Decorative member and decoration method

A decorative member includes a light-transmitting substrate which is made of resin and is formed with a recessed portion on a back surface thereof, a hot stamping foil layer which is formed on the back surface of the light-transmitting substrate except for the recessed portion, and a metal vapor deposition film layer which is laminated on the recessed portion on the back surface of the light-transmitting substrate and the hot stamping foil layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority from Japanese Patent Application No. 2017-240437, filed Dec. 15, 2017, the entire content of which is incorporated herein by reference.

TECHNICAL FIELD

Aspects of the present invention relate to a decorative member and a decoration method.

BACKGROUND ART

In recent years, there are needs for good-appearance decorations on a brand logo or the like, which has contrast between black and a metallic color. Conventionally, mask vapor deposition and hot stamping have been known for this kind of surface decoration. In the mask vapor deposition, a protruded portion is formed only on a portion to be decorated on a surface of a black substrate, and a mask is applied to perform metal vapor deposition only on the protruded portion. In the hot stamping, a protruded portion is formed only on a portion to be decorated on a surface of a black substrate, and metal foil is pressed on the protruded portion with a heated relief plate to be transferred. JP-A-2006-23272 discloses that a metal glossy half mirror layer is formed on a protruded portion of a substrate by hot stamping, and a black layer is applied to an edging portion by printing or the like. In this manner, decorations having a good appearance of a metallic color pattern can be applied to a black substrate.

However, in the above methods, the appearance may be poor as accuracy of a decoration boundary portion is poor or the decoration boundary is not clear due to occurrence of spreading out of a metal vapor deposition film, occurrence of insufficient transfer of the metal foil, or the like to the protruded portion of the portion to be decorated.

SUMMARY

Accordingly, an aspect of the present invention provides a decorative member having good appearance and a clear decoration boundary and a decoration method.

According to an embodiment of the present invention, there is provided a, a decorative member includes: a light-transmitting substrate which is made of resin and is formed with a recessed portion on a back surface thereof; a hot stamping foil layer which is formed on the back surface of the light-transmitting substrate except for the recessed portion; and a metal vapor deposition film layer which is laminated on the recessed portion on the back surface of the light-transmitting substrate and the hot stamping foil layer.

According to the above configuration, since the hot stamping foil layer is formed only on a flat portion except for the recessed portion on the back surface of the light-transmitting substrate and the metal vapor deposition film layer is laminated all over the back surface of the light-transmitting substrate (the recessed portion and the hot stamping foil layer), a boundary between the hot stamping foil layer and the metal vapor deposition film layer viewed from the front surface side is clear. Accordingly, a decorative member having a clear boundary and a good appearance can be provided.

In the above decorative member, a protruded portion may be formed on a front surface of the light-transmitting substrate to correspond to the recessed portion. According to this configuration, a sense of depth is generated in the metal vapor deposition film, so that the appearance can be improved.

In the above decorative member, the hot stamping foil layer may be black. According to this configuration, the appearance can be improved by contrast between a metallic color and black.

In the above decorative member, the metal vapor deposition film layer may be formed to have half mirror characteristics. According to this configuration, when a light source is provided on a back side, the decorative member can have a novel appearance which is different when the light source is turned on or not.

According to another embodiment of the present invention, there is provided a decoration method including: a recessed portion forming step of forming a recessed portion on a back surface of a light-transmitting substrate which is made of resin; a hot stamping step of applying hot stamping to the back surface of the light-transmitting substrate except for the recessed portion; and a metal vapor deposition step of applying metal vapor deposition to the recessed portion on the back surface of the light-transmitting substrate and a hot stamping foil layer formed by the hot stamping step. According to the decoration method, a decorative member can be provided in which a boundary of a decoration portion is clear, and accuracy of the boundary between a substrate and a pattern is high.

According to the above configuration, a decorative member having a clear decoration boundary and a good appearance can be provided.

