Resin body and imitating method of carbonfiber composite

Abstract

The present invention provides a carbonfiber-imitating resin body having at least one surface on which a pattern part is formed, wherein the pattern part comprises a plurality of regions, and the plurality of regions comprise: a first region having grooves formed in a first direction; and a second region being adjacent to the first region and having grooves formed in a second direction different from the first direction.

Description

Method for simulating synthetic resin molded articles and carbon fiber composites

[0001] The present invention relates to a synthetic resin molded article. More specifically, the present invention relates to a synthetic resin molded article having a carbon fiber composite surface texture implemented on its surface, and a method for simulating a carbon fiber composite.

[0002]

[0003] Carbon fiber is an innovative material with properties such as heat resistance, impact resistance, and high thermal conductivity, making it widely used in diverse fields such as aerospace, automobiles, electric vehicles, communications, and sporting goods. However, carbon fiber is difficult to mass-produce by infiltrating it with resin, making it expensive and difficult to use as a general-purpose material.

[0004] Meanwhile, carbon composites, manufactured by impregnating woven carbon mats with thermosetting resins, are being used in a variety of products requiring high strength and lightweight properties. The unique texture of carbon fibers enhances the appearance of the product, and thus, woven carbon mats are primarily used in high-priced products. However, the appearance of woven carbon fiber composites has recently been viewed as unattractive, and the standard for a luxurious appearance in carbon composites is shifting from woven carbon to forged carbon. Forged carbon is made by finely chopping carbon fibers, placing them in a compression mold, injecting a thermosetting resin, and then molding them under high heat and pressure. While this method offers greater freedom in shape due to the mold, it also increases the labor required, such as crushing the carbon fibers before molding. Furthermore, the use of thermosetting resins makes the material non-recyclable. Furthermore, there is a recent movement in Europe to ban sheet mold compounds (SMCs) using thermosetting resins due to environmental concerns.

[0005] Therefore, there is a need to develop a method to express the surface texture of carbon fiber composites by implementing a texture similar to forged carbon without using non-recyclable thermoplastic resins.

[0006] As a background technology of the present invention, Korean Patent No. 10-1990485 discloses a carbon sheet, a carbon frame, and a method for manufacturing the same.

[0007]

[0008] The purpose of the present invention is to provide a synthetic resin molded body that replaces a thermosetting resin that cannot be recycled and has a carbon fiber composite texture on the surface using a thermoplastic resin.

[0009] Another object of the present invention is to provide a synthetic resin molded body that can implement the appearance and texture of forged carbon and is more environmentally friendly, efficient, and cost-effective by replacing existing films or post-processing.

[0010] The above and other objects of the present invention can all be achieved by the present invention described below.

[0011]

[0012] 1. One aspect of the present invention relates to a carbon fiber-mimicking synthetic resin molded article.

[0013] The above carbon fiber imitation synthetic resin molded body has a pattern formed on at least one surface,

[0014] The above pattern portion includes multiple areas,

[0015] The above multiple areas are

[0016] A first region in which grooves are formed in a first direction; and

[0017] A second region contacting the first region and having a groove formed in a second direction different from the first direction;

[0018] 2. In the above 1 specific example, a third region may be further included, which is in contact with the first region and has a groove formed in a third direction.

[0019] 3. In the above 1 or 2 specific examples, the synthetic resin molded body may not contain carbon fiber.

[0020] 4. In any one of the above embodiments 1 to 3, the molded body may further include glass fiber.

[0021] 5. In any one of the above embodiments 1 to 4, the molded body may further include pearl, metal, or a mixture thereof.

[0022] 6. Another aspect of the present invention relates to a synthetic resin molded body having a hairline formed therein.

[0023] The above synthetic resin molded body comprises a base portion; and

[0024] including a pattern portion formed on the surface of the base portion;

[0025] The above pattern portion has unit structure cells that are irregularly distributed,

[0026] The above unit structure cell is formed by arranging multiple hairlines at a certain angle, and the hairlines are arranging at different angles from the hairlines of adjacent unit structure cells.

[0027] 7. In the above 6 specific examples, the base portion may be at least one of polypropylene (PP), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polyethylene (PE), polyethylene terephthalate (PET), polystyrene (PS), polyvinyl chloride (PVC), polyamide (PA), polycarbonate-acrylonitrile butadiene styrene (PC-ABS), and polybutylene terephthalate (PBT).

[0028] 8. In the above 6 or 7 specific examples, the unit structure cell may have a pattern determined according to a shape that mimics the three-dimensional shape of the pulverized carbon piece in a plane.

[0029] 9. In any one of the specific examples 6 to 8 above, the hairline may be formed by arranging straight lines to form a peak and a valley.

