US20170136739A1 - Decorative member and manufacturing method thereof - Google Patents
Decorative member and manufacturing method thereof Download PDFInfo
- Publication number
- US20170136739A1 US20170136739A1 US15/351,581 US201615351581A US2017136739A1 US 20170136739 A1 US20170136739 A1 US 20170136739A1 US 201615351581 A US201615351581 A US 201615351581A US 2017136739 A1 US2017136739 A1 US 2017136739A1
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- United States
- Prior art keywords
- layer
- transparent resin
- resin layer
- rear surface
- inclination
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 26
- 229920005989 resin Polymers 0.000 claims abstract description 141
- 239000011347 resin Substances 0.000 claims abstract description 141
- 229910052738 indium Inorganic materials 0.000 claims description 32
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 claims description 32
- 239000003973 paint Substances 0.000 claims description 10
- 229910052751 metal Inorganic materials 0.000 claims description 8
- 239000002184 metal Substances 0.000 claims description 8
- 239000010410 layer Substances 0.000 description 360
- 238000000926 separation method Methods 0.000 description 53
- 230000005540 biological transmission Effects 0.000 description 20
- 230000002093 peripheral effect Effects 0.000 description 19
- 238000007650 screen-printing Methods 0.000 description 17
- 238000000034 method Methods 0.000 description 12
- 238000007639 printing Methods 0.000 description 9
- 238000000465 moulding Methods 0.000 description 8
- 239000011247 coating layer Substances 0.000 description 6
- 230000015572 biosynthetic process Effects 0.000 description 5
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 238000009434 installation Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000004417 polycarbonate Substances 0.000 description 3
- -1 and for example Substances 0.000 description 2
- 238000004040 coloring Methods 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000004544 sputter deposition Methods 0.000 description 2
- 238000003854 Surface Print Methods 0.000 description 1
- 229920001923 acrylonitrile-ethylene-styrene Polymers 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000002845 discoloration Methods 0.000 description 1
- PNWJXICONNROSM-UHFFFAOYSA-N ethene;prop-2-enenitrile;styrene Chemical compound C=C.C=CC#N.C=CC1=CC=CC=C1 PNWJXICONNROSM-UHFFFAOYSA-N 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000001465 metallisation Methods 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920005668 polycarbonate resin Polymers 0.000 description 1
- 239000004431 polycarbonate resin Substances 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
- 238000001771 vacuum deposition Methods 0.000 description 1
- 230000010356 wave oscillation Effects 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
- B44C3/02—Superimposing layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
- B29C45/0055—Shaping
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/16—Surface shaping of articles, e.g. embossing; Apparatus therefor by wave energy or particle radiation, e.g. infrared heating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
- B44C3/02—Superimposing layers
- B44C3/025—Superimposing layers to produce ornamental relief structures
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
- G01S7/00—Details of systems according to groups G01S13/00, G01S15/00, G01S17/00
- G01S7/02—Details of systems according to groups G01S13/00, G01S15/00, G01S17/00 of systems according to group G01S13/00
- G01S7/03—Details of HF subsystems specially adapted therefor, e.g. common to transmitter and receiver
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
- B29C45/0055—Shaping
- B29C2045/0058—Shaping removing material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
- B29C2045/0079—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping applying a coating or covering
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/412—Transparent
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2310/00—Treatment by energy or chemical effects
- B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
- B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
- B32B2310/0843—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using laser
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2451/00—Decorative or ornamental articles
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
- G01S13/00—Systems using the reflection or reradiation of radio waves, e.g. radar systems; Analogous systems using reflection or reradiation of waves whose nature or wavelength is irrelevant or unspecified
- G01S13/88—Radar or analogous systems specially adapted for specific applications
- G01S13/93—Radar or analogous systems specially adapted for specific applications for anti-collision purposes
- G01S13/931—Radar or analogous systems specially adapted for specific applications for anti-collision purposes of land vehicles
- G01S2013/9327—Sensor installation details
- G01S2013/93271—Sensor installation details in the front of the vehicles
Definitions
- the present invention relates to a decorative member used in an emblem and the like and a manufacturing method thereof.
- a radio wave transmission cover for a vehicle is generally provided with a decorative layer for displaying various designs.
- the decorative layer is a relative thin layer formed by metal deposition, film transfer and the like.
- the radio wave transmission cover is mainly configured with a transparent resin layer of a front side and a base layer of a rear side while interposing the decorative layer between the transparent resin layer and the base layer.
- the radio wave transmission cover is formed to have a uniform thickness such that transmission/reception of millimeter waves is not affected.
- a rear surface of the transparent resin layer is employed as an uneven surface having a general part and a concave part recessed with respect to the general part, a blackened print layer is formed in the general part, and then an indium layer is formed on the entire of the uneven surface by a vacuum deposition method as disclosed in JP-A-2009-17125.
- the indium layer covers the entire of the uneven surface of the transparent resin layer.
- Indium has a radio wave transmission characteristic, but when the entire surface of the transparent resin layer is covered with the indium, since the attenuation and the phase difference of radio waves of the radio wave transmission cover become large, radio wave transmission performance is reduced.
- indium printing method a screen printing method, a hot stamping method and the like are considered.
- the screen printing method is a method in which ink is pushed out from a screen mesh and is printed.
- the boundary of a print part is shifted from the boundary part of a concave part and a convex part. Since the boundary line of characters and figures of the concave part or the convex part is not clear, appearance becomes worse.
- the hot stamping method is a method in which a transfer film having a sheet printed with the indium layer is arranged on the uneven surface of the transparent resin layer, and the transfer sheet is pressed to the uneven surface by using a hot stamp while heating it, so that the indium layer is transferred to the uneven surface.
- a transfer error such as non-attachment of the indium layer on the sheet to the uneven surface.
- the present invention has been made to solve the above-described problem, and an object of the present invention is to provide a decorative member capable of accurately forming a design on an uneven surface of a transparent resin layer and a manufacturing method thereof.
- a manufacturing method of a decorative member including: preparing a transparent resin layer provided on a rear surface thereof with a general portion, a stepped portion recessed or protrudingly provided with respect to the general portion, and an inclination portion provided between the stepped portion and the general portion, an inclination angle of the inclination portion with respect to a normal line of the general portion being equal to or more than 25° and being equal to or less than 40° and a width of the inclination portion being large beyond 0.38 mm and being equal to or less than 1 mm; disposing a first layer on at least the stepped portion and the inclination portion of the rear surface of the transparent resin layer; allowing a part covering the stepped portion in the first layer to remain and separating an excess part, other than the covering the stepped portion, in the first layer by laser irradiation; and disposing a second layer on a part not covered with at least the first layer of the rear surface of the transparent resin layer.
- a decorative member including: a transparent resin layer provided on a rear surface thereof with a general portion, a stepped portion recessed or protrudingly provided with respect to the general portion, and an inclination portion provided between the stepped portion and the general portion; and a decorative layer provided on the rear surface of the transparent resin layer, wherein: an inclination angle of the inclination portion with respect to a normal line of the general portion is equal to or more than 25° and is equal to or less than 40°; a width of the inclination portion is large beyond 0.38 mm and is equal to or less than 1 mm; and the decorative layer includes: a first layer that covers the stepped portion of the rear surface of the transparent resin layer; and a second layer that covers a part of the rear surface of the transparent resin layer, which is not covered by at least the first layer.
- the first layer is disposed on at least the concave or convex stepped portion and the inclination portion on the rear surface of the transparent resin layer, and the part covering the stepped portion in the first layer is allowed to remain, and the excess part in the first layer, other than the part covering the stepped portion, is separated by the laser irradiation. Therefore, it is possible to accurately separate the excess part.
- the first layer is viewed from the surface of the transparent resin layer, it is possible to view an accurate design.
- the inclination angle of the inclination portion with respect to the normal line of the general portion is 25° to 40° and the width of the inclination portion is large beyond 0.38 mm and is equal to or less than 1 mm.
- the width of the inclination portion is larger than separation tolerance when the first layer is separated by the laser irradiation. Therefore, even though a molding dimensional error or a positional shift at the time of installation of a laser irradiation jig occurs in the transparent resin layer, these errors are absorbed, so that the boundary line between the first layer and the separation part, from which the excess part has been separated, can be positioned on the inclination portion.
- the boundary line between the first layer and the separation part is allowed to be positioned on the inclination portion, so that the boundary line is prevented from being shifted on the general portion or the stepped portion.
- the inclination angle of the inclination portion is 25° to 40°, when the first layer is viewed from the surface side of the transparent resin layer, the first layer remaining on the inclination portion is difficult to be viewed.
- the first layer is viewed as if it covers only the stepped portion, so that it is possible to three-dimensionally view the first layer with a good appearance.
- the separation of the excess part of the first layer is performed by the laser irradiation. Since the laser has a high degree of accuracy of an irradiation position, it is possible to accurately separate the excess part of the first layer. Therefore, according to the invention, as compared with the case in which the first layer has been formed on the stepped portion by printing such as screen printing, it is possible to accurately form a design of the first layer.
- the printing may not be performed depending on the rear surface shape of the transparent resin layer. That is, in the screen printing, since ink is pushed out from a screen mesh and is printed, the screen mesh need to be parallel to the rear surface of the transparent resin layer.
- the protruding part which largely protrudes on the rear surface, since the protruding part causes flow mark or weld to the transparent resin layer at the time of molding, no design is established.
