US20220203599A1 - Method for manufacturing sheet laminate, mold for molding sheet laminate, and sheet laminate - Google Patents
Method for manufacturing sheet laminate, mold for molding sheet laminate, and sheet laminate Download PDFInfo
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- US20220203599A1 US20220203599A1 US17/698,156 US202217698156A US2022203599A1 US 20220203599 A1 US20220203599 A1 US 20220203599A1 US 202217698156 A US202217698156 A US 202217698156A US 2022203599 A1 US2022203599 A1 US 2022203599A1
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- sheet laminate
- flat
- side wall
- sheet
- mold
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- 238000004519 manufacturing process Methods 0.000 title abstract description 33
- 238000000465 moulding Methods 0.000 title description 21
- 238000010438 heat treatment Methods 0.000 claims abstract description 53
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- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 6
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Images
Classifications
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- 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
- B32B27/08—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 of synthetic resin
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- 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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
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- 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
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/005—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor characterised by the choice of material
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- 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
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/02—Bending or folding
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- 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
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/02—Bending or folding
- B29C53/04—Bending or folding of plates or sheets
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- 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
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/80—Component parts, details or accessories; Auxiliary operations
- B29C53/84—Heating or cooling
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- 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
- B32B1/00—Layered products having a non-planar shape
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- 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
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- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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- 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
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
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- B32B38/004—Heat treatment by physically contacting the layers, e.g. by the use of heated platens or rollers
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- 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
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
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- 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
- B32B37/26—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2405/00—Adhesive articles, e.g. adhesive tapes
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
- B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
Definitions
- the present invention relates to a method for manufacturing a sheet laminate, a mold for molding a sheet laminate, and a sheet laminate.
- stamping is known as a conventional method for manufacturing a sheet laminate (for example, see Japanese Patent JP 2015-229279).
- a processing method for sandwiching a sheet in a heated mold and then bending the sheet is referred to as heat stamping.
- a method for manufacturing a sheet laminate according to an embodiment of the present invention is a method for manufacturing a sheet laminate to be affixed to an adherent surface of an object and is provided with a preparing step for preparing a sheet member having a front surface to become a design surface and a rear surface on which an adhesive part has been formed, a bending step for bending an edge part of the sheet member by sandwiching the sheet member from a front surface side and a rear surface side in a mold, and a partial heating step for heating a part of a bent sheet member, where the sheet laminate has a flat surface part spreading out in a flat plate shape, a side surface on which the edge part bent by the bending step is configured, and a connecting surface protruding and curving toward the front surface side between the flat surface part and the side surface, and in the partial heating step, the connecting surface is partially heated after the side surface is molded in the bending step.
- the sheet laminate has the flat surface part spreading out in a flat plate shape, the side surface on which the edge part bent by the bending step is configured, and the connecting surface protruding and curving toward the front surface side between the flat surface part and the side surface.
- the connecting surface is partially heated in the partial heating step.
- the adhesive part becomes susceptible to peeling in a position corresponding to the connecting surface that deforms so as to curve in the bending step. Accordingly, distortion in said part can be removed by performing a partial annealing process through partial heating of the connecting surface. Therefore, adhesive part peeling can be prevented and a good quality sheet laminate can be manufactured.
- a bent sheet laminate can be provided as described above.
- a main body part for configuring the flat surface part of the sheet laminate, and a pair of side wall parts extending respectively toward the rear surface side from a pair of mutually intersecting main body part side parts are molded by the bending step, where the side surface has a first side surface corresponding to one side wall part of the pair of side wall parts, a second side surface corresponding to the other side wall part of the pair of side wall parts, and a third side surface forming a roundness having a predetermined curvature formed in a corner part between the first side surface and the second side surface, and the connecting surface has a first connecting surface for connecting the flat surface part and the first side surface, a second connecting surface for connecting the flat surface part and the second side surface, and a third connecting surface for connecting the flat surface part and the third side surface.
- the connecting surface is exposed from the mold in the partial heating step, and partial heating is performed by applying heat to the connecting surface from outside the mold.
- partial heating is performed in the partial heating step through a part in the mold that makes contact with the connecting surface.
- heat going to the flat surface part and the side surface may be insulated in the partial heating step.
- the sheet member may also be provided with a release liner covering the adhesive part of the rear surface of the sheet member.
- a mold for molding the sheet laminate according to an embodiment of the present invention is a mold for molding a sheet laminate to be affixed to an adherent surface of an object.
- the mold is provided with a first unit for supporting a sheet member, having a front surface to become a design surface and a rear surface where an adhesive part is formed, from a front surface side, and a second unit for supporting the sheet member from a rear surface side; where the first unit and the second unit are able to mold a main body part spreading in a flat plate shape and a pair of side wall parts extending respectively toward a rear surface side from a pair of mutually intersecting main body part side parts by sandwiching the sheet member and bending an edge part of the sheet member; and where, when the front surface has a flat surface part corresponding to the main body part, a first side surface corresponding to one side wall part of the pair of side wall parts, a second side surface corresponding to the other side wall part of the pair of side wall parts, and a third side surface forming a roundness having
- the mold for molding the sheet laminate is a mold for molding a sheet laminate to be affixed to an adherent surface of an object.
- the mold is provided with a first unit for supporting a sheet member, having a front surface to become a design surface and a rear surface where an adhesive part is formed, from a front surface side, and a second unit for supporting the sheet member from a rear surface side; where the first unit and the second unit are able to mold a main body part spreading in a flat plate shape sandwich in the sheet laminate and a pair of side wall parts each extending toward a rear surface side from a pair mutually intersecting main body part side parts by sandwiching the sheet member and bending an edge part of the sheet member; and where, when the front surface has a flat surface part corresponding to the main body part, a first side surface corresponding to one of the side wall parts of the pair of side wall parts, a second side surface corresponding to the other of the side wall parts of the pair of side wall parts, and a third side surface forming
- a sheet laminate according to an embodiment of the present invention is a sheet laminate that is to be affixed to an adherent surface of an object and has a flat surface part that spreads out in a flat plate shape, a side surface configured by a bent edge of the flat surface part, and a connecting surface protruding and curving toward a front surface side between the flat surface part and the side surface, where a part configuring the flat surface part, the side surface, and the connecting surface is configured of a base material part having a front surface that is to become a design surface and a rear surface on a side opposite the front surface, an adhesive layer formed on the rear surface of the base material part, and a release liner layer covering the adhesive layer that can be peeled from the adhesive layer.
- the sheet laminate according to another embodiment is provided with a main body part for configuring the flat surface part, and a pair of side wall parts extending respectively toward the rear surface side from a pair of mutually intersecting main body part side parts; where the side surface has a first side surface corresponding to one side wall part of the pair of side wall parts, a second side surface corresponding to the other side wall part of the pair of side wall parts, and a third side surface forming a roundness having a predetermined curvature formed in a corner part between the first side surface and the second side surface; and where the connecting surface may have a first connecting surface for connecting the flat surface part and the first side surface, a second connecting surface for connecting the flat surface part and the second side surface, and a third connecting surface for connecting the flat surface part and the third side surface.
- the third side surface forms the aforementioned roundness protruding toward the front surface side, and the curvature of the roundness may have a radius of 1 to 2000 mm.
- the third side surface forms the aforementioned roundness protruding toward the rear surface side, and the curvature of the roundness may have a radius of 0.5 to 2000 mm.
- a base material layer may be covered with a biaxially extended protective film layer.
- the release liner layer may be configured using a biaxially extended film.
- the adhesive layer may be configured using an acrylic pressure-sensitive adhesive.
- the base material layer may be configured using a polycarbonate.
- a bent sheet laminate can be provided.
- FIG. 1 is a plan view of a sheet laminate as seen from a design surface side.
- FIG. 2 is a cross sectional view along line II-II illustrated in FIG. 1 .
- FIG. 3( a ) is a perspective view illustrating a positive curve surface configuration of the sheet laminate.
- FIG. 3( b ) is a perspective view illustrating a negative curve surface configuration of the sheet laminate.
- FIG. 4 is a drawing illustrating steps of a method for manufacturing the sheet laminate.
- FIG. 5 is a cross sectional view illustrating a mold according to a present embodiment.
- FIG. 6 is a plan view of the mold illustrated in FIG. 5 .
- FIG. 7 is a cross sectional view illustrating the operation of a mold in the method for manufacturing the sheet laminate.
- FIG. 8 is a cross sectional view illustrating the operation of a mold in the method for manufacturing the sheet laminate.
- FIG. 9 is a cross sectional view illustrating the operation of a mold in the method for manufacturing the sheet laminate.
- FIG. 10 is a cross sectional view illustrating the operation of a mold in the method for manufacturing the sheet laminate.
- FIG. 11 is a cross sectional view illustrating a mold according to a modified example.
- FIG. 12 is a cross sectional view illustrating a mold according to a modified example.
- FIG. 13 is a cross sectional view illustrating a mold according to a modified example.
- FIG. 1 is a plan view of a sheet laminate as seen from a design surface side.
- FIG. 2 is a cross sectional view along the Line II-II illustrated in FIG. 1 .
- a sheet laminate 1 according to the present embodiment is a member to be affixed to an adherent surface of any object.
- the sheet laminate 1 has a front surface to become a design surface, and a rear surface to become a sticking surface for the object. This allows the sheet laminate 1 to cover the object so that the design surface faces outward.
- Examples of objects to which the sheet laminate can be affixed include a vehicle center pillar, rear pillar, door sash, and the like.
- a sheet member having the surface to become a design surface and a rear surface on which an adhesive part 3 is formed is prepared for the sheet laminate 1 , which is a molded product formed by bending an edge of the sheet member using a mold.
- the configuration of the sheet laminate 1 which is a finished product, will be described here in detail, after that, the method for manufacturing the sheet laminate 1 , and the mold used in said method, will also be described in detail.
