U.S. patent application number 15/312195 was filed with the patent office on 2017-03-30 for decorative parts and a method for manufacturing the same.
The applicant listed for this patent is TRINITY INDUSTRIAL CORPORATION. Invention is credited to Kouji ADACHI, Keisuke ISOGAI, Tatsuki OCHIAI.
Application Number | 20170087928 15/312195 |
Document ID | / |
Family ID | 54553631 |
Filed Date | 2017-03-30 |
United States Patent
Application |
20170087928 |
Kind Code |
A1 |
ADACHI; Kouji ; et
al. |
March 30, 2017 |
DECORATIVE PARTS AND A METHOD FOR MANUFACTURING THE SAME
Abstract
The automobile decorative-part (1) comprises a resin-compact (3)
having a decorative-layer (2) on its surface-layer and comprises a
clear-coat layer (4) for protecting said surface-layer, and that a
high-gloss region (R1) of a relatively high-gloss level is mixed
with a low-gloss region (R2) of a relatively low-gloss level on the
surface of said decorative-part, and that a clear-coat paint is
sprayed by an atomization-coating machine onto the surface of the
decorative-layer (2), and that the atomization-coating machine
contains an ester-based solvent of a low-boiling point as the
main-solvent that has a boiling-point of 100 degrees Celsius or
less and has a solid-content of 35 to 40 percent by mass, thus
forming the clear-coat layer (4) that makes it partially possible
to mat the gloss of the surface of the clear-coat layer, thus
manufacturing a decorative-part with an excellent quality
design.
Inventors: |
ADACHI; Kouji; (Aichi,
JP) ; OCHIAI; Tatsuki; (Aichi, JP) ; ISOGAI;
Keisuke; (Aichi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TRINITY INDUSTRIAL CORPORATION |
Aichi |
|
JP |
|
|
Family ID: |
54553631 |
Appl. No.: |
15/312195 |
Filed: |
August 20, 2014 |
PCT Filed: |
August 20, 2014 |
PCT NO: |
PCT/JP2014/071725 |
371 Date: |
November 18, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 3/30 20130101; B32B
2605/003 20130101; B32B 2037/246 20130101; B32B 2307/408 20130101;
B32B 2255/26 20130101; B44C 1/1758 20130101; B32B 2451/00 20130101;
B32B 37/025 20130101; B44C 1/24 20130101; B23K 26/402 20130101;
B44F 1/02 20130101; B32B 2309/66 20130101; B44C 1/228 20130101;
B44C 3/02 20130101; B23K 2103/172 20180801; B44F 9/02 20130101 |
International
Class: |
B44F 9/02 20060101
B44F009/02; B32B 37/00 20060101 B32B037/00; B32B 3/30 20060101
B32B003/30; B44C 3/02 20060101 B44C003/02; B23K 26/402 20060101
B23K026/402 |
Foreign Application Data
Date |
Code |
Application Number |
May 20, 2014 |
JP |
2014-104781 |
Aug 1, 2014 |
JP |
2014-157734 |
Claims
1. A method for manufacturing a decorative-part comprising a part
having a decorative-layer on the surface-layer and having a
clear-coat layer for protecting the surface of the
decorative-layer, wherein said surface of the clear-coat layer of a
relatively high-gloss-level region is mixed with a relatively
low-gloss-level region on the surface of the part, characterized in
comprising a decorative-layer-forming process of which the
decorative-layer is formed on the surface-layer of the part, and
then a concave-convex part is formed on the surface of the
decorative-layer that should later be placed beneath the low-gloss
region; and characterized in comprising a clear-coat-layer-forming
process of which a clear-coat layer having a surface-shaped
low-gloss region is formed over the concave-convex part by using a
clear-coat paint containing a low-boiling-point solvent (less than
100 degrees) as the main-solvent and containing a solid-content of
10 to 55 percent by mass; and thereby such clear-coat-layer-forming
process the clear-coat paint is sprayed onto the surface of the
decorative-layer by an atomization-coating machine.
2. A method for manufacturing the decorative-part according to
claim 1, characterized in that the clear-coat paint contains a
solid content of 35 to 40 percent by mass.
3. A method for manufacturing the decorative-part according to
claim 1, characterized in that during the clear-coat-layer-forming
process, the clear-coat paint is sprayed on the condition that the
atomizing-pressure of the atomization-coating machine is 0.06 MPa
to 0.09 MPa.
4. A method for manufacturing the decorative-part according to
claim 1, characterized in that during the clear-coat-forming
process, the clear-coat paint is sprayed on the condition that the
amount of discharge from the of the atomization-coating machine is
50 cc/min or more.
5. A method for manufacturing the decorative-part according to
claim 1, characterized in that during the clear-coat-forming
process, the clear-coat paint is sprayed on the condition that the
amount of discharge from the atomization-coating machine is 50
cc/min to 65 cc/min.
6. A method for manufacturing the decorative-part according to
claim 1, characterized in that during the decorative-layer-forming
process, the decorative-layer part is formed by hydraulically
transferring the transcription-film having the concave-convex part
onto the design-layer.
7. A method for manufacturing the decorative-part according to
claim 1, characterized in that during the decorative-layer-forming
process, a transcription-film, which is laminated by the
design-layer onto which the design is drawn, and laminated by the
gloss-layer onto which the gloss is given, and laminated by the
mat-layer that has the concave-convex part, is hydraulically
transferred, thus forming the design-layer and the gloss-layer and
the mat-layer that makes the decorative-layer.