[0030] 10. In any one of the embodiments 6 to 9 above, the hairlines may be arranged at the same angle.

[0031] 11. In any one of the specific examples 6 to 10 above, the bone portion may be formed as a flat surface and may be made of black.

[0032] 12. In any one of the specific examples 6 to 11 above, the depth of the groove may be about 2 µm to 60 µm, the width of the peak may be about 10 µm to 300 µm, and the distance between the peak and adjacent peaks may be about 10 µm to 300 µm.

[0033] 13. In any one of the specific examples 6 to 12 above, the depths of the grooves within the same unit structure cell may all be the same.

[0034] 14. In any one of the specific examples 6 to 13 above, the unit structure cell may be irregular and may be limited to be arranged within a rectangle having a width of about 0.25 mm to 5 mm and a length of about 0.5 mm to 7 mm, or may be limited to be arranged within a rectangle having a width of about 20 mm to 70 mm and a length of about 100 mm to 250 mm.

[0035] 15. In any one of the embodiments 6 to 14 above, the base portion may further include glass fiber.

[0036] 16. In any one of the embodiments 6 to 15 above, the base portion may include pearls, metal particles, or a mixture thereof.

[0037] 17. In any one of the specific examples 6 to 16 above, a coating layer may be formed on the pattern portion to a thickness of about 5 μm to 50 μm.

[0038] 18. In any one of the specific examples 6 to 17 above, the hairline can be formed by imprinting according to a pattern formed in a mold.

[0039] 19. Another aspect of the present invention is a method for simulating a carbon fiber composite.

[0040] The above carbon fiber composite simulation method forms a carbon fiber simulation pattern on the surface of a synthetic resin,

[0041] The above carbon fiber imitation pattern is formed by forming a groove in which part or all of the synthetic resin surface is imprinted from a mold, and light is diffusely reflected in the groove.

[0042] 20. Another aspect of the present invention is a method for simulating a carbon fiber composite using a synthetic resin that does not contain carbon fiber.

[0043] The above carbon fiber composite simulation method includes a step of injecting a synthetic resin that does not contain carbon fibers into a mold having a pattern formed thereon.

[0044] The above pattern is formed by etching the surface of the mold and can be imprinted on the surface of the synthetic resin.

[0045] 21. In the above 20 specific examples, the pattern can be formed by etching or laser processing the surface of the mold.

[0046]

[0047] The synthetic resin molded article according to the present invention is not only recyclable by selecting a recyclable thermoplastic resin as a base, but also implements a texture similar to a carbon fiber composite on the surface without using expensive carbon fiber, so that it can be used as a molded article for the exterior of various products requiring a carbon fiber composite material. In particular, since a synthetic resin molded article with a forged carbon surface texture is provided simply by forming a pattern imprinted from a mold on the surface of a thermoplastic synthetic resin, it can replace carbon fiber composites with high manufacturing efficiency and low cost.

[0048]

[0049] Figure 1 is a schematic diagram showing the surface of a synthetic resin molded body according to one specific example of the present invention and a cross-section taken along line I-I'.

[0050] FIG. 2 is a schematic diagram showing a process of converting a 3D stereoscopic structure into a 2D image in a method for manufacturing a synthetic resin molded body according to one specific example of the present invention.

[0051] FIG. 3 is a schematic diagram showing a process of forming a pattern portion on a surface with a 2D image in a synthetic resin molded body according to one specific example of the present invention.

[0052] Figure 4 compares a synthetic resin molded body and a forged carbon composite material according to one specific example of the present invention.

[0053]

[0054] Hereinafter, the present invention will be described in more detail with reference to the attached drawings. However, the drawings are provided solely to aid understanding of the present invention and are not intended to limit the present invention. Furthermore, the shapes, sizes, ratios, angles, numbers, etc. disclosed in the drawings are exemplary and the present invention is not limited to the details depicted.

[0055] Throughout the specification, identical reference numerals designate identical components. Furthermore, in describing the present invention, detailed descriptions of related known technologies are omitted if they are deemed to unnecessarily obscure the gist of the present invention.

[0056] In the specification, when "includes," "has," and "consists of" are used, other parts may be added unless "only" is used. When a component is expressed in the singular, it includes cases where the plural is included unless there is a special explicit description.

[0057] When interpreting a component, it is interpreted as including the error range even if there is no separate explicit description.

[0058] When the positional relationship between two parts is described as 'on top of', 'upper part of', 'lower part of', 'next to', etc., one or more other parts can be located between the two parts unless 'right away' or 'directly' is used.

[0059] Positional relationships such as "upper," "top surface," "lower surface," and "lower surface" are merely described based on the drawing and do not represent absolute positional relationships. In other words, depending on the viewing position, the positions of "upper" and "lower" or "upper surface" and "lower surface" may change.

