Molded articles and methods for manufacturing molded articles

Abstract

The present invention provides molded articles and methods for manufacturing molded articles that can improve design aesthetics. [Solution] The molded product 10 has a base material 20 and a coating film 30 covering the surface of the base material 20. The base material 20 includes a matrix material 21 and a porous body 22 exposed on the surface of the matrix material 21. The coating film 30 includes a binder resin 31 and a glossing agent 32. The coating film 30 has a first region 30a covering the surface of the matrix material 21 and a second region 30b covering the surface of the porous body 22. The inside of the porous body 22 is impregnated with the binder resin 31. The orientation of the glossing agent 32 to the surface of the porous body 22 in the second region 30b is higher than the orientation of the glossing agent 32 to the surface of the base material 20 in the first region 30a.

Description

Technical Field

[0005] , ,

[0001] The present invention relates to a molded product and a method for manufacturing the molded product.

Background Art

[0002] Conventionally, for example, the surface of an exterior material of a vehicle is painted for the purpose of improving design. Patent Document 1 discloses a metallic painted product having a painting base material, a metallic paint layer formed on the surface of the painting base material, and a clear paint layer formed on the surface of the metallic paint layer. The metallic paint layer has a plurality of brightening materials oriented along the surface of the painting base material.

Prior Art Documents

[0006] During the formation of the coating film, a decrease in volume occurs in the thickness direction of the coating as the coating applied to the surface of the substrate dries. This makes it easier for the glossy material, which was unevenly oriented within the coating, to become aligned with the surface of the substrate.

[0007] According to the above configuration, the interior of the porous body is impregnated with a binder resin. When the binder resin is impregnated into the porous body during the formation of the coating film, the degree of volume reduction in the thickness direction of the paint in the second region is greater than the degree of volume reduction in the thickness direction of the paint in the first region. As a result, in the second region, the glossy material is more easily oriented along the surface of the porous body compared to when the interior of the porous body is not impregnated with binder resin. Consequently, the orientation of the glossy material to the surface of the porous body in the second region is higher than the orientation of the glossy material to the surface of the substrate in the first region. Therefore, when the molded product is viewed from the same observation angle, the appearance differs between the first and second regions. More specifically, the difference in brightness between the first and second regions becomes larger. Thus, the aesthetic appeal of the molded product can be improved.

[0008] [Aspect 2] The molded article according to [Aspect 1], wherein the surface of the porous body exposed on the surface of the base material includes an inclined surface that is inclined with respect to the surface of the base material, and the glossy material is oriented along the inclined surface.

[0009] According to the above configuration, the luminous material is oriented along the surface of the substrate in the first region and along the inclined surface of the porous material in the second region. Furthermore, the orientation of the luminous material relative to the inclined surface of the porous material is enhanced in the second region. As a result, the orientation of the luminous material in the second region tends to be inclined relative to the orientation of the luminous material in the first region, making the difference in brightness between the first and second regions more pronounced. Therefore, the aesthetic appeal of the molded product can be further improved.

[0010] [Aspect 3] A method for manufacturing a molded article comprising a substrate including a base material and a porous body exposed on the surface of the base material, a coating film covering the surface of the substrate comprising a binder resin and a glossing agent, wherein the coating film has a first region covering the surface of the base material and a second region covering the surface of the porous body, and comprises a coating step of applying a paint containing the binder resin and the glossing agent to the surface of the substrate and impregnating the interior of the porous body with the binder resin, and a coating film forming step of forming the coating film by drying the paint applied to the surface of the substrate, wherein in the coating film forming step, the orientation of the glossing agent to the surface of the porous body in the second region is made higher than the orientation of the glossing agent to the surface of the substrate in the first region by drying the paint.

[0011] During the coating process, as the paint applied to the substrate surface dries, a decrease in volume occurs in the thickness direction of the paint. This makes it easier for the glossy material, which was unevenly oriented within the paint, to become aligned with the surface of the substrate.