DETAILED DESCRIPTION OF EMBODIMENTS

Hereinafter, a decorative member according to embodiments of the present invention will be described with reference to the drawings. The embodiments are illustrative rather than limiting the invention, and all features and combinations thereof described in the embodiments are not necessarily essential to the invention.

First Embodiment

FIG. 1illustrates an example where a decorative member according to an embodiment of the present invention is applied to a rear window member (window panel member)1.FIG. 2is an enlarged partial sectional view taken along an II-II line inFIG. 1.FIG. 2illustrate a ratio of thicknesses of layers which does not reflect an actual ratio and schematically illustrate the configuration (same applied toFIGS. 3 and 4).

As illustrated inFIG. 1, the rear window member1is funned as a rectangular panel extending in a horizontal direction. On an edge of the rear window member1, a decoration4of a stripe having a metallic color is applied to a black substrate over an entire periphery of an outer peripheral side region.

A decorative region6to which the decoration4is applied extends in a width direction at a predetermined width on both sides in a longitudinal direction and extends in the width direction at a constant width different from the predetermined width on both sides in the width direction. In order to clarify presence of the decorative region6, the decorative region6is exaggeratedly drawn inFIG. 1.

As illustrated inFIG. 2, the rear window member1includes a transparent resin member2having light-transmitting characteristics as a main body. Therefore, in a non-decorative region3on the inside bounded by the decorative region6, the inside and outside can be seen through as the rear window.

The transparent resin member2is made of, for example, a resin such as a polycarbonate resin or an acrylic resin such as a polymethyl methacrylate resin. In the present embodiment, although the rear window member is transparent, the rear window member may be colored as long as the rear window member has high transmittance and light-transmitting characteristics.

Recessed portions7are formed on a back surface side of the stripe portion of the decoration4. The recessed portions7are formed over the entire length as grooves from a right end to a left end in an upper portion and a lower portion of the rear window member1, and are formed at a predetermined distance from ends on left and right portions. The recessed portions7have constant width and are equally separated from each other.

A black hot stamping foil layer8is formed on the decorative region6other than the recessed portion7on the back surface of the transparent resin member2. The hot stamping foil layer8is basically black, but is not limited to black, and may be other opaque colors.

The hot stamping foil layer8has a thickness of about several tens of μm in which a release layer, a colored layer, and an adhesive layer are sequentially laminated on a base film made of polyester, for example. If yellow or blue is selected as the colored layer besides black, a color tone of a metallic tone of gold or blue can be obtained by a combination with a metal vapor deposition film layer9described later.

The hot stamping foil layer8is laminated with a substantially uniform thickness on a flat portion of the back surface of the transparent resin member2, and the entire of the hot stamping foil layer8is present on the same plane.

On the recessed portion7and the hot stamping foil layer8on the back surface of the transparent resin member2(back surface side of the rear window member1), the metal vapor deposition film layer9is laminated with a substantially uniform thickness over the entire of the decorative region6. That is, the metal vapor deposition film layer9is formed on the recessed portion7on the back surface of the decorative region6of the transparent resin member2, and the two layers of the hot stamping foil layer8and the metal vapor deposition film layer9are formed on portions other than the recessed portion7.

The metal vapor deposition film layer9is selected from, for example, aluminum, SUS, and chromium, and has a film thickness of about 100 nm, but is adjusted to a thickness of 80 nm or less in a case of a half mirror.

A decoration method of the decoration4will be described referring toFIG. 3. First, the recessed portion7is formed on a back surface of a portion to which a pattern (stripe) of the decoration4of the transparent resin member2is applied (recessed portion forming step S1). For example, a technique such as laser decoration or metal molding of forming a recessed portion by irradiating, for example, a laser to foam or melt the transparent resin member2may be used. When the recessed portion7is formed with a metal mold, a protruded portion is formed in one mold to correspond to the recessed portion7, and the transparent resin member2is injection molded in combination with the other metal mold. At this time, if a height of the protruded portion (the depth of the recessed portion7) is set to 0.5 mm or more, the hot stamping foil is not transferred to the inside of the recessed portion7at the time of transfer of a later-described hot stamping foil. In the present embodiment, the pattern is a stripe, but may be a dot, a character, a curve, a geometric pattern, or the like.