[0060] In this specification, “a to b” indicating a numerical range is defined as “≥ and ≤”.

[0061]

[0062] Hereinafter, a synthetic resin molded body according to one specific example of the present invention will be described with reference to the drawings.

[0063] Figure 1 is a schematic diagram showing the surface of a synthetic resin molded body according to one specific example of the present invention and a cross-section taken along line I-I'.

[0064] Referring to FIG. 1, the synthetic resin molded body (1000) has a groove (220) in which a portion of the surface is imprinted from a mold, and light is reflected in the groove (220) to implement a carbon fiber composite surface texture.

[0065] The above synthetic resin molded body (1000) can be manufactured using a molding method using a general synthetic resin, so molding is easy, and since molding is possible in various shapes and there are no restrictions on the shape, manufacturing efficiency is high, and since the shape is complex, it can be manufactured in a shape that cannot be provided as a general carbon fiber composite.

[0066] The above groove (220) can be formed by imprinting from a mold during molding of the synthetic resin base portion (100). The shape of the groove (220) is not particularly limited as long as it can form a straight line with a certain depth.

[0067] When light is incident on the groove (220), the light is diffusely reflected within the groove (220) depending on the depth of the groove (220), and the degree of gloss and difference in contrast may occur depending on the position and division of the groove (220). Specifically, the plurality of grooves (220) form one unit structure cell (210a), and the grooves (220) are arranged at different angles from the adjacent unit structure cell (210b), so that when the angle and intensity of the light reflected from one unit structure cell (210a) and the reflected light from the adjacent unit structure cell (210b) are adjusted differently, diffuse reflection may occur in the entire groove (220). When observing the entire surface of the synthetic resin molded body (1000), gloss and difference in contrast may occur for each unit structure cell (210).

[0068] The above groove (220) diffusely reflects light, and when each unit structure cell (210) formed by the groove (220) mimics the shape of irregular pieces of forged carbon on the surface of a carbon fiber composite, the surface texture of an actual forged carbon composite can be implemented as is by the gloss and difference in brightness of each unit structure cell (210).

[0069] A more specific description of the composition of the synthetic resin molded body of the present invention is as follows.

[0070] The above synthetic resin molded body has a pattern portion formed on at least one surface, and the pattern portion includes a plurality of regions, the plurality of regions including a first region in which grooves are formed in a first direction and a second region in contact with the first region and in which grooves are formed in a second direction different from the first direction.

[0071] The above pattern portion may generate differences in gloss and contrast in each region due to diffuse reflection in multiple regions. Each region may have a straight groove formed therein, and specifically, in the first region and the second region, grooves in the first direction and the second direction may be arranged in different directions.

[0072] The above groove may be formed by a series of grooves.

[0073] In one specific example, a third region may be further provided, wherein at least one side of the third region is in contact with the first region, and a groove may be formed in a third direction different from the first direction and the second direction.

[0074] In one specific example, the synthetic resin molded body does not contain carbon fibers, and can implement the texture of a carbon fiber composite, particularly the surface texture of a forged carbon composite, without containing carbon fibers.

[0075] In one specific example, the synthetic resin molded body may further include glass fibers, which may be uniformly dispersed throughout the molded body. When the glass fibers are dispersed throughout the molded body, not only can the strength of the molded body be enhanced, but the texture of the carbon fiber composite can also be more effectively implemented on the surface.

[0076] In one specific example, the molded body may further include pearls and metal particles, which may be uniformly dispersed throughout the molded body. When the pearls and metal particles are dispersed throughout the molded body, the gloss of the molded body may be enhanced, thereby more closely resembling the texture of an actual carbon fiber composite.

[0077] Another aspect of the present invention relates to a thermoplastic synthetic resin molded body (1000) having the surface texture of a forged carbon composite.

[0078] The above thermoplastic synthetic resin molded body (1000) includes a base portion (100) and a pattern portion (200).

[0079] The above base portion (100) may be made of a thermoplastic resin. For example, it may be at least one of polypropylene (PP), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polyethylene (PE), polyethylene terephthalate (PET), polystyrene (PS), polyvinyl chloride (PVC), polyamide (PA), polycarbonate-acrylonitrile butadiene styrene (PC-ABS), and polybutylene terephthalate (PBT).

[0080] The above type of thermoplastic resin is very environmentally friendly as it can be freely molded and can be manufactured into molded articles of various shapes, and can be reused after use.

[0081] Conventional carbon fiber composites have the problem of being impossible to recycle because thermosetting resin is compression-molded together with carbon fibers. However, if the base part (100) of a synthetic resin molded body (1000) is manufactured with a thermoplastic resin, there is an advantage in that the synthetic resin molded body (1000) discarded after use can be recycled.

