Decorated parts having a decorative surface with a design drawn thereon
10974275 · 2021-04-13
Assignee
Inventors
Cpc classification
B23K26/082
PERFORMING OPERATIONS; TRANSPORTING
B23K26/043
PERFORMING OPERATIONS; TRANSPORTING
B23K2103/172
PERFORMING OPERATIONS; TRANSPORTING
B23K2103/42
PERFORMING OPERATIONS; TRANSPORTING
B60R13/02
PERFORMING OPERATIONS; TRANSPORTING
B23K26/364
PERFORMING OPERATIONS; TRANSPORTING
C08J7/046
CHEMISTRY; METALLURGY
B41M5/24
PERFORMING OPERATIONS; TRANSPORTING
B23K26/0006
PERFORMING OPERATIONS; TRANSPORTING
B23K26/402
PERFORMING OPERATIONS; TRANSPORTING
B23K26/0861
PERFORMING OPERATIONS; TRANSPORTING
B23K26/359
PERFORMING OPERATIONS; TRANSPORTING
B23K2101/34
PERFORMING OPERATIONS; TRANSPORTING
B44F1/02
PERFORMING OPERATIONS; TRANSPORTING
C08J7/0427
CHEMISTRY; METALLURGY
International classification
B44C1/22
PERFORMING OPERATIONS; TRANSPORTING
B23K26/364
PERFORMING OPERATIONS; TRANSPORTING
B23K26/00
PERFORMING OPERATIONS; TRANSPORTING
B44F1/02
PERFORMING OPERATIONS; TRANSPORTING
B60R13/02
PERFORMING OPERATIONS; TRANSPORTING
B23K26/359
PERFORMING OPERATIONS; TRANSPORTING
B41M5/24
PERFORMING OPERATIONS; TRANSPORTING
B23K26/402
PERFORMING OPERATIONS; TRANSPORTING
B23K26/08
PERFORMING OPERATIONS; TRANSPORTING
B23K26/04
PERFORMING OPERATIONS; TRANSPORTING
Abstract
This invention provides a method for manufacturing a decorated part having a dynamic visual effect of a design that is drawn onto the surface of a work, thus reducing the manufacturing cost. The decorated part is manufactured by a laser-irradiating process, which involves irradiating a laser onto a decorative surface 4, thus forming a design 20 having many laser-processed linear grooves 21 closely aligned in a specific direction F1 on said decorative surface. Also, in the laser-irradiating process, said design 20 is formed such that the angle θ2 that is made by the specific direction F1 and by the direction F2 in which the laser-processed linear grooves 21 are extending is gradually changing into the direction in which such laser-processed linear grooves are aligned.
Claims
1. A decorated part comprising: a three-dimensional resin-molding work, the three-dimensional resin-molding work having a surface; and a thermoset coating-film consisting of a gloss black-coating material with a thermosetting property, the thermoset coating-film formed on the surface of the three-dimensional resin-molding work, the thermoset coating-film having multiple laser-processed grooves formed therein, the thermoset coating-film with the multiple laser-processed grooves forming a design-containing decorative surface, the multiple laser-processed linear grooves aligned in a specific direction as part of the decorative surface, the design of the design-containing decorative surface formed such that an angle that is made by the specific direction and by a direction in which the multiple laser-processed linear grooves extend changes into a direction in which such multiple laser-processed linear grooves are aligned, wherein for the multiple laser-processed grooves, a number of the multiple laser-processed grooves are not parallel to each other in the specific direction and the direction that changes, wherein each of the multiple laser-processed grooves have opposing ends, and ends of each of the multiple laser-processed grooves are separate from adjacent multiple laser-processed grooves, and wherein for the multiple laser-processed grooves, a number of the multiple laser-processed grooves have different lengths along the specific direction and the direction that changes, and a brilliant agent-containing coating layer covering the thermoset coating-film having the multiple laser-processed grooves formed therein, wherein a thickness of the brilliant-agent-containing coating layer is less than a depth of the multiple laser-processed grooves and that a surface of the brilliant-agent-containing coating layer has a shape that follows an inner surface of the multiple laser-processed grooves.
2. A decorated part according to claim 1, characterized in that the design is a combination of plural blocks.
Description
BRIEF EXPLANATION OF THE DRAWINGS
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MODES FOR CARRYING OUT THE INVENTION
First Embodiment
(13) Hereinafter, the first embodiment of this invention is described in reference to the drawings.
(14) As shown in
(15) The surface 3 of the work 2 is covered with the thermoset coating layer 11 that is made of a high-gloss black-coating material (e.g. piano black, which is a two-liquid type acrylic-urethane coating material for the embodiment of this invention). The thickness H1 (see
(16) As described in
(17) As shown in
(18) Next, the surface-decorative scheme 30 for manufacturing the automotive-decorated part 1 is shown.