- the sheet laminate 1 is provided with a main body part 11 , and a side wall part 12 .
- the main body part 11 is a part spreading out in a flat plate shape taking any form.
- the main body part 11 has a rectangular shape when seen from a thickness direction.
- the shape of the main body part 11 when seen from the thickness direction is not particularly limited, and thus may form a long rectangular shape, a T shape, or a cross shape.
- the main body part 11 has four side parts 11 a , 11 b , 11 c , and 11 k .
- a curved part 11 d is formed by forming a roundness facing outward at a prescribed curvature in a corner where the side part 11 a and the side part 11 b intersect.
- a curved part 11 e is formed by forming a roundness facing outward at a prescribed curvature in a corner where the side part 11 b and the side part 11 c intersect.
- the side wall part 12 is a wall part extending toward a rear surface side from each of the side parts 11 a , 11 b , and 11 c of the main body part 11 .
- the side wall part 12 is also formed in positions corresponding to the curved parts 11 d and 11 e of the main body part 11 .
- a side wall part 12 A is formed in the side part 11 a of the main body part 11
- a side wall part 12 B is formed in the side part 11 b thereof
- a side wall part 12 C is formed in the side part 11 c thereof.
- a side wall part 12 D is formed in the curved part 11 d of the main body
- a side wall part 12 E is formed in a curved part 11 e thereof.
- the side wall parts 12 A through 12 E are connected together so as to surround the main body part 11 in a continuous fashion. That is, the side wall part 12 A corresponding to the side part 11 a and the side wall part 12 D corresponding to the curved part 11 d are integrally connected. The side wall part 12 D corresponding to the curved part 11 d and the side wall part 12 B corresponding to side part llb are also integrally connected. The side wall part 12 B corresponding to the side part 11 b and the side wall part 12 E corresponding to curved part 11 e are also integrally connected. The side wall part 12 E corresponding to the curved part 11 e and the side wall part 12 C corresponding to side part 11 c are also integrally connected. Note that while no side wall part is formed in a position corresponding to the side part 11 k in the embodiment of FIG. 1 , such a part may be formed.
- a connecting part 13 is formed between the main body part 11 and the side wall part 12 , and curves so as to protrude toward a front surface side.
- Connecting parts 13 A, 13 B, 13 C, 13 D, and 13 E are formed between the main body part 11 and the side wall parts 12 A, 12 B, 12 C, 12 D, and 12 E, respectively.
- the connecting parts 13 A, 13 B, 13 C, 13 D, and 13 E are integrally connected to the main body part 11 and to the side wall parts 12 A, 12 B, 12 C, 12 D, and 12 E.
- the sheet laminate 1 (also referred to as molded sheet laminate 1 ) is provided with a base material part (base material layer) 2 , an adhesive part (adhesive layer) 3 , a release liner (release liner layer) 4 , and a protective film (protective film layer) 6 .
- the sheet laminate 1 is configured by molding, as-is, a sheet member formed by laminating the base material part 2 , the adhesive part 3 , the release liner 4 , and the protective film 6 .
- the main body part 11 , the side wall part 12 , and the connecting part 13 are each provided with the base material part 2 , the adhesive part 3 , the release liner 4 , and the protective film 6 .
- the base material part 2 is a member that forms a base for the sheet laminate 1 .
- the base material part 2 has a front surface 2 a to become a design surface, and a rear surface 2 b on a side opposite the front surface 2 a .
- the base material part 2 is configured from a material, such as polycarbonate, PET, ABS resin, and the like. Furthermore, a thickness of the base material part 2 is not particularly limited, and thus may be 0.2 to 1.5 mm.
- a surface treatment using, for example, polyurethane, acrylic, or the like, is applied to the front surface 2 a to become the design surface.
- the adhesive part 3 is a member for joining the sheet laminate 1 to an object by adhering to said object.
- the adhesive part 3 is laminated onto the rear surface 2 b of the base material part 2 .
- the adhesive part 3 is laminated onto the rear surface 2 b of the base material part 2 so as to cover nearly the entire surface thereof.
- an adhesive surface 3 a functions as a surface on a side opposite the base material part 2 .
- the adhesive part 3 is configured from a material, such as acrylic, rubber, and the like. More specifically, the adhesive layer may be configured using an acrylic pressure-sensitive adhesive.
- a thickness of the adhesive part 3 is not particularly limited, and thus may be 0.005 to 0.4 mm.
- the release liner 4 is a member for protecting the adhesive part 3 .
- the release liner 4 covers the entire surface of the adhesive surface 3 a of the adhesive part 3 .
- the release liner 4 is peeled from the adhesive part 3 to thus expose the adhesive part 3 .
- the release liner 4 may be configured using a biaxially extended film.
- the release liner 4 is provided with a release layer of silicone, and the like, on a biaxially extended material, such as PET, PEN, or the like, and a polyolefin layer of PE, or the like, may also be provided there between.
- a thickness of the release liner 4 is not particularly limited, and thus may be 0.01 to 0.3 mm.
- the protective film 6 covers the front surface 2 a of the base material part 2 , said film serves as a member for protecting the front surface 2 a , which is the design surface.
- the protective film 6 is a biaxially extended film. That is, while the front surface 2 a in the connecting part 13 of the base material part 2 deforms so as to stretch somewhat when the sheet laminate 1 is molded from a sheet member state, there is only a small degree of following.
- the material of the protective film 6 is configured from PET, PEN, or the like. Furthermore, a thickness of the protective film 6 is not particularly limited, and thus may be 0.005 to 0.3 mm.
- the sheet laminate 1 has a flat surface part 20 spreading out in a flat plate shape, a side surface 21 on which a bent edge part of the flat surface part 20 is configured, and a connecting surface 22 protruding and curving toward the front surface 2 a side between the flat surface part 20 and the side surface 21 .
- the flat surface part 20 is formed on a part corresponding to the main body part 11 portion of the front surface 2 a .
- the side surface 21 is formed on a part corresponding to the side wall parts 12 A through 12 E portion of the front surface 2 a .
- the connecting surface 22 is formed on parts corresponding to the connecting parts 13 A through 13 E portion of the front surface 2 a.
- FIG. 3( a ) illustrates a configuration in the vicinity of the side wall part 12 C, the side wall part 12 B, and the side wall part 12 E, the same gist holds for descriptions of different parts so long as a pair of mutually intersecting side walls 12 is provided.
- the flat surface part 20 corresponds to the main body part 11 , and forms a primary surface, that is, a flat surface.
- the side surface 21 has a first side surface 21 B corresponding to the side wall part 12 B, which is one of the pair made up of the side wall parts 12 B and 12 C, a second side surface 21 C corresponding to the side wall part 12 C, which is the other of said pair, and a third side surface 21 E corresponding to the side wall part 12 E that forms a roundness.
- the first side surface 21 B and the second side surface 21 C form a primary surface, that is, a flat surface.
- the third side surface 21 E is formed in a corner between the first side surface 21 B and the second side surface 21 C, and is a surface for forming a roundness having a predetermined curvature.
- the third side surface 21 E forms a secondary surface, that is, a curved surface having a component bent with reference to a single axis.
- the third side surface 21 E forms a roundness protruding toward the front surface side.
- a radius of a curvature of the roundness is 1 to 2000 mm.
- the connecting surface 22 has a first connecting surface 22 B for connecting the flat surface part 20 and the first side surface 21 B, a second connecting surface 22 C for connecting the flat surface part 20 and the second side surface 21 C, and a third connecting surface 22 E for connecting the flat surface part 20 and the third side surface 21 E.
- the first connecting surface 22 B is a secondary surface corresponding to a connecting part 13 B. When seen from a thickness direction of the side wall part 12 C, the first connecting surface 22 B forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 0.5 to 200 mm.
- the second connecting surface 22 C is a secondary surface corresponding to a connecting part 13 C.
- the third connecting surface 22 E is a tertiary surface corresponding to a connecting part 13 E.
- the tertiary surface forms a curved surface having a component bent with reference to two axes.
- the third connecting surface 22 E has a curved component of the third side surface 21 E and a curved component of the first connecting surface 22 B and the second connecting surface 22 C.
- first side surface and second side surface are expedient names for clearly describing a structure and thus may be a first side surface 21 C and a second side surface 21 B. Accordingly, these are sometimes referred to in the following description simply as “side surface” without distinguishing between “first side surface” and “second side surface.”
- first connecting surface and second connecting surface are also expedient names for clearly describing a structure and thus may be a first connecting surface 22 C and a second connecting surface 22 B. Accordingly, these are sometimes referred to in the following description simply as “connecting surface” without distinguishing between “first connecting surface” and “second connecting surface.”
- FIG. 3( a ) A structure in a case where a third side surface protrudes toward the front surface side and thus draws a so-called positive curve was described using FIG. 3( a ) .
- this may also be a structure where the third side surface protrudes toward the rear surface side and thus draws a so-called negative curve.
- the structure illustrated in FIG. 3( b ) may be used.
- a side wall part 12 H forming a roundness so as to protrude toward the rear surface side is formed by a corner between a pair of side wall parts 12 E and 12 G that extend straight from said corner.
- connecting parts 13 F, 13 G, and 13 H are formed between the main body part 11 and the side wall parts 12 F, 12 G and 12 H, respectively.
- the side surface 21 has a first side surface 21 F corresponding to the side wall part 12 F, which is one of the pair made up of the side wall parts 12 F and 12 G, a second side surface 21 G corresponding to the side wall part 12 G, which is the other of said pair, and a third side surface 21 H corresponding to the side wall part 12 H that forms a roundness.
- the first side surface 21 F and the second side surface 21 G form a primary surface, that is, a flat surface.
- the third side surface 21 H is formed in a corner between the first side surface 21 F and the second side surface 21 G, and is a surface for forming a roundness having a predetermined curvature.
