Decorative molded article and production method for same

Abstract

Provided is a decorative molded article capable of improving the visibility of an object visually recognized through a decorative sheet.　A decorative sheet (2) comprises a transparent film (10); a design layer (11) disposed on the transparent film (10); and a shielding layer (12) disposed on the design layer (11). A plurality of holes (14) are provided in the design layer (11) and the shielding layer (12). Laser processing marks (18) are formed on the surface, among the surfaces defining the plurality of holes (14), closest to the transparent film (10). The plurality of holes (14) are filled with a molded body (22).

Description

Decorated molded product and method for manufacturing the same

[0001] This disclosure relates to a decorated molded article and a method for manufacturing the same.

[0002] International Publication No. 2020 / 196906 discloses a display device with a decorative sheet, which includes a display device and a decorative sheet positioned opposite the display device. The decorative sheet includes a base film, a design layer, and a light-shielding layer. Holes are formed in the design layer and the light-shielding layer as light-transmitting portions. When the display device is in the off state, a person viewing the display device with the decorative sheet sees the design layer. When the display device is in the on state, a person viewing the display device with the decorative sheet sees the image light from the display device through the holes.

[0003] International Publication No. 2020 / 196906

[0004] The purpose of this disclosure is to provide a decorative molded article and a method for manufacturing the same that can improve the visibility of an object seen through a decorative sheet.

[0005] The decorative molded article of this disclosure comprises a transparent film, a design layer disposed on the transparent film, a shielding layer disposed on the design layer, and a molded body disposed on the shielding layer. A plurality of holes are provided in the design layer and the shielding layer. Laser processing marks are formed on the surface closest to the transparent film among the surfaces defining the plurality of holes. The plurality of holes are filled with the molded body.

[0006] The method for manufacturing a decorated molded article according to this disclosure includes forming a design layer on a transparent film, forming a shielding layer on the design layer, and forming a plurality of holes in the design layer and the shielding layer by irradiating them with laser light from the side of the shielding layer opposite to the side of the transparent film. Laser processing marks are formed on the surface closest to the transparent film among the surfaces that define the plurality of holes. The method for manufacturing a decorated molded article according to this disclosure also includes forming a molded body on the shielding layer. Forming the molded body includes filling the plurality of holes with the molded body.

[0007] The decorative molded articles and methods for manufacturing the same described herein can improve the visibility of objects visible through the decorative sheet.

[0008] This is a schematic perspective view of the decorated molded product and display device according to the embodiment. This is a schematic plan view of the decorated molded product and display device according to the embodiment when the object is not visible. This is a schematic plan view of the decorated molded product and display device according to the embodiment when the object is visible. This is a schematic partially enlarged plan view of the decorated molded product and display device according to the embodiment. This is a schematic partially enlarged cross-sectional view of the decorated molded product and display device according to the embodiment along the cross-sectional line V-V shown in Figure 4. This is a flowchart of the manufacturing method of the decorated molded product according to the embodiment. This is a schematic partially enlarged cross-sectional view showing the process of forming a plurality of holes. This is a schematic partially enlarged cross-sectional view showing one step in the process of forming a molded body. This is a schematic partially enlarged cross-sectional view showing the next step in the process of forming a molded body, following the step shown in Figure 8. This is a schematic partially enlarged cross-sectional view of the decorated molded product and display device according to the first modified example of the embodiment. This is a schematic partially enlarged cross-sectional view of the decorated molded product and display device according to the second modified example of the embodiment.

[0009] Embodiments of the present disclosure will be described below. The same components will be given the same reference numerals, and their descriptions will not be repeated.

[0010] An embodiment of the decorative molded product 1 will be described with reference to Figures 1 to 5. The decorative molded product 1 is, for example, a cover panel such as an interior or exterior panel of a car. The decorative molded product 1 is applied, for example, to a display device 6 equipped with a light-emitting element 23. The decorative molded product 1 comprises a decorative sheet 2 and a molded body 22. The decorative molded product 1 may further include an adhesive layer 20.