- the general portion and the stepped portion of the rear surface of the transparent resin layer may be a concave portion or a convex portion.
- the first layer is formed on the stepped portion.
- the decorative member of the invention is manufactured by the aforementioned decorative member manufacturing method, so that it is possible to view a design accurately formed on the uneven surface of the transparent resin layer.
- FIG. 1 is a front view of a front grill to which a decorative member of a first embodiment of the invention has been attached:
- FIG. 2 is a front view of the decorative member of the first embodiment:
- FIG. 3 is a sectional view taken along line A-A of FIG. 2 ;
- FIG. 4 is an enlarged view of a circled part of FIG. 3 ;
- FIG. 5 is an explanation diagram of an inclination portion of a rear surface of a transparent resin layer of the first embodiment
- FIG. 6 is a flowchart illustrating a manufacturing method of the decorative member of the first embodiment
- FIG. 7 is a sectional view of the transparent resin layer, in which an outer peripheral part of the rear surface has been subjected to black printing, for explaining the manufacturing method of the decorative member of the first embodiment
- FIG. 8 is a sectional view of the transparent resin layer on which a first layer has been disposed, which is subsequent to FIG. 7 ;
- FIG. 9 is a sectional view of the transparent resin layer after a separation step, which is subsequent to FIG. 8 :
- FIG. 10 is a sectional view of the transparent resin layer on which a second layer has been disposed, which is subsequent to FIG. 9 :
- FIG. 11 is a front view of a decorative member of a second embodiment
- FIG. 12 is a sectional view taken along line B-B of FIG. 11 ;
- FIG. 13 is a flowchart illustrating a manufacturing method of the decorative member of the second embodiment
- FIG. 14 is a sectional view of the transparent resin layer, on which a pattern layer and a first layer have been disposed, for explaining the manufacturing method of the decorative member of the second embodiment:
- FIG. 15 is a sectional view of the transparent resin layer after a separation step, which is subsequent to FIG. 14 ;
- FIG. 16 is a sectional view of the transparent resin layer on which a second layer has been disposed, which is subsequent to FIG. 15 ;
- FIG. 17 is a partially enlarged sectional view of a decorative member of a third embodiment:
- FIG. 18 is a sectional view of a transparent resin layer, in which a screen mesh has been arranged at a rear surface side, for explaining a manufacturing method of the decorative member of the third embodiment
- FIG. 19 is a sectional view of a transparent resin layer on which a first layer has been formed on a rear surface by a screen printing method, which is subsequent to FIG. 18 ;
- FIG. 20 is a sectional view of the transparent resin layer when a separation step is being performed, which is subsequent to FIG. 19 .
- a decorative member 1 is a millimeter wave transmission cover attached to the center of a front grill 9 of a vehicle.
- the decorative member 1 is provided at a rear surface side thereof with a millimeter wave oscillation receiver (not illustrated).
- the decorative member 1 is a thin plate and thicknesses of its all parts are set to be n times of 1 ⁇ 2 of a wavelength of a millimeter wave.
- the center is gently curved to protrude to a surface 1 a side.
- the decorative member 1 has a transparent resin layer 2 , a base layer 5 , and a decorative layer 3 interposed between the transparent resin layer 2 and the base layer 5 .
- the transparent resin layer 2 is made of a transparent resin material, and for example, PC (polycarbonate) is used.
- a surface 2 a of the transparent resin layer 2 is a smooth surface.
- a rear surface 2 b of the transparent resin layer 2 has an outer peripheral part 21 and an inner part 22 positioned at an inner side from the outer peripheral part 21 and recessed with respect to the outer peripheral part 21 .
- a depth T of the inner part 22 from the outer peripheral part 21 is 2.5 mm.
- the outer peripheral part 21 has a flat shape.
- the outer peripheral part 21 is covered by a black translucent outer peripheral print part 35 .
- the inner part 22 has a general portion 23 , a stepped portion 25 recessed with respect to the general portion 23 , and an inclination portion 26 provided between the general portion 23 and the stepped portion 25 .
- a height difference H between the stepped portion 25 and the general portion 23 of the rear surface 2 b of the transparent resin layer 2 that is, a height of the inclination portion 26 is equal to or more than 0.3 mm and is equal to or less than 1.0 mm.
- the height difference H between the stepped portion 25 and the general portion 23 of the rear surface 2 b of the transparent resin layer 2 is 0.5 mm.
- the inclination portion 26 is interposed between the general portion 23 and the stepped portion 25 .
- An inclination angle ⁇ of the inclination portion 26 with respect to a normal line D of the general portion 23 is 30°.
- An upper end 26 a of the inclination portion 26 is a part connected to the general portion 23
- a lower end 26 b of the inclination portion 26 is a part connected to the recessed stepped portion 25 .
- R 1 and R 2 of the upper end 26 a and the lower end 26 b of the inclination portion 26 are all chamfered in an arc shape having a curvature radius of 0.3 mm.
- a width W from the upper end 26 a to the lower end 26 b of the inclination portion 26 when the inclination portion 26 has been projected along the normal line of the rear surface 2 b of the transparent resin layer 2 is 0.6 mm.
- the decorative layer 3 is provided to the rear surface 2 b side of the transparent resin layer 2 , and has a first layer 31 and a second layer 32 sequentially arranged from the rear surface 2 b side.
- the first layer 31 includes a metal layer having a radio wave transmission characteristic.
- an indium layer is preferable.
- the indium layer may have a sea-island structure in which indium exists insularly in various places from the standpoint of a radio wave transmission characteristic.
- the second layer 32 is a black coating layer.
- the first layer 31 has a thickness of about 40 nm to 50 nm and the second layer 32 has a thickness of about 30 ⁇ m to 40 ⁇ m.
- the first layer 31 covers the recessed stepped portion 25 of the rear surface 2 b of the transparent resin layer 2 .
- the second layer 32 covers the entire of the rear surface 2 b of the transparent resin layer 2 .
- the first layer 31 including the indium is positioned at the recessed stepped portion 25 and is positioned near the surface 1 a of the decorative member 1 as compared with the second layer 32 including the black coating layer.
- a black character of the black coating layer is viewed in the brightly colored area of the indium.
- the brightly colored figure floats up to a front side from the black area and is three-dimensionally viewed.
- the base layer 5 is made of a colored resin material, for example, AES (acrylonitrile ethylene styrene copolymer).
- a manufacturing method of the decorative member 1 of the present embodiment will be described using a flowchart of FIG. 6 .
- step S 10 (preparation step) polycarbonate resin is injection-molded using a mold, so that the transparent resin layer 2 is obtained.
- step S 20 surface hard coat step
- a hard coat process is performed for the surface 2 a of the transparent resin layer 2 .
- step S 30 (rear surface printing step), as illustrated in FIG. 7 , blank ink is printed on the outer peripheral part 21 of the rear surface 2 b of the transparent resin layer 2 by a screen printing method and the like, so that the black translucent outer peripheral print part 35 is formed on the outer peripheral part 21 .
- step S 40 first layer disposing step
- the first layer 31 including indium is formed on the entire of the inner part 22 of the rear surface 2 b of the transparent resin layer 2 by a sputtering method.
- the first layer 31 may be formed by a deposition method.
- step S 50 separation step
- the transparent resin layer 2 is fixed to a jig such that the rear surface 2 b of the transparent resin layer 2 is upward.
- laser is irradiated to an excess part B, other than a part A covering the stepped portion 25 , so that the excess part B is separated.
- MDV9920 product name manufactured by keyence Corporation has been used.
- the laser irradiation energy per unit area is 0.45 mJ.
- a laser spot diameter is 0.08 mm
- a laser spot pitch is 0.064 mm
- a laser frequency is 120 kHz
- a laser wavelength is 1064 nm. It is sufficient if laser transmittance is 5% to 90%, and it is preferable that a laser movement speed is 600 mm/sec to 1300 mm/sec. In this case, there is no discoloration due to laser burning of the transparent resin layer 2 and residue of the indium, which is the first layer 31 , is also not seen.
- the boundary between the irradiation area and the non-irradiation area of the laser is set as a center 26 c in the width direction of the inclination portion 26 .
- the excess part B separated by the laser is an area from the general portion 23 and the upper end 26 a of the inclination portion 26 to the center 26 c in terms of design.
- the width W of the inclination portion 26 is 0.6 mm and the inclination portion 26 exists in an area of ⁇ 0.3 mm from the center 26 c of the inclination portion 26 . Since the shift range of the laser irradiation position with respect to the transparent resin layer 2 is ⁇ 0.29 mm, the laser enters into the width ( ⁇ 0.3 mm) from the center 26 c of the inclination portion 26 .
- a boundary line L between the first layer 31 and the separation part is positioned on the inclination portion 26 .
- the first layer 31 does not almost remain in the upper end 26 a side of the inclination portion 26 and mainly remains in the lower end 26 b as compared with the upper end 26 a side.
- the boundary line L between the first layer 31 and the separation part is positioned in the center 26 c of the inclination portion 26 in many cases.
- step S 60 second layer disposing step
- the second layer 32 is formed on the inner part 22 of the rear surface 2 b side of the transparent resin layer 2 by coating using a black paint.
- the second layer 32 is an opaque black layer.
- the black paint has been obtained by mixing coloring with a resin material.
- the coloring is carbon black and the resin material is acryl resin; however, the invention is not limited thereto.