(19) As shown in
(20) The work-displacement robot 32 comprises a robot arm 46 and a work-support member 47 attached to the front edge of the robot arm 46. The work-displacement robot 32 has the function of changing the position and the angle of the work 2 by activating the robot arm 46 so that the irradiation position and the irradiation angle of the laser L1, with respect to the surface 3 of the work 2, can be changed.
(21) Next, the electrical configuration of the surface-decorative scheme 30 is described herein.
(22) As shown in
(23) The laser-irradiation data for the irradiating laser is stored in the memory 51. The laser-irradiation data is the data obtained by converting the CAD data. The CAD data is data made by converting the image-data showing the thermoset coating layer 11 on which the laser-processed linear grooves 21 are formed. The memory 51 stores the data showing the laser-irradiation parameter (the irradiation position, the focal position, the irradiation angle, the irradiation area, the irradiation intensity, the irradiation frequency, the irradiation pitch or the like) that is used in the laser irradiation.
(24) Next, the method for manufacturing the automotive-decorated part 1 is described herein.
(25) Firstly, prepare the work 2 that is specifically formed three-dimensionally by using a black thermoplastic resin (e.g. an ABS resin for the embodiment of this invention). In the work-forming process, specifically, the work 2 is formed by using a mold (no drawing provided) not having an emboss (i.e. a fine concave and convex) for forming the laser-processed linear grooves 21. The work 2 is manually set onto the work-support member 47 (see
(26) Next, in the process of forming the thermoset coating layer, the thermoset coating layer 11 for covering the surface 3 of the work 2 is formed (see
(27) The CPU50 retrieves the laser-irradiation data stored in the memory 51. Then, the robot-activating signal is produced according to the laser-irradiation data that is being retrieved, thus generating the robot-activating signal to the work-displacement robot 32. The work-displacement robot 32 activates the robot arm 46 according to the robot-activating signal being generated by the CPU50, thus transferring the work 2 being supported by the work-support member 47 to the place where the laser L1 can be irradiated onto the decorative surface 4 provided on the surface 12 of the thermoset coating layer 11. At the same time, the angle of the work 2 being supported by the work-support member 47 is adjusted, thus adjusting the irradiation-angle of the laser L1 with respect to the decorative surface 4.
(28) Then, in the laser-irradiation process, the laser L1 is irradiated onto the decorative surface 4 that is set on the surface 12 of the thermoset coating layer 11. More precisely, at first, the CPU50 retrieves the laser-irradiation data stored in the memory 51 and then produces, based on such laser-irradiation data being retrieved, the laser-processed linear-groove forming signal that is the activating signal for forming the laser-processed linear grooves. Then, the CPU50 generates the laser-processed linear-groove forming signal to the laser-irradiation device 31. The laser-irradiation device 31 then irradiates, according to the laser-processed linear-groove forming signal generated by the CPU50, the laser L1 onto the specific irradiation area configuring the decorative surface 4 (see
(29) Therefore, the embodiment of this invention achieves the following effects.
(30) (1) In the laser-irradiation process of the method for manufacturing the automotive-decorated part 1 as the embodiment of this invention, the design 20 is formed such that the angle θ1 made by the direction (the specific direction F1) in which the laser-processed linear grooves 21 are aligned and by the direction F2 in which these linear grooves 21 are extending is gradually changed into the direction in which these linear grooves 21 are aligned. Therefore, as the direction of one's eye changes, the eye catches the light that is being reflected by the different laser-processed linear grooves 21. Thus, the design 20 becomes an active one having a dynamic visual effect (specifically, a sparkling effect) that achieves a more excellent design than one having a static visual effect (e.g. a three-dimensional effect or a feeling-of-depth effect).
(31) (2) The embodiment of this invention eliminates the need for the conventionally known process of attaching the decorative film onto the surface of the work, reducing the material cost of such decorative film, and eliminates the need for plate-making or the like that is used in printing a design onto the decorative film, thus reducing escalating manufacturing cost. In the case that the work has a squeezed shape, it is difficult to adopt the conventional process to form the design by attaching the decorative film onto the surface of such a work. However, the embodiment of this invention, of that of irradiating the laser L1, can fully achieve the design 20 regardless of the shape of the work 2.
(32) (3) The thermoset coating layer 11 configuring the automotive-decorated part 1 as the embodiment of this invention is made of a black two-liquid type acrylic-urethane coating material, i.e. a dark colored coating material that readily absorbs heat. Compared to the case of which the thermoset coating layer 11 is covered with a light colored coating material, the energy of the laser L1 is easily absorbed into the heated surface layer of the thermoset coating layer 11, thus forming the laser-processed linear grooves 21 in a short time. Therefore, the efficiency of manufacturing the automotive decorated part 1 is improved.