8. A method for manufacturing the decorative-part according to
claim 7, characterized in that the roughness Ra of the surface of
the mat-layer is 2 .mu.m or less.
9. A method for manufacturing the decorative-part according to
claim 7, characterized in that the mat-layer should contain the
same pigment that is contained in the design-layer formed on the
side of the lower-layer.
10. A method for manufacturing the decorative-part according to
claim 7, characterized in that the design is a wood-effect one, and
that the mat-layer is formed on the section corresponding to the
knot of the wood-grain.
11. A method for manufacturing the decorative-part according to
claim 7, characterized in that the gloss-layer is a transparent
resin-layer made of an acryl-polyol resin and formed of a uniform
thickness on the whole surface of the design-layer on which the
design is provided.
12. A method for manufacturing the decorative-part according to
claim 1, characterized in that the gloss-value indicating the
gloss-level of the high-gloss region becomes 30 or more, and that
the gloss-value of the low-gloss region is 10 or less.
13. A method for manufacturing the decorative-part according to
claim 1, characterized in that during the decorative-layer-forming
process, the concave-convex part is formed on the surface-layer of
the decorative-part by an emboss-processing procedure.
14. A method for manufacturing the decorative-part according to
claim 1, characterized in that during the decorative-layer-forming
process, the concave-convex part is formed on the surface-layer of
the decorative-part by a laser-processing procedure.
15. A decorative-part comprising a part having a decorative-layer
on the surface-layer and having a clear-coat layer for protecting
the surface of the decorative-layer, wherein said surface of the
clear-coat layer of a relatively high-gloss-level region is mixed
with a relatively low-gloss-level region on the surface of the
part, characterized in that the concave-convex part is formed
beneath the low-gloss region on the surface of the
decorative-layer, with the low-gloss region of the clear-coat layer
being of the surface formed upon the concave-convex part; with the
roughness Ra of the surface of the clear-coat layer being 1 .mu.m
or less; and with the difference in the gloss-level between the
high-gloss region and the low-gloss region being twice as much or
more.
16. A decorative-part according to claim 15, characterized in that
the decorative-layer is made of the design-layer onto which the
design is drawn; characterized in that the gloss-layer is one onto
which the gloss is given; and characterized in that the mat-layer
is one having the concave-convex part.
17. A decorative-part according to claim 16, characterized in that
the roughness Ra of the surface of the mat-layer is 2 .mu.m or
less.
18. A decorative-part according to claim 16, characterized in that
the mat-layer should contain the same pigment that is contained in
the design-layer formed on the side of the lower-layer.
19. A decorative-part according to claim 16, characterized in that
the design is a wood-effect one, and that the mat-layer is formed
on the section corresponding to the knot of the wood-grain.
20. A decorative part according to claim 16, characterized in that
the gloss-layer is a transparent resin-layer made of an
acryl-polyol resin formed of a uniform thickness on the whole
surface of the design-layer on which the design is provided.
21. A decorative-part according to claim 16, characterized in that
the gloss-value indicating the gloss-level of the high-gloss region
is 30 or more, and that the gloss-value of the low-gloss region is
10 or less.
Description
TECHNICAL FIELD
[0001] This invention relates to a decorative-part of a
high-gloss-level region mixed with a low-gloss-level region on the
surface of the part, and relates to a method for manufacturing the
same.
TECHNICAL BACKGROUND
[0002] To improve the quality of the design of automobile
interior-parts, the decorative-parts (i.e. console-boxes,
instrument-panels, armrests or the like) of which a decoration is
added onto the surface of a resin-compact, are nowadays put to
practical use. As a method for enhancing the decoration of the
decorative-parts, the hydraulic-transfer method is generally used.
(see for example Patent Document 1)
[0003] The hydraulic-transfer method is one by which a special film
with some predetermined design (i.e. a wood-grain pattern, a
geometric-pattern or the like) is floated on the surface of water
to transfer by water-pressure such design to the surface of the
resin-compact. Of the hydraulic-transfer method, the
decorative-layer (print-layer) that is transferred to the surface
of the resin-compact is weaker and un-durable, compared to the
coat-layer. Therefore, a clear-coat layer (protective-surface
layer) for protecting the surface of the decorative-layer is formed
by a clear-coating process. Furthermore, to increase the quality of
the design on the surface of the part, the clear-coat layer, with
or without gloss, is formed depending on the design-pattern.
[0004] Patent Document 1 shows a method for forming a
concave-convex part on the surface of the decorative-part by
hydraulically transferring the film of an ink-layer
(decorative-layer) with a repellent effect of the ink-layer and
with a convergence of the activator. Such a concave-convex part on
the surface of the part provides a visually and tactually
three-dimensional look (concave-convex texture)
PRIOR ARTS
Patent Documents
Patent Document 1: Published Unexamined Patent Application
2009-101657
SUMMARY OF THE INVENTION
Problems to be Resolved by the Invention
[0005] The conventional decorative-part, on which surface a
clear-coat layer is formed by a clear-coating procedure, can
provide only a monotonous glossing (specifically, the condition of
which the gloss is formed on the whole surface of said part or of
which no gloss is formed on the whole surface). Thus, it was
impossible to realize visually the representative cube by partially
changing the gloss on the surface of said decorative-part.
