Mold for embossing and method of manufacturing embossed product

Abstract

To provide a new embossing mold for improving the design quality of embossed products, and a method for manufacturing embossed products using the mold.SOLUTION: A mold for embossing comprises a substrate, a decorative protruding portion protruding from the substrate, and a frame portion protruding from the substrate and surrounding the decorative protruding portion, and the protruding length (L1) of the frame portion from the substrate and the maximum protruding length (L2) of the decorative protruding portion from the substrate satisfy L1≥L2.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to an embossing die and a method for producing an embossed product. [Background technology]

[0002] Patent Document 1 discloses an embossing method in which a mold is pressed against a resin sheet in which a skin material and a foam are laminated together to form a design.

[0003] In this embossing method, a mold presses a heated resin sheet, causing the skin material of the resin sheet to melt and deform to fit the shape of the outer surface of the mold, while the foam is thermally compressed, resulting in a design including a concave-convex pattern appearing on the surface of the resin sheet. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2020-179570 Summary of the Invention [Problem to be solved by the invention]

[0005] In such an embossing method, in order to improve the design of the uneven pattern that appears on the surface of the resin sheet, it is preferable that the mold be kept parallel to the resin sheet and press the resin sheet evenly.

[0006] An object of the present disclosure is to provide a novel embossing die that improves the design of an embossed product, and a method for manufacturing an embossed product using the die.

[0007] An embossing mold according to one embodiment of the present disclosure comprises a substrate, a decorative convex portion protruding from the substrate, and a frame portion protruding from the substrate and surrounding the decorative convex portion, wherein the protruding length (L1) of the frame portion from the substrate and the maximum protruding length (L2) of the decorative convex portion from the substrate satisfy L1≧L2.

[0008] Furthermore, in a method for producing an embossed product according to another embodiment of the present disclosure, a resin sheet is embossed by thermal compression using an embossing mold according to one embodiment of the present disclosure. [Effects of the Invention]

[0009] According to the present disclosure, it is possible to provide a novel embossing die and a method for manufacturing an embossed product that improves the design of the embossed product. [Brief explanation of the drawings]

[0010] [Figure 1] Schematic diagram of the manufacturing equipment. [Figure 2] 2A and 2B are a bottom view and a cross-sectional view showing a first embodiment of a mold. [Figure 3] Enlarged view of part B in Figure 3(b). [Figure 4] FIG. [Figure 5] FIG. 1 is an explanatory diagram showing a method for manufacturing an embossed product using a mold. [Figure 6] FIG. 1 is an explanatory diagram showing a method for manufacturing an embossed product using a mold. [Figure 7] FIG. 1 is an explanatory diagram showing a method for manufacturing an embossed product using a mold. [Figure 8] FIG. 8 is an enlarged explanatory diagram of part C in FIG. 7. [Figure 9] FIG. 10 is a bottom view showing a second embodiment of the mold. DETAILED DESCRIPTION OF THE INVENTION

[0011] First, a mold 1 according to an embodiment of the present disclosure and an embossed product manufacturing apparatus M using the mold 1 will be described with reference to FIGS.

[0012] The manufacturing device M produces an embossed product by embossing a resin sheet S to form a decorative pattern. The embossed product is used as a surface material for covering interior components of a vehicle, such as a seat, door trim, or instrument panel.

[0013] As shown in FIG. 1, the manufacturing device M includes an embossing die 1, a base 3 disposed opposite the die 1, an actuator 5 for moving the die 1, and a heating unit .

[0014] As shown in FIG. 2( a ), the mold 1 includes a substrate 10 , a frame portion 11 , and a decorative protrusion 12 surrounded by the frame portion 11 .

[0015] The substrate 10 is, for example, a plate having dimensions of 1000 mm or more and 2000 mm or less in the width direction (arrow X direction in Figure 2(a)) and depth direction (arrow Y direction in Figure 2(a)), and a dimension of 50 mm or more and 100 mm or less in the vertical direction (arrow Z direction in Figure 2(b)).