Next, the hot stamping foil layer8is formed by pressing (hot stamping) a metal foil (hot stamping foil) on the decorative region6on the back surface of the transparent resin member2other than the recessed portion7with a heated relief plate (hot stamping step S2). In the hot stamping, since the metal foil is deposited only on a protruded portion, the protruded portion is formed in a portion to which the hot stamping is to be applied, and the metal foil is pressed. In the present embodiment, by forming the recessed portion7in the flat portion of the transparent resin member2, the flat portion is formed as a relatively protruded portion, and the metal foil is pressed on the back surface of the transparent resin member2other than the recessed portion7. Therefore, the metal foil can be transferred to all intended portions, so that insufficient transfer of the metal foil can be reduced and the accuracy of the boundary can be improved. Even in a minute pattern, high-accuracy decoration can be applied.

Next, a mask is applied to a non-decorative region3and metal vapor deposition is applied on the entire back surface of the transparent resin member2(metal vapor deposition step S3). For example, a metal such as aluminum is laminated by a technique such as vacuum vapor deposition to form the metal vapor deposition film layer9. Materials such as SUS and Cr may be used for vapor deposition. Thus, the metal vapor deposition film layer9is formed on the entire of the recessed portion7and the hot stamping foil layer8.

In general, in a case of decoration using the metal vapor deposition, a mask is applied to a portion other than a place to be decorated (a pattern portion) to perform metal vapor deposition. However, since the decoration is very fine and complicated, it is difficult to form a precise mask, and spreading out of the metal vapor deposition film occurs in general. In the present embodiment, it is not necessary to mask on the pattern portion only by applying the mask merely to the non-decorative region3having a large rectangular area. Since vapor deposition is applied to the entire surface of the decorative region6, there is no concern about spreading out of the metal vapor deposition film.

FIG. 4is an explanatory diagram illustrating operations and effects of the rear window member1. Arrows indicate paths of light. As illustrated inFIG. 4, when the decorative region6of the rear window member1is viewed from the front surface side, the recessed portion7appears to be a metallic color line and the hot stamping foil layer8appears to be black, so that the decorative region6is recognized by a user as the decoration4of the metallic color stripe on the black substrate. In the non-decorative region3, light is transmitted, and the user can visually recognize the inside of the vehicle.

Since the decoration4has the recessed portion7on the back surface, it has sense of depth more than that is decorated merely on a surface, it has a stereoscopic effect, and contrast between black and metallic color makes the appearance good.

Since the hot stamping foil layer8is formed on the flat portion and the metal vapor deposition film layer9is laminated on the entire surface from the above, the boundary between the substrate (the hot stamping foil layer8) and the pattern (the metal vapor deposition film layer9) of the decoration4is clear, which provides a sharp impression where a partitioning is high and a high-grade sense.

In addition, by the decoration method, a decrease in accuracy of the boundary can be reduced between the substrate and the pattern due to spreading out or lack of vapor deposition, and a minute decoration having a clear boundary can be applied. By laminating the metal vapor deposition film layer9all over the decorative region6, the boundary with the hot stamping foil layer8viewed from the front surface stands out, and the rear window member1can have a good appearance.