[0006] When doing the hydraulic-transfer using the
transcription-film of Patent Document 1, a concave-convex part is
provided on the surface of the part. However, forming the
clear-coated layer to protect the surface of the part causes the
problem of the three-dimensional look of the concave-convex part to
deteriorate. Contrarily, if such a protective-surface layer
(clear-coat layer) is not formed, since the height of the
convex-part projecting from the surface of the part is
approximately 12 .mu.m, such a convex-part becomes worn by friction
after long use. Thereby the three-dimensional look will be lost,
thus causing the problem of the quality of the design to
deteriorate.
[0007] This invention was achieved in light of the foregoing
problems and provides a decorative-part of an excellent design of
which the gloss on the surface of the clear-coat layer for
protecting the decorative-layer is lowered, and which invention
provides a method for manufacturing the same.
Means for Solving the Problems
[0008] To solve the aforementioned problems, the first-aspect of
this invention refers to a method for manufacturing a
decorative-part comprising a part having a decorative-layer on the
surface-layer and having a clear-coat layer for protecting the
surface of the decorative-surface, wherein said surface of the
clear-coat layer of a relatively high-gloss-level region is mixed
with a relatively low-gloss-level region on the surface of the
part, characterized in comprising a decorative-layer-forming
process of which the decorative-layer is formed on the
surface-layer of the part, and then a concave-convex part is formed
on the surface of the decorative-layer that should later be placed
beneath the low-gloss region; and characterized in comprising a
clear-coat-layer-forming process of which a clear-coat layer having
a surface-shaped low-gloss region is formed over the concave-convex
part by using a clear-coat paint containing a low-boiling-point
solvent (less than 100 degrees) as the main solvent and containing
a solid-content of 10 to 55 percent by mass; and thereby such
clear-coat-layer-forming process the clear-coat paint is sprayed
onto the surface of the decorative-layer by an atomization-coating
machine.
[0009] The first-aspect of this invention allows for the formation
of a decorative-layer onto the surface-layer of a decorative-part
by a decorative-layer-forming process, and for the formation of a
concave-convex part on the surface of a decorative-coating, and
then for conducting the clear-coat-layer-forming process in which a
clear-coat paint is used that contains as the main-solvent, one
(i.e. ester-based solvent) with a low boiling-point (less than 100
degrees Celsius) and is of a solid-content of 10 to 55 percent by
mass. The clear-coat paint, compared to the conventional
hydrocarbon-system clear-coat paint widely used, has a
low-boiling-point solvent (less than 100 degrees Celsius) as the
main solvent, and has a less solid content. When spraying the
clear-coat paint onto the surface of the decorative-layer by the
atomization-coating machine, the ester-based main-solvent is
vaporized before the surface is smoothened, thus allowing for the
formation of the clear-coat layer upon the surface of the
decorative-layer. As such, the region in which there is a
concave-convex part of the decorative-layer beneath the surface
shows a fine concave-convex-surface look, thus producing a
low-gloss region of a relatively low-gloss level. Contrarily, the
region in which there is no concave-convex part of the
decorative-layer beneath the surface shows a flat-surface look,
thus producing a high-gloss region of a relatively high-gloss
level. As such, this invention makes it possible in partially
lowering the gloss-level of the low-gloss region on the surface of
the decorative-part, thus fully improving the quality of the design
on said part.
[0010] The solid-content of the clear-coat paint can be 30 to 50
percent by mass. Preferably, it should be 35 to 40 percent by mass,
which increases the difference in the gloss-level between the
low-gloss region and the high-gloss region of the surface of the
clear-coat layer, thus enhancing the quality of the design on the
decorative-part.
[0011] During the clear-coat-forming process, it is preferable to
spray the clear-coat paint on the condition that the
atomizing-pressure of the atomization-coating machine is 0.06 MPa
to 0.09 MPa. The clear-coat paint can be sprayed on the condition
that the amount of discharge of the coating-machine is 50 cc/min or
more. Preferably, it should be 50 cc/min or more and 65 cc/min or
less, which increases the particle-diameter of the mist being
sprayed from the coating-machine, thus allowing the coating-paint
to settle the concave-convex part smoothly onto the
decorative-layer. Therefore, it makes it possible to form the
clear-coat layer surely upon the concave-convex shape on the
surface of the decorative-layer.
[0012] During the decorative-layer-forming process, it is possible
to form the decorative-layer by hydraulically transferring the
transcription-film having the concave-convex part on the
design-layer. This hydraulic-transfer process makes it possible in
surely forming the decorative-layer of the concave-convex part and
also possible in forming the concave-convex part onto the
surface-layer of the part by an emboss-processing procedure or by a
laser-processing procedure.
[0013] During the decorative-layer-forming process, it is possible
to form a design-layer, a gloss-layer and a mat-layer respectively
as the decorative-layer by hydraulically transferring the
transcription-film that is laminated by the design-layer onto which
the design is drawn, and laminated by the gloss-layer onto which
the gloss is given, and laminated by the mat-layer that has the
concave-convex part. In this case, the region that is right above
the concave-convex part on the mat-layer is the low-gloss region,
thus surely matting the gloss. On the other hand, the region that
is right above the gloss-layer of the less concave-convex part on
the clear-coat layer is the high-gloss region, thus improving the
gloss-level. As such, it is surely possible to obtain a
three-dimensional look, thus improving the quality of the design on
the decorative-part.
[0014] The second-aspect of this invention refers to a
decorative-part comprising a part having a decorative-layer on the
surface and comprising a clear-coat layer to protect the surface of
the decorative-surface wherein a relatively high-gloss-level region
is mixed with a relatively low-gloss-level region on the surface of
said part, characterized in that the concave-convex part is formed
beneath the low-gloss region on the surface of the
decorative-layer; with the low-gloss region of the clear-coat layer
being of the surface that is formed upon the concave-convex part;
with the roughness Ra of the surface of the clear-coat layer being
1 .mu.m or less; and with the difference in the gloss-level between
the high-gloss region and the low-gloss region being twice as much
or more.