[0082] The above base part (100) may further include a dye to express a specific color, but it is preferable to form it in an achromatic color to display a color similar to an actual carbon-carbon composite.

[0083] The above pattern portion (200) is formed on the surface of the base portion (100).

[0084] The above pattern portion (200) is formed on a portion of the surface of the base portion (100), and specifically, unit structure cells (210a, 210b) are irregularly distributed.

[0085] The above unit structure cell (210) is formed by arranging a plurality of hairlines (213) at a certain angle. Specifically, a single unit structure cell (210a) is formed by arranging a plurality of hairlines (213) at a certain angle, and the hairlines (213) may be arranging at different angles from the hairlines (213) of the adjacent unit structure cell (210b).

[0086] The above hairline (213) is a straight line extended in the longitudinal direction and imprinted according to the pattern formed on the mold surface during the molding of the base portion (100). The above unit structure cell (210) has multiple hairlines (213) spaced evenly apart at the same angle (θ). 1) , and a groove (220) is formed between the hairlines (213) so that the incident light can be reflected at the groove (220). At this time, the angle (θ1) of the hairline (213) of one unit structure cell (210a) and the angle (θ2) of the hairline (213) of the adjacent unit structure cell (210b) are arranged differently from each other.

[0087] The above unit structure cell (210a) reflects light by the groove (220) of the hairline (213), and the adjacent unit structure cell (210b) has hairlines (213) arranged at different angles, so that light is reflected in different directions, resulting in diffuse reflection, and the pattern portion (200) causes differences in gloss and brightness for each unit structure cell (210a, 210b).

[0088] For example, the hairlines (213) of each unit structure cell (210a, 220b) can be arranged in at least two directions, and considering the angles at which they are arranged, hairlines (213) facing up to 16 directions can be formed in different directions and arranged within the unit structure cell (210), and as the directions in which the hairlines (213) face become more diverse, the diffuse reflection effect increases, so that a more diverse range of gloss and contrast differences can be exhibited depending on the viewing angle of the synthetic resin molded body (1000), and thus the effect of implementing the surface texture of the carbon fiber composite can be increased.

[0089] In one specific example, the unit structure cell (210) may be determined according to a shape that mimics the three-dimensional shape of a pulverized forged carbon piece in a plane. Specifically, the unit structure cell (210) may have a pattern determined according to a shape that mimics the three-dimensional carbon piece pulverized in the production of the forged carbon in a plane, and since the unit structure cell (210) has a pattern determined according to a shape that mimics the forged carbon piece in a plane, the entire pattern portion (200) is arranged to mimic the actual forged carbon pattern as is, so that the synthetic resin molded body (1000) can implement the surface texture of the forged carbon composite as is.

[0090] Specifically, the pattern of the above-mentioned forged carbon can be implemented in 2D using a 3D image viewed from above of an actual three-dimensional carbon piece.

[0091] In one specific example, the hairline (213) may be formed by lining up straight lines to form a peak (211) and a valley (212).

[0092] Referring to the cross-sectional view I-I' of Fig. 1, the hairline (213) may be arranged with multiple straight lines and may form a peak (211) and a valley (212). Specifically, the hairline (213) may be arranged with multiple straight lines and may form a valley (212) between the straight lines.

[0093] In one specific example, the hairlines (213) may be arranged at the same angle.

[0094] Specifically, the hairlines (213) arranged in any one of the unit structure cells (210a) among the above unit structure cells (210) may all be arranged at the same angle, and in this case, the angles at which the hairlines (213) are arranged in each of the unit structure cells (210a, 210b) may be different from each other.

[0095] Among the above unit structure cells (210), the angle of the hairline (213) of one unit structure cell (210a) and the angle of the hairline (213) of one or more unit structure cells (210b) that contact one side of the unit structure cell (213a) have different angles, so that the diffuse reflection effect is increased, and the synthetic resin molded body (1000) exhibits different gloss depending on the angle at which it is viewed, and the difference in brightness is increased, so that the shape of the unit structure cell (210) can exhibit the shape of forged carbon that has been pulverized and dispersed in the synthetic resin.

[0096] In one specific example, the bone (212) is formed as a flat surface and may be made of black.

[0097] Specifically, the hairline (213) is composed of a peak (211) and a valley (212), which are arranged at the same angle, and the lower surface of the valley (212) is formed as a flat surface. When the valley (212) has a flat surface, light incident on the valley (212) is reflected on the flat surface, and some of the light is reflected from the side perpendicular to the lower surface and reflected together in the incident direction to travel straight, so that retroreflection can occur at the valley (212), and gloss can be increased around the valley (212). When gloss is increased through the valley (212), the effect of implementing texture on the surface of the carbon fiber composite can be increased.