[0016] As shown in FIG. 2(b), the substrate 10 includes a first surface 10a facing the base 3 (see FIG. 1) and a second surface 10b opposite to the first surface 10a.

[0017] 2(a), the frame 11 includes a first linear portion 11a, a second linear portion 11b intersecting the first linear portion 11a, and a corner portion 11c connecting the first linear portion 11a and the second linear portion 11b. The frame 11 of this embodiment has an annular shape including two parallel first linear portions 11a, two parallel second linear portions 11b, and four corner portions 11c.

[0018] However, the frame 11 may have a shape in which a portion of the annular shape is interrupted. For example, the first linear portion 11a and the second linear portion 11b of the frame 11 may have a shape in which a portion of the first linear portion 11a and the second linear portion 11b is interrupted.

[0019] The frame 11 is disposed between the outer edge 10c of the substrate 10 and the decorative protrusion 12 in the horizontal direction (the directions of arrows X and Y in FIG. 2(a)), and surrounds the decorative protrusion 12. The frame 11 is disposed, for example, at a distance of 10 mm or more and 50 mm or less from the outer edge 10c of the substrate 10 in the horizontal direction.

[0020] The width d1 of the first linear portion 11a and the width d2 of the second linear portion 11b are, for example, 3 mm or more and 10 mm or less. The width d1 of the first linear portion 11a and the width d2 of the second linear portion 11b may be constant over the entire area of the frame portion 11, or may vary.

[0021] As shown in FIG. 2(b), the frame portion 11 protrudes from the first surface 10a of the substrate 10.

[0022] 3, the frame 11 further includes a base 11d and a top surface 11e provided at the tip of the base 11d. The base 11d is formed, for example, perpendicular to the first surface 10a of the substrate 10. The top surface 11e is parallel to the first surface 10a of the substrate 10.

[0023] However, the base 11d may be formed so as to be inclined with respect to the first surface 10a of the substrate 10. For example, the base 11d may have an inclination of 3 degrees or more and 7 degrees or less with respect to the first surface 10a of the substrate 10. The inclination angle of the base 11d with respect to the first surface 10a can be changed as appropriate.

[0024] The protrusion length L1 of the frame portion 11 from the first surface 10a is the distance from the first surface 10a to the top surface 11e of the substrate 10 in the vertical direction (the direction of the arrow Z in FIG. 3). The protrusion length L1 is, for example, 5 mm or more and 50 mm or less. In this embodiment, the protrusion length L1 of the frame portion 11 is constant over the entire area of the frame portion 11. That is, the protrusion length L1 is constant in all of the first linear portion 11a, the second linear portion 11b, and the corner portions 11c (all of which are shown in FIG. 2(a)).

[0025] As shown in Fig. 2(a), the decorative protrusion 12 is disposed in the center 10d of the substrate 10 in the horizontal direction (the directions of arrows X and Y in Fig. 2(a)), and is surrounded by the frame 11. The decorative protrusion 12 is disposed, for example, at a distance of 10 mm to 50 mm from the inner edge 11f of the frame 11 in the horizontal direction.

[0026] The decorative protrusions 12 press the resin sheet S to form a decorative embossed pattern on the resin sheet S. As shown in FIG. 2(b), the decorative protrusions 12 protrude from the first surface 10a of the substrate 10, similar to the frame portion 11. The shape and number of the decorative protrusions 12 are designed according to the design to be formed on the resin sheet S. In this embodiment, the design to be formed on the resin sheet S is four parallel lines, so the mold 1 has four parallel decorative protrusions 12.

[0027] As shown in FIG. 3, the decorative protrusion 12 includes a base 12a and a top surface 12b provided at the tip of the base 12a.

[0028] The base 12a is preferably formed perpendicular to the first surface 10a of the substrate 10. However, the base 12a may be formed so as to be inclined with respect to the first surface 10a of the substrate 10. For example, the base 12a may have an inclination of 3 degrees or more and 7 degrees or less with respect to the first surface 10a of the substrate 10. The inclination angle of the base 12a with respect to the first surface 10a can be changed as appropriate.

