JPH01100290A - Production of electroformed mold for forming back skin-toned surface - Google Patents

Abstract

PURPOSE:To obtain an electroformed mold with the inner surface of desired structure and capable of giving a back skin-toned surface to a formed product by this mold, by forming an electrically conductive metal layer on the surface of a pile-flocked master model, and then releasing the layer. CONSTITUTION:A duplicate electrode 3 is obtained from a master model wherein the microstructured surface is omitted by the conventional method, and the surface of the electrode 3 is electrostatically and directly flocked with 10-40-denier fiber piles 4 having 0.3-2.0mm length. Instead of the direct flocking, a sheet flocked with the piles 4 of the same specification can be stuck on the electrode 3. The surface of the flocked electrode 3 is silver-mirror finished and made conductive, as required, then the electrode is dipped in an electroforming cell 5 and electroformed to deposit copper on the surface and to form a coating film 6. When the thickness of the film 6 reaches a specified value, the film 6 is released from the electrode 3, the electrode 3 is reinforced in a specified manner, and an electroformed mold 7 is produced.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention provides a molded product having the appearance and feel of a high-quality fabric with a buckskin-like surface, such as automobile interior parts and furniture furnishings. This invention relates to a method for manufacturing an electroforming mold for.

[Conventional technology]

Conventionally, the method of obtaining a molded product with an elegant buckskin-like appearance and feel is to create a master model with the detailed surface structure omitted, as disclosed in Japanese Patent Application Laid-Open No. 61-215017. A foam sheet with microporous cells is pasted on a predetermined area so that the cell surface is exposed to the outside, and then the sheet is inverted and a foaming urethane stock solution is injected into the inner surface of the resulting mold to perform foam molding. A method has been proposed that is characterized by:

According to this method, the surface of the bubbles in the foam sheet, which has bubbles that are close to spherical in the flat form, receives tension on the convex surface of the master model, and compressive force on the concave surface of the master model, causing subtle changes.
When a liquid resin such as silicone resin is poured in this state, an inverted mold is obtained in which the liquid resin is appropriately press-fitted in relation to the depth of the cells in the foam. It is said that the surface of a molded product obtained by injecting and foaming a urethane foam stock solution using this mold exhibits a surface condition that closely resembles that of buckskin.

[Problem that the invention seeks to solve]

However, according to the inventor's follow-up tests, the product obtained in this way was far from having a buckskin-like appearance and feel with fine fluff on the surface, and only the characteristics of the foam surface were emphasized. You only get the product.

[Means for solving problems]

An object of the present invention is to provide a method for manufacturing an electroforming mold capable of reproducing the original buckskin-like surface and condition by solving the problems of the prior art.

The purpose of this was to (1) produce a master model that omitted the fine structure on the surface, and (2) apply a pile length of 0.3 to
2.0fi, pile thickness in the range of 10 to 40 deniers at the required density, or alternatively, a flocked sheet having a pile in the above numerical range is applied to the surface of the master model or its replica. pasting, (3) conductive treatment if necessary, and then immersing it in an electroforming tank to form a layer of conductive metal with a predetermined thickness on the surface;
) This is achieved by a method for manufacturing an electroforming mold capable of reproducing a buckskin-like surface condition, in which the conductive metal layer is peeled off from the surface to obtain an electroforming mold having a desired surface structure on the inner surface.

Example C] Hereinafter, the present invention will be described in more detail based on an example shown in the drawings in which the present invention is applied to slush molding using vinyl chloride resin.

FIG. 1 shows a master model l of a molded product to be obtained, for example an armrest of a chair, made from a wooden mold.

In this case, the details of the buckskin-like structure of the surface that is ultimately desired are omitted, and only a smooth surface shape is sufficient.

Next, from the master model 1, an inverted model 2 having the same shape is created using a material such as silicon by a conventional method (FIG. 2).

The inverted model 2 is used as a mold and inverted again to create an electrode 3 (FIG. 3). That is, the formed electrode 3 has the same shape as the master model 1, and its surface is smooth like the master model 1.

Next, in order to give the surface of this electrode 3 a desired buckskin-like fine structure, it is flocked using a fiber pile 4 (FIG. 4). As a flocking method, flocking or the like is preferable, in which fiber piles 4 are vertically adhered to the surface of the electrode 30 at a predetermined density using static electricity. In this case, the pile 4 preferably has a length in the range of 0.3 to 2.0 m and a thickness in the range of 10 to 40 deniers. If the length range is shorter than 0.3 m, the finished molded product will feel rough and hard; If the length exceeds Ovns, the transferability during electroforming, which will be described later, will deteriorate, resulting in disadvantages such as poor appearance of the molded product.

In addition, if the thickness is as thin as 10 deniers, the pile itself becomes too stiff and transferability during electroforming deteriorates.
On the other hand, if the thickness exceeds 40 denier, the molded product may have a poor feel to the touch.

Instead of directly flocking the pile 4 to the electrode 3 by flocking as described above, it is also possible to attach a separately prepared flocking sheet to the electrode 3.

The electrode 3 which has been flocked in this way is subjected to conductive treatment such as silver mirror treatment on the surface as necessary, and then immersed in the electroforming bath 5, where copper is deposited on the surface and the coating 6 is formed. The electroforming process is carried out so that a is formed (Fig. 5).

The electroformed wave 1f that reached the predetermined thickness obtained in this way
Q6 is peeled off from the electrode 3, and a predetermined reinforcement is added thereto to create an electroforming mold 7 (FIG. 6). FIG. 7 is an enlarged sectional view of the surface portion thereof.

By repeating this process, it becomes possible to create a desired number of electroforming molds 7. In this case, if only one electroforming mold is sufficient, create an inverted model 2 from the master model 1, omit the process of making the electrode 3, and directly implant the hair on the surface of the master model 1. It is possible to create an electroforming mold 7 as an electrode.

Since this electroforming mold 7 has a surface structure directly copied from a fine pile surface that has been naturally flocked onto a preformed curved surface, no matter how tightly drawn the surface is, the The fluff stands upright in a very natural manner and does not have any unreasonable distortion. Therefore, this electroforming mold 7
The natural and elegant surface structure is also reproduced on the surface of the molded product recycled from the molded product, resulting in a buckskin-like product with an unprecedented sense of luxury.

[Brief explanation of the drawing]

1 to 6 are process diagrams showing the procedure of the present invention, and FIG. 7 is an enlarged sectional view showing the detailed structure of the surface of the electroforming mold obtained by the present invention. 1...-master model, 2...-inverted model, 3-...
-electrode, 4-pile, 5-electroforming tank,
6...Coating, 7...-electroforming mold.

Claims (1)

[Claims] (1) (1) A master model with the surface microstructure omitted is manufactured, and (2) a pile length of 0.3 to 2.0 is applied to the surface of the master model or a replica obtained from it by a conventional method.
Flocking is performed at the desired density with fibers having a pile thickness of 10 to 40 denier, or alternatively, a flocked sheet having a pile in the numerical range is pasted on the surface of the master model or its replica. , (3) If necessary, conductive treatment is performed on this material, and then immersed in an electroforming bath to form a layer of conductive metal with a predetermined thickness on the surface. (4) The conductive metal layer is removed from the surface. A method for producing an electroforming mold capable of reproducing a buckskin-like surface condition by peeling to obtain an electroforming mold having a desired surface structure on the inner surface.