- the third side surface 21 H forms a secondary surface, that is, a curved surface having a component bent with reference to a single axis. When seen from a thickness direction of the main body part 11 , the third side surface 21 H forms a roundness protruding toward the rear surface side. A radius of a curvature of the roundness is 0.5 to 2000 mm.
- the connecting surface 22 has a first connecting surface 22 F connecting the flat surface part 20 and the first side surface 21 F, a second connecting surface 22 G connecting the flat surface part 20 and the second side surface 21 G, and a third connecting surface 22 H connecting the flat surface part 20 and the third side surface 21 H.
- the first connecting surface 22 F is a secondary surface corresponding to a connecting part 13 F.
- the first connecting surface 22 F When seen from a thickness direction of the side wall part 12 G, the first connecting surface 22 F forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 0.5 to 200 mm.
- the second connecting surface 22 G is a secondary surface corresponding to a connecting part 13 G. When seen from a thickness direction of the side wall part 12 F, the second connecting surface 22 G forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 0.5 to 200 mm.
- the third connecting surface 22 H is a tertiary surface corresponding to a connecting part 13 H. The tertiary surface forms a curved surface having a component bent with reference to two axes.
- the third connecting surface 22 H has a curved component of the third side surface 21 H and a curved component of the first connecting surface 22 F and the second connecting surface 22 G.
- the method for manufacturing the sheet laminate 1 according to the present embodiment and a mold 100 for molding the sheet laminate 1 are described next with reference to FIG. 4 through FIG. 10 .
- the mold 100 is a mold for molding the sheet laminate 1 to be affixed to an adherent surface of an object.
- the mold 100 is provided with a first unit 110 a second unit 120 .
- the first unit is a unit for supporting a sheet member 50 , having a front surface 50 a to become a design surface and a rear surface 50 b on which the adhesive part 3 is formed, from the front surface 50 a side.
- the second unit 120 is a unit for supporting the sheet member 50 from the rear surface 50 b side.
- the first unit 110 and the second unit 120 are able to mold the main body part 11 spreading in a flat plate shape portion of the sheet laminate 1 , and the side wall parts 12 extending respectively toward the rear surface 50 b side from mutually intersecting side parts of the main body part 11 by sandwiching the sheet member and bending an edge part of the sheet member 50 .
- the mold 100 for molding the sheet laminate 1 having the shape illustrated in FIG. 1 . That is, this is a description of the mold 100 for molding the sheet laminate 1 having the side wall parts 12 A through 12 F.
- the configuration of the mold 100 can be changed appropriately to match the form of the sheet laminate 1 .
- the first unit 110 is provided with a first piece 111 for supporting the flat surface part 20 of the main body part 11 , and a second piece 112 for supporting each surface of the side wall part 12 .
- the first piece 111 is configured as a block forming a rectangular shape to match the form of the flat surface part 20 of the main body part 11 (see FIG. 6 ).
- An upper surface of the first piece 111 is configured as a supporting surface 113 for making contact with and thus supporting the flat surface part 20 of the main body part 11 .
- the second piece 112 is configured as a frame member having an opening that matches the form of the side surface 21 of the side wall part 12 (see FIG. 6 ).
- a third piece 121 of the second piece 112 and of the second unit 120 to be described later is provided inside the opening of the second piece 112 .
- An inner circumferential surface of the opening of the second piece 112 is configured as a supporting surface 114 for supporting the side surface 21 of the side wall part 12 . Furthermore, an arranging part 116 for arranging the previously molded sheet member 50 is formed near an upper edge of the opening of the second piece 112 .
- the arranging part 116 faces an end part of an outer circumferential side of the sheet member 50 , and has an aligning surface 117 for performing alignment in a plane direction of the sheet member 50 .
- the arranging part 116 also has a guide surface 118 for smoothly guiding (see FIG. 7 ) the side wall part 12 toward the supporting surface 114 side when an edge part of the sheet member 50 is bent during molding. Note that while the guide surface 118 is a curved surface curved so as to protrude outward in the present embodiment, said surface may be an inclined surface extending in a straight manner.
- the second unit 120 is provided with a third piece 121 for pressing the sheet member 50 from the rear surface 50 b side toward the front surface 50 a side.
- a lower surface of the third piece 121 is configured as a supporting surface 122 for pressing the rear surface side of the main body part 11 of the sheet laminate 1 .
- an outer circumferential surface of the third piece 121 is configured as a supporting surface 123 for making contact with and thus supporting the rear surface side (surface on the opposite side of the side surface 21 ) of the side wall part 12 of the sheet laminate 1 .
- the side wall part 12 is sandwiched by the supporting surface 114 of the second piece 112 and the supporting surface 123 of the third piece 121 (see FIG. 8 ). Accordingly, a dimension in a horizontal direction gap between the supporting surface 114 and the supporting surface 123 is set to a thickness dimension of the side wall part 12 .
- the first unit 110 supports the flat surface part 20 and the side surface 21 (first side surface, second side surface, and third side surface), in a state where the connecting surface 22 (first connecting surface, second connecting surface, and third connecting surface) of the sheet laminate 1 is exposed. That is, in FIG. 3( a ) , the connecting surfaces 22 B, 22 C, and 22 E are exposed from the first unit 110 , and the flat surface part 20 and the side surfaces 21 B, 21 C, and 21 E are supported by the first unit 110 .
- the method for manufacturing the sheet laminate 1 includes a preparing step S 10 , a bending step S 20 , a partial heating step S 30 , and an extracting step S 40 .
- the preparing step S 10 is a step for preparing the sheet member 50 .
- the sheet member 50 is pre-cut to a form that matches the mold 100 . Furthermore, the prepared sheet member 50 is provided in the arranging part 116 of the second piece 112 of the mold 100 (see FIG. 5 ).
- the bending step S 20 is a step for bending an edge part of the sheet member 50 by sandwiching the sheet member 50 from the front surface 50 a side and the rear surface 50 b side.
- the rear surface 50 b of the sheet member 50 is pressed downward by the supporting surface 122 (see FIG. 7 ).
- the front surface 50 a of the sheet member 50 may be supported by the supporting surface 113 of the first piece 111 of the first unit 110 .
- an edge part of the sheet member 50 abuts with the guide surface 118 of the arranging part 116 , which guides said member toward the supporting surface 114 side while thus bending said part toward the rear surface 50 b side.
- the third piece 121 When the third piece 121 is lowered all the way down, an edge part of the sheet member 50 is sandwiched between the supporting surface 114 of the first piece 111 of the first unit and the supporting surface 123 of the third piece 121 of the second unit (see FIG. 8 ). This forms the side wall part 12 of the sheet laminate 1 . Furthermore, the rear surface 50 b of the sheet member 50 is sandwiched between the supporting surface 122 of the third piece and the supporting surface 113 of the second piece 112 . This forms the main body part 11 of the sheet laminate 1 . Furthermore, by pressing a curved part of a corner of the third piece, a corner between the main body part 11 and the side wall part 12 forms the bent connecting part 13 . In this state, the first unit 110 is supporting the flat surface part 20 and the side surface 21 in a state where the connecting surface 22 of the sheet laminate 1 is exposed.
- the partial heating step S 30 is a step for heating part of the bent sheet member 50 .
- the partial heating step S 30 heats the connecting surface 22 exposed from the first unit 110 but does not heat the flat surface part 20 or the side surface 21 being supported and covered by the first unit 110 (see FIG. 9 ). This anneals the bent connecting part 13 , which was significantly bent in the bending step, to thus remove distortion produced in said part.
- a predetermined heating device 140 is provided with respect to the connecting part 13 , and the heating device 140 supplies heat.
- the heating device 140 may heat the connecting surface 22 by supplying, for example, infrared rays (IR), heated air, high pressure steam, or heated liquid. Or, a heating pad itself may be pressed against the connecting surface 22 , or housed inside a heating furnace for each mold.
- IR infrared rays
- the extracting step S 40 extracts the sheet laminate 1 from the mold 100 by raising the third piece 121 together with the sheet laminate 1 (see FIG. 10 ).
- the connecting surface 22 may be cooled through contact with cooling air, a cooling liquid, or a cooling pad. Or, the connecting surface 22 may be cooled naturally by letting said surface stand.
- the manufacturing step illustrated in FIG. 4 is complete when the extracting step S 40 ends.
- a method for manufacturing a sheet laminate according to a comparative example will be described first.
- Examples of methods for manufacturing according to the comparative example include heat stamping which sandwiches a sheet in a heated mold, and then bends the sheet.
- heat stamping which sandwiches a sheet in a heated mold, and then bends the sheet.
- a problem occurs when heat stamping is performed where the adhesive part peels during molding.
- the sheet laminate 1 has the flat surface part 20 spreading out in a flat plate shape, the side surface 21 on which an edge part bent by the bending step is configured, and the connecting surface 22 protruding and curving toward the front surface side between the flat surface part 20 and the side surface 21 .
- the connecting surface 22 is partially heated in the partial heating step.
- the adhesive part 3 or the protective film 6 become susceptible to peeling in a position corresponding to the connecting surface 22 that deforms so as to curve in the bending step. Accordingly, distortion in said part can be removed by partially removing stress (performing an annealing process) through partial heating of the connecting surface 22 . Therefore, the sheet laminate 1 can be manufactured with good quality while preventing peeling of the adhesive part 3 and the protective film 6 .
- the adhesive part 3 and the protective film 6 may displace due to a shear force between molds, which can lead to peeling (the impact from displacement caused by the adhesive part 3 is particularly significant).
- heating is performed in a static state after stamping has been performed without heating.
- a peripheral part here this is a flat surface part or side surface of a periphery of the connecting surface 22
- this part is also not softened through heating. This makes it possible to prevent layers from peeling due to the displacement of a part (that is a part corresponding to the connecting surface 22 ) to be partially heated sandwiched in the peripheral part.