[0011] Referring to Figure 2, when the light-emitting element 23 (see Figure 5) does not emit light, a person viewing the decorated molded product 1 will see the design layer 11 of the decorative sheet 2 (see Figure 5). Referring to Figure 3, when the light-emitting element 23 emits light, a person viewing the decorated molded product 1 will see, in addition to the design layer 11, the light passing through the multiple holes 14 of the decorative sheet 2 (see Figures 4 and 5) as object 7.

[0012] Referring to Figures 4 and 5, the decorative sheet 2 has a front surface 3 and a back surface 4 opposite to the front surface 3. A person viewing the decorative molded product 1 views the decorative sheet 2 from the front surface 3. The decorative sheet 2 includes a transparent film 10, a design layer 11, and a shielding layer 12.

[0013] The transparent film 10 is transparent to visible light, such as light from the light-emitting body 23. The transparent film 10 is formed of, for example, at least one of a resin or an elastomer. Examples of resins that make up the transparent film 10 include polyester resin, polyethylene terephthalate (PET) resin, acrylic resin, polycarbonate resin, polybutylene terephthalate (PBT) resin, triacetylcellulose resin, styrene resin, or acrylonitrile-butadiene-styrene (ABS) resin. Examples of elastomers that make up the transparent film 10 include thermoplastic elastomers (TPE). Examples of thermoplastic elastomers include amide-based TPE (TPA), ester-based TPE (TPC), olefin-based TPE (TPO), styrene-based TPE (TPS), and urethane-based TPE (TPU). The transparent film 10 may be a single-layer film or a multi-layer film.

[0014] The transparent film 10 may contain a weather-resistant agent. Examples of weather-resistant agents include ultraviolet absorbers, light stabilizers, or ultraviolet blockers. This improves the weather resistance of the decorative sheet 2.

[0015] The transparent film 10 is a base film that supports the design layer 11 and the shielding layer 12. The transparent film 10 is positioned near the front surface 3 of the decorative sheet 2 relative to the design layer 11. The transparent film 10 has a main surface 10a that faces the design layer 11. The main surface 10a is the main surface of the transparent film that is distal to the front surface 3 of the decorative sheet 2.

[0016] Referring to Figure 5, the design layer 11 is arranged on the main surface 10a of the transparent film 10. The design layer 11 includes, for example, a binder and a pigment dispersed in the binder. The pigment is, for example, an interference pigment, an absorption pigment, or a metallic pigment, or a combination of two or more of these pigments. An interference pigment is a pigment that generates colored light through the interference of light reflected by the interference pigment. An absorption pigment is a pigment that generates colored light by absorbing light of a certain wavelength from the light incident on the absorption pigment. A metallic pigment is a pigment that exhibits metallic luster, such as metal flakes such as aluminum flakes. A pattern such as wood grain may be formed on the design layer 11. The design layer 11 may be a single layer or multiple layers.

[0017] Referring to Figure 5, the shielding layer 12 is positioned on the design layer 11. The shielding layer 12 is positioned near the back surface 4 of the decorative sheet 2 relative to the design layer 11. The shielding layer 12 is positioned on the side opposite to the transparent film 10 relative to the design layer 11. The shielding layer 12 blocks visible light, such as light from the light-emitting element 23, and also conceals objects on the back surface 4 side of the decorative sheet 2 (e.g., the light-emitting element 23) from those viewing the decorated molded product 1. The shielding layer 12 includes, for example, a binder and a black pigment dispersed in the binder.

[0018] Referring to Figures 4 and 5, a plurality of holes 14 are provided in the design layer 11 and the shielding layer 12. In a plan view of the main surface 10a of the transparent film 10, the shape of each of the plurality of holes 14 is not particularly limited, but may be circular, elliptical, triangular, square, or hexagonal. The plurality of holes 14 penetrate the design layer 11 and the shielding layer 12.

[0019] Each of the multiple holes 14 is of a size that is difficult for an observer of the decorated molded product 1 to see. In a plan view of the main surface 10a of the transparent film 10, the area of ​​each of the multiple holes 14 is, for example, 1.8 mm. ２ The following applies: The area of ​​each of the multiple holes 14 is 1.0 mm². ２ The following is also possible: The area of ​​each of the multiple pores 14 is, for example, 3840 μm². ２ That concludes the explanation. The area of ​​each of the multiple holes 14 is 0.018 mm².２ The above is also acceptable. The area of ​​each of the multiple pores 14 is, for example, 3840 μm². ２ 1.8 mm ２ The following applies: The area of ​​each of the multiple holes 14 is 0.018 mm². ２ 1.0 mm or more ２ The following is also acceptable.