[0098] Meanwhile, the surface of the above-mentioned mountain portion (211) may be an uneven surface, but when the mountain portion (211) is formed as an uneven surface, the roughness of the surface of the mountain portion (211) is not limited because it does not have a significant effect on the gloss or contrast of the unit structure cell (210). On the other hand, when unevenness is formed on the valley portion (212), a problem of reduced gloss may occur, and it may be difficult to exhibit the effects of the present invention.

[0099] In one specific example, the groove (212) may be made of black, and specifically, the flat surface may be made of black. If the flat surface of the groove (212) is made of black, the surface texture of the carbon fiber composite can be implemented as is, and if it is made of a chromatic color rather than black, the reflectivity of light is reduced and it is difficult to implement the surface texture of the carbon fiber composite.

[0100] In one specific example, the depth of the groove (212) may be about 2 µm to 60 µm, the width of the peak (211) may be about 10 µm to 300 µm, and the distance between the peak (211) and the adjacent peak (211) may be about 10 µm to 300 µm.

[0101] When the depth (D) of the bone (212), the width (W) of the peak (211), and the pitch between the peaks (211) are adjusted within the above range, the gloss and contrast difference of the unit structure cell (210) can be adjusted.

[0102] In one specific example, the depths of the grooves (212) within the same unit structure cell (210) may all be the same. When the depths of the grooves (212) are the same, it is very easy to maintain the gloss and brightness of one unit structure cell (210) differently from the adjacent unit structure cell (210).

[0103] The above hairline (213) can be formed according to a pattern formed in advance on a mold when forming the base portion (100). Specifically, since the base portion (100) is made of a thermoplastic synthetic resin, injection molding using the mold is possible, and if a pattern including various unit structure cells (210) is etched in advance on the mold, the pattern can be precisely imprinted on the surface of the synthetic resin base portion (100) when forming the base portion (100). In this case, if a synthetic resin with high fluidity is used, the hairline (213) of the pattern portion can be formed more precisely, which is more preferable.

[0104] In one specific example, the unit structure cell (210) is irregular and has a size of about 0.25 mm to 5 mm in width (e.g., 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, 0.8, 0.85, 0.9, 0.95, 1, 1.05, 1.1, 1.15, 1.2, 1.25, 1.3, 1.35, 1.4, 1.45, 1.5, 1.55, 1.6, 1.65, 1.7, 1.75, 1.8, 1.85, 1.9, 1.95, 2, 2.05, 2.1, 2.15, 2.2, 2.25, 2.3, 2.35, 2.4, 2.45, 2.5, 2.55, 2.6, 2.65, 2.7, 2.75, 2.8, 2.85, 2.9, 2.95, 3, 3.05, 3.1, 3.15, 3.2, 3.25, 3.3, 3.35, 3.4, 3.45, 3.5, 3.55, 3.6, 3.65, 3.7, 3.75, 3.8, 3.85, 3.9, 3.95, 4, 4.05, 4.1, 4.15, 4.2, 4.25, 4.3, 4.35, 4.4, 4.45, 4.5, 4.55, 4.6, 4.65, 4.7, 4.75, 4.8, 4.85, 4.9, 4.95 or 5 mm), or is limited to being placed within a rectangle having a length of about 0.5 mm to 7 mm (e.g., 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5 or 7 mm), or is limited to being placed within a rectangle having a length of about 20 mm to 70 mm (e.g., 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, or 70 mm), or a length of about 100 mm to 250 mm (e.g., 100, 110, 120, It may be restricted to be placed within a rectangle of size 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240 or 250 mm.

[0105] The above unit structure cell (210) can be formed by imitating the 2D shape of actual forged carbon, and thus can be irregularly shaped. Specifically, the unit structure cell (210) may be formed to be arranged within a rectangle having a size of about 0.25 mm to 5 mm in width (e.g., 0.25, 0.5, 0.75, 1, 1.25, 1.5, 1.75, 2, 2.25, 2.5, 2.75, 3, 3.25, 3.5, 3.75, 4, 4.25, 4.5, 4.75 or 5 mm), preferably about 0.3 mm to 4.5 mm, and a size of about 0.5 mm to 7 mm in length (e.g., 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5 or 7 mm), preferably about 1 mm to 6 mm, on the surface of a small IT device. It is desirable to use forged carbon to achieve a surface texture more similar to that of carbon fiber composites.

[0106] The above unit structure cell (210) can be arranged in a rectangle having a size of about 20 mm to 70 mm in width (e.g., 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, or 70 mm), preferably about 30 mm to 60 mm, and a size of about 100 mm to 250 mm in height (e.g., 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, or 250 mm), preferably about 180 mm to 220 mm, in which case it is preferable to implement the surface texture of a carbon fiber composite of a bulky object such as a large electronic product or a vehicle. However, the rectangular dimensions that limit the specifications of the above unit structure cell (210) may be changed depending on the type of product to which the synthetic resin molded body (1000) is applied.