- step S 70 base layer formation step
- the transparent resin layer 2 is inserted into the mold and colored AES is injection-molded at the rear surface 2 b side of the transparent resin layer 2 , so that the base layer 5 is formed on the entire of the rear surface 2 b side.
- the decorative member 1 of the present embodiment is obtained.
- the first layer 31 is disposed on the entire of the rear surface 2 b of the transparent resin layer 2 , the part A covering the stepped portion 25 in the first layer 31 is allowed to remain, and the excess part B, other than the part A, is separated by laser irradiation. Therefore, it is possible to accurately separate the excess part B.
- the first layer 31 is viewed from the surface 2 a of the transparent resin layer 2 , it is possible to view an accurate design.
- the inclination angle ⁇ of the inclination portion 26 with respect to the normal line D of the general portion 23 is 25° to 40° and the width W of the inclination portion 26 is large beyond 0.38 mm and is equal to or less than 1 mm.
- the inclination angle ⁇ of the inclination portion 26 with respect to the normal line D of the general portion 23 is 30°, and the width W of the inclination portion 26 is 0.6 mm.
- the width W of the inclination portion 26 is larger than the range 0.58 mm of the separation tolerance ( ⁇ 0.29 mm).
- the boundary line L between the first layer 31 and the separation part is positioned on the inclination portion 26 , the boundary line L is prevented from being shifted on the general portion 23 or the stepped portion 25 .
- the first layer 31 is viewed from the surface 2 a of the transparent resin layer 2 , since the first layer 31 is viewed as if it covers only the stepped portion 25 , it is possible to three-dimensionally view the first layer 31 with a good appearance.
- the inclination portion 26 may not absorb the shift, or the boundary line L between the first layer 31 and the separation part may be positioned on the general portion 23 or the stepped portion 25 .
- the inclination angle ⁇ exceeds 40°, if it is viewed from the surface 1 a side of the decorative member 1 , the inclination portion 26 is viewed.
- the boundary line L on the inclination portion 26 is apparently viewed and the contour of the first layer 31 appears to protrude as compared with the contour of the stepped portion 25 , so that the appearance of the first layer 31 may be reduced.
- the separation of the excess part B of the first layer 31 is performed by the laser irradiation. Since the laser has a high degree of accuracy of an irradiation position, it is possible to accurately separate the excess part B of the first layer 31 . Therefore, according to the separation step of the present embodiment, as compared with the case in which the first layer 31 has been formed on the stepped portion 25 by printing such as screen printing, it is possible to accurately form a design of the first layer 31 .
- the printing may not be performed depending on the rear surface shape of the transparent resin layer 2 . That is, in the screen printing, since ink is pushed out from a screen mesh and is printed, the screen mesh need to be parallel to the rear surface 2 b of the transparent resin layer 2 .
- the protruding part which largely protrudes on the rear surface 2 b , since the protruding part causes flow mark or weld to the transparent resin layer 2 at the time of molding, no design is established.
- the decorative member 1 of the present embodiment is manufactured by the aforementioned decorative member manufacturing method, so that it is possible to view a design accurately formed on the uneven surface of the transparent resin layer 2 .
- the color of the transparent resin layer (a resin layer before being processed) before the first layer is formed and the color of the transparent resin layer (a resin layer after separation) after laser separation have been measured with an L*a*b* display system.
- the laser irradiation conditions are similar to the aforementioned conditions of the present embodiment. From the measured values of the color of the resin layer before being processed and the color of the resin layer after separation, a color difference ⁇ E of the resin layer after separation from the resin layer before being processed has been obtained. When the color difference ⁇ E is smaller than 1.5, it can be understood that it is not possible to recognize the color difference of the two.
- the color difference ⁇ E from the resin layer before being processed and the resin layer after separation is 0.65. From this fact, it can be understood that laser is irradiated to the first layer, so that it is possible to separate the first layer from the rear surface of the transparent resin layer to the extent that the first layer is not recognizable.
- a decorative member 1 of the present embodiment is different from the first embodiment in that a pattern layer 36 is coated on the outer peripheral part 21 of the rear surface 2 b of the transparent resin layer 2 as illustrated in FIGS. 11 and 12 .
- steps S 10 , S 20 , S 30 , and S 40 have been performed as illustrated in FIG. 13 , similarly to the first embodiment.
- the first layer 31 is formed on the entire of the inner part 22 (see FIG. 8 ).
- step S 45 (a partial coating step) is performed.
- the pattern layer 36 is coated on a part of the outer peripheral part 21 of the rear surface 2 b of the transparent resin layer 2 or the entire of the inner part 22 as illustrated in FIG. 14 .
- the rear surface 2 b of the transparent resin layer 2 is coated, and then the mask 8 is removed.
- an opaque colored paint of a brown and the like has been used for the pattern layer 36 .
- step S 50 (separation step), as illustrated in FIG. 15 , in the first layer 31 and the pattern layer 36 on the rear surface 2 b of the transparent resin layer 2 , laser is irradiated to an excess part B, other than the part A covering the stepped portion 25 , so that the excess part B is separated.
- the laser irradiation conditions are similar to those of the first embodiment except that the irradiation energy per unit area is 3.2 mJ.
- the width W of the inclination portion 26 of the rear surface 2 b of the transparent resin layer 2 is 0.6 mm and the inclination angle ⁇ of the inclination portion 26 is 30°.
- the width W and the inclination angle ⁇ are similar to those of the first embodiment.
- the width W is larger than separation tolerance ( ⁇ 0.29 mm) due to the difference of laser irradiation as described in the first embodiment, even though positional shift of laser irradiation occurs, the boundary line L between the first layer 31 and the pattern layer 36 remaining after the separation and the separation part thereof is positioned on the inclination portion 26 .
- step S 60 (second layer disposing step), as illustrated in FIG. 16 , a black coating layer is disposed at the rear surface 2 b side of the transparent resin layer 2 as the second layer 32 .
- step S 70 base layer formation step
- the rear surface 2 b of the transparent resin layer 2 on which the second layer 32 has been formed, is covered with the base layer 5 .
- the formation of the base layer 5 has been performed similarly to the first embodiment.
- the decorative member 1 of the present embodiment has been obtained.
- the pattern layer 36 is recognized at the outer peripheral part 21 through a transparent black outer peripheral print part 35 .
- the pattern layer 36 is conceal to the rear surface side of the first layer 31 and is not seen.
- the bright color of the indium of the first layer 31 stands out on a front side and is three-dimensionally recognized in the black area of the second layer 32 similarly to the first embodiment.
- a decorative member 1 of the present embodiment is different from the first embodiment in that a first layer 310 of the decorative layer 3 is a black coating layer and a second layer 320 is an indium layer as illustrated in FIG. 17 .
- the first layer 310 is formed on a stepped portion 250 protrudingly provided in the inner part 22 of the rear surface 2 b of the transparent resin layer 2 .
- the second layer 320 which is the indium layer, is formed on the entire of the inner part 22 , including the first layer 310 .
- steps S 10 , S 20 , and S 30 have been performed (see FIG. 6 ), similarly to the first embodiment.
- a black translucent outer peripheral print part 35 is formed on the outer peripheral part 21 (see FIG. 7 ).
- step S 40 first layer disposing step
- a screen mesh 7 is arranged at the rear surface 2 b side of the transparent resin layer 2 .
- holes 70 are opened in parts corresponding to the stepped portion 250 and an inclination portion 260 .
- black ink is pushed out from the holes 70 of the screen mesh 7 , so that the first layer 310 is formed on the stepped portion 250 and the inclination portion 260 .
- the first layer 310 is formed on the inclination portion 260 as well as the stepped portion 250 by the screen printing, and the first layer 310 on the inclination portion 260 is separated by laser in a subsequent separation step.
- the black ink used in the screen printing is similar to the black ink in step S 60 (second layer disposing step) in the first embodiment.
- step S 50 separation step
- laser is irradiated to an excess part B of the first layer 310 , so that the excess part B is separated.
- the first layer 310 remains on the stepped portion 250 of the rear surface 2 b of the transparent resin layer 2 .
- laser is set to be irradiated to an area from a general portion 230 to a center 260 c of the inclination portion 260 .
- the excess part B separated by the laser is an area from a lower end 260 b to the center 260 c of the inclination portion 260 in the first layer 310 in terms of design.
- separation tolerance is +0.29 mm.
- the separation tolerance is smaller than the width W ( ⁇ 0.30 mm) from the center 260 c of the inclination portion 260 . Therefore, also in the present embodiment, when the excess part B of the first layer 310 is separated by laser irradiation, the boundary line L between the first layer 310 and the separation part is positioned on the inclination portion 260 .
- step S 60 second layer disposing step
- the indium layer as the second layer 320 is disposed on the entire of the inner part 22 .
- the indium layer can be disposed by a sputtering method or a deposition method.
- step S 70 base layer formation step
- step S 70 base layer formation step
- the decorative member 1 of the present embodiment When the decorative member 1 of the present embodiment is viewed from the surface 1 a side, the bright color part of the second layer 320 formed on the general portion 230 and including indium floats up and is three-dimensionally and clearly seen during black coating.
- step S 40 first layer disposing step
- the first layer 310 is formed as a coating layer by using the screen mesh 7 .
- the first layer 310 causes positional shift.
- the first layer 310 is accurately trimmed by laser in step S 50 (separation step), it is possible to form the first layer 310 at an accurate position.
