portion formed on a surface thereof due to a difference in the number of layers in which the printing layer is laminated is formed in advance, In the attaching step, a sheet body having the printed portion formed thereon is attached to the plurality of surfaces so as to span the corner portions.

Images