[0107] In one specific example, the pattern portion (200) may further include glass fiber.

[0108] Since the carbon fiber composite manufactured from forged carbon has fiber strands protruding at one end and exposed to the outside, it is very advantageous to implement the surface material of the carbon fiber composite manufactured from forged carbon when the pattern portion (200) further includes glass fiber.

[0109] Specifically, the glass fiber may be round or flat depending on the cross-sectional shape, and may be included in an amount of about 1 wt% to 60 wt% based on the base portion (100). When the glass fiber is round, the radius may be about 1 μm to 20 μm, and the length may be about 1 mm to 5 mm, and when the glass fiber is flat, the dimensions may be about 20 μm to 40 μm × about 2 μm to 10 μm based on the cross-sectional area. By adding the glass fiber within the above range, not only can the mechanical properties such as the tensile strength of the synthetic resin molded body (1000) be improved, but also the same surface material as that provided with actual carbon fibers, such as the surface of a carbon fiber composite, can be implemented.

[0110] In one specific example, the pattern portion (200) may further include pearls, metal particles, or a mixture thereof. Specifically, the pearls, metal particles, or a mixture thereof may be included in the synthetic resin molded body (1000) at about 0.05 wt% to 10 wt%, and the pearls are mica components with particle lengths of about 2 μm to 12 μm, and are added at about 0.05 wt% to 10 wt%, and the main component of the metal particles may be selected from aluminum, and the size is about 5 μm to 30 μm. When added at about 0.05 wt% to 10 wt%, the gloss of the synthetic resin molded body (1000) can be effectively increased, thereby implementing the unique gloss of the forged carbon composite, which is preferable.

[0111] In one specific example, when the pattern portion (200) further includes glass fibers, pearls, metal particles, or a mixture thereof, the coating layer may be formed on the pattern portion (200) to a thickness of about 5 μm to 50 μm.

[0112] The above coating layer can be formed with the above thickness to maintain gloss for a long period of time, and can effectively prevent the glass fiber from peeling off or the pearl or metal particles from separating from the molded body.

[0113] Therefore, a synthetic resin molded body (1000) according to a specific example of the present invention forms a pattern portion (200) by imprinting using a mold in which a pattern is etched in advance on a base portion (100) made of a thermoplastic synthetic resin, thereby implementing a surface texture almost identical to that of a carbon fiber composite manufactured by compressing actual forged carbon with a thermosetting resin, and thus can replace a carbon fiber composite.

[0114] Another aspect of the present invention is a method for simulating a carbon fiber composite.

[0115] The above carbon fiber composite simulation method forms a carbon fiber simulation pattern on the surface of a synthetic resin, and the carbon fiber simulation pattern is formed by forming a groove imprinted from a mold on part or all of the surface of the synthetic resin, and light is diffusely reflected in the groove.

[0116] The above carbon fiber composite simulation method uses a thermoplastic synthetic resin that is easy to recycle instead of a thermosetting synthetic resin that cannot be recycled, forms a certain pattern in advance in a mold, and imprints the pattern on the surface of the carbon fiber composite to simulate the surface texture of the carbon fiber composite as it is, and specifically, can simulate and implement the surface texture of forged carbon.

[0117] Another aspect of the present invention is a method for manufacturing a synthetic resin molded body using a synthetic resin that does not contain carbon fiber.

[0118] The above method for manufacturing a synthetic resin molded body includes a step of injecting a synthetic resin that does not contain carbon fibers into a mold having a pattern formed thereon, wherein the pattern is formed by etching the surface of the mold, and the pattern may be imprinted on the surface of the synthetic resin.

[0119] The above method for manufacturing a synthetic resin molded body can form a pattern by etching a mold to imitate the texture of carbon fiber without using actual carbon fiber, and then imprint the pattern on the surface of the synthetic resin by injection molding the synthetic resin.

[0120] The above pattern is a three-dimensional shape of a pulverized piece of forged carbon, which is more specifically copied in a plane, and a straight groove can be formed within the unit structure cell. Depending on the pattern, the arrangement angle of each groove can be adjusted differently so that each pattern portion can exhibit different gloss and contrast.

[0121] In one specific example, the pattern can be formed by etching or laser processing the surface of the mold.

[0122] The above mold can be etched or laser processed to implement various patterns in intaglio and relief, and it is very easy to form a pattern portion on the surface when molding the synthetic resin base portion.