- the method for manufacturing the sheet laminate 1 molds the main body part 11 for configuring the flat surface part 20 portion of the sheet laminate 1 , and the pair of side wall parts 12 B and 12 C extending respectively toward the rear surface side from the pair of mutually intersecting side parts l lb and 11 c of the main body part 11 .
- the side surface 21 has the first side surface 21 B corresponding to the side wall part 12 B, the second side surface 21 C corresponding to the side wall part 12 C, and the third side surface 21 E formed in the corner between the first side surface 21 B and the first side surface 21 C forming a roundness having a predetermined curvature.
- the connecting surface 22 may have the first connecting surface 22 B connecting the flat surface part 20 and the first side surface 21 B, the second connecting surface 22 C connecting the flat surface part 20 and the second side surface 21 C, and the third connecting surface 22 E connecting the flat surface part 20 and the third side surface 21 E.
- the connecting surface 22 is exposed from the mold 100 in the partial heating step, and partial heating is performed by applying heat to the connecting surface 22 from outside the mold 100 . This enables the connecting surface to be partially heated using a simple configuration.
- the sheet member 50 is also provided with the release liner 4 for covering the adhesive part 3 of the rear surface 50 b of the sheet member 50 . This enables molding to be performed in a state where the adhesive part 3 is protected.
- the mold 100 for molding the sheet laminate 1 is the mold 100 for molding the sheet laminate 1 to be affixed to the adherent surface of an object, and is provided with the first unit 110 for supporting the sheet member 50 , having the front surface 50 a to become the design surface and the rear surface 50 b in which the adhesive part 3 has been formed, from the front surface 50 a side, and the second unit 120 for supporting the sheet member 50 from the rear surface 50 b side.
- the first unit 110 and the second unit 120 are able to mold the main body part 11 spreading in a flat plate shape portion of the sheet laminate 1 , and the pair of side wall parts 12 B and 12 C extending respectively toward the rear surface 50 b side from the pair of mutually intersecting side parts 11 b and 11 c of the main body part 11 by sandwiching the sheet member 50 and then bending the sheet member 50 .
- the first unit 110 supports the flat surface part 20 , the first side surface 21 B, the second side surface 21 C, and the third side surface 21 E in a state where the first connecting surface 22 B, the second connecting surface 22 C, and the third connecting surface 22
- Using a mold like the mold 100 makes it possible to execute a manufacturing method like that described above, and to obtain the same operation and effect.
- the sheet laminate 1 is the sheet laminate 1 that is to be affixed to an adherent surface of an object and has the flat surface part 20 that spreads out in a flat plate shape, the side surface 21 configured by a bent edge of the flat surface part 20 , and the connecting surface 22 protruding and curving toward the front surface side between the flat surface part 20 and the side surface 21 , where the part configuring the flat surface part 20 , the side surface 21 , and the connecting surface 22 is configured of the base material part 2 having the front surface that is to become the design surface, and the rear surface on the side opposite the front surface, an adhesive part 3 formed on the rear surface of the base material part 2 , and the release liner 4 covering the adhesive part 3 that can be peeled from the adhesive part 3 .
- Using a laminate like the sheet laminate 1 enables achieving an operation and effect during manufacture having the same gist as the manufacturing method described above.
- the sheet laminate 1 is provided with the main body part 11 for configuring the flat surface part 20 , and the pair of side wall parts 12 B and 12 C extending respectively toward the rear surface side from the pair of mutually intersecting side parts llb and 11 c of the main body part 11 .
- the side surface 21 has the first side surface 21 B corresponding to the side wall part 12 B, the second side surface 21 C corresponding to the side wall part 12 C, and the third side surface 21 E formed in the corner between the first side surface 21 B and the second side surface 21 C forming a roundness having a predetermined curvature.
- the connecting surface 22 has a first connecting surface 22 B for connecting the flat surface part 20 and the first side surface 21 B, a second connecting surface 22 C for connecting the flat surface part 20 and the second side surface 21 C, and a third connecting surface 22 E for connecting the flat surface part 20 and the third side surface 21 E.
- the manufacturing method according to the present embodiment becomes particularly noteworthy when the sheet laminate 1 having this type of configuration is manufactured.
- the third side surface 21 E forms a roundness protruding toward the front surface side, and the curvature of the roundness has a radius of 1 to 2000 mm.
- the third side surface 21 H forms a roundness protruding toward the rear surface side, and the curvature of the roundness has a radius of 0.5 to 2000 mm.
- the base material part 2 is covered by the biaxially extended protective film 6 . This makes it possible to protect a front surface of the base material part 2 .
- the release liner 4 is configured using a biaxially extended film. This makes it possible to reduce an impact on the release liner 4 during partial heating of the connecting surface.
- the adhesive part 3 is configured using an acrylic pressure-sensitive adhesive.
- the base material part is configured using a polycarbonate.
- the sheet member 50 is provided in the mold 100 after having been cut beforehand.
- an un-cut sheet member that is not cut until it is supplied in the mold may also be used.
- a cutting member 210 may be provided on an outer circumferential side of the third piece 121 of the first unit 110 , as illustrated in FIG. 11 and FIG. 12 .
- a base material 250 of a sheet member is cut by the cutting member 210 simultaneous to pressurization in the third piece 121 to thus form the sheet member 50 in a desired shape. Note that the cutting member 210 is retracted upward after the cutting, as illustrated in FIG. 12 .
- the connecting surface to be partially heated was exposed from the mold.
- the first unit has a piece for supporting the connecting surface, and may partially heat the connecting surface through said piece.
- the first unit 110 is provided with a heating part 310 provided with a fourth piece 115 that makes contact with the connecting surface (first connecting surface, second connecting surface, and third connecting surface) 22 , for heating the part making contact, an insulating part 302 for insulating a space between the flat surface part 20 and the heating part 310 , and an insulating part 301 for insulating a space between the side surface (first side surface, second side surface, and third side surface) 21 and the heating part 310 , and for insulating the insulating part 301 .
- the heating part 310 may be configured using a flow path, and the like, of a heating medium such as a heating wire, a liquid, a gas, or the like.
- partial heating is performed in the partial heating step through a part (the fourth piece 115 ) in the mold 300 that makes contact with the connecting surface 22 . Furthermore, heat going to the flat surface part 20 and the side surface 21 is insulated in the partial heating step. This kind of configuration allows partial heating to be performed while a shape is sustained because the connecting surface 22 is supported by the fourth piece 115 . Note that if the fourth piece 115 does not have the heating part 310 , the fourth piece 115 is retracted during the partial heating step, and partial heating may be performed by exposing the connecting surface 22 .
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
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- Thermal Sciences (AREA)
- Laminated Bodies (AREA)
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- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
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Abstract
A method for manufacturing a sheet laminate to be affixed to an adherent surface of an object, the method comprising preparing a sheet member having a front surface to become a design surface and a rear surface on which an adhesive part has been formed, bending an edge part of the sheet member by sandwiching the sheet member from a front surface side and a rear surface side in a mold, and heating a part of a bent sheet member. The sheet laminate has a flat part spreading out in a flat plate shape, a side surface on which the edge part bent by the bending step is configured, and a connecting surface protruding and curving toward the front surface side between the flat part and the side surface, and in the heating step, the connecting surface is partially heated after the side surface is molded in the bending step.
Description
- The present invention relates to a method for manufacturing a sheet laminate, a mold for molding a sheet laminate, and a sheet laminate.
- A molding method called stamping is known as a conventional method for manufacturing a sheet laminate (for example, see Japanese Patent JP 2015-229279). In particular, a processing method for sandwiching a sheet in a heated mold and then bending the sheet is referred to as heat stamping.
- Thus, there is a requirement to bend an edge part of a sheet laminate having an adhesive part on a rear surface and a protective sheet on a front surface. However, this presents a problem in that when heat stamping like that described above is performed with respect to this type of sheet laminate, the adhesive part, a liner, and the protective sheet peel away during molding. There is a demand to resolve this type of problem by manufacturing a bent sheet laminate.
- A method for manufacturing a sheet laminate according to an embodiment of the present invention is a method for manufacturing a sheet laminate to be affixed to an adherent surface of an object and is provided with a preparing step for preparing a sheet member having a front surface to become a design surface and a rear surface on which an adhesive part has been formed, a bending step for bending an edge part of the sheet member by sandwiching the sheet member from a front surface side and a rear surface side in a mold, and a partial heating step for heating a part of a bent sheet member, where the sheet laminate has a flat surface part spreading out in a flat plate shape, a side surface on which the edge part bent by the bending step is configured, and a connecting surface protruding and curving toward the front surface side between the flat surface part and the side surface, and in the partial heating step, the connecting surface is partially heated after the side surface is molded in the bending step.
- With this kind of embodiment, the sheet laminate has the flat surface part spreading out in a flat plate shape, the side surface on which the edge part bent by the bending step is configured, and the connecting surface protruding and curving toward the front surface side between the flat surface part and the side surface. After the sheet member has been bent into this kind of shape in the bending step, the connecting surface is partially heated in the partial heating step. When the sheet member is molded in a state where the adhesive part has been formed, the adhesive part becomes susceptible to peeling in a position corresponding to the connecting surface that deforms so as to curve in the bending step. Accordingly, distortion in said part can be removed by performing a partial annealing process through partial heating of the connecting surface. Therefore, adhesive part peeling can be prevented and a good quality sheet laminate can be manufactured. A bent sheet laminate can be provided as described above.
- With a method for manufacturing a sheet laminate according to another embodiment, a main body part for configuring the flat surface part of the sheet laminate, and a pair of side wall parts extending respectively toward the rear surface side from a pair of mutually intersecting main body part side parts are molded by the bending step, where the side surface has a first side surface corresponding to one side wall part of the pair of side wall parts, a second side surface corresponding to the other side wall part of the pair of side wall parts, and a third side surface forming a roundness having a predetermined curvature formed in a corner part between the first side surface and the second side surface, and the connecting surface has a first connecting surface for connecting the flat surface part and the first side surface, a second connecting surface for connecting the flat surface part and the second side surface, and a third connecting surface for connecting the flat surface part and the third side surface.