[0029] The top surface 12b has a shape corresponding to the design of the concave-convex pattern to be expressed on the embossed product, and may be formed as a flat or curved surface. Note that the base 12a and the top surface 12b can be configured using a conventionally known embossing mold.

[0030] The maximum protrusion length L2 of the decorative protrusion 12 from the first surface 10a is the maximum distance from the first surface 10a of the substrate 10 to the top surface 12b in the vertical direction (the direction of arrow Z in FIG. 4). In this embodiment, the top surface 12b is parallel to the first surface 10a of the substrate 10. Therefore, the distance from the first surface 10a of the substrate 10 to the top surface 12b is the same at any point on the top surface 12b. However, depending on the design to be formed on the resin sheet S, the top surface 12b may be inclined from the first surface 10a of the substrate 10 or may be curved, so that the distance from the first surface 10a of the substrate 10 to the top surface 12b may take on multiple values. The maximum protrusion length L2 is the maximum of these distances. The maximum protrusion length L2 of the decorative protrusion 12 satisfies the relationship L1 ≧ L2 with respect to the protrusion length L1 of the frame portion 11. In this embodiment, the maximum protruding length L2 of the decorative protrusion 12 is equal to the protruding length L1 of the frame portion 11. Like the protruding length L1 of the frame portion 11, the maximum protruding length L2 is, for example, 10 mm or more and 50 mm or less.

[0031] As shown in Figure 1, the base 3 includes a substrate 30 having a first surface 30a facing the mold 1, a mounting portion 31 on which the resin sheet S is placed, and a plurality of protrusions 32 protruding from the first surface 30a of the substrate 30.

[0032] The mounting portion 31 is provided at the center portion 30b of the first surface 30a in the horizontal direction (the direction of the arrow X in FIG. 1). The mounting portion 31 faces the decorative protrusion 12 of the mold 1.

[0033] The protrusions 32 are provided on the outer edge 30c of the first surface 30a in the horizontal direction (the direction of arrow X in FIG. 1). The protrusions 32 are spacers that abut against the substrate 10 of the mold 1, thereby maintaining an appropriate distance between the substrate 10 of the mold 1 and the substrate 30 of the base 3.

[0034] The protrusion 32 includes a base 32a and a top surface 32b provided at the tip of the base 32a. The base 32a is formed perpendicular to the first surface 30a of the substrate 30. The top surface 32b is parallel to the first surface 30a of the substrate 30.

[0035] The protrusion length L3 from the first surface 30a of the protrusion 32 is the distance from the first surface 30a to the top surface 32b of the substrate 30 in the vertical direction (the direction of arrow Z in FIG. 2). The protrusion length L3 satisfies L3≧L1 in relation to the protrusion length L1 of the frame portion 11 of the mold 1. Similarly, the protrusion length L3 satisfies L3≧L2 in relation to the maximum protrusion length L2 of the decorative protrusion 12 of the mold 1. The protrusion length L3 is, for example, 12 mm or more and 60 mm or less. The protrusion length L3 is constant throughout the entire protrusion 32.

[0036] The actuator 5 moves the mold 1 in the vertical direction (the direction of the arrow Z in FIG. 1) to change the distance between the mold 1 and the base 3.

[0037] The actuator 5 is provided at the center 10d of the second surface 10b of the mold 1, and moves the mold 1 while it is suspended in the air. The actuator 5 is, for example, a hydraulic cylinder.

[0038] The actuator 5 moves the mold 1 between an initial position shown by a solid line and a pressing position shown by a dashed line.

[0039] In the initial position, the mold 1 and the base 3 are spaced apart. That is, the top surface 11e of the frame 11 of the mold 1 and the top surface 12b of the decorative protrusion 12 are completely out of contact with the top surface 32b of the protrusion 32 of the base 3.