[0123] Therefore, a method for manufacturing a synthetic resin molded body according to another aspect of the present invention can provide a synthetic resin molded body that imitates the surface of a carbon fiber composite, particularly a forged carbon composite, by injection molding a recyclable thermoplastic resin rather than a thermosetting resin.

[0124]

[0125] Hereinafter, preferred examples are presented to help understand the present invention, but the following examples are only to illustrate the present invention and the scope of the present invention is not limited to the following examples.

[0126]

[0127] Manufacturing example

[0128] An image of the carbon fibers cut and arranged in a three-dimensional, irregular manner was obtained from one side.

[0129] FIG. 2 is a schematic diagram showing a process of converting a 3D stereoscopic structure into a 2D image in a method for manufacturing a synthetic resin molded body according to one specific example of the present invention.

[0130] In Fig. 2, (a) is a 3D image of carbon fiber, and (b) is a 2D image observed from the front.

[0131] Referring to Fig. 2, the three-dimensional shape of an actual cut forged carbon piece was converted into a 2D image to obtain an image for hairline shaping.

[0132]

[0133] Example 1

[0134] FIG. 3 is a schematic diagram showing a process of forming a pattern portion on a surface with a 2D image in a synthetic resin molded body according to one specific example of the present invention.

[0135] In Fig. 3, (a) is a 3D image of a unit structure cell, (b) is a shape of a unit structure cell simulated after 2D conversion of the unit structure cell, and (c) shows a group-by-group stripe pattern or hairline pattern of the unit structure cell.

[0136] Referring to Fig. 3, in (a), a 2D image of forged carbon arranged on a plane was acquired, and in (b), similar unit structure cells were grouped together on the image. Based on the grouped image, the surface of an injection mold was chemically etched to form a pattern, and then polycarbonate (PC), a thermoplastic resin, was injection-molded into the mold to manufacture a base portion having a thickness of 2 mm and having a pattern imprinted thereon. A pattern portion was formed on the upper portion of the base portion, and the pattern portion included a plurality of unit structure cells including a hairline according to the mold pattern.

[0137] At this time, the depth of the hairline valley was adjusted to 30㎛, the width of the peak was adjusted to approximately 100㎛, and the spacing between adjacent peaks was adjusted to approximately 100㎛. In order to utilize it as a synthetic resin molded body for the exterior of a small IT device, a pattern part was formed by injection molding so that each unit structure cell was formed within a rectangle of approximately 0.5mm Х 6mm.

[0138]

[0139] Example 2

[0140] A synthetic resin molded body was manufactured according to Example 1, and about 1 wt% of round glass fibers with a radius of about 5 ㎛ were added, and about 0.1 wt% of mica and about 0.1 wt% of aluminum particles were added together to manufacture a base portion, and a pattern portion was formed on the surface to manufacture a synthetic resin molded body.

[0141]

[0142] Example 3

[0143] Matte and glossy coatings were applied to the surface of the synthetic resin molded body manufactured according to Example 2.

[0144]

[0145] Comparative Example 1

[0146] Carbon fibers were cut and bonded with epoxy resin to produce a forged carbon composite. The forged carbon fibers were placed within approximately 2 to 4 mm in width and 1 to 2 mm in length.

[0147]

[0148] Comparative Example 2

[0149] A carbon-mimetic film was transferred onto a synthetic resin substrate.

[0150]

[0151] Comparative Example 3

[0152] We prepared a small IT device with a forged carbon composite pattern, the G-Shock Mudmaster (CASIO).

[0153]

[0154] Confirmation of carbon fiber composite texture implementation

[0155] By comparing the appearance of Examples 1 to 3 and Comparative Examples 1 to 3, it was confirmed whether the texture of a forged carbon composite could be implemented.

[0156] Figure 4 compares a synthetic resin molded body and a forged carbon composite material according to one specific example of the present invention.

[0157] Referring to Fig. 4, simply by providing a pattern portion in which unit structure cells with hairlines are formed on the surface of a base portion made of thermoplastic synthetic resin, diffuse reflection occurs in each unit structure cell, and differences in gloss and brightness occur depending on the viewing angle. Accordingly, it was confirmed that the surface texture of Comparative Example 1, which was manufactured by pressing actual forged carbon into a thermosetting resin, can be implemented as is, and compared to the film attachment of Comparative Example 2 or the manufacturing process of the forged carbon composite of Comparative Example 3, it was confirmed that the surface texture of the forged carbon composite can be imitated and shaped into a spherical shape only with an injection molding process using a simple etching mold.

[0158] Meanwhile, in Examples 2 and 3, when glass fibers, pearls, and metal particles were further added and a pattern portion was formed, it was confirmed that not only was the texture of the forged carbon composite material directly implemented, but also that it was more similar to the appearance of an actual forged carbon composite material. In addition, when a matte or glossy coating layer was formed on the surface, the pattern portion was effective in displaying the surface texture of the forged carbon composite material, and it was confirmed that the durability of the pattern portion was improved by the formation of the coating layer, so that the synthetic resin molded body could replace the forged carbon composite material.