- In the method for manufacturing a sheet laminate according to another embodiment, the connecting surface is exposed from the mold in the partial heating step, and partial heating is performed by applying heat to the connecting surface from outside the mold.
- In the method for manufacturing a sheet laminate according to another embodiment, partial heating is performed in the partial heating step through a part in the mold that makes contact with the connecting surface.
- In the method for manufacturing a sheet laminate according to another embodiment, heat going to the flat surface part and the side surface may be insulated in the partial heating step.
- In the method for manufacturing a sheet laminate according to another embodiment, the sheet member may also be provided with a release liner covering the adhesive part of the rear surface of the sheet member.
- A mold for molding the sheet laminate according to an embodiment of the present invention is a mold for molding a sheet laminate to be affixed to an adherent surface of an object. The mold is provided with a first unit for supporting a sheet member, having a front surface to become a design surface and a rear surface where an adhesive part is formed, from a front surface side, and a second unit for supporting the sheet member from a rear surface side; where the first unit and the second unit are able to mold a main body part spreading in a flat plate shape and a pair of side wall parts extending respectively toward a rear surface side from a pair of mutually intersecting main body part side parts by sandwiching the sheet member and bending an edge part of the sheet member; and where, when the front surface has a flat surface part corresponding to the main body part, a first side surface corresponding to one side wall part of the pair of side wall parts, a second side surface corresponding to the other side wall part of the pair of side wall parts, and a third side surface forming a roundness having a predetermined curvature formed in a corner part between the first side surface and the second side surface, a first connecting surface protruding curving toward the front surface side for connecting the flat surface part and the first side surface, a second connecting surface protruding curving toward the front surface side for connecting the flat surface part and the second side surface, and a third connecting surface protruding curving toward the front surface side for connecting the flat surface part and the third side surface; the first unit supports the flat surface part, the first side surface, the second side surface, and the third side surface in a state where the first connecting surface, the second connecting surface and the third connecting surface are exposed.
- The mold for molding the sheet laminate according to an embodiment of the present invention is a mold for molding a sheet laminate to be affixed to an adherent surface of an object. The mold is provided with a first unit for supporting a sheet member, having a front surface to become a design surface and a rear surface where an adhesive part is formed, from a front surface side, and a second unit for supporting the sheet member from a rear surface side; where the first unit and the second unit are able to mold a main body part spreading in a flat plate shape sandwich in the sheet laminate and a pair of side wall parts each extending toward a rear surface side from a pair mutually intersecting main body part side parts by sandwiching the sheet member and bending an edge part of the sheet member; and where, when the front surface has a flat surface part corresponding to the main body part, a first side surface corresponding to one of the side wall parts of the pair of side wall parts, a second side surface corresponding to the other of the side wall parts of the pair of side wall parts, and a third side surface forming a roundness having a predetermined curvature formed in a corner part between the first side surface and the second side surface, a first connecting surface protruding curving toward the front surface side for connecting the flat surface part and the first side surface, a second connecting surface protruding curving toward the front surface side for connecting the flat surface part and the second side surface, and a third connecting surface protruding curving toward the front surface side for connecting the flat surface part and the third side surface; the first unit is provided with a heating part for heating a part in contact with the first connecting surface, the second connecting surface and the third connecting surface, and an insulating part for insulating a space between the flat surface part, the first side surface, the second side surface, and the third side surface.
- A sheet laminate according to an embodiment of the present invention is a sheet laminate that is to be affixed to an adherent surface of an object and has a flat surface part that spreads out in a flat plate shape, a side surface configured by a bent edge of the flat surface part, and a connecting surface protruding and curving toward a front surface side between the flat surface part and the side surface, where a part configuring the flat surface part, the side surface, and the connecting surface is configured of a base material part having a front surface that is to become a design surface and a rear surface on a side opposite the front surface, an adhesive layer formed on the rear surface of the base material part, and a release liner layer covering the adhesive layer that can be peeled from the adhesive layer.
- The sheet laminate according to another embodiment is provided with a main body part for configuring the flat surface part, and a pair of side wall parts extending respectively toward the rear surface side from a pair of mutually intersecting main body part side parts; where the side surface has a first side surface corresponding to one side wall part of the pair of side wall parts, a second side surface corresponding to the other side wall part of the pair of side wall parts, and a third side surface forming a roundness having a predetermined curvature formed in a corner part between the first side surface and the second side surface; and where the connecting surface may have a first connecting surface for connecting the flat surface part and the first side surface, a second connecting surface for connecting the flat surface part and the second side surface, and a third connecting surface for connecting the flat surface part and the third side surface.
- With the sheet laminate according to another embodiment, the third side surface forms the aforementioned roundness protruding toward the front surface side, and the curvature of the roundness may have a radius of 1 to 2000 mm. With the sheet laminate according to another embodiment, the third side surface forms the aforementioned roundness protruding toward the rear surface side, and the curvature of the roundness may have a radius of 0.5 to 2000 mm.
- In the sheet laminate according to another embodiment, a base material layer may be covered with a biaxially extended protective film layer.
- In the sheet laminate according to another embodiment, the release liner layer may be configured using a biaxially extended film.
- In the sheet laminate according to another embodiment, the adhesive layer may be configured using an acrylic pressure-sensitive adhesive.
- In the sheet laminate according to another embodiment, the base material layer may be configured using a polycarbonate. According to the present invention, a bent sheet laminate can be provided.
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FIG. 1 is a plan view of a sheet laminate as seen from a design surface side. -
FIG. 2 is a cross sectional view along line II-II illustrated inFIG. 1 . -
FIG. 3(a) is a perspective view illustrating a positive curve surface configuration of the sheet laminate. -
FIG. 3(b) is a perspective view illustrating a negative curve surface configuration of the sheet laminate. -
FIG. 4 is a drawing illustrating steps of a method for manufacturing the sheet laminate. -
FIG. 5 is a cross sectional view illustrating a mold according to a present embodiment. -
FIG. 6 is a plan view of the mold illustrated inFIG. 5 . -
FIG. 7 is a cross sectional view illustrating the operation of a mold in the method for manufacturing the sheet laminate. -
FIG. 8 is a cross sectional view illustrating the operation of a mold in the method for manufacturing the sheet laminate. -
FIG. 9 is a cross sectional view illustrating the operation of a mold in the method for manufacturing the sheet laminate. -
FIG. 10 is a cross sectional view illustrating the operation of a mold in the method for manufacturing the sheet laminate. -
FIG. 11 is a cross sectional view illustrating a mold according to a modified example. -
FIG. 12 is a cross sectional view illustrating a mold according to a modified example. -
FIG. 13 is a cross sectional view illustrating a mold according to a modified example. - Detailed descriptions of embodiments according to the present invention are given below with reference to the attached drawings. Note that, in the following descriptions, the same reference symbols have been assigned to elements that are the same or equivalent, and that redundant descriptions thereof have been omitted.