- the first layer 310 is formed in advance on the stepped portion 250 and the inclination portion 260 around the stepped portion 250 by the screen printing, and a part of the first layer 310 covering the stepped portion 250 is separated by laser afterward. Therefore, an area of a laser separation area becomes small. It is possible to shorten a laser separation time.
- the decorative member 1 of the aforementioned embodiment is a radio wave transmission cover for millimeter waves, but can also be used in a radio wave transmission cover for other electric waves.
- the decorative member 1 of the aforementioned embodiment can also be used as emblems for decoration. These emblems are not limited to vehicles, and can be used in all scenes.
- the manufacturing method of the decorative member 1 of the present embodiment includes a preparation step of preparing the transparent resin layer 2 provided on the rear surface 2 b thereof with the general portions 23 and 230 , the stepped portion 25 recessed or the stepped portion 250 protrudingly provided with respect to the general portions 23 and 230 , and the inclination portions 26 and 260 provided between the stepped portions 25 and 250 and the general portions 23 and 230 , inclination angles ⁇ of the inclination portions 26 and 260 with respect to the normal lines D of the general portions 23 and 230 being 25° to 40° and widths W of the inclination portions 26 and 260 being large beyond 0.38 mm and being equal to or less than 1 mm, a first layer disposing step of disposing first layers 31 and 310 on at least the stepped portions 25 and 250 and the inclination portions 26 and 260 of the rear surface 2 b of the transparent resin layer 2 , a separation step of allowing parts A covering the stepped portions 25 and 250 in the first layers 31 and 310 to remain and separating
- the first layers 31 and 310 are disposed on at least the concave or convex stepped portions 25 and 250 and the inclination portions 26 and 260 in the rear surface 2 b of the transparent resin layer 2 , and the parts A covering the stepped portions 25 and 250 in the first layers 31 and 310 are allowed to remain, and the excess parts B, other than the parts A, are separated by the laser irradiation. Therefore, it is possible to accurately separate the excess parts B.
- the first layers 31 and 310 are viewed from the surface 2 a of the transparent resin layer 2 , it is possible to view an accurate design.
- the inclination angles ⁇ of the inclination portions 26 and 260 with respect to the normal lines D of the general portions 23 and 230 are 25° to 40° and the widths W of the inclination portions 26 and 260 are large beyond 0.38 mm and are equal to or less than 1 mm.
- the widths W of the inclination portions 26 and 260 are larger than separation tolerance when the first layers 31 and 310 are separated by the laser irradiation.
- the inclination angles ⁇ of the inclination portions 26 and 260 are 25° to 40°, when the first layers 31 and 310 are viewed from the surface side of the transparent resin layer, the first layers 31 and 310 remaining on the inclination portions 26 and 260 are difficult to be viewed.
- the first layer 31 is viewed as if it covers only the stepped portion 25 , so that it is possible to three-dimensionally view the first layer 31 with a good appearance.
- the separation of the excess parts B of the first layers 31 and 310 is performed by the laser irradiation. Since the laser has a high degree of accuracy of an irradiation position, it is possible to accurately separate the excess parts B of the first layers 31 and 310 . Therefore, according to the separation step of the aforementioned embodiment, as compared with the case in which the first layers 31 and 310 are formed on the stepped portions 25 and 250 by printing such as screen printing, it is possible to accurately form designs of the first layers 31 and 310 .
- the printing may not be performed depending on the rear surface shape of the transparent resin layer 2 . That is, in the screen printing, since ink is pushed out from a screen mesh and is printed, the screen mesh need to be parallel to the rear surface 2 b of the transparent resin layer 2 . When there is a protruding part which largely protrudes on the rear surface 2 b , since the protruding part causes flow mark or weld to the transparent resin layer 2 at the time of molding, no design is established.
- the general portions 23 and 230 and the stepped portions 25 and 250 of the rear surface 2 b of the transparent resin layer 2 may be concave portions or convex portions.
- the first layers 31 and 310 remain on the stepped portions 25 and 250 .
- the first layer is made of indium, and in the separation step, irradiation energy per unit area of laser irradiated to the first layer is 0.3 mJ to 0.6 mJ. In this case, it is possible to sufficiently separate the excess part B of the first layer 31 by laser irradiation without a change in the color of the transparent resin layer 2 .
- the first layer disposing step it is preferable to perform a coating step of forming a paint layer (the pattern layer 36 ) including a paint on the rear surface 2 b of the transparent resin layer 2 and including a part in which the first layer 31 has been formed. It is possible to form a design with a good appearance.
- the first layer 31 is made of indium and in the separation step, irradiation energy per unit area of laser irradiated to an overlap part of the first layer 31 and the paint layer (the pattern layer 36 ) is 2.5 mJ to 3.8 mJ. In this case, it is possible to sufficiently separate the excess parts B of the first layer 31 and the paint layer by laser irradiation without a change in the color of the transparent resin layer 2 .
- the boundary between an irradiation area and a non-irradiation area of the laser is set as the centers 26 c and 260 c in the width direction of the inclination portions 26 and 260 . Even though a molding dimensional error or a positional shift at the time of installation of a laser irradiation jig occurs in the transparent resin layer 2 , the inclination portions 26 and 260 absorb these errors, so that the boundary lines L between the first layers 31 and 310 and the separation parts, from which the excess parts B have been separated, can be positioned on the inclination portions 26 and 260 .
- the decorative member 1 of the aforementioned embodiment is the decorative member 1 having the transparent resin layer 2 provided on the rear surface 2 b thereof with the general portions 23 and 230 , the stepped portions 25 and 250 recessed or protrudingly provided with respect to the general portions 23 and 230 , and the inclination portions 26 and 260 provided between the stepped portions 25 and 250 and the general portions 23 and 230 , and the decorative layer 3 provided on the rear surface 2 b of the transparent resin layer 2 , the inclination portions 26 and 260 are provided between the stepped portions 25 and 250 and the general portions 23 and 230 , the inclination angles ⁇ of the inclination portions 26 and 260 with respect to the normal lines D of the general portions 23 and 230 being 25° to 40°, the widths W of the inclination portions 26 and 260 are large beyond 0.38 mm and are equal to or less than 1 mm, and the decorative layer 3 has the first layers 31 and 310 that cover the stepped portions 25 and 250 of the rear surface 2 b of the transparent resin layer 2
- the decorative member 1 of the present embodiment is manufactured by the aforementioned manufacturing method of the decorative member 1 , so that it is possible to view a design accurately formed on the uneven surface of the transparent resin layer 2 .
- a height difference H with the general portions 23 and 230 is equal to or more than 0.3 mm and is equal to or less than 1.0 mm.
- any one of the first layers 31 and 310 and the second layers 32 and 320 is a metal layer and the other one of the first layers 31 and 310 and the second layers 32 and 320 is a colored layer.
- a bright design due to the metal layer and a design due to the colored layer, it is possible to realize a design having an appearance.
- the metal layer is made of indium. Since the indium has a radio wave transmission characteristic, the decorative member 1 of the present embodiment can be used as a radio wave transmission cover.
- the boundary line L between parts covered with the first layers 31 and 310 on the rear surface 2 b of the transparent resin layer 2 and parts not covered with the first layers 31 and 310 is positioned on the inclination portions 26 and 260 .
- the first layer even though disposal positions of the first layers 31 and 310 are shifted during a manufacturing process, it is possible to allow the first layer to reliably cover the entire of the stepped portions 25 and 250 .
- the inclination portions 26 and 260 have the aforementioned predetermined inclination angle ⁇ , when it is viewed from the surface 1 a side of the decorative member 1 , the first layers 31 and 310 on the inclination portions 26 and 260 are not almost seen and it seems as if the first layers 31 and 310 are disposed only on the stepped portions 25 and 250 .
- the height difference H between the first layers 31 and 310 and the second layers 32 and 320 it is possible to view a three-dimensional design.
- a decorative member has the following aspects.
- the rear surface 2 b of the transparent resin layer 2 has a base area (the outer peripheral part 21 ) and a main area (the inner part 22 ) recessed or protrudingly provided with respect to the base area, the main area has the general portions 23 and 230 , the stepped portions 25 and 250 , and the inclination portions 26 and 260 , and a height difference between the main area and the base area is equal to or more than 2.5 mm.
- a design is formed by the decorative layer 3 covering the stepped portions 25 and 250 .
- the design formed in the main area is seen to float up.
- the design formed in the main area is seen to be deeply sunk with respect to the base area.
- the height difference of the main area with respect to the base area is equal to or more than 2.5 mm, it is possible to more three-dimensionally view the design formed in the main area. Even if there is a large height difference equal to or more than 2.5 mm, it is possible to accurately and reliably perform the separation step by laser irradiation.
- the decorative layer 3 is covered by the base layer 5 .
- the decorative layer is disposed between the transparent resin layer 2 and the base layer 5 , so that the decorative member is easily used as an emblem or a radio wave transmission cover.
- the decorative member is a radio wave transmission cover.
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Abstract
Description
- This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2015-224061, filed on Nov. 16, 2015, the entire contents of which are incorporated herein by reference.
- 1. Field of the Invention
- The present invention relates to a decorative member used in an emblem and the like and a manufacturing method thereof.