[0020] The aperture ratio of the multiple holes 14 is, for example, 10% or more. The aperture ratio of the multiple holes 14 is, for example, 20% or less. The aperture ratio of the multiple holes 14 is, for example, 10% or more and 20% or less. In this specification, the aperture ratio of the multiple holes 14 is the ratio of the area of ​​the multiple holes 14 to the area of ​​the shielding layer 12 in a plan view of the main surface 10a of the transparent film 10. Because the aperture ratio is 20% or less, it is possible to prevent objects on the back side 4 of the decorative sheet 2 (for example, light-emitting body 23, etc.) from being visible to a person viewing the decorative sheet 2. Because the aperture ratio is 10% or more, the visibility of the object 7 visible through the multiple holes 14 is improved.

[0021] In a plan view of the main surface 10a, the multiple holes 14 are arranged, for example, in a staggered pattern (see Figure 4), a triangular grid pattern, a square grid pattern, or a hexagonal grid pattern. Referring to Figure 4, the multiple holes 14 are arranged along a first direction DR1 and a second direction DR2 that intersects the first direction DR1. The second direction DR2 may be perpendicular to the first direction DR1. The first direction DR1 may be the longitudinal direction of the transparent film 10, and the second direction DR2 may be the short direction of the transparent film 10. The main surface 10a of the transparent film 10 extends in the first direction DR1 and the second direction DR2. The multiple holes 14 may also be arranged along a third direction DR3 that is oblique to the first direction DR1 and the second direction DR2. The third direction DR3 may be at an angle of 45° with respect to the first direction DR1 and the second direction DR2.

[0022] Multiple holes 14 are arranged in a first direction DR1 with a first pitch. The first pitch is the distance between the centers of two adjacent holes 14 in the first direction DR1. Multiple holes 14 are arranged in a second direction DR2 with a second pitch. The second pitch is the distance between the centers of two adjacent holes 14 in the second direction DR2. Multiple holes 14 are arranged in a third direction DR3 with a third pitch. The third pitch is the distance between the centers of two adjacent holes 14 in the third direction DR3.

[0023] Laser processing marks 18 are formed on the bottom surface 16 of the multiple holes 14. The bottom surface 16 of the multiple holes 14 is the surface closest to the transparent film 10 among the surfaces that define the multiple holes 14. The bottom surface 16 of the multiple holes 14 is part of the main surface 10a of the transparent film 10. This part of the main surface 10a of the transparent film 10 is rougher than other parts of the main surface 10a of the transparent film 10. The laser processing marks 18 are formed on the bottom surface 16 of the multiple holes 14 by irradiating the design layer 11 and the shielding layer 12 with laser light 27 (see Figure 7) from the side opposite to the transparent film 10 in order to form the multiple holes 14.

[0024] The total light transmittance of the decorative sheet 2 is, for example, 5% or more. The total light transmittance of the decorative sheet 2 may be 10% or more. The total light transmittance of the decorative sheet 2 is, for example, 50% or less. The total light transmittance of the decorative sheet 2 may be 30% or less. The total light transmittance of the decorative sheet 2 is, for example, 5% or more and 50% or less. The total light transmittance of the decorative sheet 2 may be 10% or more and 30% or less.

[0025] The molded body 22 is placed on the shielding layer 12 of the decorative sheet 2. The molded body 22 is placed on the back surface 4 of the decorative sheet 2. The molded body 22 supports the decorative sheet 2. The molded body 22 is placed between the decorative sheet 2 and the light-emitting body 23. The molded body 22 is transparent to visible light, such as light from the light-emitting body 23. The molded body 22 is formed from a resin such as a thermoplastic resin or a thermosetting resin, or from glass, for example. The molded body 22 is shaped into a three-dimensional form, such as a flat plate or a curved plate.