[0015] The second-aspect of this invention provides the
surface-layer of the decorative-part with a decorative-layer, which
allows the clear-coat layer to protect the surface of said
decorative-layer. The region in which there is a concave-convex
part of the decorative-layer beneath the surface of the clear-coat
layer is a surface-shape with a relatively low-gloss look. On the
other hand, the region in which there is no concave-convex part of
the decorative-layer beneath the surface of the clear-coat layer is
a flat-surface shape with a relatively high-gloss look. The
difference in the gloss-level between the high-gloss region and the
low-gloss region on the clear-coat-layer surface of the
decorative-layer of this invention is twice as much or more, which
makes it possible to express visibly the three-dimensional look,
thus improving the quality of the design. Also, with the roughness
Ra of the surface of the clear-coat layer being 1 .mu.m or less,
the surface-abrasion of the decorative-part does not change much of
the three-dimensional look. Thus, a favorable condition of the
design on the decorative-part is maintained even after long
use.
[0016] The roughness Ra of the surface of the mat-layer comprising
the decorative-layer should be 2 .mu.m or less. Coating the
clear-coat paint over the mat-layer can make the roughness Ra of
the surface of the clear-coat layer be 1 .mu.m or less. Also, the
mat-layer should contain the same pigment that is contained in the
design-layer formed on the side of the lower-layer. In this case, a
concave and convex can surely be provided corresponding to the
design. Specifically, if the design is a wood-effect one, the
mat-layer is formed on the section corresponding to the knot of the
wood-grain. Thus, the design obtains a three-dimensional look
according to the actual wood-grain.
[0017] The gloss-layer comprising the decorative-layer should
preferably be a transparent resin-layer made of i.e. an
acryl-polyol resin or the like and be of a uniform thickness on the
whole surface of the design-layer on which the design is provided.
Forming the gloss-layer by such a procedure makes it surely
possible in providing the gloss on the design of the
design-layer.
[0018] Of the clear-coat-layer surface, the gloss-value indicating
the gloss-level of the high-gloss region should preferably be 30 or
more, and the gloss-value of the low-gloss region should preferably
be 10 or less. As such, increasing the difference in the
gloss-level of the surface of the clear-coat layer makes it surely
possible in obtaining the three-dimensional look of the
decorative-part.
Effects of the Invention
[0019] As described above, the first-aspect or the second-aspect of
this invention makes it partially possible to mat the gloss onto
the surface of the clear-coat layer, thus improving the quality of
the design of the decorative-part.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is the flat-view showing a part of the automobile
decorative-part as the embodiment of this invention.
[0021] FIG. 2 is the enlarged cross-sectional view showing the
automobile decorative-part as an embodiment of this invention.
[0022] FIG. 3 is the explanatory-diagram showing the
decorative-layer-forming process.
[0023] FIG. 4 is the explanatory-diagram showing the
clear-coat-layer-forming process.
[0024] FIG. 5 is the explanatory-diagram showing the surface of the
sample-product that is the standard characteristic-value.
[0025] FIG. 6 is the graph showing the relationship between the
solid-content and the G-M expression.
[0026] FIG. 7 is the graph showing the relationship between the
main-solvent boiling point and the G-M expression.
[0027] FIG. 8 is the graph showing the relationship between the
atomization-pressure and the G-M expression.
[0028] FIG. 9 is the graph showing the relationship between the
solid-content and the G-M expression.
[0029] FIG. 10 is another graph showing the relationship between
the atomization-pressure and the G-M expression.
[0030] FIG. 11 is the explanatory-diagram showing the SEM (scanning
electron microscope) image of the automobile decorative-part as the
embodiment of this invention.
MODES FOR CARRYING OUT THE INVENTION
[0031] Hereinafter, the embodiment of this invention, an automobile
decorative-part, is described in reference to the drawings.
[0032] As shown in FIGS. 1 and 2, the automobile decorative-part 1
comprises a resin-compact 3 (decorative part) with a
decorative-layer 2 on the surface-layer and a clear-coat layer 4 to
protect the surface of the decorative-layer 2. Also, the automobile
decorative-part 1 is an interior-part as part of the armrest of an
automobile-door. The decorative-layer 2 consists of a design-layer
5, a gloss-layer 6 and a mat-layer 7 formed on the surface-layer of
the resin-compact 3 by hydraulic-transfer. Of the embodiment of
this invention, the thickness of the design-layer 5, of the
gloss-layer 6 and of the mat-layer 7 is approximately 4 .mu.m, 1
.mu.m and 2 .mu.m respectively.
[0033] The design-layer 5 is the print-layer for the design 8 to be
drawn, and which contains cellulose nitrate and a pigment. For
instance, the wood-effect design 8 is drawn on the design-layer 5
that is an embodiment of this invention. The gloss-layer 6 is a
transparent resin-layer for the gloss to be provided on the design
8 of the design-layer 5 and is made by i.e. an acryl-polyol resin.
The gloss-layer 6 is provided on the upper-layer side of the
design-layer 5 and is evenly formed on the whole surface thereof.