- 2. Description of the Related Art
- A radio wave transmission cover for a vehicle is generally provided with a decorative layer for displaying various designs. The decorative layer is a relative thin layer formed by metal deposition, film transfer and the like. The radio wave transmission cover is mainly configured with a transparent resin layer of a front side and a base layer of a rear side while interposing the decorative layer between the transparent resin layer and the base layer. The radio wave transmission cover is formed to have a uniform thickness such that transmission/reception of millimeter waves is not affected.
- In order to express three-dimensional characters or figures on the radio wave transmission cover, for example, a rear surface of the transparent resin layer is employed as an uneven surface having a general part and a concave part recessed with respect to the general part, a blackened print layer is formed in the general part, and then an indium layer is formed on the entire of the uneven surface by a vacuum deposition method as disclosed in JP-A-2009-17125.
- In the manufacturing method of the radio wave transmission cover disclosed in JP-A-2009-17125, however, the indium layer covers the entire of the uneven surface of the transparent resin layer. Indium has a radio wave transmission characteristic, but when the entire surface of the transparent resin layer is covered with the indium, since the attenuation and the phase difference of radio waves of the radio wave transmission cover become large, radio wave transmission performance is reduced.
- In this regard, it is considered to partially print the indium layer only in the concave part of the uneven surface of the transparent resin layer. As an indium printing method, a screen printing method, a hot stamping method and the like are considered.
- However, the screen printing method is a method in which ink is pushed out from a screen mesh and is printed. When the position of the screen mesh is slightly shifted, the boundary of a print part is shifted from the boundary part of a concave part and a convex part. Since the boundary line of characters and figures of the concave part or the convex part is not clear, appearance becomes worse.
- The hot stamping method is a method in which a transfer film having a sheet printed with the indium layer is arranged on the uneven surface of the transparent resin layer, and the transfer sheet is pressed to the uneven surface by using a hot stamp while heating it, so that the indium layer is transferred to the uneven surface. In this method, there may occur a transfer error such as non-attachment of the indium layer on the sheet to the uneven surface.
- Furthermore, accurately forming a metal layer of indium and the like only in the concave part of the uneven surface of the transparent resin layer is an issue of the decorative member other than the radio wave transmission cover.
- The present invention has been made to solve the above-described problem, and an object of the present invention is to provide a decorative member capable of accurately forming a design on an uneven surface of a transparent resin layer and a manufacturing method thereof.
- According to an aspect of the present invention, there is provided a manufacturing method of a decorative member including: preparing a transparent resin layer provided on a rear surface thereof with a general portion, a stepped portion recessed or protrudingly provided with respect to the general portion, and an inclination portion provided between the stepped portion and the general portion, an inclination angle of the inclination portion with respect to a normal line of the general portion being equal to or more than 25° and being equal to or less than 40° and a width of the inclination portion being large beyond 0.38 mm and being equal to or less than 1 mm; disposing a first layer on at least the stepped portion and the inclination portion of the rear surface of the transparent resin layer; allowing a part covering the stepped portion in the first layer to remain and separating an excess part, other than the covering the stepped portion, in the first layer by laser irradiation; and disposing a second layer on a part not covered with at least the first layer of the rear surface of the transparent resin layer.
- According to another aspect of the present invention, there is provided a decorative member including: a transparent resin layer provided on a rear surface thereof with a general portion, a stepped portion recessed or protrudingly provided with respect to the general portion, and an inclination portion provided between the stepped portion and the general portion; and a decorative layer provided on the rear surface of the transparent resin layer, wherein: an inclination angle of the inclination portion with respect to a normal line of the general portion is equal to or more than 25° and is equal to or less than 40°; a width of the inclination portion is large beyond 0.38 mm and is equal to or less than 1 mm; and the decorative layer includes: a first layer that covers the stepped portion of the rear surface of the transparent resin layer; and a second layer that covers a part of the rear surface of the transparent resin layer, which is not covered by at least the first layer.
- According to the manufacturing method of the decorative member of the invention, the first layer is disposed on at least the concave or convex stepped portion and the inclination portion on the rear surface of the transparent resin layer, and the part covering the stepped portion in the first layer is allowed to remain, and the excess part in the first layer, other than the part covering the stepped portion, is separated by the laser irradiation. Therefore, it is possible to accurately separate the excess part. When the first layer is viewed from the surface of the transparent resin layer, it is possible to view an accurate design.
- The inclination angle of the inclination portion with respect to the normal line of the general portion is 25° to 40° and the width of the inclination portion is large beyond 0.38 mm and is equal to or less than 1 mm. The width of the inclination portion is larger than separation tolerance when the first layer is separated by the laser irradiation. Therefore, even though a molding dimensional error or a positional shift at the time of installation of a laser irradiation jig occurs in the transparent resin layer, these errors are absorbed, so that the boundary line between the first layer and the separation part, from which the excess part has been separated, can be positioned on the inclination portion. The boundary line between the first layer and the separation part is allowed to be positioned on the inclination portion, so that the boundary line is prevented from being shifted on the general portion or the stepped portion.
- Since the inclination angle of the inclination portion is 25° to 40°, when the first layer is viewed from the surface side of the transparent resin layer, the first layer remaining on the inclination portion is difficult to be viewed. The first layer is viewed as if it covers only the stepped portion, so that it is possible to three-dimensionally view the first layer with a good appearance.
- The separation of the excess part of the first layer is performed by the laser irradiation. Since the laser has a high degree of accuracy of an irradiation position, it is possible to accurately separate the excess part of the first layer. Therefore, according to the invention, as compared with the case in which the first layer has been formed on the stepped portion by printing such as screen printing, it is possible to accurately form a design of the first layer.
- For example, in the case of forming the first layer on the stepped portion by screen printing, the printing may not be performed depending on the rear surface shape of the transparent resin layer. That is, in the screen printing, since ink is pushed out from a screen mesh and is printed, the screen mesh need to be parallel to the rear surface of the transparent resin layer. When there is a protruding part which largely protrudes on the rear surface, since the protruding part causes flow mark or weld to the transparent resin layer at the time of molding, no design is established.
- In contrast, when the laser is used, it is possible to reliably separate the excess part of the first layer regardless of the rear surface shape of the transparent resin layer.
- In the invention, the general portion and the stepped portion of the rear surface of the transparent resin layer may be a concave portion or a convex portion. The first layer is formed on the stepped portion.
- The decorative member of the invention is manufactured by the aforementioned decorative member manufacturing method, so that it is possible to view a design accurately formed on the uneven surface of the transparent resin layer.
- Since the inclination angle and the width of the inclination portion are in the aforementioned range, it is possible to three-dimensionally view the first layer with a good appearance.
- The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawing which is given by way of illustration only, and thus is not limitative of the present invention and wherein:
-
FIG. 1 is a front view of a front grill to which a decorative member of a first embodiment of the invention has been attached: -
FIG. 2 is a front view of the decorative member of the first embodiment: -
FIG. 3 is a sectional view taken along line A-A ofFIG. 2 ; -
FIG. 4 is an enlarged view of a circled part ofFIG. 3 ; -
FIG. 5 is an explanation diagram of an inclination portion of a rear surface of a transparent resin layer of the first embodiment; -
FIG. 6 is a flowchart illustrating a manufacturing method of the decorative member of the first embodiment; -
FIG. 7 is a sectional view of the transparent resin layer, in which an outer peripheral part of the rear surface has been subjected to black printing, for explaining the manufacturing method of the decorative member of the first embodiment; -
FIG. 8 is a sectional view of the transparent resin layer on which a first layer has been disposed, which is subsequent toFIG. 7 ; -
FIG. 9 is a sectional view of the transparent resin layer after a separation step, which is subsequent toFIG. 8 : -
FIG. 10 is a sectional view of the transparent resin layer on which a second layer has been disposed, which is subsequent toFIG. 9 : -
FIG. 11 is a front view of a decorative member of a second embodiment; -
FIG. 12 is a sectional view taken along line B-B ofFIG. 11 ; -
FIG. 13 is a flowchart illustrating a manufacturing method of the decorative member of the second embodiment; -
FIG. 14 is a sectional view of the transparent resin layer, on which a pattern layer and a first layer have been disposed, for explaining the manufacturing method of the decorative member of the second embodiment: -
FIG. 15 is a sectional view of the transparent resin layer after a separation step, which is subsequent toFIG. 14 ; -
FIG. 16 is a sectional view of the transparent resin layer on which a second layer has been disposed, which is subsequent toFIG. 15 ; -
FIG. 17 is a partially enlarged sectional view of a decorative member of a third embodiment: -
FIG. 18 is a sectional view of a transparent resin layer, in which a screen mesh has been arranged at a rear surface side, for explaining a manufacturing method of the decorative member of the third embodiment; -
FIG. 19 is a sectional view of a transparent resin layer on which a first layer has been formed on a rear surface by a screen printing method, which is subsequent toFIG. 18 ; and -
FIG. 20 is a sectional view of the transparent resin layer when a separation step is being performed, which is subsequent toFIG. 19 . - A decorative member and a manufacturing method thereof according to a first embodiment will be described with reference to each of drawings.