[0040] At the pressing position, the first surface 10a of the mold 1 comes into contact with the top surface 32b of the protrusion 32 of the base 3. A gap h1 may be formed between the top surface 11e of the frame 11 of the mold 1 and the first surface 30a of the base 3. In addition, a gap h2 is formed between the top surface 12b of the decorative protrusion of the mold 1 and the first surface 30a of the base 3.

[0041] In this embodiment, at the pressing position, a gap h1 is generated between the top surface 11e of the frame portion 11 of the mold 1 and the first surface 30a of the base 3, and a gap h2 is generated between the top surface 12b of the decorative protrusion 12 of the mold 1 and the first surface 30a of the base 3. Furthermore, the gap h1 and the gap h2 are equal.

[0042] The heating unit 7 heats the mold 1, the base 3, or the resin sheet S. The heating unit 7 in this embodiment is an electric heater that is provided integrally with the mold 1 and the base 3 and heats the mold 1 and the base 3.

[0043] 4 to 8, a method for manufacturing an embossed product using the manufacturing apparatus M will be described. The manufacturing method includes a step S1 of placing a resin sheet S in the manufacturing apparatus M, a step S2 of moving a mold 1, and a step S3 of pressing the resin sheet S with the mold 1.

[0044] First, in step S1, a resin sheet S is prepared.

[0045] 4 is a cross-sectional view showing the laminated structure of the resin sheet S. As shown in FIG. 4, the resin sheet S includes a foamed resin layer 21 and a skin layer 22 laminated on the foamed resin layer 21.

[0046] The foamed resin layer 21 is in the form of a sheet made of a foamed resin material. The foamed resin material may be selected from, for example, soft polyurethane foam, polyethylene foam, EVA foam, etc. The foamed resin layer 81 may be made of one or more types of foamed resin material, or may be made by laminating multiple foamed resin materials.

[0047] The foamed resin layer 21 of this embodiment is made of soft polyurethane foam and is in the form of a sheet having a thickness (direction of arrow Z in FIG. 4) of 1.3 mm to 30 mm. Furthermore, the thickness of the foamed resin layer 81 is preferably 10 mm or more.

[0048] The skin layer 22 forms the design surface of the resin sheet S and, ultimately, the embossed product. The skin layer 22 is formed thinner than the foamed resin layer 21 and is in the form of a sheet with a thickness (in the direction of arrow Z in FIG. 4) of 0.5 mm to 3 mm.

[0049] The skin layer 22 includes a surface layer 22a on which an embossed pattern is formed, and a colored resin layer 22b provided between the surface layer 22a and the foamed resin layer 21.

[0050] The surface layer 22a is a sheet made of a fiber mainly composed of fibers such as flexible and stretchable knitted fabric, woven fabric, or nonwoven fabric, or a sheet made of synthetic leather, natural leather, or the like.

[0051] Fiber sheets can be selected from, for example, knitted fabrics such as tricot, jersey, and double raschel; woven and nonwoven fabrics made of fibers containing elastic fibers with stretchability; nonwoven fabrics made by stretching raw fabrics with numerous embossed sections to give them stretchability; and needle-punched nonwoven fabrics made by spirally crimping fibers to give them excellent stretchability.

[0052] The fiber sheet may be made of natural fibers such as cotton, linen, or wool, or synthetic fibers such as rayon, acetate, polyamide, polyacrylonitrile, polyethylene terephthalate, or vinylon.

[0053] Furthermore, synthetic leather sheets can be formed by a conventionally known method in which a substrate made of knitted fabric, woven fabric, nonwoven fabric, or the like is impregnated or coated with a synthetic resin such as polyvinyl chloride or thermosetting polyurethane.

[0054] The colored resin layer 22b is made of a thermoplastic synthetic resin that has been colored with a colorant or pigment. The synthetic resin is not particularly limited, and polyethylene, polyvinyl chloride, polyethylene terephthalate, or other conventionally known thermoplastic synthetic resins can be selected.

[0055] The thickness of the colored resin layer 22b (in the direction of arrow Z in FIG. 4) may be between one-fourth and two times the thickness of the surface layer 22a. The thickness of the colored resin layer 22b is, for example, between one-half and one-and-a-half times the thickness of the surface layer 22a.