[0026] As shown in Figure 5, the multiple holes 14 are filled with the molded body 22. The laser processing marks 18 are filled with the molded body 22. The portion of the molded body 22 that fills the multiple holes 14 is in contact with the transparent film 10. The difference between the refractive index of the molded body 22 and the refractive index of the transparent film 10 is smaller than the difference between the refractive index of the molded body 22 and the refractive index of air. Therefore, the portion of the molded body 22 that fills the multiple holes 14 reduces the scattering of visible light caused by the laser processing marks 18. The visibility of the object 7 seen through the multiple holes 14 is improved. The molded body may be formed from the same resin material as the transparent film 10.

[0027] The molded body 22 may be bonded to the shielding layer 12 using an adhesive layer 20. The adhesive layer 20 is transparent to visible light, such as light from the light-emitting body 23. The adhesive layer 20 is formed of, for example, an optically transparent adhesive (OCA) or an optically transparent resin (OCR).

[0028] Referring to Figures 1 and 5, the display device 6 includes a decorated molded product 1 and a light-emitting element 23. The display device 6 may further include an adhesive layer 24.

[0029] The light-emitting element 23 is positioned on the back surface 4 of the decorative sheet 2. The light-emitting element 23 is positioned on the side opposite to the decorative sheet 2 relative to the molded body 22.

[0030] The light-emitting element 23 may be an illumination light source such as a light-emitting diode (LED) light source. The illumination light source itself does not have the function of displaying characters, numbers, icons, symbols, or figures. When the light-emitting element 23 is an illumination light source, the multiple holes 14 are arranged in the shape of characters, numbers, icons, symbols, or figures. The multiple holes 14 can function as multiple pixels of characters, numbers, icons, symbols, or figures. When the illumination light source illuminates the decorative sheet 2, a person viewing the decorative molded product 1 can see characters, numbers, icons, symbols, or figures as objects 7 through the multiple holes 14, along with the design layer 11.

[0031] The light-emitting element 23 may be a display device such as an LED display, an organic electroluminescent (EL) display, or a liquid crystal display (LCD). The display device outputs image light such as characters, numbers, icons, symbols, or figures toward the molded body 22 and the decorative sheet 2. When the light-emitting element 23 is a display device, the plurality of holes 14 are arranged two-dimensionally and periodically and can function as a plurality of pixels. A person viewing the decorated molded product 1 will see the characters, numbers, icons, symbols, or figures displayed by the display device, along with the design layer 11, as objects 7 through the plurality of holes 14.

[0032] The light-emitting element 23 may be bonded to the molded body 22 using an adhesive layer 24. The adhesive layer 24 is transparent to visible light, such as light from the light-emitting element 23. The adhesive layer 24 is formed of, for example, an optically transparent adhesive (OCA) or an optically transparent resin (OCR). The difference between the refractive index of the molded body 22 and the refractive index of the adhesive layer 24 is smaller than the difference between the refractive index of the molded body 22 and the refractive index of air. The difference between the refractive index of the front surface of the light-emitting element 23 facing the molded body 22 and the refractive index of the adhesive layer 24 is smaller than the difference between the refractive index of the front surface of the light-emitting element 23 and the refractive index of air. Therefore, the adhesive layer 24 reduces the reflection of light from the light-emitting element 23 on the back surface of the molded body 22 and the front surface of the light-emitting element 23. The visibility of the object 7, which is visible through the multiple holes 14, is improved.

[0033] An example of a manufacturing method for the decorated molded product 1 of this embodiment will be described, mainly with reference to Figures 6 to 9.

[0034] Referring to Figures 6 and 7, a design layer 11 is formed on the main surface 10a of the transparent film 10 (Step S1). For example, an ink containing a binder and a pigment is printed on the main surface 10a of the transparent film 10. The ink is dried. In this way, the design layer 11 is formed.

[0035] Referring to Figures 6 and 7, a shielding layer 12 is formed on the design layer 11 (step S2). For example, a black ink containing a binder and black pigment dispersed in the binder is printed on the design layer 11. The black ink is dried. In this way, the shielding layer 12 is formed.