- As illustrated in
FIGS. 1 and 2 , adecorative member 1 according to the present embodiment is a millimeter wave transmission cover attached to the center of afront grill 9 of a vehicle. Thedecorative member 1 is provided at a rear surface side thereof with a millimeter wave oscillation receiver (not illustrated). - As illustrated in
FIG. 3 , thedecorative member 1 is a thin plate and thicknesses of its all parts are set to be n times of ½ of a wavelength of a millimeter wave. In thedecorative member 1, the center is gently curved to protrude to asurface 1 a side. Thedecorative member 1 has atransparent resin layer 2, abase layer 5, and adecorative layer 3 interposed between thetransparent resin layer 2 and thebase layer 5. Thetransparent resin layer 2 is made of a transparent resin material, and for example, PC (polycarbonate) is used. - A
surface 2 a of thetransparent resin layer 2 is a smooth surface. Arear surface 2 b of thetransparent resin layer 2 has an outerperipheral part 21 and aninner part 22 positioned at an inner side from the outerperipheral part 21 and recessed with respect to the outerperipheral part 21. A depth T of theinner part 22 from the outerperipheral part 21 is 2.5 mm. - The outer
peripheral part 21 has a flat shape. The outerperipheral part 21 is covered by a black translucent outerperipheral print part 35. - As illustrated in
FIGS. 4 and 5 , theinner part 22 has ageneral portion 23, a steppedportion 25 recessed with respect to thegeneral portion 23, and aninclination portion 26 provided between thegeneral portion 23 and the steppedportion 25. A height difference H between the steppedportion 25 and thegeneral portion 23 of therear surface 2 b of thetransparent resin layer 2, that is, a height of theinclination portion 26 is equal to or more than 0.3 mm and is equal to or less than 1.0 mm. In the present embodiment, the height difference H between the steppedportion 25 and thegeneral portion 23 of therear surface 2 b of thetransparent resin layer 2 is 0.5 mm. - As illustrated in
FIG. 5 , theinclination portion 26 is interposed between thegeneral portion 23 and the steppedportion 25. An inclination angle α of theinclination portion 26 with respect to a normal line D of thegeneral portion 23 is 30°. Anupper end 26 a of theinclination portion 26 is a part connected to thegeneral portion 23, and alower end 26 b of theinclination portion 26 is a part connected to the recessed steppedportion 25. R1 and R2 of theupper end 26 a and thelower end 26 b of theinclination portion 26 are all chamfered in an arc shape having a curvature radius of 0.3 mm. A width W from theupper end 26 a to thelower end 26 b of theinclination portion 26 when theinclination portion 26 has been projected along the normal line of therear surface 2 b of thetransparent resin layer 2 is 0.6 mm. - As illustrated in
FIG. 4 , thedecorative layer 3 is provided to therear surface 2 b side of thetransparent resin layer 2, and has afirst layer 31 and asecond layer 32 sequentially arranged from therear surface 2 b side. Thefirst layer 31 includes a metal layer having a radio wave transmission characteristic. As the metal layer, an indium layer is preferable. The indium layer may have a sea-island structure in which indium exists insularly in various places from the standpoint of a radio wave transmission characteristic. Thesecond layer 32 is a black coating layer. Thefirst layer 31 has a thickness of about 40 nm to 50 nm and thesecond layer 32 has a thickness of about 30 μm to 40 μm. - The
first layer 31 covers the recessed steppedportion 25 of therear surface 2 b of thetransparent resin layer 2. Thesecond layer 32 covers the entire of therear surface 2 b of thetransparent resin layer 2. Thefirst layer 31 including the indium is positioned at the recessed steppedportion 25 and is positioned near thesurface 1 a of thedecorative member 1 as compared with thesecond layer 32 including the black coating layer. As illustrated inFIG. 2 , when thedecorative member 1 is viewed from thesurface 1 a side, a black character of the black coating layer is viewed in the brightly colored area of the indium. The brightly colored figure floats up to a front side from the black area and is three-dimensionally viewed. - The
base layer 5 is made of a colored resin material, for example, AES (acrylonitrile ethylene styrene copolymer). - A manufacturing method of the
decorative member 1 of the present embodiment will be described using a flowchart ofFIG. 6 . - In step S10 (preparation step), polycarbonate resin is injection-molded using a mold, so that the
transparent resin layer 2 is obtained. - In step S20 (surface hard coat step), a hard coat process is performed for the
surface 2 a of thetransparent resin layer 2. - In step S30 (rear surface printing step), as illustrated in
FIG. 7 , blank ink is printed on the outerperipheral part 21 of therear surface 2 b of thetransparent resin layer 2 by a screen printing method and the like, so that the black translucent outerperipheral print part 35 is formed on the outerperipheral part 21. - In step S40 (first layer disposing step), as illustrated in
FIG. 8 , thefirst layer 31 including indium is formed on the entire of theinner part 22 of therear surface 2 b of thetransparent resin layer 2 by a sputtering method. Thefirst layer 31 may be formed by a deposition method. - In step S50 (separation step), as illustrated in
FIG. 9 , thetransparent resin layer 2 is fixed to a jig such that therear surface 2 b of thetransparent resin layer 2 is upward. In thefirst layer 31 on therear surface 2 b of thetransparent resin layer 2, laser is irradiated to an excess part B, other than a part A covering the steppedportion 25, so that the excess part B is separated. As the laser irradiation device, MDV9920 (product name) manufactured by keyence Corporation has been used. The laser irradiation energy per unit area is 0.45 mJ. In the laser irradiation conditions, a laser spot diameter is 0.08 mm, a laser spot pitch is 0.064 mm, a laser frequency is 120 kHz, and a laser wavelength is 1064 nm. It is sufficient if laser transmittance is 5% to 90%, and it is preferable that a laser movement speed is 600 mm/sec to 1300 mm/sec. In this case, there is no discoloration due to laser burning of thetransparent resin layer 2 and residue of the indium, which is thefirst layer 31, is also not seen. - The boundary between the irradiation area and the non-irradiation area of the laser is set as a center 26 c in the width direction of the
inclination portion 26. The excess part B separated by the laser is an area from thegeneral portion 23 and theupper end 26 a of theinclination portion 26 to the center 26 c in terms of design. When measuring a molding error range of thetransparent resin layer 2, a positional shift range of a fixing jig for laser irradiation, and a variation range of a laser irradiation position, they are sequentially ±0.17 mm, ±0.1 mm, and ±0.02 mm. Their total error is ±0.29 mm, and is separation tolerance by which a separation position may be shifted with respect to thetransparent resin layer 2. On the other hand, as illustrated inFIGS. 4 and 9 , the width W of theinclination portion 26 is 0.6 mm and theinclination portion 26 exists in an area of ±0.3 mm from the center 26 c of theinclination portion 26. Since the shift range of the laser irradiation position with respect to thetransparent resin layer 2 is ±0.29 mm, the laser enters into the width (±0.3 mm) from the center 26 c of theinclination portion 26. Therefore, when the excess part B of thefirst layer 31 is separated by the laser irradiation, a boundary line L between thefirst layer 31 and the separation part is positioned on theinclination portion 26. Thefirst layer 31 does not almost remain in theupper end 26 a side of theinclination portion 26 and mainly remains in thelower end 26 b as compared with theupper end 26 a side. The boundary line L between thefirst layer 31 and the separation part is positioned in the center 26 c of theinclination portion 26 in many cases. - In step S60 (second layer disposing step), as illustrated in
FIG. 10 , thesecond layer 32 is formed on theinner part 22 of therear surface 2 b side of thetransparent resin layer 2 by coating using a black paint. Thesecond layer 32 is an opaque black layer. - The black paint has been obtained by mixing coloring with a resin material. For example, the coloring is carbon black and the resin material is acryl resin; however, the invention is not limited thereto.