- A
sheet laminate 1 according to an embodiment of the present invention will be described with reference toFIG. 1 andFIG. 2 .FIG. 1 is a plan view of a sheet laminate as seen from a design surface side.FIG. 2 is a cross sectional view along the Line II-II illustrated inFIG. 1 . Asheet laminate 1 according to the present embodiment is a member to be affixed to an adherent surface of any object. Thesheet laminate 1 has a front surface to become a design surface, and a rear surface to become a sticking surface for the object. This allows thesheet laminate 1 to cover the object so that the design surface faces outward. Examples of objects to which the sheet laminate can be affixed include a vehicle center pillar, rear pillar, door sash, and the like. A sheet member having the surface to become a design surface and a rear surface on which anadhesive part 3 is formed is prepared for thesheet laminate 1, which is a molded product formed by bending an edge of the sheet member using a mold. The configuration of thesheet laminate 1, which is a finished product, will be described here in detail, after that, the method for manufacturing thesheet laminate 1, and the mold used in said method, will also be described in detail. - As illustrated in
FIG. 1 andFIG. 2 , thesheet laminate 1 is provided with amain body part 11, and aside wall part 12. Themain body part 11 is a part spreading out in a flat plate shape taking any form. In the present embodiment, themain body part 11 has a rectangular shape when seen from a thickness direction. However, the shape of themain body part 11 when seen from the thickness direction is not particularly limited, and thus may form a long rectangular shape, a T shape, or a cross shape. InFIG. 1 , themain body part 11 has fourside parts sides sides sides sides curved part 11 d is formed by forming a roundness facing outward at a prescribed curvature in a corner where theside part 11 a and theside part 11 b intersect. Acurved part 11 e is formed by forming a roundness facing outward at a prescribed curvature in a corner where theside part 11 b and theside part 11 c intersect. - The
side wall part 12 is a wall part extending toward a rear surface side from each of theside parts main body part 11. Theside wall part 12 is also formed in positions corresponding to thecurved parts main body part 11. Specifically, aside wall part 12A is formed in theside part 11 a of themain body part 11, aside wall part 12B is formed in theside part 11 b thereof, and aside wall part 12C is formed in theside part 11 c thereof. Furthermore, aside wall part 12D is formed in thecurved part 11 d of the main body, and aside wall part 12E is formed in acurved part 11 e thereof. Theside wall parts 12A through 12E are connected together so as to surround themain body part 11 in a continuous fashion. That is, theside wall part 12A corresponding to theside part 11 a and theside wall part 12D corresponding to thecurved part 11 d are integrally connected. Theside wall part 12D corresponding to thecurved part 11 d and theside wall part 12B corresponding to side part llb are also integrally connected. Theside wall part 12B corresponding to theside part 11 b and theside wall part 12E corresponding tocurved part 11 e are also integrally connected. Theside wall part 12E corresponding to thecurved part 11 e and theside wall part 12C corresponding to sidepart 11 c are also integrally connected. Note that while no side wall part is formed in a position corresponding to theside part 11 k in the embodiment ofFIG. 1 , such a part may be formed. - Furthermore, a connecting
part 13 is formed between themain body part 11 and theside wall part 12, and curves so as to protrude toward a front surface side.Connecting parts main body part 11 and theside wall parts parts main body part 11 and to theside wall parts - As illustrated in
FIG. 2 , the sheet laminate 1 (also referred to as molded sheet laminate 1) is provided with a base material part (base material layer) 2, an adhesive part (adhesive layer) 3, a release liner (release liner layer) 4, and a protective film (protective film layer) 6. Furthermore, thesheet laminate 1 is configured by molding, as-is, a sheet member formed by laminating thebase material part 2, theadhesive part 3, therelease liner 4, and theprotective film 6. Accordingly, themain body part 11, theside wall part 12, and the connectingpart 13 are each provided with thebase material part 2, theadhesive part 3, therelease liner 4, and theprotective film 6. - The
base material part 2 is a member that forms a base for thesheet laminate 1. Thebase material part 2 has afront surface 2 a to become a design surface, and arear surface 2 b on a side opposite thefront surface 2 a. Thebase material part 2 is configured from a material, such as polycarbonate, PET, ABS resin, and the like. Furthermore, a thickness of thebase material part 2 is not particularly limited, and thus may be 0.2 to 1.5 mm. - Furthermore, a surface treatment using, for example, polyurethane, acrylic, or the like, is applied to the
front surface 2 a to become the design surface. - The
adhesive part 3 is a member for joining thesheet laminate 1 to an object by adhering to said object. Theadhesive part 3 is laminated onto therear surface 2 b of thebase material part 2. Theadhesive part 3 is laminated onto therear surface 2 b of thebase material part 2 so as to cover nearly the entire surface thereof. Of the surfaces of theadhesive part 3, anadhesive surface 3 a functions as a surface on a side opposite thebase material part 2. Theadhesive part 3 is configured from a material, such as acrylic, rubber, and the like. More specifically, the adhesive layer may be configured using an acrylic pressure-sensitive adhesive. Furthermore, a thickness of theadhesive part 3 is not particularly limited, and thus may be 0.005 to 0.4 mm. - The
release liner 4 is a member for protecting theadhesive part 3. Therelease liner 4 covers the entire surface of theadhesive surface 3 a of theadhesive part 3. When thesheet laminate 1 is adhered to an object, therelease liner 4 is peeled from theadhesive part 3 to thus expose theadhesive part 3. Therelease liner 4 may be configured using a biaxially extended film. For example, therelease liner 4 is provided with a release layer of silicone, and the like, on a biaxially extended material, such as PET, PEN, or the like, and a polyolefin layer of PE, or the like, may also be provided there between. Furthermore, a thickness of therelease liner 4 is not particularly limited, and thus may be 0.01 to 0.3 mm. - Because the
protective film 6 covers thefront surface 2 a of thebase material part 2, said film serves as a member for protecting thefront surface 2 a, which is the design surface. Theprotective film 6 is a biaxially extended film. That is, while thefront surface 2 a in the connectingpart 13 of thebase material part 2 deforms so as to stretch somewhat when thesheet laminate 1 is molded from a sheet member state, there is only a small degree of following. The material of theprotective film 6 is configured from PET, PEN, or the like. Furthermore, a thickness of theprotective film 6 is not particularly limited, and thus may be 0.005 to 0.3 mm. - A surface configuration of the design surface (that is, the
front surface 2 a of the base material part 2) of thesheet laminate 1 will be described next. Thesheet laminate 1 has aflat surface part 20 spreading out in a flat plate shape, aside surface 21 on which a bent edge part of theflat surface part 20 is configured, and a connectingsurface 22 protruding and curving toward thefront surface 2 a side between theflat surface part 20 and theside surface 21. Theflat surface part 20 is formed on a part corresponding to themain body part 11 portion of thefront surface 2 a. Theside surface 21 is formed on a part corresponding to theside wall parts 12A through 12E portion of thefront surface 2 a. The connectingsurface 22 is formed on parts corresponding to the connectingparts 13A through 13E portion of thefront surface 2 a. - The surface configuration of the
sheet laminate 1 is described in further detail below with reference toFIG. 3(a) . Note that whileFIG. 3(a) illustrates a configuration in the vicinity of theside wall part 12C, theside wall part 12B, and theside wall part 12E, the same gist holds for descriptions of different parts so long as a pair of mutually intersectingside walls 12 is provided. - As illustrated in
FIG. 3(a) , theflat surface part 20 corresponds to themain body part 11, and forms a primary surface, that is, a flat surface. Theside surface 21 has afirst side surface 21B corresponding to theside wall part 12B, which is one of the pair made up of theside wall parts second side surface 21C corresponding to theside wall part 12C, which is the other of said pair, and athird side surface 21E corresponding to theside wall part 12E that forms a roundness. Thefirst side surface 21B and thesecond side surface 21C form a primary surface, that is, a flat surface. Thethird side surface 21E is formed in a corner between thefirst side surface 21B and thesecond side surface 21C, and is a surface for forming a roundness having a predetermined curvature. The third side surface 21E forms a secondary surface, that is, a curved surface having a component bent with reference to a single axis. When seen from a thickness direction of themain body part 11, the third side surface 21E forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 1 to 2000 mm. The connectingsurface 22 has a first connectingsurface 22B for connecting theflat surface part 20 and thefirst side surface 21B, a second connectingsurface 22C for connecting theflat surface part 20 and thesecond side surface 21C, and a third connectingsurface 22E for connecting theflat surface part 20 and thethird side surface 21E. The first connectingsurface 22B is a secondary surface corresponding to a connectingpart 13B. When seen from a thickness direction of theside wall part 12C, the first connectingsurface 22B forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 0.5 to 200 mm. The second connectingsurface 22C is a secondary surface corresponding to a connectingpart 13C. When seen from a thickness direction of theside wall part 12B, the second connectingsurface 22C forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 0.5 to 200 mm. The third connectingsurface 22E is a tertiary surface corresponding to a connectingpart 13E. The tertiary surface forms a curved surface having a component bent with reference to two axes. The third connectingsurface 22E has a curved component of thethird side surface 21E and a curved component of the first connectingsurface 22B and the second connectingsurface 22C. - Note that “first side surface” and “second side surface” are expedient names for clearly describing a structure and thus may be a
first side surface 21C and asecond side surface 21B. Accordingly, these are sometimes referred to in the following description simply as “side surface” without distinguishing between “first side surface” and “second side surface.” Furthermore, “first connecting surface” and “second connecting surface” are also expedient names for clearly describing a structure and thus may be a first connectingsurface 22C and a second connectingsurface 22B. Accordingly, these are sometimes referred to in the following description simply as “connecting surface” without distinguishing between “first connecting surface” and “second connecting surface.” - A structure in a case where a third side surface protrudes toward the front surface side and thus draws a so-called positive curve was described using
FIG. 3(a) . However, this may also be a structure where the third side surface protrudes toward the rear surface side and thus draws a so-called negative curve. Specifically, the structure illustrated inFIG. 3(b) may be used. As illustrated inFIG. 3(b) , aside wall part 12H forming a roundness so as to protrude toward the rear surface side is formed by a corner between a pair ofside wall parts parts main body part 11 and theside wall parts - In the configuration of