[0036] Referring to FIGS. 6 and 7, a plurality of holes 14 are formed in the design layer 11 and the shielding layer 12 (step S3). The plurality of holes 14 penetrate through the design layer 11 and the shielding layer 12. For example, the design layer 11 and the shielding layer 12 are irradiated with laser light 27 from the side opposite to the side of the transparent film 10. A part of the design layer 11 and a part of the shielding layer 12 absorb the laser light 27 and are removed. Thus, the plurality of holes 14 are formed in a shorter time. The productivity of the decorative sheet 2 is improved. The laser light 27 has a wavelength of, for example, 0.2 μm or more and 11 μm or less. The light source of the laser light 27 is, for example, a carbon dioxide laser, a fiber laser or a solid laser (for example, yttrium vanadate (YVO ４ ) laser or yttrium aluminum garnet (YAG) laser, etc.).

[0037] By irradiating the design layer 11 and the shielding layer 12 with the laser light 27, laser processing marks 18 are formed on the bottom surfaces 16 of the plurality of holes 14. The bottom surfaces 16 of the plurality of holes 14 are part of the main surface 10a of the transparent film 10. A part of the main surface 10a of the transparent film 10 is rougher than other parts of the main surface 10a of the transparent film 10.

[0038] When forming the plurality of holes 14 in the design layer 11 and the shielding layer 12, since the laser light 27 is incident on the design layer 11 and the shielding layer 12 from the back surface 4 of the decorative sheet 2, it can be prevented that the weather resistance improver contained in the transparent film 10 absorbs the laser light 27. A plurality of holes 14 having a clean shape can be formed. The visibility of the object 7 viewed through the plurality of holes 14 is improved.

[0039] By steps S1 - S3, the decorative sheet of the present embodiment is obtained. In other words, the manufacturing method of the decorative sheet of the present embodiment includes steps S1 - S3.

[0040] Referring to FIGS. 5, 6, 8, and 9, a molded body 22 is formed on the shielding layer 12 of the decorative sheet 2 (step S4).

[0041] Referring to FIGS. 8 and 9, in the first example of step S4, when the molded body 22 is injection molded, the decorative sheet 2 is adhered to the molded body 22. Specifically, an adhesive layer 20 is formed on the shielding layer 12 of the decorative sheet 2. Referring to FIG. 8, the decorative sheet 2 is disposed on the first mold 31. The first mold 31 and the second mold 32 are clamped. The adhesive layer 20 of the decorative sheet 2 faces the second mold 32. The second mold 32 is provided with a sprue 34 which is a passage for molten resin. The first mold 31 may be a movable mold with a recess formed therein, and the second mold 32 may be a fixed mold with a protrusion formed therein. A cavity 33 is formed between the decorative sheet 2 and the second mold 32. The sprue 34 communicates with the cavity 33. Referring to FIG. 9, molten resin is injected into the cavity 33 through the sprue 34. The plurality of holes 14 are filled with the molten resin. The molten resin is cooled and solidified. Thus, the molded body 22 is formed. The plurality of holes 14 are filled with the molded body 22. The decorative sheet 2 is adhered to the molded body 22 by the adhesive layer 20.

[0042] In the second example of step S4, without the adhesive layer 20, when the molded body 22 is injection molded, the decorative sheet 2 is transferred to the molded body 22.

[0043] (Modification) Referring to FIG. 10, in the first modification of the present embodiment, the plurality of holes 14 may terminate within the design layer 11. The bottom surface 16 of the plurality of holes 14 in which the laser processing marks 18 are formed may be a part of the surface of the design layer 11. The difference between the refractive index of the molded body 22 and the refractive index of the design layer 11 is smaller than the difference between the refractive index of the molded body 22 and the refractive index of air. Therefore, the portion of the molded body 22 filled with the plurality of holes 14 reduces the scattering of visible light due to the laser processing marks 18. The visibility of the object 7 viewed through the plurality of holes 14 is improved.

[0044] Referring to FIG. 11, in the second modification of the present embodiment, the light emitter 23 may be disposed on the side opposite to the decorative sheet 2 with respect to the molded body 22 without using the adhesive layer 24. The light emitter 23 may be disposed at an interval from the molded body 22 as shown in FIG. 11, or may be in contact with the molded body 22.