The mat-layer 7, the de-lustering layer, is provided on the
upper-layer side of the gloss-layer 6 and is formed specifically on
the section corresponding to the knot of the wood-grain. The
mat-layer 7 structurally contains cellulose nitrate, pigment and
silica, with the concave-convex part 7a being formed on the surface
thereon. The roughness Ra of the surface of the mat-layer 7 is
approximately 1 .mu.m. The pigment of the mat-layer 7 is the same
pigment (specifically, black pigment) used in making the
design-layer 5 that is formed thereunder the mat-layer 7.
[0034] The clear-coat layer 4 that is formed on the uppermost-layer
of the automobile decorative-part 1 is made by coating thereon said
uppermost layer a transparent clear-coat paint containing a
de-lustering agent. The thickness of the clear-coat layer 4 is
approximately 10 .mu.m to 30 .mu.m, and is formed upon the
concave-convex shape of the surface of the mat-layer 7.
[0035] Of the automobile decorative-part 1 as an embodiment of this
invention, the high-gloss region R1 of a relatively high-gloss
level is mixed with the low-gloss region R2 of a relatively
low-gloss level on the surface of the clear-coat layer 4.
Specifically, the mat-layer 7 (concave-convex part 7a) is formed
beneath the low-gloss region R2 of the surface of the clear-coat
layer 4, and a fine concave-convex part 4a is formed on the surface
of the low-gloss region R2. Also, the mat-layer 7 is not formed
beneath the high-gloss region R1, and the surface of the high-gloss
region R1 is flat.
[0036] Regarding the surface-layer of the automobile
decorative-part 1, the concave-convex part 4a is formed on the
surface of the clear-coat layer 4, which is the section (low-gloss
region R2 corresponding to the wood-grain) on which the mat-layer 7
is formed according to the design 8, thus decreasing the
gloss-level of the low-gloss region R2, with the gloss-value
indicating the gloss-level becoming approximately 10. Contrarily,
the gloss-layer 6 is exposed on the high-gloss region R1 where the
mat-layer 7 is not formed, thus increasing the gloss-level of the
high-gloss region R1, with the gloss-value indicating the
gloss-level becoming approximately 30. As such, of the automobile
decorative-part 1 as an embodiment of this invention, the
gloss-level decreases at the place corresponding to the knot of the
wood-grain of the wood-effect design 8, thus making it possible to
obtain a three-dimensional look that is similar to that of actual
wood-grain.
[0037] Also, the fine concave-convex part 4a of the surface of the
clear-coat 4 is one that cannot be recognized tactually.
Specifically, the roughness Ra of the surface of the clear-coat
layer 4 is 1 .mu.m or less, even in the low-gloss region R2 where
the fine concave-convex part 4a exists.
[0038] The method for manufacturing the automobile decorative-part
1 of the embodiment of this invention is described hereinafter.
[0039] Firstly, prepare the resin-compact 3 by forming the
resin-material (i.e. an ABS resin) into a three-dimensional shape.
Then, proceed to the decorative-layer-forming process of which a
hydraulic-transferring apparatus is used to transfer the
design-layer 5, the gloss-layer 6 and the mat-layer 7 consisting of
the decorative-layer 2 onto the surface-layer of the resin-compact
3 by the use of water-pressure (see FIG. 3). Specifically, the
hydraulic-transferring apparatus has a transfer-tank in which is
stored treated water. By using the hydraulic-transferring
apparatus, the transcription-film (not shown in the drawings)
formed with the mat-layer 7, the gloss-layer 6 and the design-layer
5 on the base-material is floated on the surface of the treated
water within the transfer-tank, and the resin-compact 3 is pressed
down from the top of the transcription-film, thus transferring the
design-layer 5, the gloss-layer 6 and the mat-layer 7 onto the
surface of the resin-compact 3 by water-pressure. As such, the
design-layer 5 is formed on the surface-layer of the resin-compact
3. Then, the concave-convex part 7a of the mat-layer 7 is formed at
the place that is to be beneath the low-gloss region R2.
[0040] Then, a clear-coating procedure is done as the
clear-coat-layer-forming process. Specifically, as shown in FIG. 4,
the transparent clear-coat paint P1 is sprayed by the
atomization-coating machine 11 to make the clear-coat layer 4 that
is coated onto the surface of the resin-compact 3 consisting of the
decorative-layer 2 (the design-layer 5, the gloss-layer 6 and the
mat-layer 7). During the clear-coating procedure, the ester-based
clear-coat paint P1 is used that contains a low-boiling-point
solvent (i.e. ethyl acetate that is used for this invention) of 70
to 90 degrees Celsius as the main-solvent. Specifically, as the
clear-coat paint P1, a bi-component urethane-coating paint
containing a solid-content (a de-lustering agent, a resin-material
or the like) in the proportion of 35 to 40 percent by mass is used.
Also, under the condition that the discharging-amount of the
clear-coat paint P1 is 50 cc/min and the atomization-pressure is
0.08 MPa and the distance (spray-distance) between the jet-orifice
12 of the atomization-coating machine 11 and the surface of the
resin-compact 3 is 100 mm, the coating-paint is over-sprayed four
times. After that, the resin-compact 3 is stored in a drying-device
(not shown in the drawings) to dry the clear-coat layer 4 at a
temperature of approximately 80 degrees Celsius. As such, as shown
in FIGS. 1 and 2, the clear-coat layer 4 having the low-gloss
region R2 that is the surface upon the concave-convex part 7a of
the mat-layer 7 is formed, thus allowing for the manufacture of the
automobile decorative-part 1.
[0041] The inventors of this invention conducted coating-tests to
determine the optimum-condition for the clear-coating procedure.