[0056] Although the resin sheet S of the present embodiment has been described as including the foamed resin layer 21 and the skin layer 22, the present disclosure is not limited thereto. The resin sheet S may further include a base fabric laminated on the foamed resin layer 21 on the side opposite to the skin layer 22. The base fabric may be formed of a woven fabric or nonwoven fabric with little elasticity.

[0057] 5, in step S1, the resin sheet S is placed on the mounting portion 31 of the base 3. The resin sheet S is placed so that the foamed resin layer 21 faces the first surface 30a of the base 3. As a result, the skin layer 22 of the resin sheet S faces the decorative protrusion 12 of the mold 1.

[0058] In step S1, the heating unit 7 may heat the base 3 and, in turn, the resin sheet S placed on the base 3. The foamed resin layer 81 of the resin sheet S is heated to, for example, 150° C. or higher and 190° C. or lower, and the skin layer 82 is heated to, for example, 50° C. or higher and 200° C. or lower. The heating unit 7 may heat the mold 1 together with the base 3.

[0059] Next, in step S2, the actuator 5 moves the mold 1 from the initial position to the pressing position (see FIG. 2 for both).

[0060] 6A and 6B are explanatory diagrams showing the state of the mold 1 being moved by the actuator 5. FIG. 6A is a schematic diagram showing the state of the mold 1 being moved by the actuator 5. FIG.

[0061] As shown in FIG. 6(a), the actuator 5 is provided at the center 10d of the substrate 10 of the mold 1. The mold 1 is suspended by the actuator 5 at the center 10d of the substrate 10. Therefore, the center 10d of the mold 1 is held by the actuator 5, while the outer edge 10c of the mold 1 is displaceable left and right and up and down. As a result, the mold 1 may rotate or tilt in the horizontal direction (the direction of arrow X in FIG. 6(a)) and up and down direction (the direction of arrow Z in FIG. 6(a)) around the center 10d where the actuator 5 is provided.

[0062] In Figure 6(a), the black arrow indicates the case where the mold 1 tilts up and down around the center portion 10d. The mold 1 moves, for example, in a horizontal state W0, which is an attitude parallel to the horizontal direction (the direction of arrow X in Figure 6(a)) shown by the dashed line, in an attitude W slightly tilted at an inclination angle θ. The magnitude of the inclination angle θ changes as the actuator 5 moves the mold 1.

[0063] The amount of displacement of the mold 1 moving in the posture W in the vertical direction (the direction of the arrow Z in FIG. 6(a)) relative to the horizontal state W0 increases as the distance from the actuator 5 and hence the central portion 10d increases. That is, when the mold 1 is tilted at the tilt angle θ, the amount of displacement at the frame portion 11 is greater than the amount of displacement at the decorative protrusion 12.

[0064] In Figure 6(a), the first position P1 indicates the top surface 11e of the frame portion 11, and the second position P2 indicates the position of the top surface 12b of the decorative protrusion 12. The displacement amount b1 indicates the displacement amount in the vertical direction (direction of arrow Z in Figure 6(a)) relative to the horizontal state W0 at the first position P1. The displacement amount b2 indicates the displacement amount in the vertical direction relative to the horizontal state W0 at the second position P2. The displacement amounts b1 and b2 satisfy b1 ≥ b2. In other words, the first position P1 of the mold 1 moves while being positioned lower than the second position P2.

[0065] 6(b) shows how the mold 1 reaches the vicinity of the pressing position (see FIG. 1) while in a posture W tilted at an inclination angle θ and comes into contact with the resin sheet S. As shown in FIG. 6(b), the first position P1 of the mold 1 reaches the resin sheet S before the second position P2. In other words, the top surface 11e of the frame portion 11 of the mold 1 reaches the resin sheet S before the top surface 12b of the decorative protrusion 12.