FIG. 3(b) , theside surface 21 has afirst side surface 21F corresponding to theside wall part 12F, which is one of the pair made up of theside wall parts second side surface 21G corresponding to theside wall part 12G, which is the other of said pair, and athird side surface 21H corresponding to theside wall part 12H that forms a roundness. Thefirst side surface 21F and thesecond side surface 21G form a primary surface, that is, a flat surface. Thethird side surface 21H is formed in a corner between thefirst side surface 21F and thesecond side surface 21G, and is a surface for forming a roundness having a predetermined curvature. The third side surface 21H forms a secondary surface, that is, a curved surface having a component bent with reference to a single axis. When seen from a thickness direction of themain body part 11, the third side surface 21H forms a roundness protruding toward the rear surface side. A radius of a curvature of the roundness is 0.5 to 2000 mm. The connectingsurface 22 has a first connectingsurface 22F connecting theflat surface part 20 and thefirst side surface 21F, a second connectingsurface 22G connecting theflat surface part 20 and thesecond side surface 21G, and a third connectingsurface 22H connecting theflat surface part 20 and thethird side surface 21H. The first connectingsurface 22F is a secondary surface corresponding to a connectingpart 13F. When seen from a thickness direction of theside wall part 12G, the first connectingsurface 22F forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 0.5 to 200 mm. The second connectingsurface 22G is a secondary surface corresponding to a connectingpart 13G. When seen from a thickness direction of theside wall part 12F, the second connectingsurface 22G forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 0.5 to 200 mm. The third connectingsurface 22H is a tertiary surface corresponding to a connectingpart 13H. The tertiary surface forms a curved surface having a component bent with reference to two axes. The third connectingsurface 22H has a curved component of thethird side surface 21H and a curved component of the first connectingsurface 22F and the second connectingsurface 22G. - The method for manufacturing the
sheet laminate 1 according to the present embodiment and amold 100 for molding thesheet laminate 1 are described next with reference toFIG. 4 throughFIG. 10 . - A configuration of the
mold 100 for molding thesheet laminate 1 will be described first. Themold 100 is a mold for molding thesheet laminate 1 to be affixed to an adherent surface of an object. As illustrated inFIG. 5 , themold 100 is provided with a first unit 110 asecond unit 120. The first unit is a unit for supporting asheet member 50, having afront surface 50 a to become a design surface and arear surface 50 b on which theadhesive part 3 is formed, from thefront surface 50 a side. Thesecond unit 120 is a unit for supporting thesheet member 50 from therear surface 50 b side. Thefirst unit 110 and thesecond unit 120 are able to mold themain body part 11 spreading in a flat plate shape portion of thesheet laminate 1, and theside wall parts 12 extending respectively toward therear surface 50 b side from mutually intersecting side parts of themain body part 11 by sandwiching the sheet member and bending an edge part of thesheet member 50. Note that what is described here is themold 100 for molding thesheet laminate 1 having the shape illustrated inFIG. 1 . That is, this is a description of themold 100 for molding thesheet laminate 1 having theside wall parts 12A through 12F. However, because the form of thesheet laminate 1 is not particularly limited, the configuration of themold 100 can be changed appropriately to match the form of thesheet laminate 1. - The
first unit 110 is provided with afirst piece 111 for supporting theflat surface part 20 of themain body part 11, and asecond piece 112 for supporting each surface of theside wall part 12. When seen from a thickness direction, thefirst piece 111 is configured as a block forming a rectangular shape to match the form of theflat surface part 20 of the main body part 11 (seeFIG. 6 ). An upper surface of thefirst piece 111 is configured as a supportingsurface 113 for making contact with and thus supporting theflat surface part 20 of themain body part 11. When seen from a thickness direction, thesecond piece 112 is configured as a frame member having an opening that matches the form of theside surface 21 of the side wall part 12 (seeFIG. 6 ). Athird piece 121 of thesecond piece 112 and of thesecond unit 120 to be described later is provided inside the opening of thesecond piece 112. - An inner circumferential surface of the opening of the
second piece 112 is configured as a supportingsurface 114 for supporting theside surface 21 of theside wall part 12. Furthermore, an arrangingpart 116 for arranging the previously moldedsheet member 50 is formed near an upper edge of the opening of thesecond piece 112. The arrangingpart 116 faces an end part of an outer circumferential side of thesheet member 50, and has an aligningsurface 117 for performing alignment in a plane direction of thesheet member 50. The arrangingpart 116 also has aguide surface 118 for smoothly guiding (seeFIG. 7 ) theside wall part 12 toward the supportingsurface 114 side when an edge part of thesheet member 50 is bent during molding. Note that while theguide surface 118 is a curved surface curved so as to protrude outward in the present embodiment, said surface may be an inclined surface extending in a straight manner. - The
second unit 120 is provided with athird piece 121 for pressing thesheet member 50 from therear surface 50 b side toward thefront surface 50 a side. A lower surface of thethird piece 121 is configured as a supportingsurface 122 for pressing the rear surface side of themain body part 11 of thesheet laminate 1. Furthermore, an outer circumferential surface of thethird piece 121 is configured as a supportingsurface 123 for making contact with and thus supporting the rear surface side (surface on the opposite side of the side surface 21) of theside wall part 12 of thesheet laminate 1. During molding, theside wall part 12 is sandwiched by the supportingsurface 114 of thesecond piece 112 and the supportingsurface 123 of the third piece 121 (seeFIG. 8 ). Accordingly, a dimension in a horizontal direction gap between the supportingsurface 114 and the supportingsurface 123 is set to a thickness dimension of theside wall part 12. - At least during the execution of a partial heating step to be described later, the
first unit 110 supports theflat surface part 20 and the side surface 21 (first side surface, second side surface, and third side surface), in a state where the connecting surface 22 (first connecting surface, second connecting surface, and third connecting surface) of thesheet laminate 1 is exposed. That is, inFIG. 3(a) , the connectingsurfaces first unit 110, and theflat surface part 20 and the side surfaces 21B, 21C, and 21E are supported by thefirst unit 110. - A manufacturing step of the method for manufacturing the
sheet laminate 1 will be described next with reference toFIG. 4 . As illustrated inFIG. 4 , the method for manufacturing thesheet laminate 1 includes a preparing step S10, a bending step S20, a partial heating step S30, and an extracting step S40. - The preparing step S10 is a step for preparing the
sheet member 50. In the preparing step S10, thesheet member 50 is pre-cut to a form that matches themold 100. Furthermore, theprepared sheet member 50 is provided in the arrangingpart 116 of thesecond piece 112 of the mold 100 (seeFIG. 5 ). - The bending step S20 is a step for bending an edge part of the
sheet member 50 by sandwiching thesheet member 50 from thefront surface 50 a side and therear surface 50 b side. By lowering thethird piece 121 of thesecond unit 120 downward in the bending step S20, therear surface 50 b of thesheet member 50 is pressed downward by the supporting surface 122 (seeFIG. 7 ). At this time, thefront surface 50 a of thesheet member 50 may be supported by the supportingsurface 113 of thefirst piece 111 of thefirst unit 110. At this time, an edge part of thesheet member 50 abuts with theguide surface 118 of the arrangingpart 116, which guides said member toward the supportingsurface 114 side while thus bending said part toward therear surface 50 b side. - When the
third piece 121 is lowered all the way down, an edge part of thesheet member 50 is sandwiched between the supportingsurface 114 of thefirst piece 111 of the first unit and the supportingsurface 123 of thethird piece 121 of the second unit (seeFIG. 8 ). This forms theside wall part 12 of thesheet laminate 1. Furthermore, therear surface 50 b of thesheet member 50 is sandwiched between the supportingsurface 122 of the third piece and the supportingsurface 113 of thesecond piece 112. This forms themain body part 11 of thesheet laminate 1. Furthermore, by pressing a curved part of a corner of the third piece, a corner between themain body part 11 and theside wall part 12 forms the bent connectingpart 13. In this state, thefirst unit 110 is supporting theflat surface part 20 and theside surface 21 in a state where the connectingsurface 22 of thesheet laminate 1 is exposed. - The partial heating step S30 is a step for heating part of the
bent sheet member 50. The partial heating step S30 heats the connectingsurface 22 exposed from thefirst unit 110 but does not heat theflat surface part 20 or theside surface 21 being supported and covered by the first unit 110 (seeFIG. 9 ). This anneals the bent connectingpart 13, which was significantly bent in the bending step, to thus remove distortion produced in said part. Apredetermined heating device 140 is provided with respect to the connectingpart 13, and theheating device 140 supplies heat. Theheating device 140 may heat the connectingsurface 22 by supplying, for example, infrared rays (IR), heated air, high pressure steam, or heated liquid. Or, a heating pad itself may be pressed against the connectingsurface 22, or housed inside a heating furnace for each mold. - After the partial heating step S30 has completed, the extracting step S40 extracts the
sheet laminate 1 from themold 100 by raising thethird piece 121 together with the sheet laminate 1 (seeFIG. 10 ). Note that after the partial heating step S30 has completed, the connectingsurface 22 may be cooled through contact with cooling air, a cooling liquid, or a cooling pad. Or, the connectingsurface 22 may be cooled naturally by letting said surface stand. The manufacturing step illustrated inFIG. 4 is complete when the extracting step S40 ends. - The operations and effects of the method for manufacturing the
sheet laminate 1, themold 100 for molding thesheet laminate 1, and thesheet laminate 1 according to the present invention will be described next. Note that the part illustrated inFIG. 3(a) will be used as an example for describing the “flat surface part,” “first side surface,” “second side surface,” “third side surface,” “first connecting surface,” “second connecting surface,” and “third connecting surface” in the following description. However, the same operations and effects can be obtained for other parts having the same gist in thesheet laminate 1. - A method for manufacturing a sheet laminate according to a comparative example will be described first. Examples of methods for manufacturing according to the comparative example include heat stamping which sandwiches a sheet in a heated mold, and then bends the sheet. However, in cases where an edge part of a sheet member having an adhesive part on a rear surface is bent, a problem occurs when heat stamping is performed where the adhesive part peels during molding.