[0045] The effects of the decorated molded product 1 and its manufacturing method according to this embodiment will be described. The decorated sheet 2 according to this embodiment comprises a transparent film 10, a design layer 11 disposed on the transparent film 10, and a shielding layer 12 disposed on the design layer 11. Multiple holes 14 are provided in the design layer 11 and the shielding layer 12. Laser processing marks 18 are formed on the surface closest to the transparent film 10 among the surfaces defining the multiple holes 14 (the bottom surface 16 of the multiple holes 14). The multiple holes 14 are filled with a molded body 22.

[0046] Therefore, the laser processing marks 18 are filled with the molded body 22. The molded body 22 reduces the scattering of visible light caused by the laser processing marks 18. The decorated molded product 1 of this embodiment can improve the visibility of the object 7 that is viewed through the decorative sheet 2.

[0047] In the decorated molded product 1 of this embodiment, the portion of the molded body 22 that fills the plurality of holes 14 is in contact with the transparent film 10. The difference between the first refractive index of the transparent film 10 and the second refractive index of the molded body 22 is smaller than the difference between the first refractive index of the transparent film 10 and the refractive index of air.

[0048] Therefore, the molded body 22 reduces the scattering of visible light caused by the laser processing marks 18. The decorated molded product 1 of this embodiment can improve the visibility of the object 7 that is visible through the decorative sheet 2.

[0049] The manufacturing method for the decorated molded product 1 of this embodiment includes forming a design layer 11 on a transparent film 10 (step S1), forming a shielding layer 12 on the design layer 11 (step S2), and forming a plurality of holes 14 in the design layer 11 and the shielding layer 12 by irradiating the design layer 11 and the shielding layer 12 with laser light 27 from the side of the shielding layer 12 opposite to the side of the transparent film 10 (step S3). Laser processing marks 18 are formed on the surface closest to the transparent film 10 among the surfaces defining the plurality of holes 14 (the bottom surface 16 of the plurality of holes 14). The manufacturing method for the decorated molded product 1 of this embodiment includes forming a molded body 22 on the shielding layer 12 (step S4). Forming the molded body 22 (step S4) includes filling the plurality of holes 14 with the molded body 22.

[0050] Therefore, the laser processing marks 18 are filled in by the molded body 22. The molded body 22 reduces the scattering of visible light caused by the laser processing marks 18. The manufacturing method of the decorated molded product 1 of this embodiment can provide a decorated molded product 1 that can improve the visibility of the object 7 that is visible through the decorative sheet 2.

[0051] The embodiments and variations thereof disclosed herein should be considered in all respects to be illustrative and not restrictive. The scope of this disclosure is indicated by the claims rather than the foregoing description and is intended to include all modifications in the sense and scope equivalent to the claims.

[0052] 1 Decorative molded product, 2 Decorative sheet, 3 Front, 4 Back, 6 Display device, 7 Object, 10 Transparent film, 10a Main surface, 11 Design layer, 12 Shielding layer, 14 Hole, 16 Bottom surface, 18 Laser processing marks, 20, 24 Adhesive layer, 22 Molded body, 23 Light emitter, 27 Laser beam, 31 First mold, 32 Second mold, 33 Cavity, 34 Sprue.

Claims

1. A decorative molded product comprising: a transparent film; a design layer disposed on the transparent film; a shielding layer disposed on the design layer; and a molded body disposed on the shielding layer, wherein the design layer and the shielding layer are provided with a plurality of holes, laser processing marks are formed on the surface closest to the transparent film among the surfaces defining the plurality of holes, and the plurality of holes are filled with the molded body.

2. The portion of the molded body that fills the plurality of holes is in contact with the transparent film, and the difference between the first refractive index of the transparent film and the second refractive index of the molded body is smaller than the difference between the first refractive index of the transparent film and the refractive index of air, as described in claim 1.

3. A method for manufacturing a decorated molded article, comprising: forming a design layer on a transparent film; forming a shielding layer on the design layer; and irradiating the design layer and the shielding layer with laser light from the side of the shielding layer opposite to the side of the transparent film, thereby forming a plurality of holes in the design layer and the shielding layer, wherein laser processing marks are formed on the surface closest to the transparent film among the surfaces defining the plurality of holes; and further comprising forming a molded body on the shielding layer, wherein forming the molded body includes filling the plurality of holes with the molded body.

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