[0012] According to the above configuration, during the coating process, the binder resin is impregnated into the interior of the porous body. Therefore, during the coating film formation process, the degree of volume reduction in the thickness direction of the paint in the second region is greater than the degree of volume reduction in the thickness direction of the paint in the first region. As a result, in the second region, the gloss material is more easily oriented along the surface of the porous body compared to the case where the binder resin is not impregnated into the interior of the porous body. Consequently, the orientation of the gloss material to the surface of the porous body in the second region can be made higher than the orientation of the gloss material to the surface of the substrate in the first region. Therefore, when the molded product is viewed from the same observation angle, the appearance differs between the first and second regions. More specifically, the difference in brightness between the first and second regions becomes larger. Thus, the aesthetic appeal of the molded product can be improved.

[0013] [Aspect 4] The manufacturing method for a molded article according to [Aspect 3], wherein the surface of the porous body exposed on the surface of the base material includes an inclined surface that is inclined with respect to the surface of the base material, and in the coating film forming step, the paint is dried with the binder resin impregnated into the interior of the porous body, thereby orienting the gloss material along the inclined surface.

[0014] According to the above configuration, the luminous material is oriented along the surface of the substrate in the first region and along the inclined surface of the porous material in the second region. In the second region, the orientation of the luminous material with respect to the inclined surface of the porous material is enhanced. As a result, the orientation of the luminous material in the second region tends to be inclined relative to the orientation of the luminous material in the first region, making the difference in brightness between the first and second regions more pronounced. Therefore, the aesthetic appeal of the molded product can be further improved. [Effects of the Invention]

[0015] According to the present invention, the aesthetic appeal of molded products can be improved. [Brief explanation of the drawing]

[0016] [Figure 1] Figure 1 is a cross-sectional view showing a molded product according to one embodiment. [Figure 2]FIG. 2 is a cross-sectional view showing the base material of the molded product of FIG. 1. [Figure 3] FIG. 3 is a cross-sectional view showing a state where paint is applied to the base material of FIG. 2. [Figure 4] FIG. 4 is a cross-sectional view showing a state where light is irradiated on the molded product of FIG. 1. [Figure 5] FIG. 5 is a cross-sectional view showing the molded product of the modified example.

Mode for Carrying Out the Invention

[0017] Hereinafter, referring to FIGS. 1 to 4, an embodiment of a molded product and a method for manufacturing the molded product will be described. (Configuration of Molded Product 10) As shown in FIG. 1, the molded product 10 is applied to, for example, a panel constituting the exterior or interior of an automobile. The molded product 10 has a base material 20 and a coating film 30 covering the surface of the base material 20. Although not shown, a coloring layer or a coating layer may be formed on the surface of the coating film 30.

[0018] (Configuration of Base Material 20) The base material 20 includes a resin-made base material 21 and a plurality of porous bodies 22. The porous body 22 is a porous filler dispersed in the base material 21.

[0019] The base material 21 is, for example, a thermoplastic resin. As the thermoplastic resin, for example, one kind can be used alone or two or more kinds can be appropriately combined from polypropylene resin, polyethylene resin, ABS resin, acrylic resin, polyester resin, polyurethane resin, polystyrene resin, polyamide resin, polyvinyl chloride resin, polycarbonate resin, etc. The base material 21 of the present embodiment is a polypropylene resin.

[0020] As the porous body 22, for example, one kind can be used alone or two or more kinds can be appropriately combined from natural materials such as wood and stone, various resin materials, fiber materials such as non-woven fabric and paper, etc. The porous body 22 of the present embodiment is wood powder. The average particle size of the wood powder is, for example, 50 μm to 1000 μm.

[0021] A portion of the multiple porous bodies 22 is exposed on the surface of the base material 21. These porous bodies 22 have inclined surfaces 23 that are exposed from the surface of the base material 21. The inclined surfaces 23 are inclined with respect to the surface of the base material 21. The inclined surfaces 23 are the outer surfaces of the porous bodies 22 through which multiple fine pores open, and are different from the inner surfaces of these fine pores. For example, the inclined surfaces 23 are concave surfaces that are recessed compared to the surface of the base material 21.

[0022] (Composition of coating film 30) The coating film 30 includes a binder resin 31, a glossing agent 32, and a solvent (not shown). As the binder resin 31, for example, one type can be used alone or two or more types can be used in appropriate combinations from polyester resin, urethane resin, epoxy resin, melamine resin, alkyd resin, phenolic resin, acrylic resin, etc.