[0066] When the top surface 11e of the frame portion 11 comes into contact with the resin sheet S, the mold 1 is inclined at an inclination angle θ, and therefore the top surface 11e of the frame portion 11 is also inclined at an inclination angle θ relative to the resin sheet S. Therefore, the outer edge 11g of the top surface 11e of the frame portion 11 comes into contact with the resin sheet S first.

[0067] After the outer edge 11g of the top surface 11e of the frame 11 comes into contact with the resin sheet S, the actuator 5 moves the mold 1 further downward (in the direction opposite to the arrow Z in FIG. 6(b)). As a result, a pressing force from above (in the direction of the arrow Z in FIG. 6(b)) and a reaction force from the contact point with the resin sheet S act on the frame 11.

[0068] 6(b), the outer edge 11g of the frame 11 slides on the resin sheet S toward the outside of the mold 1. As a result, the top surface 11e of the frame 11 becomes horizontal to the resin sheet S. As a result, the frame 11 becomes perpendicular to the resin sheet S, and the entire mold 1 is adjusted from the posture W inclined at the inclination angle θ to the horizontal state W0.

[0069] The actuator 5 moves the mold 1 to the pressing position (see FIG. 1) while keeping the mold 1 in the horizontal position W0.

[0070] Although FIG. 6 illustrates an example in which the mold 1 is tilted in the direction of arrow X, even when the mold 1 is in a position W inclined in any or all of the width, depth, and up-down directions (see arrows X, Y, and Z in FIG. 2), the top surface 11e of the frame 11 contacts the resin sheet S before the decorative protrusions 12. This causes the frame 11 to slide along the resin sheet S, adjusting the position of the mold 1 to a horizontal state W0. As a result, the mold 1 can bring the decorative protrusions 12 into vertical contact with the resin sheet S and reach the pressing position (see FIG. 1).

[0071] 7 and 8 are schematic diagrams showing the state in which the mold 1 presses the resin sheet S at the pressing position. As shown in Fig. 7 and 8, in step S3, the mold 1 presses the resin sheet S to thermally compress the resin sheet S. The decorative protrusion 12 of the mold 1 presses the heated resin sheet S from above (the direction of arrow Z in Fig. 7).

[0072] As shown in Figure 8, the top surfaces 12b of the decorative protrusions 12 are pressed perpendicularly against the skin layer 22 of the resin sheet S. As a result, the skin layer 22 is melted and deformed to fit the top surfaces 12b of the decorative protrusions 12 and the surface shape of part of the base 12a. Furthermore, the foamed resin layer 21 of the resin sheet S is also pressed against the top surfaces 12b of the decorative protrusions 12 and thermally compressed. As a result, the thickness (direction of arrow Z in Figure 8) of the resin sheet S at the locations pressed by the decorative protrusions 12 becomes equal to the gap h2 generated between the top surfaces 12b of the decorative protrusions 12 of the mold 1 and the first surface 30a of the base 3 at the pressing position. As a result, a concave-convex pattern corresponding to the decorative protrusions 12 of the mold 1 is formed in the resin sheet S at the locations pressed by the decorative protrusions 12 and in other locations.

[0073] In step S3, the mold 1 is kept in a horizontal position W0 while pressing the resin sheet S. This allows the top surfaces 12b of the decorative protrusions 12 to press the resin sheet S evenly across the entire area of the top surfaces 12b. As a result, the resin sheet S is evenly thermally compressed by the decorative protrusions 12, and a clear and uniform uneven pattern corresponding to the surface shape of the decorative protrusions 12 is formed. As a result, a highly designed embossed product can be obtained in which an uneven pattern is applied to the resin sheet S.

[0074] Finally, the actuator 5 moves the mold 1 to the initial position. This completes the embossed product. The embossed product has a relief pattern formed by the decorative protrusions 12 in its central region, and recesses formed by the frame 11 in the peripheral region surrounding the central region. The peripheral region is removed from the central region to form a product with a relief pattern. <Second embodiment of mold>

[0075] Next, a mold 101 according to a second embodiment of the present disclosure will be described with reference to Fig. 9. Descriptions of configurations common to the mold 1 will be omitted. As shown in Fig. 9, the mold 101 includes a frame portion 111. The frame portion 111 has a rounded portion 111c that connects the first linear portion 11a and the second linear portion 11b.