Second Embodiment

FIG. 5is a front view of a vehicle lamp11including an extension reflector10(hereinafter, simply referred to as “extension”) as a constituent member using a decorative member according to a second embodiment, as viewed from the front of the vehicle. The vehicle lamp11illustrated inFIG. 5is a right headlamp as viewed from the front of the vehicle. For ease of explanation,FIG. 5does not illustrate a color of a decoration104of the extension10unlikeFIG. 1, and a pattern ratio does not reflect an actual ratio.FIG. 6is an enlarged partial sectional view taken along a VI-VI line inFIG. 5.FIG. 7is an enlarged sectional view of a decorative region106of the extension10. Terms relating to directions such as “front”, “rear”, “front surface”, and “back surface” indicate directions with respect to the vehicle lamp11in a posture in which the vehicle lamp11is mounted on the vehicle unless otherwise specified.

The vehicle lamp11includes a lamp body12, an outer cover13, a lamp unit14, a clearance lamp light source15, and an extension10.

The lamp body12has a container shape which is opened on the front surface. An outer cover13covers the opening of the lamp body12to define a lamp chamber19by the lamp body12and the outer cover13.

The lamp unit14is for a headlamp and is configured to switch light emitted from a light source16such as an LED light source to a high beam and a low beam.

The clearance lamp light source15is, for example, an LED light source and is disposed on the side of the lamp unit14.

The extension10is disposed between the lamp unit14and the outer cover13. The extension10is configured such that a front surface shape of the transparent resin member2corresponds to a front surface shape of the vehicle lamp11by, for example, injection molding.

A lamp opening portion17is provided on a side of a vehicle center (left side inFIG. 5) with respect to a center of the extension10, and a clearance lamp opening18is provided on a side of a vehicle side (right side inFIG. 5). The lamp unit14is disposed on a back surface side of the lamp opening portion17, and the clearance lamp light source15is disposed on a back surface side of the clearance lamp opening portion18. When the light source16of the lamp unit14and the clearance lamp light source15are turned on, irradiation light passes through the lamp opening portion17and the clearance lamp opening portion18respectively, and is emitted forward.

The decorative region106of the extension10is provided around the clearance lamp opening portion18. The decoration104having a lattice pattern is applied to the decorative region106. As illustrated inFIG. 7, similarly to the first embodiment, the extension10includes a transparent resin member102as a member main body, and a recessed portion107is formed on the back surface thereof to correspond to the lattice pattern of the decoration104. It is different from the first embodiment that a bulging protruded portion105is formed on a front surface of the recessed portion107to correspond to the recessed portion107. The recessed portion107and the protruded portion105are molded by injection molding or the like. By providing the protruded portion105, a stereoscopic effect of the decoration104increases, and a high-grade sense increases.

A black hot stamping foil layer108is laminated on a flat portion of the back surface of the decorative region106of the extension10except for the recessed portion107. The metal vapor deposition film layer109laminated on the recessed portion107and the hot stamping foil layer108is formed by half vapor deposition and has characteristics of a half mirror.

FIGS. 8A and 8Bare sectional views of the extension10for explaining operations and effects of the metal vapor deposition film layer109having characteristics of the half mirror, and arrows indicate a light path. As illustrated inFIG. 8, when the clearance lamp light source15is turned off, the metal vapor deposition film layer109reflects light from the outside of the lamp, for example, sunlight in the daytime (part of the light is transmitted) and is recognized as a lattice pattern having a metallic color by a user. When the clearance lamp light source15is turned on, the metal vapor deposition film layer109transmits light from the clearance lamp light source15on the back side (part of the light is reflected). An appearance in which lattice-pattern light appears on the front surface of the extension10is recognized by the user.

Due to the half mirror characteristics of the metal vapor deposition film layer109, the decoration104is different in appearance when the clearance lamp light source15is turned on or off. According to this configuration, the extension10can have a high partitioning and a novel appearance.

Although the rear window and the extension have been described in the above embodiments, the present invention is not limited thereto, and can be widely applied to various parts such as an inner lens and an outer cover.

Although embodiments of the present invention have been described above, the above embodiments are mere examples of the present invention, and these embodiments can be combined based on knowledge of those skilled in the art, and such forms are also included in the scope of the present invention.