[0023] As the luminous material 32, one type can be used alone or two or more types can be used in appropriate combinations from metal flakes, glass flakes, mica, etc. In this embodiment, the luminous material 32 is aluminum flake. The luminous material 32 is non-spherical, more specifically, flaky. The thickness of the luminous material 32 is, for example, several μm. The length of the luminous material 32 is, for example, several tens of μm. The length of the luminous material 32 refers to the maximum length of the planar portion of the luminous material 32. The ratio of the length to the thickness of the luminous material 32, i.e., the aspect ratio, is preferably greater than 1, and more preferably 10 or more.

[0024] As solvents, one or more can be used individually or in appropriate combinations of water, hydrocarbons, ketones, esters, ethers, alcohols, etc. The coating film 30 has a first region 30a that covers the surface of the base material 21 and a second region 30b that covers the surface of the porous body 22 exposed from the base material 21. The interior of the porous body 22 is impregnated with a binder resin 31. The thickness of the coating film 30 in the second region 30b is smaller than the thickness of the coating film 30 in the first region 30a.

[0025] The luminous material 32 is oriented along the surface of the substrate 20. More specifically, in the first region 30a, the luminous material 32 is oriented along the surface of the substrate 20, and in the second region 30b, it is oriented along the surface of the porous body 22, i.e., the inclined surface 23. The orientation of the luminous material 32 to the surface of the porous body 22 in the second region 30b is higher than the orientation of the luminous material 32 to the surface of the substrate 20 in the first region 30a. In other words, the average orientation angle of the luminous material 32 to the surface of the porous body 22 in the second region 30b is smaller than the average orientation angle of the luminous material 32 to the surface of the substrate 20 in the first region 30a. The average orientation angle of the luminous material 32 is the average of the absolute values ​​of the orientation angles of multiple luminous materials 32 with respect to the paint-coated surface. A smaller average orientation angle means that the multiple luminous materials 32 are in a position parallel to the paint-coated surface.

[0026] (Method of manufacturing molded product 10) The method for manufacturing the molded product 10 comprises a base material molding step, a coating step, and a coating film formation step.

[0027] As shown in Figure 2, in the substrate molding process, a substrate 20 is formed in which the porous body 22 is exposed on the surface of the base material 21. Although not shown in the figure, in the substrate molding process, for example, a substrate 20 of a predetermined shape is formed by injecting a material, which is a mixture of the base material 21 and the porous body 22, into the cavity of a mold using an injection molding machine.

[0028] As shown in Figure 3, in the coating process, the paint constituting the coating film 30 is applied to the surface of the substrate 20. The paint includes the binder resin 31, the glossing agent 32, and the solvent described above. In the coating process, the paint is applied to the surface of the substrate 20 by, for example, a spray coating method or a roll coating method. In the coating process, by applying the paint to the surface of the substrate 20, the binder resin 31 and the solvent are impregnated into the interior of the porous body 22. Note that the binder resin 31 and the solvent are not impregnated into the interior of the base material 21.

[0029] As shown in Figure 1, in the coating film formation process, a coating film 30 is formed by drying the paint applied to the surface of the substrate 20. In the coating film formation process, as the paint dries, the solvent evaporates and the binder resin 31 solidifies. At this time, a volume reduction occurs in the thickness direction of the paint. Due to this volume reduction of the paint, the gloss material 32, which was unevenly oriented within the paint, becomes more easily oriented along the surface of the substrate 20.

[0030] As described above, in the coating process, the binder resin 31 and solvent are impregnated into the porous body 22. Therefore, in the film formation process, the paint is dried with the binder resin 31 impregnated into the porous body 22. As a result, in the second region 30b, in addition to the volume reduction due to the evaporation of the solvent, a volume reduction occurs due to the impregnation of the binder resin 31 and solvent into the porous body 22. Consequently, when the paint dries, the degree of volume reduction in the thickness direction of the paint in the second region 30b is greater than the degree of volume reduction in the first region 30a. As a result, the film thickness in the second region 30b becomes smaller than the film thickness in the first region 30a. At this time, depressions are formed on the surface of the second region 30b. Such depressions are more likely to occur when the viscosity of the paint is higher than a predetermined viscosity.