[0076] The rounded portion 111c has an arc shape that smoothly connects the first linear portion 111a and the second linear portion 111b. This allows the rounded portion 111c to slide smoothly on the resin sheet S when it first reaches the resin sheet S.

[0077] The embossing mold 1 (101) of the present disclosure comprises a substrate 10, a decorative protrusion 12 protruding from the substrate 10, and a frame portion 11 (111) protruding from the substrate 10 and surrounding the decorative protrusion 12, and the protrusion length L1 of the frame portion 11 (111) from the substrate 10 and the maximum protrusion length L2 of the decorative protrusion 12 from the substrate 10 satisfy L1 ≧ L2.

[0078] As a result, when the mold 1 (101) contacts the base 3 while tilting at an inclination angle θ with respect to the horizontal state W0, the frame portion 11 (111) can contact the first surface 30a of the base 3 before the decorative protrusion 12. The frame portion 11 (111) moves while sliding on the first surface 30a of the base 3, and the entire mold 1 (101) can be adjusted to the horizontal state W0. As a result, the mold 1 (101) can bring the decorative protrusion 12 into contact with the resin sheet S perpendicularly and press it evenly.

[0079] Furthermore, the tip of the frame portion 11 (111) is parallel to the substrate .

[0080] As a result, when the frame 11 (111) comes into contact with the first surface 30a of the base 3, it slides on the first surface 30a and moves so that the top surface 11e of the frame 11 (111) and the first surface 30a become parallel to each other. This makes it possible to make the entire frame 11 (111) perpendicular to the base 3, and ultimately to adjust the entire mold 1 (101) to the horizontal state W0.

[0081] The frame portion 11 (111) surrounds the decorative protrusion 12 continuously.

[0082] This allows the frame portion 11 (111) to contact the first surface 30a of the base 3 before the decorative protrusion 12, regardless of whether the mold 1 (101) is tilted up, down, left, or right with respect to the horizontal state W0.

[0083] Furthermore, in the method for producing an embossed product, an embossing mold 1 (101) is used to thermally compress the resin sheet S to perform embossing.

[0084] As a result, even if the mold 1 (101) contacts the base 3 while tilted relative to the horizontal state W0, the frame portion 11 (111) can contact the first surface 30a of the base 3 before the decorative protrusion 12. The frame portion 11 (111) moves while sliding on the first surface 30a of the base 3, and the entire mold 1 (101) can be adjusted to the horizontal state W0. As a result, the mold 1 (101) can contact the decorative protrusion 12 perpendicularly to the resin sheet S and press it evenly.

[0085] As described above, the present disclosure provides a novel embossing mold 1 (101) that improves the design of embossed products and a method for manufacturing embossed products using mold 1 (101).

[0086] Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above embodiments, and various modifications are possible within the scope of the gist of the invention. In particular, the multiple modifications described in this specification can be arbitrarily combined as necessary. [Explanation of symbols]

[0087] 1 (101): mold 10: substrate 11 (111): frame 12: decorative convex portion M: Manufacturing method S: Resin sheet

Claims

1. A substrate; A decorative protrusion protruding from the substrate; a frame portion that protrudes from the substrate and surrounds the decorative convex portion; Equipped with a protruding length (L1) of the frame portion from the substrate and a maximum protruding length (L2) of the decorative convex portion from the substrate satisfy L1≧L2; Embossing mold.

2. The tip of the frame is parallel to the substrate. The embossing die according to claim 1 .

3. The frame portion continuously surrounds the decorative convex portion. The embossing die according to claim 1 .

4. 4. The embossing process is performed by thermally compressing a resin sheet using the embossing mold according to any one of claims 1 to 3. A method for manufacturing embossed products.

5. The resin sheet includes a skin layer and a foamed resin layer. A method for producing the embossed product according to claim 4.

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