(33) (4) The embodiment of this invention allows for the laser-processed linear grooves 21 to be formed by irradiating the laser L1 onto the thermoset coating layer 11, which makes it possible to form the fine laser-processed linear grooves 21 more properly than in the case of forming the laser-processed linear grooves 21 by injection-metal molding.
Second Embodiment
(34) Hereinafter, the second embodiment of this invention is described in reference to the drawings. Different points than those of the above first embodiment are mainly described herein. The design configuration of the second embodiment is different than that of the first embodiment.
(35) As shown in
(36) Each block 92 is configured by the forming of the laser-processed linear grooves 91 in parallel with an even pitch. Specifically, the line pitch P1 of the laser-processed linear grooves 91 on the whole blocks 92 is set at 0.1 mm or more and 1.0 mm or less (i.e. 0.2 mm for the embodiment of this invention). Also, as shown in
(37) As shown in
(38) Next, a method for manufacturing the automotive decorated part 71 is described herein.
(39) In the laser-irradiation process for the embodiment of this invention, each of the laser-processed linear grooves 91 configuring the specific block 92a (or 92b) is formed, in order, by laser irradiation. Then, another laser-processed groove 91 adjoining another block 92a (92b) is formed by the same series of operations as above. Each time, the operation is shifting from the first step (or the second step) to form the specific block 92a (or 92b) to the second step (or the third step) to form a different block 92b (or 92c). The angle θ2 of the different block 92b (or 92c) is lessened by 10 degrees, each, from the angle θ2 of the specific block 92a (or 92b).
(40) Firstly, the CPU50 retrieves the laser-irradiation data from the memory 51 and produces according to that laser-irradiation data an activating signal for forming the laser-processed linear grooves on the block 92a, i.e. the first laser-processed linear-groove-forming signal. Then, such CPU50 transmits that first laser-processed linear-groove-forming signal to the laser-irradiation device 31. Then, the laser-irradiation device 31, according to the first laser-processed linear-groove-forming signal generated by the CPU50, irradiates the laser L1 onto the block 92a. Thus, the block 92a of which the laser-processed linear grooves 91 are aligned in parallel is formed on the surface 12 of the thermoset coating layer 11.
(41) Secondly, the CPU50, according to the laser-irradiation data being retrieved from the memory 51, produces the activating signal for forming the laser-processed linear grooves on the block 92b, i.e. the second laser-processed linear-groove-forming signal. Then, the CPU50 generates that second laser-processed linear-groove-forming signal to the laser-irradiation device 31. The laser irradiation device 31, according to the second laser-processed linear-groove-forming signal, irradiates the laser L1 onto the block 92b. Thus, the block 92b, of which the laser-processed linear grooves 91 are aligned in parallel, is formed on the surface 12 of the thermoset coating layer 11.
(42) Each time that the laser-processed linear grooves 91 are completely formed on the specific block 92, the CPU50 repeats the control process to form the laser-processed linear grooves 21 on a different block 92 adjoining the specific block 92. After that, the laser-processed linear grooves 21 are completely formed on the whole block 92. Then, the design 90, as shown in
(43) After the laser-irradiating process, the process of forming the brilliant-agent-containing coating layer is done, thus forming the brilliant-agent containing coating layer 100 that covers the surface 12 (i.e. the decorative surface 74 and the region 5 except for the decorative surface 74) of the thermoset coating layer 11 (see
(44) Therefore, the embodiments of this invention achieve the following effects.
(45) (5) The method for manufacturing the automotive-decorated part 71 as the embodiment of this invention makes it possible to change the angle θ2 that is made by the direction (i.e. the specific direction F3) in which the laser-processed linear grooves 91 are aligned and the direction F4 in which the laser-processed linear grooves 91 are extending and changing by 10 degrees each time that the operation is shifting from the specific block 92a (or 92b) to a different adjoining block 92b (or 92c). As a result, the block 92, reflecting the light according to the direction of the eye, changes. Thus, such a design 90 is made seemingly to be an active one such that a dynamic visual effect is achieved. Also, the image data of the simply formed block 92, of which the laser-processed linear grooves 91 are aligned in parallel, is united to form the laser-irradiation data for the irradiating laser, thus making it easier in producing such laser-irradiation data.
(46) (6) Of the embodiment of this invention, the brilliant agent 101 within the coating layer 100 makes it possible beautifully to change the degree of light being reflected from sections (of the decorative surface 74) in which the laser-processed linear grooves 91 exist or from sections (region 5 except for the decorative surface 74) in which the laser-processed linear grooves 91 do not exist. Thus, such a coating layer 100 makes it possible to express the change in color and the depth of feeling of the design, thus improving the excellence of the design. Besides, in forming such a coating layer 100 with such a brilliant agent, such coating layer 100 protects the decorative surface 74 and the surface 93 of the laser-processed linear grooves 91 and the region 5 except for the decorative surface 74, thus improving the anti-scratch effect of the work.