[0031] Incidentally, the greater the volume reduction in the thickness direction of the paint, the easier it is for the luminous material 32 to be oriented along the surface of the substrate 20, that is, the higher the orientation. As described above, the degree of volume reduction of the paint in the second region 30b is greater than the degree of volume reduction of the paint in the first region 30a. For this reason, in the second region 30b, the luminous material 32 is easier to be oriented along the surface of the porous body 22. From the above, it can be said that the coating film formation process is a process that, by drying the paint, makes the orientation of the luminous material 32 to the surface of the porous body 22 in the second region 30b higher than the orientation of the luminous material 32 to the surface of the substrate 20 in the first region 30a.

[0032] <Operation of this embodiment> During the formation of the coating film 30, a volume reduction occurs in the thickness direction of the coating as the coating applied to the surface of the substrate 20 dries. This makes it easier for the glossy material 32, which was unevenly oriented within the coating, to be oriented along the surface of the substrate 20.

[0033] In this embodiment, according to the molded product 10, the inside of the porous body 22 is impregnated with a binder resin 31. When the coating film 30 is formed, the impregnation of the binder resin 31 into the porous body 22 causes the degree of volume reduction in the thickness direction of the paint in the second region 30b to be greater than the degree of volume reduction in the thickness direction of the paint in the first region 30a. As a result, in the second region 30b, the gloss material 32 is more easily oriented along the surface of the porous body 22 compared to the case where the binder resin 31 is not impregnated into the inside of the porous body 22. Consequently, the orientation of the gloss material 32 to the surface of the porous body 22 in the second region 30b is higher than the orientation of the gloss material 32 to the surface of the substrate 20 in the first region 30a.

[0034] As shown in Figure 4, the luminous material 32 in the second region 30b is oriented in an inclined position with respect to the surface of the substrate 20. Therefore, as shown by the dashed line in Figure 4, the direction of the reflected light reflected from the luminous material 32 in the second region 30b is different from the direction of the reflected light reflected from the luminous material 32 in the first region 30a. As a result, the appearance of the molded product 10 differs between the first region 30a and the second region 30b. More specifically, when the molded product 10 is viewed from a direction where the brightness of the first region 30a is high, the brightness of the second region 30b is low. On the other hand, when the molded product 10 is viewed from a direction where the brightness of the second region 30b is high, the brightness of the first region 30a is low. Consequently, when the molded product 10 is viewed from the same observation angle, the difference in brightness between the first region 30a and the second region 30b becomes large.

[0035] <Effects of this embodiment> (1) The molded product 10 has a base material 20 and a coating film 30 covering the surface of the base material 20. The coating film 30 has a first region 30a covering the surface of the base material 21 and a second region 30b covering the surface of the porous body 22. The interior of the porous body 22 is impregnated with a binder resin 31. The orientation of the luminous material 32 to the surface of the porous body 22 in the second region 30b is higher than the orientation of the luminous material 32 to the surface of the base material 20 in the first region 30a.

[0036] According to the above configuration, the above-mentioned effects can be achieved, thereby improving the aesthetic appeal of the molded product 10. (2) The luminous material 32 is oriented along the inclined surface 23.

[0037] According to the above configuration, the luminous material 32 is oriented along the surface of the substrate 20 in the first region 30a, and along the inclined surface 23 of the porous body 22 in the second region 30b. In the second region 30b, the orientation of the luminous material 32 with respect to the inclined surface 23 of the porous body 22 is enhanced. As a result, the orientation of the luminous material 32 in the second region 30b tends to be inclined relative to the orientation of the luminous material 32 in the first region 30a, making the difference in brightness between the first region 30a and the second region 30b more pronounced. Therefore, the aesthetic appeal of the molded product 10 can be further improved.

[0038] (3) The method for manufacturing the molded product 10 comprises a coating step and a coating film forming step. In the coating step, a paint containing a binder resin 31 and a glossing agent 32 is applied to the surface of the substrate 20 and the binder resin 31 is impregnated into the interior of the porous body 22. In the coating film forming step, the paint is dried to make the orientation of the glossing agent 32 to the surface of the porous body 22 in the second region 30b higher than the orientation of the glossing agent 32 to the surface of the substrate 20 in the first region 30a.