[0159]

[0160] The present invention has been described with reference to exemplary embodiments. Those skilled in the art will appreciate that the present invention can be implemented in modified forms without departing from its essential characteristics. Therefore, the disclosed embodiments should be considered illustrative rather than limiting. The scope of the present invention is set forth in the claims, not the foregoing description, and all differences within the scope equivalent thereto should be construed as being encompassed by the present invention.

Claims

1. A pattern is formed on at least one side, The above pattern portion includes multiple areas, The above multiple areas are A first region in which grooves are formed in a first direction; and A second region in contact with the first region and having a groove formed in a second direction different from the first direction; A carbon fiber-mimicking synthetic resin molded body including:

2. A carbon fiber-mimicking synthetic resin molded body according to claim 1, further comprising a third region in contact with the first region and having a groove formed in a third direction.

3. In the first or second paragraph, the synthetic resin molded body is a carbon fiber-imitation synthetic resin molded body that does not contain carbon fiber.

4. A carbon fiber-mimicking synthetic resin molded body according to any one of claims 1 to 3, wherein the molded body further comprises glass fiber.

5. A carbon fiber-mimicking synthetic resin molded body according to any one of claims 1 to 4, wherein the molded body further comprises pearls, metal particles, or a mixture thereof.

6. Base section; and including a pattern portion formed on the surface of the base portion; The above pattern portion has unit structure cells that are irregularly distributed, The above unit structure cell is formed by arranging multiple hairlines at a certain angle, and the hairlines are arranged at different angles from the hairlines of adjacent unit structure cells. Synthetic resin molded body.

7. A synthetic resin molded body in the 6th paragraph, wherein the base part is at least one of polypropylene (PP), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polyethylene (PE), polyethylene terephthalate (PET), polystyrene (PS), polyvinyl chloride (PVC), polyamide (PA), polycarbonate-acrylonitrile butadiene styrene (PC-ABS), and polybutylene terephthalate (PBT).

8. A synthetic resin molded body according to claim 6 or 7, wherein the unit structure cell has a pattern determined according to a shape that mimics the three-dimensional shape of the pulverized carbon piece in a plane.

9. A synthetic resin molded body according to any one of claims 6 to 8, wherein the hairline is formed by straight lines lining up to form a peak and a valley.

10. A synthetic resin molded body according to any one of claims 6 to 9, wherein the hairlines are arranged at the same angle.

11. A synthetic resin molded body according to any one of claims 6 to 10, wherein the bone portion is formed as a flat surface and is black in color.

12. A synthetic resin molded body according to any one of claims 6 to 11, wherein the depth of the groove is about 2 µm to 60 µm, the width of the peak is about 10 µm to 300 µm, and the distance between adjacent peaks is about 10 µm to 300 µm.

13. A synthetic resin molded body according to any one of claims 6 to 12, wherein the depths of the grooves within the same unit structure cell are all the same.

14. A synthetic resin molded body according to any one of claims 6 to 13, wherein the unit structure cell is irregular and is limited to be arranged within a rectangle having a width of about 0.25 mm to 5 mm and a length of about 0.5 mm to 7 mm, or is limited to be arranged within a rectangle having a width of about 20 mm to 70 mm and a length of about 100 mm to 250 mm.

15. A synthetic resin molded body according to any one of claims 6 to 14, wherein the base part further comprises glass fiber.

16. A synthetic resin molded body according to any one of claims 6 to 15, wherein the base part further comprises pearls, metal particles, or a mixture thereof.

17. A synthetic resin molded body according to any one of claims 6 to 16, wherein a coating layer is formed on the pattern portion to a thickness of about 5 µm to 50 µm.

18. A synthetic resin molded body according to any one of claims 6 to 17, wherein the hairline is formed by imprinting according to a pattern formed in a mold.

19. Carbon fiber composite simulation method, Forming a carbon fiber imitation pattern on the surface of a synthetic resin, The above carbon fiber imitation pattern is a carbon fiber composite imitation method in which a part or all of a synthetic resin surface forms a groove imprinted from a mold, and light is diffusely reflected from the groove.

20. A step of injecting a synthetic resin that does not contain carbon fiber into a mold having a pattern formed therein, A method for manufacturing a synthetic resin molded body, wherein the above pattern is formed by etching the surface of a mold, and the pattern is imprinted on the surface of a synthetic resin.

21. A method for manufacturing a synthetic resin molded body, wherein the pattern is formed by etching or laser processing the surface of the mold in the 20th paragraph.

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