- In step S70 (base layer formation step), the
transparent resin layer 2 is inserted into the mold and colored AES is injection-molded at therear surface 2 b side of thetransparent resin layer 2, so that thebase layer 5 is formed on the entire of therear surface 2 b side. - As above, the
decorative member 1 of the present embodiment is obtained. - According to the manufacturing method of the
decorative member 1 of the present embodiment, thefirst layer 31 is disposed on the entire of therear surface 2 b of thetransparent resin layer 2, the part A covering the steppedportion 25 in thefirst layer 31 is allowed to remain, and the excess part B, other than the part A, is separated by laser irradiation. Therefore, it is possible to accurately separate the excess part B. When thefirst layer 31 is viewed from thesurface 2 a of thetransparent resin layer 2, it is possible to view an accurate design. - The inclination angle α of the
inclination portion 26 with respect to the normal line D of thegeneral portion 23 is 25° to 40° and the width W of theinclination portion 26 is large beyond 0.38 mm and is equal to or less than 1 mm. In the present embodiment, the inclination angle α of theinclination portion 26 with respect to the normal line D of thegeneral portion 23 is 30°, and the width W of theinclination portion 26 is 0.6 mm. - The width W of the
inclination portion 26 is larger than the range 0.58 mm of the separation tolerance (±0.29 mm). When laser is irradiated aiming at the center 26 c of theinclination portion 26, even though a laser irradiation positional shift occurs at theupper end 26 a side or thelower end 26 b side from the center 26 c, theinclination portion 26 absorbs the shift, so that it is possible to allow the boundary line L between thefirst layer 31 and the separation part, from which the excess part B has been separated, to be positioned on theinclination portion 26. Since the shift of the boundary line L between thefirst layer 31 and the separation part is positioned on theinclination portion 26, the boundary line L is prevented from being shifted on thegeneral portion 23 or the steppedportion 25. When thefirst layer 31 is viewed from thesurface 2 a of thetransparent resin layer 2, since thefirst layer 31 is viewed as if it covers only the steppedportion 25, it is possible to three-dimensionally view thefirst layer 31 with a good appearance. - When the inclination angle α is smaller than 25°, even though a molding dimensional error of the
transparent resin layer 2 or a laser irradiation positional shift at the time of installation of a laser irradiation jig occurs, theinclination portion 26 may not absorb the shift, or the boundary line L between thefirst layer 31 and the separation part may be positioned on thegeneral portion 23 or the steppedportion 25. When the inclination angle α exceeds 40°, if it is viewed from thesurface 1 a side of thedecorative member 1, theinclination portion 26 is viewed. The boundary line L on theinclination portion 26 is apparently viewed and the contour of thefirst layer 31 appears to protrude as compared with the contour of the steppedportion 25, so that the appearance of thefirst layer 31 may be reduced. - In the separation step, the separation of the excess part B of the
first layer 31 is performed by the laser irradiation. Since the laser has a high degree of accuracy of an irradiation position, it is possible to accurately separate the excess part B of thefirst layer 31. Therefore, according to the separation step of the present embodiment, as compared with the case in which thefirst layer 31 has been formed on the steppedportion 25 by printing such as screen printing, it is possible to accurately form a design of thefirst layer 31. - For example, when the
first layer 31 is formed on the steppedportion 25 by screen printing, the printing may not be performed depending on the rear surface shape of thetransparent resin layer 2. That is, in the screen printing, since ink is pushed out from a screen mesh and is printed, the screen mesh need to be parallel to therear surface 2 b of thetransparent resin layer 2. When there is a protruding part which largely protrudes on therear surface 2 b, since the protruding part causes flow mark or weld to thetransparent resin layer 2 at the time of molding, no design is established. - In contrast, when the laser is used, it is possible to reliably separate the excess part B of the
first layer 31 regardless of the rear surface shape of thetransparent resin layer 2, so that thefirst layer 31 can remain on the steppedportion 25. - The
decorative member 1 of the present embodiment is manufactured by the aforementioned decorative member manufacturing method, so that it is possible to view a design accurately formed on the uneven surface of thetransparent resin layer 2. - When the
rear surface 2 b of thetransparent resin layer 2 after laser irradiation is observed by SEM (scanning electronic microscope), a sea-island structure is recognized in which indium exists insularly in many places of the part A of thefirst layer 31 subjected to no laser irradiation. Thefirst layer 31 has not been observed in the separation part. In theinclination portion 26, the boundary line L between the part A of thefirst layer 31 and the separation part is arranged. When thedecorative member 1 is viewed from thesurface 1 a side, since thefirst layer 31 is viewed as if it covers only the steppedportion 25, it is possible to three-dimensionally view thefirst layer 31 with a good appearance. Around the boundary line L of the part A, the sea-island structure of the indium remains. Around the boundary line L of the part A, residues of PC (components of the transparent resin layer) having a size of about 1 μm have been observed. Since the thickness of thesecond layer 32 is 30 μm, the residues of about 1 μm do not affect external appearance, an adhesion property, and millimeter wave attenuation. - In the transparent resin layer, when measuring optical attenuation of the separation part, from which the first layer has been separated by laser irradiation, and optical attenuation of the transparent resin layer before the first layer is formed, both are low with the same degree.
- The color of the transparent resin layer (a resin layer before being processed) before the first layer is formed and the color of the transparent resin layer (a resin layer after separation) after laser separation have been measured with an L*a*b* display system. The laser irradiation conditions are similar to the aforementioned conditions of the present embodiment. From the measured values of the color of the resin layer before being processed and the color of the resin layer after separation, a color difference ΔE of the resin layer after separation from the resin layer before being processed has been obtained. When the color difference ΔE is smaller than 1.5, it can be understood that it is not possible to recognize the color difference of the two. These results are illustrated in Table 1 below.
-
TABLE 1 Transmission color tone L*a*b* value L* a* b* Color difference ΔE Resin layer before being 95.79 −0.08 0.31 processed Resin layer after separation 95.33 −0.09 0.77 0.65 - The color difference ΔE from the resin layer before being processed and the resin layer after separation is 0.65. From this fact, it can be understood that laser is irradiated to the first layer, so that it is possible to separate the first layer from the rear surface of the transparent resin layer to the extent that the first layer is not recognizable.
- A
decorative member 1 of the present embodiment is different from the first embodiment in that apattern layer 36 is coated on the outerperipheral part 21 of therear surface 2 b of thetransparent resin layer 2 as illustrated inFIGS. 11 and 12 . - In order to manufacture the
decorative member 1 of the present embodiment, steps S10, S20, S30, and S40 have been performed as illustrated inFIG. 13 , similarly to the first embodiment. On therear surface 2 b of thetransparent resin layer 2 after step S40, thefirst layer 31 is formed on the entire of the inner part 22 (seeFIG. 8 ). - After step S40 (first layer disposing step), step S45 (a partial coating step) is performed. In step S45, the
pattern layer 36 is coated on a part of the outerperipheral part 21 of therear surface 2 b of thetransparent resin layer 2 or the entire of theinner part 22 as illustrated inFIG. 14 . In order to form thepattern layer 36, in the state in which a part of the outerperipheral part 21, other than a pattern layer formation part, is covered with amask 8, therear surface 2 b of thetransparent resin layer 2 is coated, and then themask 8 is removed. For thepattern layer 36, an opaque colored paint of a brown and the like has been used. - In step S50 (separation step), as illustrated in
FIG. 15 , in thefirst layer 31 and thepattern layer 36 on therear surface 2 b of thetransparent resin layer 2, laser is irradiated to an excess part B, other than the part A covering the steppedportion 25, so that the excess part B is separated. The laser irradiation conditions are similar to those of the first embodiment except that the irradiation energy per unit area is 3.2 mJ. The width W of theinclination portion 26 of therear surface 2 b of thetransparent resin layer 2 is 0.6 mm and the inclination angle α of theinclination portion 26 is 30°. The width W and the inclination angle α are similar to those of the first embodiment. Since the width W is larger than separation tolerance (±0.29 mm) due to the difference of laser irradiation as described in the first embodiment, even though positional shift of laser irradiation occurs, the boundary line L between thefirst layer 31 and thepattern layer 36 remaining after the separation and the separation part thereof is positioned on theinclination portion 26. - In step S60 (second layer disposing step), as illustrated in
FIG. 16 , a black coating layer is disposed at therear surface 2 b side of thetransparent resin layer 2 as thesecond layer 32. - In step S70 (base layer formation step), as illustrated in
FIG. 12 , therear surface 2 b of thetransparent resin layer 2, on which thesecond layer 32 has been formed, is covered with thebase layer 5. The formation of thebase layer 5 has been performed similarly to the first embodiment. - As above, the
decorative member 1 of the present embodiment has been obtained. - When the obtained
decorative member 1 is viewed from the surface, thepattern layer 36 is recognized at the outerperipheral part 21 through a transparent black outerperipheral print part 35. At theinner part 22, thepattern layer 36 is conceal to the rear surface side of thefirst layer 31 and is not seen. At theinner part 22, the bright color of the indium of thefirst layer 31 stands out on a front side and is three-dimensionally recognized in the black area of thesecond layer 32 similarly to the first embodiment. - A
decorative member 1 of the present embodiment is different from the first embodiment in that afirst layer 310 of thedecorative layer 3 is a black coating layer and asecond layer 320 is an indium layer as illustrated inFIG. 17 . - The
first layer 310 is formed on a steppedportion 250 protrudingly provided in theinner part 22 of therear surface 2 b of thetransparent resin layer 2. On therear surface 2 b of thetransparent resin layer 2, thesecond layer 320, which is the indium layer, is formed on the entire of theinner part 22, including thefirst layer 310. - In order to manufacture the
decorative member 1 of the present embodiment, steps S10, S20, and S30 have been performed (seeFIG. 6 ), similarly to the first embodiment. On therear surface 2 b of thetransparent resin layer 2 after step S30, a black translucent outerperipheral print part 35 is formed on the outer peripheral part 21 (seeFIG. 7 ). - In step S40 (first layer disposing step), as illustrated in