(47) The above embodiment of this invention can be modified as follows. As described in the above embodiments, the automotive-decorated part 1, 71 is embodied as the armrest of a vehicle door. However, it is possible that such an automotive-decorated part be embodied as another interior part such as a console box, an instrument panel or the like or as an exterior part such as a radiator grill or a rocker molding or the like.
(48) Also, the automotive-decorated part can be embodied as a center-cluster. For example, as shown in
(49) As such, the level of gloss on the outer periphery 129 of the decorative surface 127, which is the character line of the automotive-decorated part 121 changes, which makes it possible to express a three-dimensional feeling. Also, it is possible to change the design 140 to the same as that of the design 90 for the above second embodiment of this invention. In which case, it is also possible to form the brilliant-agent-containing coating layer so that it covers the decorative surface 127 (and the non-decorative surface 126). Of the second embodiment, the design 90 having a combination of the plural block 92, is drawn on the decorative surface 74. Of the first embodiment, the design 20, having a block 92, is drawn on the decorative surface 4. However, it is possible to draw the design with the block (i.e. the same design as the design 90 for the second embodiment of this invention) on the decorative surface 4 for the first embodiment of this invention. It is still possible to draw the design without the block (i.e. the same design as that of the design 20 for the first embodiment of this invention) on the decorative surface 74 for the second embodiment of this invention. Of each embodiment, above, of this invention, the laser-processed linear grooves 21, 91 are formed on the surface 12 of the thermoset coating layer 11. However, it is possible to form such grooves 21, 91 on the surface of a coated layer that is formed by evaporation coating and not on the surface of a coating layer that is formed by such a coating. Furthermore, it is possible to form such grooves 21, 91 directly onto the surface 3 of the work 2 without the thermoset coating layer 11 to cover the surface 3 of the work 2. Of the above second embodiment, it is possible to conduct, after the brilliant-agent-containing coating layer-forming process, a clear-coat-layer forming process for forming the clear-coat layer to protect the brilliant-agent-containing coating layer 100. Contrarily, it is also possible to omit the brilliant-agent-containing coating layer-forming process for the second embodiment of this invention. The above surface-decorative scheme 30 for each embodiment is for manufacturing the automotive-decorated part 1, 71. Yet, it is not limited to that but is for manufacturing decorated parts such as electrical appliances or furniture or the like.
(50) Besides the technical ideas of this invention, as described above, other technical ideas to be understood are described hereinafter.
(51) (1) A method for manufacturing a decorated part according to the first aspect of this invention, characterized in including a process for forming the thermoset coating layer consisting of a coating material with a thermosetting property to form a thermoset coating layer that covers the surface of the work before the laser-irradiation process and includes a work-forming process to form the work by using a mold having no emboss for forming the laser-processed linear grooves before the thermoset coating layer-forming process.
(52) (2) A decorated part according to the second aspect of this invention, characterized in that the design is a combination of the plural blocks of which the laser-processed linear grooves are aligned in parallel with each other, whereby the difference between the angle of the laser-processed linear grooves configuring the specific block and the angle of the laser-processed linear grooves configuring a different block is 15 degrees or less.
(53) (3) A decorated part according to the second aspect of this invention, characterized in that the line-pitch of the laser-processed linear grooves is 0.1 mm or more and 1.0 mm or less.
(54) (4) A decorated part according to the second aspect of this invention, characterized in that the surface of the work is covered with the thermoset coating layer consisting of a coating material having the thermosetting property, whereby the laser-processed linear grooves are formed on the surface of the thermoset coating layer that is the decorative surface.
(55) (5) A decorated part according to the second aspect of this invention, characterized in that the decorative surface is covered with the brilliant-agent-containing coating layer consisting of a coating material with the scale-shaped brilliant agent.
(56) (6) A decorated part according to the second aspect of this invention, characterized in that the surface of the work is made of the many members, whereby the outer periphery of the decorative surface is located on the character line consisting of the plural joint members.
DESCRIPTION OF THE REFERENCE SIGNS
(57) 1, 71, 121: Automotive decorated parts as the decorated part 2, 122: Work 3, 123: Surface of the work 4, 74, 127: Decorative surface 11, 124: Thermoset coating layer 12, 125: Surface of the thermoset coating layer 20, 90, 140: Design 21, 91, 141: Laser-processed linear groove 92: Block 92a, 92b: Specific block 92b, 92c: Another block 100: Brilliant-agent containing coating layer 101: Brilliant agent 128: Plurality of surfaces configuring the surface of the work 129: Outer periphery of the decorative surface 130: Character line F1, F3: Specific direction F2, F4: The direction in which the laser-processed linear grooves are extending L1: Laser P1: Line pitch θ1, θ2: Angle made by the specific direction and by the direction in which the laser-processed linear grooves are extending