[0039] According to the above configuration, during the coating process, the binder resin 31 is impregnated into the interior of the porous body 22. Therefore, during the coating film formation process, the degree of volume reduction in the thickness direction of the paint in the second region 30b is greater than the degree of volume reduction in the thickness direction of the paint in the first region 30a. Thus, an effect similar to the above effect (1) can be achieved.

[0040] (4) In the coating film formation process, the paint is dried with the binder resin 31 impregnated into the interior of the porous body 22, thereby orienting the gloss material 32 along the inclined surface 23. According to the above configuration, the luminous material 32 is oriented along the surface of the substrate 20 in the first region 30a, and along the inclined surface 23 of the porous body 22 in the second region 30b. In the second region 30b, the orientation of the luminous material 32 with respect to the inclined surface 23 of the porous body 22 is enhanced. Therefore, an effect similar to the above effect (2) can be achieved.

[0041] (5) The porous material 22 is wood powder. According to the above configuration, the weight of the molded product 10 can be reduced compared to, for example, the case in which a porous metal body 22 is used.

[0042] <Example of changes> This embodiment can be implemented with the following modifications. This embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0043] • In the base material molding process, the base material 20 may be molded by extrusion molding. As shown in Figure 5, the surface of the porous body 22 exposed from the surface of the base material 21 may extend along the surface of the base material 21. In this modified example, the porous body 22 is plate-shaped. Even in this case, since the binder resin 31 is impregnated into the interior of the porous body 22, the orientation of the luminous material 32 oriented along the surface of the porous body 22 is higher than the orientation of the luminous material 32 oriented along the surface of the substrate 20. Therefore, an effect similar to the above effect (1) can be achieved.

[0044] The film thickness of the second region 30b may be the same as the film thickness of the first region 30a. This configuration can be achieved by setting the viscosity of the paint to such a viscosity that no depressions occur on the surface of the second region 30b when the paint dries.

[0045] The base material 21 may be a thermosetting resin. Examples of thermosetting resins include phenolic resins, epoxy resins, melamine resins, urea resins, etc., which can be used individually or in appropriate combinations of two or more.

[0046] The molded product 10 is not limited to panels that constitute the exterior or interior of an automobile, but may also be applied to other applications such as functional parts for automobiles, furniture, tableware, etc. [Explanation of Symbols]

[0047] 10...Molded product 20...Base material 21...Base material 22…Porous material 23…Slope surface 30…coating 30a…First area 30b…Second area 31… Binder resin 32…Shining material

Claims

1. A substrate comprising a base material and a porous body exposed on the surface of the base material, A molded article comprising a binder resin and a glossing material, and having a coating film covering the surface of the substrate, The coating film has a first region that covers the surface of the base material and a second region that covers the surface of the porous body. The inside of the porous body is impregnated with the binder resin. The orientation of the luminous material to the surface of the porous body in the second region is higher than the orientation of the luminous material to the surface of the substrate in the first region. Molded products.

2. The surface of the porous body exposed on the surface of the base material includes an inclined surface that is inclined with respect to the surface of the base material. The luminous material is oriented along the inclined surface. The molded article according to claim 1.

3. A substrate comprising a base material and a porous body exposed on the surface of the base material, A method for manufacturing a molded article comprising a binder resin and a glossy material, and a coating film covering the surface of the substrate, The coating film has a first region that covers the surface of the base material and a second region that covers the surface of the porous body. A coating step comprising applying a paint containing the binder resin and the glossing agent to the surface of the substrate and impregnating the inside of the porous body with the binder resin, The process includes a coating film forming step, in which the coating film is formed by drying the paint applied to the surface of the substrate, In the coating film forming step, the orientation of the luminous material to the surface of the porous body in the second region is made higher than the orientation of the luminous material to the surface of the substrate in the first region by drying the paint. A method for manufacturing molded products.

4. The surface of the porous body exposed on the surface of the base material includes an inclined surface that is inclined with respect to the surface of the base material. In the coating film forming step, the paint is dried with the binder resin impregnated into the interior of the porous body, thereby orienting the glossy material along the inclined surface. A method for manufacturing a molded article as described in claim 3.

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