The coating-tests designate the test-factors that seem to
contribute to the degree of gloss and mat expression (degree of G-M
expression). The test-factors were specified as the solid-content
ratio of the clear-coat paint P1; the boiling point of the
main-solvent of the clear-coat paint P1; the discharging-amount;
the atomization-pressure; spraying distance; and the number of
over-sprayings. The coating-tests were done modifying these factors
many times. Hence, the coating-tests employed the resin-compact 3
of which the decorative-layer 2 had been formed by the
manufacturing method (hydraulic-transfer or the like) as mentioned
above under the same conditions except for the clear-coating
procedure.
[0042] Chart 1 below shows each of the factors A to F and the
standards of each of the factors A to F that had been modified for
the coating-tests. Chart 2 below shows the test-results.
TABLE-US-00001 CHART 1 Standard Factor 1 2 A: Solid content 55%~65%
30%~40% B: Boiling point of 110.degree. C.~130.degree. C.
70.degree. C.~90.degree. C. the main solvent C: Discharging amount
65 cc/min 50 cc/min D: Atomization pressure 0.10 MPa 0.06 MPa E:
Spray distance 150 mm 100 mm F: Overspray Four times Twice
TABLE-US-00002 CHART 2 Characteristic Factor value No. A B C D E F
(Expression) 1 1 1 1 1 1 1 1 2 1 2 1 1 2 1 2 3 2 1 1 2 1 1 2 4 2 2
1 2 2 1 5 5 1 2 1 2 1 2 3 6 1 1 1 2 2 2 1 7 2 2 1 1 1 2 3 8 2 1 1 1
2 2 2 9 1 2 2 2 1 1 3 10 1 1 2 2 2 1 2 11 2 2 2 1 1 1 4 12 2 1 2 1
2 1 2 13 1 1 2 1 1 2 1 14 1 2 2 1 2 2 1 15 2 1 2 2 1 2 3 16 2 2 2 2
2 2 4
[0043] As the test result, Chart 2 shows the five-level rating of
the sensory-evaluation about the G-M expression on the surface of
the clear-coat layer 4 (of the surface of the decorative-part 1)
after the coating-procedure. Specifically, as shown in FIG. 5, the
samples that can be the criteria for the G-M expression levels
(Characteristic Values 1 to 5) are prepared to compare the G-M
expression levels as shown on the surface of the decorative-part 1
(Test Nos. 1 to 16) that were obtained by the coating-tests to
those shown on the samples, thus visually judging the identical G-M
expression levels. Regarding the characteristic-values showing the
G-M expression levels, Level 1 shows the worst expression, and
Level 5 shows the best expression.
[0044] Then, the dispersion-analysis was done based on the
test-results, as shown in Chart 2. Chart 3 shows the result of the
dispersion-analysis.
TABLE-US-00003 CHART 3 Degree Con- Square of tribution Factor sum
freedom Dispersion FO Test ratio (%) A: Solid 7.563 1 7.563 22.224
** 33.43% content B: Boiling 7.563 1 7.563 22.224 ** 33.43% point
of the main solvent C: 0.063 1 0.063 0.184 Discharging amount D:
3.063 1 3.063 9 * 12.92% Atomization pressure E: Spray 0.063 1
0.063 0.184 distance F: Overspray 0.563 1 0.563 1.653 Error 1.375 9
0.229 20.22% Total 21.938 15 100.00%
[0045] As shown in Chart 3, it was verified that there was a
significant difference among Factor A (Solid Content), Factor B
(Boiling Point of the Main Solvent), and Factor D (Atomization
Pressure), and that those factors were also the conditions
contributing to the G-M expressions. Specifically, Factor A (the
solid-content ratio) is significant at the level of 1%, and, as
shown in FIG. 6, when using the clear-coat paint P1 of the
low-ratio solid-content (solid-content 30 to 40 percent by mass),
the G-M expression is favorable. Factor B (the boiling-point of the
main-solvent) is significant at the level of 1%. As shown in FIG.
7, when using the clear-coat paint P1 of a low boiling point of the
main-solvent (ester-based clear-coat paint of a boiling-point of 70
to 90 degrees Celsius), the G-M expression is favorable. Also,
Factor D (the atomization-pressure) is significant at the level of
5%. As shown in FIG. 8, when the atomization-pressure is lowered,
the G-M expression is favorable.
[0046] Next, to determine the optimum-condition of Factor A (the
solid-content ratio) and of Factor D (the atomization-pressure)
that contributes to the G-M expression, the standard was modified
into a smaller range. Then, the coating-tests were conducted. Chart
4 shows the standards of each factor A and D, as well as each
factor A and D that were modified during the coating-tests. Chart 5
shows the result of the coating-tests. Also, the other factors B,
C, E and F were fixed conditions. In other words, of Factor B, the
boiling-point of the main-solvent is 70 to 90 degrees Celsius; of
Factor C, the discharging-amount is 50 cc/min; of Factor E, the
spraying distance is 100 mm; and of Factor F, the number of
over-sprayings is four. Then, the standard of Factor A and D was
modified, and the coating-tests were done.
TABLE-US-00004 CHART 4 Standard Factor 1 2 3 4 A: Solid content (%)
30 35 40 45 D: Atomization 0.04 0.06 0.08 0.10 pressure (MPa)
TABLE-US-00005 CHART 5 Characteristic Factor value No. A D
(Expression) 1 1 1 1 2 1 2 1 3 1 3 2 4 1 4 3 5 2 1 1 6 2 2 5 7 2 3
4 8 2 4 4 9 3 1 1 10 3 2 4 11 3 3 5 12 3 4 4 13 4 1 1 14 4 2 3 15 4
3 4 16 4 4 3
[0047] The dispersion-analysis was done based on the test-result,
as shown in Chart 5. Chart 6 shows the result of such a
dispersion-analysis.