FIG. 18 , ascreen mesh 7 is arranged at therear surface 2 b side of thetransparent resin layer 2. In thescreen mesh 7, holes 70 are opened in parts corresponding to the steppedportion 250 and aninclination portion 260. As illustrated inFIGS. 18 and 19 , black ink is pushed out from theholes 70 of thescreen mesh 7, so that thefirst layer 310 is formed on the steppedportion 250 and theinclination portion 260. In the screen printing using thescreen mesh 7, since printing position accuracy is lower than that of laser, thefirst layer 310 is formed on theinclination portion 260 as well as the steppedportion 250 by the screen printing, and thefirst layer 310 on theinclination portion 260 is separated by laser in a subsequent separation step. The black ink used in the screen printing is similar to the black ink in step S60 (second layer disposing step) in the first embodiment. - In step S50 (separation step), as illustrated in
FIG. 20 , laser is irradiated to an excess part B of thefirst layer 310, so that the excess part B is separated. In this way, thefirst layer 310 remains on the steppedportion 250 of therear surface 2 b of thetransparent resin layer 2. - In the present embodiment, laser is set to be irradiated to an area from a
general portion 230 to acenter 260 c of theinclination portion 260. The excess part B separated by the laser is an area from alower end 260 b to thecenter 260 c of theinclination portion 260 in thefirst layer 310 in terms of design. Similarly to the first embodiment, separation tolerance is +0.29 mm. The separation tolerance is smaller than the width W (±0.30 mm) from thecenter 260 c of theinclination portion 260. Therefore, also in the present embodiment, when the excess part B of thefirst layer 310 is separated by laser irradiation, the boundary line L between thefirst layer 310 and the separation part is positioned on theinclination portion 260. - In step S60 (second layer disposing step), as illustrated in
FIG. 17 , the indium layer as thesecond layer 320 is disposed on the entire of theinner part 22. The indium layer can be disposed by a sputtering method or a deposition method. - Thereafter, step S70 (base layer formation step) is performed similarly to the first embodiment, so that the
decorative member 1 of the present embodiment is obtained. - When the
decorative member 1 of the present embodiment is viewed from thesurface 1 a side, the bright color part of thesecond layer 320 formed on thegeneral portion 230 and including indium floats up and is three-dimensionally and clearly seen during black coating. - In step S40 (first layer disposing step), the
first layer 310 is formed as a coating layer by using thescreen mesh 7. When positional shift occurs in thescreen mesh 7, thefirst layer 310 causes positional shift. However, since thefirst layer 310 is accurately trimmed by laser in step S50 (separation step), it is possible to form thefirst layer 310 at an accurate position. - The
first layer 310 is formed in advance on the steppedportion 250 and theinclination portion 260 around the steppedportion 250 by the screen printing, and a part of thefirst layer 310 covering the steppedportion 250 is separated by laser afterward. Therefore, an area of a laser separation area becomes small. It is possible to shorten a laser separation time. - The
decorative member 1 of the aforementioned embodiment is a radio wave transmission cover for millimeter waves, but can also be used in a radio wave transmission cover for other electric waves. Thedecorative member 1 of the aforementioned embodiment can also be used as emblems for decoration. These emblems are not limited to vehicles, and can be used in all scenes. - (1) The manufacturing method of the decorative member 1 of the present embodiment includes a preparation step of preparing the transparent resin layer 2 provided on the rear surface 2 b thereof with the general portions 23 and 230, the stepped portion 25 recessed or the stepped portion 250 protrudingly provided with respect to the general portions 23 and 230, and the inclination portions 26 and 260 provided between the stepped portions 25 and 250 and the general portions 23 and 230, inclination angles α of the inclination portions 26 and 260 with respect to the normal lines D of the general portions 23 and 230 being 25° to 40° and widths W of the inclination portions 26 and 260 being large beyond 0.38 mm and being equal to or less than 1 mm, a first layer disposing step of disposing first layers 31 and 310 on at least the stepped portions 25 and 250 and the inclination portions 26 and 260 of the rear surface 2 b of the transparent resin layer 2, a separation step of allowing parts A covering the stepped portions 25 and 250 in the first layers 31 and 310 to remain and separating excess parts B, other than the parts A, in the first layers 31 and 310 by laser irradiation, and a second layer disposing step of covering parts not covered with at least the first layers 31 and 310 of the rear surface 2 b of the transparent resin layer 2.
- According to the aforementioned configuration, the
first layers portions inclination portions rear surface 2 b of thetransparent resin layer 2, and the parts A covering the steppedportions first layers first layers surface 2 a of thetransparent resin layer 2, it is possible to view an accurate design. - The inclination angles α of the
inclination portions general portions inclination portions inclination portions first layers transparent resin layer 2, these errors are absorbed, so that the boundary lines L between thefirst layers inclination portions first layers inclination portions general portions portions - Since the inclination angles α of the
inclination portions first layers first layers inclination portions first layer 31 is viewed as if it covers only the steppedportion 25, so that it is possible to three-dimensionally view thefirst layer 31 with a good appearance. - In the separation step, the separation of the excess parts B of the
first layers first layers first layers portions first layers - For example, in the case of forming the
first layers transparent resin layer 2. That is, in the screen printing, since ink is pushed out from a screen mesh and is printed, the screen mesh need to be parallel to therear surface 2 b of thetransparent resin layer 2. When there is a protruding part which largely protrudes on therear surface 2 b, since the protruding part causes flow mark or weld to thetransparent resin layer 2 at the time of molding, no design is established. - In contrast, when the laser is used, it is possible to reliably separate the excess parts B of the
first layers rear surface 2 b of thetransparent resin layer 2, so that it is possible to form designs of thefirst layers - In the aforementioned embodiment, the
general portions portions rear surface 2 b of thetransparent resin layer 2 may be concave portions or convex portions. In the separation step, thefirst layers portions - (2) Preferably, the first layer is made of indium, and in the separation step, irradiation energy per unit area of laser irradiated to the first layer is 0.3 mJ to 0.6 mJ. In this case, it is possible to sufficiently separate the excess part B of the
first layer 31 by laser irradiation without a change in the color of thetransparent resin layer 2. - (3) After the first layer disposing step, it is preferable to perform a coating step of forming a paint layer (the pattern layer 36) including a paint on the
rear surface 2 b of thetransparent resin layer 2 and including a part in which thefirst layer 31 has been formed. It is possible to form a design with a good appearance. - (4) In the aforementioned (3), preferably, the
first layer 31 is made of indium and in the separation step, irradiation energy per unit area of laser irradiated to an overlap part of thefirst layer 31 and the paint layer (the pattern layer 36) is 2.5 mJ to 3.8 mJ. In this case, it is possible to sufficiently separate the excess parts B of thefirst layer 31 and the paint layer by laser irradiation without a change in the color of thetransparent resin layer 2. - (5) In the separation step, preferably, the boundary between an irradiation area and a non-irradiation area of the laser is set as the
centers 26 c and 260 c in the width direction of theinclination portions transparent resin layer 2, theinclination portions first layers inclination portions - (6) The
decorative member 1 of the aforementioned embodiment is thedecorative member 1 having thetransparent resin layer 2 provided on therear surface 2 b thereof with thegeneral portions portions general portions inclination portions portions general portions decorative layer 3 provided on therear surface 2 b of thetransparent resin layer 2, theinclination portions portions general portions inclination portions general portions inclination portions decorative layer 3 has thefirst layers portions rear surface 2 b of thetransparent resin layer 2, and thesecond layers rear surface 2 b of thetransparent resin layer 2, which are not covered by at least thefirst layers - The
decorative member 1 of the present embodiment is manufactured by the aforementioned manufacturing method of thedecorative member 1, so that it is possible to view a design accurately formed on the uneven surface of thetransparent resin layer 2. - Since the inclination angle α and the width W of the
inclination portion 26 are in the aforementioned range, it is possible to three-dimensionally view thefirst layers - (7) Preferably, in the stepped
portions rear surface 2 b of thetransparent resin layer 2, a height difference H with thegeneral portions first layers portions second layers general portions - (8) Preferably, any one of the
first layers second layers first layers second layers - (9) Preferably, the metal layer is made of indium. Since the indium has a radio wave transmission characteristic, the
decorative member 1 of the present embodiment can be used as a radio wave transmission cover. - (10) Preferably, the boundary line L between parts covered with the
first layers rear surface 2 b of thetransparent resin layer 2 and parts not covered with thefirst layers inclination portions first layers portions inclination portions surface 1 a side of thedecorative member 1, thefirst layers inclination portions first layers portions first layers second layers - In addition, it is sufficient if a decorative member has the following aspects.
- (11) Preferably, the
rear surface 2 b of thetransparent resin layer 2 has a base area (the outer peripheral part 21) and a main area (the inner part 22) recessed or protrudingly provided with respect to the base area, the main area has thegeneral portions portions inclination portions decorative layer 3 covering the steppedportions - (12) Preferably, the
decorative layer 3 is covered by thebase layer 5. The decorative layer is disposed between thetransparent resin layer 2 and thebase layer 5, so that the decorative member is easily used as an emblem or a radio wave transmission cover. - (13) Preferably, the decorative member is a radio wave transmission cover.
Claims (10)
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2016
- 2016-11-15 US US15/351,581 patent/US20170136739A1/en not_active Abandoned
- 2016-11-15 KR KR1020160151795A patent/KR101985578B1/en active IP Right Grant
- 2016-11-15 EP EP16198848.0A patent/EP3168056A1/en active Pending
- 2016-11-16 CN CN201611022012.XA patent/CN106696848A/en active Pending
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2020
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Cited By (5)
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US11199609B2 (en) * | 2016-12-09 | 2021-12-14 | Faltec Co. Ltd. | Radar cover and method for manufacturing radar cover |
US11199610B2 (en) * | 2018-10-22 | 2021-12-14 | Toyoda Gosei Co., Ltd. | Onboard sensor cover |
US11273619B2 (en) * | 2019-03-29 | 2022-03-15 | Honda Motor Co., Ltd. | Molded resin product |
CN112578364A (en) * | 2019-09-27 | 2021-03-30 | 丰田合成株式会社 | Near-infrared sensor cover |
US20210096221A1 (en) * | 2019-09-27 | 2021-04-01 | Toyoda Gosei Co., Ltd. | Near-infrared sensor cover |
Also Published As
Publication number | Publication date |
---|---|
CN106696848A (en) | 2017-05-24 |
EP3168056A1 (en) | 2017-05-17 |
US20200223183A1 (en) | 2020-07-16 |
JP6450671B2 (en) | 2019-01-09 |
JP2017090384A (en) | 2017-05-25 |
US11298917B2 (en) | 2022-04-12 |
KR101985578B1 (en) | 2019-06-03 |
KR20170057152A (en) | 2017-05-24 |
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