TABLE-US-00006 CHART 6 Degree Square of Contribution Factor sum
freedom Dispersion FO Test ratio (%) A: Solid 8.25 3 2.75 3.96 *
18.28% content D: 19.25 3 6.417 9.24 ** 50.87% Atomization pressure
Error 6.25 9 0.694 30.86% Total 33.75 15 100.00%
[0048] As shown in Chart 6, Factor A of the solid-content ratio is
significant at the level of 5%. As shown in FIG. 9, when the
solid-content ratio is 35 to 40 percent by mass, the G-M expression
is most favorable. Also, Factor D, the atomization-pressure is
significant at the level of 1%. As shown in FIG. 10, when the
atomization-pressure is 0.08 MPa, the G-M expression is most
favorable.
[0049] As such, as the embodiment of this invention, the
clear-coating procedure was done using the ester-based clear-coat
paint P1 that contains a solid-content ratio of 35 to 40 percent by
mass. The boiling point of the main-solvent is 70 to 90 degrees
Celsius under the conditions that the discharging-amount is 50
cc/min; that the atomization-pressure is 0.08 MPa; that the
spraying-distance is 100 mm; and that the number of over-sprays is
four. Therefore, the automobile decorative-part 1 of the gloss and
mat expression is manufactured.
[0050] Regarding the automobile decorative-part 1 of the embodiment
of this invention that was manufactured by the above manufacturing
method, the cross-section of the automobile decorative-part 1 was
examined using a scanning electron microscope (SEM). FIG. 11 is the
SEM image showing the cross-sectional view of the automobile
decorative-part 1. As shown in FIG. 11, there is no mat-layer 7
beneath the high-gloss region R1 of the clear-coat layer 4, thus
showing a smooth surface. Contrarily, there is the mat-layer 7
beneath the low-gloss region R2 of the clear-coat layer 4. Thus,
the fine concave-convex part 4a is formed on the surface of the
automobile decorative-part 1.
[0051] Therefore, the embodiments of this invention realize the
following effects.
(1) For conducting the clear-coat-paint procedure, a clear-coat
paint P1 is used that contains, as the main-solvent, the
ester-based solvent with a low boiling-point (less than 100 degrees
Celsius) and is of a solid-content of 35 to 40 percent by mass. The
clear-coat paint P1, compared to the conventional
hydrocarbon-system clear-coat paint (of which the boiling-point is
110 to 140 degrees Celsius, and the solid-content is 50 to 60
percent by mass) that is widely used, has a low boiling-point
solvent and a less solid-content. When spraying the clear-coat
paint P1 onto the surface of the decorative-part 1 by the
atomization-coating machine 11, the ester-based main-solvent is
vaporized before the surface is smoothened, thus allowing for the
formation of the clear-coat layer 4 upon the surface-shape of the
mat-layer 7 of the decorative-layer 2. As such, the region in which
there is a concave-convex part 7a on the mat-layer 7 beneath the
surface of the clear-coat layer 4 shows a fine-surface look of the
concave-convex part 4a, thus producing a low-gloss region R2 of a
relatively low-gloss level. On the other hand, the region in which
there is no concave-convex part 7a on the mat-layer 7 beneath the
surface of clear-coat layer 4 shows a flat-surface look, thus
producing a high-gloss region R1 of a relatively high-gloss level.
As such, this invention makes it possible in partially lowering the
gloss-level of the low-gloss region R2 on the surface of the
clear-coat layer 4, which further makes it possible to produce
visibly a three-dimensional look according to the decorative-layer
2 (the design-layer 8 of the design-layer 5), thus fully improving
the quality of the design on the automobile decorative-part 1.
Also, the embodiment of this invention employs the clear-coat paint
P1 under the optimum condition of which the solid-content is 35 to
40 percent by mass. Even when using the clear-coat paint of which
the above optimum-range of the solid-content is expanded, such as
from 10 to 55 percent by mass, it is possible to manufacture the
automobile decorative-part 1 having a better gloss and mat
expression compared to the conventional automobile decorative-part
100. (2) During the clear-coating procedure of the embodiment of
this invention, when spraying the clear coat paint on the condition
that the atomizing-pressure of the atomization-coating machine 11
is 0.06 MPa to 0.09 MPa, the particle-diameter of the mist being
sprayed from the atomization-coating-machine 11 increases, thus
allowing the coat-paint P1 to settle smoothly onto the
concave-convex part 7a of the mat-layer 7. Therefore, it makes it
surely possible to form the clear-coat layer 4 upon the
concave-convex shape on the surface of the mat-layer 7 of the
decorative-layer 2. (3) During the decorative-layer-forming process
of the embodiment of this invention, the decorative-layer 2
(design-layer 5, gloss-layer 6 and mat-layer 7) is formed by
hydraulically transferring the transcription-film onto the
surface-layer of the resin-compact 3. Then, the clear-coat layer 4
is formed by the clear-coating procedure, thus making it surely
possible to form the decorative-layer 2 having the concave-convex
part 7a on the mat-layer 7 at the position corresponding to the
wood-effect design 8 of the design-layer 5. In this case, the
region that is right above the concave-convex part 7a on the
mat-layer 7 that is formed according to the design 8 on the
design-layer 5 is the low-gloss region R2, thus surely matting the
gloss. On the other hand, regarding the clear-coat layer 4, the
gloss-layer 6 is exposed in the region of which the mat-layer 7 is
not formed, and such region then becomes a high-gloss region R1,
thus improving the gloss-level. As such, it is surely possible to
obtain a three-dimensional look corresponding to the design 8 (wood
grain) of the design layer 5, thus improving the quality of the
design on the automobile decorative-part 1. (4) The difference in
the gloss-level between the high-gloss region R1 and the low-gloss
region R2 on the surface of the clear-coat-layer 4 of the
automobile decorative-part 1 of this invention is thrice as much.
Hence making it possible to express visibly the three-dimensional
look, thus improving the quality of the design. Also, with the
roughness Ra of the surface of the clear-coat layer 4 being 1 .mu.m
or less, the surface-abrasion of the automobile decorative-part 1
does not change much of the three-dimensional look. Thus, the
favorable condition of the design on the automobile decorative-part
1 is maintained even after long use.
[0052] The embodiments of this invention can be modified, as
described below. [0053] During the decorative-layer-forming process
of the embodiment of this invention, the transcription-film having
the concave-convex part 7a of the mat-layer 7 on the design-layer 5
is hydraulically transferred onto the surface-layer of the
resin-compact 3, thus forming the decorative-layer 2. However, it
is not limited to this. For example, it is possible to form the
concave-convex part on the surface-layer of the resin-compact 3 by
an emboss-processing procedure or by a laser-processing procedure,
in which case the surface-layer of the resin-compact 3 on which the
concave-convex part is formed on the surface-layer is the
decorative-layer. Also, it is possible to form a coat-layer as the
decorative-layer on the surface-layer of the resin-compact 3 by a
coating-procedure and then to form the concave-convex part on the
coat-layer by the laser-processing procedure. Furthermore, it is
possible to form the concave-convex part on the surface-layer
(coat-layer) of the resin-compact 3 by sandblasting or by
shotblasting or the like. [0054] The embodiment of this invention
employs a hi-component urethane-coat paint as the clear-coat paint.
It is possible however to use a single-component urethane-coat
paint. Of course, other than the urethane-coat paint, it is
possible also to use a clear-coat paint such as an acrylic-coat
paint or the like. [0055] As described in the above embodiment, the
automobile decorative-part 1 is embodied as the armrest of an
automobile door. However, it is possible that the automobile
decorative-part 1 be embodied as a different automobile
decorative-part, such as a console box or an instrument panel or
the like. Of course, it is possible to apply this invention to a
decorative-part other than that of an automobile decorative-part,
such as to a decorative-panel for furniture or for electrical
appliances or the like.
[0056] Besides the technical ideas of this invention, as described
above, other technical ideas to be understood are described
hereinafter.
(1) A method for manufacturing the decorative-part according to the
first-aspect of this invention, characterized in that during the
clear-coat-layer-forming process, the clear-coat paint is sprayed
under the condition that the amount of discharge of the
atomization-coating machine is 50 cc/min to 65 cc/min. (2) A method
for manufacturing the decorative-part, according to the
first-aspect of this invention, characterized in that during the
decorative-layer-forming process, a transcription-film, which is
laminated by the design-layer onto which the design is drawn and by
the gloss-layer on which the gloss is given and by the mat-layer
that has the concave-convex part, is hydraulically transferred,
thus forming the design-layer, the gloss-layer and the mat-layer
comprising the decorative-layer. (3) A method for manufacturing the
decorative-part according to the above technical idea (2),
characterized in that the roughness Ra of the surface of the
mat-layer is 2 .mu.m or less. (4) A method for manufacturing the
decorative-part, according to the above technical idea (2),
characterized in that the mat-layer should contain the same pigment
that is contained in the design-layer formed on the side of the
lower-layer. (5) A method for manufacturing the decorative-part
according to the above technical idea (2), characterized in that
the design is a wood-effect one, and that the mat-layer is formed
on the section corresponding to the knot of the wood-grain. (6) A
method for manufacturing the decorative-part according to the above
technical idea (2), characterized in that the gloss-layer is a
transparent-resin layer made of an acryl-polyol resin and formed of
a uniform thickness on the whole surface of the design-layer on
which the design is provided. (7) A method for manufacturing the
decorative-part according to the first-aspect of this invention,
characterized in that the gloss-value indicating the gloss-level of
the high-gloss region is 30 or more, and that the gloss-value of
the low-gloss region is 10 or less. (8) A method for manufacturing
the decorative-part according to the first aspect of this
invention, characterized in that during the
decorative-layer-forming process, the concave-convex part is formed
on the surface-layer of the decorative-part by an emboss-processing
procedure. (9) A method for manufacturing the decorative-part
according to the first-aspect of this invention, characterized in
that during the decorative-layer-forming process, the
concave-convex part is formed on the surface-layer of the
decorative-part by a laser-processing procedure. (10) A method for
manufacturing the decorative-part according to the first-aspect of
this invention, characterized in that the decorative-part is the
automobile decorative-part.
DESCRIPTION OF THE REFERENCE NUMERALS
[0057] 1: Automobile decorative-part as the decorative-part [0058]
2: Decorative-layer [0059] 3: Resin-compact as the part [0060] 4:
Clear-coat layer [0061] 5: Design-layer [0062] 7a: Concave-convex
part [0063] 11: Atomization-coating machine [0064] P1: Clear-coat
paint [0065] R1: High-gloss region [0066] R2: Low-gloss region
* * * * *