- By contrast, with the method for manufacturing the
sheet laminate 1 according to the present embodiment, thesheet laminate 1 has theflat surface part 20 spreading out in a flat plate shape, theside surface 21 on which an edge part bent by the bending step is configured, and the connectingsurface 22 protruding and curving toward the front surface side between theflat surface part 20 and theside surface 21. After thesheet member 50 has been bent into this kind of shape in the bending step, the connectingsurface 22 is partially heated in the partial heating step. When thesheet member 50 is molded in a state where theadhesive part 3 or theprotective film 6 has been formed, theadhesive part 3 or theprotective film 6 become susceptible to peeling in a position corresponding to the connectingsurface 22 that deforms so as to curve in the bending step. Accordingly, distortion in said part can be removed by partially removing stress (performing an annealing process) through partial heating of the connectingsurface 22. Therefore, thesheet laminate 1 can be manufactured with good quality while preventing peeling of theadhesive part 3 and theprotective film 6. - The merits of partially heating the connecting
surface 22 will be described here. For example, if stamping is done in a state where theadhesive part 3, theprotective film 6, and therelease liner 4 have been heated and softened, theadhesive part 3 and theprotective film 6 may displace due to a shear force between molds, which can lead to peeling (the impact from displacement caused by theadhesive part 3 is particularly significant). To prevent this, heating is performed in a static state after stamping has been performed without heating. Additionally, movement of a peripheral part (here this is a flat surface part or side surface of a periphery of the connecting surface 22), other than a major curved part where stress is to be relaxed by heating, is suppressed by keeping said part sandwiched between molds, and this part is also not softened through heating. This makes it possible to prevent layers from peeling due to the displacement of a part (that is a part corresponding to the connecting surface 22) to be partially heated sandwiched in the peripheral part. - The method for manufacturing the
sheet laminate 1 molds themain body part 11 for configuring theflat surface part 20 portion of thesheet laminate 1, and the pair ofside wall parts main body part 11. In the example inFIG. 3(a) , theside surface 21 has thefirst side surface 21B corresponding to theside wall part 12B, thesecond side surface 21C corresponding to theside wall part 12C, and thethird side surface 21E formed in the corner between thefirst side surface 21B and thefirst side surface 21C forming a roundness having a predetermined curvature. The connectingsurface 22 may have the first connectingsurface 22B connecting theflat surface part 20 and thefirst side surface 21B, the second connectingsurface 22C connecting theflat surface part 20 and thesecond side surface 21C, and the third connectingsurface 22E connecting theflat surface part 20 and thethird side surface 21E. - The connecting
surface 22 is exposed from themold 100 in the partial heating step, and partial heating is performed by applying heat to the connectingsurface 22 from outside themold 100. This enables the connecting surface to be partially heated using a simple configuration. - The
sheet member 50 is also provided with therelease liner 4 for covering theadhesive part 3 of therear surface 50 b of thesheet member 50. This enables molding to be performed in a state where theadhesive part 3 is protected. - The
mold 100 for molding thesheet laminate 1 is themold 100 for molding thesheet laminate 1 to be affixed to the adherent surface of an object, and is provided with thefirst unit 110 for supporting thesheet member 50, having thefront surface 50 a to become the design surface and therear surface 50 b in which theadhesive part 3 has been formed, from thefront surface 50 a side, and thesecond unit 120 for supporting thesheet member 50 from therear surface 50 b side. Thefirst unit 110 and thesecond unit 120 are able to mold themain body part 11 spreading in a flat plate shape portion of thesheet laminate 1, and the pair ofside wall parts rear surface 50 b side from the pair of mutually intersectingside parts main body part 11 by sandwiching thesheet member 50 and then bending thesheet member 50. When the front surface is formed on theflat surface part 20 corresponding to themain body part 11, thefirst side surface 21B corresponding to theside wall part 12B, thesecond side surface 21C corresponding to theside wall part 12C, and in a corner between thefirst side surface 21B and thesecond side surface 21C; and has thethird side surface 21E forming a roundness having a predetermined curvature, the first connectingsurface 22B protruding and curving toward the front surface side for connecting theflat surface part 20 and thefirst side surface 21B, the second connectingsurface 22C protruding and curving toward the front surface side for connecting theflat surface part 20 and thesecond side surface 21C, and the third connectingsurface 22E protruding and curving toward the front surface side for connecting theflat surface part 20 and thethird side surface 21E, thefirst unit 110 supports theflat surface part 20, thefirst side surface 21B, thesecond side surface 21C, and thethird side surface 21E in a state where the first connectingsurface 22B, the second connectingsurface 22C, and the third connectingsurface 22E are exposed. - Using a mold like the
mold 100 makes it possible to execute a manufacturing method like that described above, and to obtain the same operation and effect. - The
sheet laminate 1 is thesheet laminate 1 that is to be affixed to an adherent surface of an object and has theflat surface part 20 that spreads out in a flat plate shape, theside surface 21 configured by a bent edge of theflat surface part 20, and the connectingsurface 22 protruding and curving toward the front surface side between theflat surface part 20 and theside surface 21, where the part configuring theflat surface part 20, theside surface 21, and the connectingsurface 22 is configured of thebase material part 2 having the front surface that is to become the design surface, and the rear surface on the side opposite the front surface, anadhesive part 3 formed on the rear surface of thebase material part 2, and therelease liner 4 covering theadhesive part 3 that can be peeled from theadhesive part 3. - Using a laminate like the
sheet laminate 1 enables achieving an operation and effect during manufacture having the same gist as the manufacturing method described above. - The
sheet laminate 1 is provided with themain body part 11 for configuring theflat surface part 20, and the pair ofside wall parts main body part 11. Theside surface 21 has thefirst side surface 21B corresponding to theside wall part 12B, thesecond side surface 21C corresponding to theside wall part 12C, and thethird side surface 21E formed in the corner between thefirst side surface 21B and thesecond side surface 21C forming a roundness having a predetermined curvature. The connectingsurface 22 has a first connectingsurface 22B for connecting theflat surface part 20 and thefirst side surface 21B, a second connectingsurface 22C for connecting theflat surface part 20 and thesecond side surface 21C, and a third connectingsurface 22E for connecting theflat surface part 20 and thethird side surface 21E. The manufacturing method according to the present embodiment becomes particularly noteworthy when thesheet laminate 1 having this type of configuration is manufactured. The third side surface 21E forms a roundness protruding toward the front surface side, and the curvature of the roundness has a radius of 1 to 2000 mm. - In the example in
FIG. 3(b) , the third side surface 21H forms a roundness protruding toward the rear surface side, and the curvature of the roundness has a radius of 0.5 to 2000 mm. - The
base material part 2 is covered by the biaxially extendedprotective film 6. This makes it possible to protect a front surface of thebase material part 2. - The
release liner 4 is configured using a biaxially extended film. This makes it possible to reduce an impact on therelease liner 4 during partial heating of the connecting surface. - For example, the
adhesive part 3 is configured using an acrylic pressure-sensitive adhesive. For example, the base material part is configured using a polycarbonate. - The present invention is not intended to be limited to the embodiments described above.
- In the embodiments described above, the
sheet member 50 is provided in themold 100 after having been cut beforehand. However, an un-cut sheet member that is not cut until it is supplied in the mold may also be used. For example, a cuttingmember 210 may be provided on an outer circumferential side of thethird piece 121 of thefirst unit 110, as illustrated inFIG. 11 andFIG. 12 . For example, abase material 250 of a sheet member is cut by the cuttingmember 210 simultaneous to pressurization in thethird piece 121 to thus form thesheet member 50 in a desired shape. Note that the cuttingmember 210 is retracted upward after the cutting, as illustrated inFIG. 12 . - Note that in the embodiments described above, the connecting surface to be partially heated was exposed from the mold. In addition, the first unit has a piece for supporting the connecting surface, and may partially heat the connecting surface through said piece. Specifically, as illustrated in
FIG. 13 , in amold 300, thefirst unit 110 is provided with aheating part 310 provided with afourth piece 115 that makes contact with the connecting surface (first connecting surface, second connecting surface, and third connecting surface) 22, for heating the part making contact, an insulatingpart 302 for insulating a space between theflat surface part 20 and theheating part 310, and aninsulating part 301 for insulating a space between the side surface (first side surface, second side surface, and third side surface) 21 and theheating part 310, and for insulating the insulatingpart 301. Theheating part 310 may be configured using a flow path, and the like, of a heating medium such as a heating wire, a liquid, a gas, or the like. - According to the description above, in the method for manufacturing the
sheet laminate 1, partial heating is performed in the partial heating step through a part (the fourth piece 115) in themold 300 that makes contact with the connectingsurface 22. Furthermore, heat going to theflat surface part 20 and theside surface 21 is insulated in the partial heating step. This kind of configuration allows partial heating to be performed while a shape is sustained because the connectingsurface 22 is supported by thefourth piece 115. Note that if thefourth piece 115 does not have theheating part 310, thefourth piece 115 is retracted during the partial heating step, and partial heating may be performed by exposing the connectingsurface 22.
Claims (8)
1. A sheet laminate manufactured according to the method comprising
providing a sheet member having:
a) a front surface to become a design surface and
b) a rear surface on which an adhesive part has been formed;
bending an edge part of the sheet member by sandwiching the sheet member from a front surface side and a rear surface side in a mold to create the sheet laminate; and
partially heating the connecting surface after the side surface is molded in the said bending, and
wherein the sheet laminate has a flat surface part spreading out in a flat plate shape, a side surface on which an edge part bent by said bending is configured, and a connecting surface protruding and curving toward the front surface side between the flat surface part and the side surface
wherein the connecting surface does not contact the mold during the partial heating, and partial heating is performed by applying heat to the connecting surface from outside the mold,
wherein a part configuring the flat surface part, the side surface and the connecting surface is configured of a base material layer having a front surface that is to become a design surface, and a rear surface on a side opposite the front surface, an adhesive layer formed on the rear surface of the base material layer, and a release liner layer covering the adhesive layer that can be peeled from the adhesive layer.
2. The sheet laminate according to claim 1 , further comprising:
a main body part for configuring the flat surface part portion of the sheet laminate; and
a pair of side wall parts each extending respectively toward the rear surface side from a pair of mutually intersecting side parts of the main body,
wherein the side surface has a first side surface corresponding to one side wall part of the pair of side wall parts, a second side surface corresponding to the other side wall part of the pair of side wall parts, and a third side surface forming a roundness having a predetermined curvature formed in a corner part between the first side surface and the second side surface; and the connecting surface has a first connecting surface for connecting the flat surface part and the first side surface, a second connecting surface for connecting the flat surface part and the second side surface, and a third connecting surface for connecting the flat surface part and the third side surface.
3. The sheet laminate according to claim 2 , wherein the third side surface forms the roundness protruding toward the front surface side, and a curvature of the roundness has a radius in the range of from about 1 mm to about 2000 mm.
4. The sheet laminate according to claim 2 , wherein the third side surface forms the roundness protruding toward the front surface side, and a curvature of the roundness has a radius in the range of from about 0.5 mm to about 2000 mm.
5. The sheet laminate according to claim 1 , wherein the base material layer is covered by a biaxially extended protective film layer.
6. The sheet laminate according to claim 1 , wherein the release liner layer is configured of a biaxially extended protective film layer.
7. The sheet laminate according to claim 1 , wherein the adhesive layer is configured using an acrylic pressure-sensitive adhesive.
8. The sheet laminate according to claim 1 , wherein the base material layer is configured using a polycarbonate.
Priority Applications (1)
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US17/698,156 US20220203599A1 (en) | 2016-12-28 | 2022-03-18 | Method for manufacturing sheet laminate, mold for molding sheet laminate, and sheet laminate |
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
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JP2016255468A JP6914035B2 (en) | 2016-12-28 | 2016-12-28 | A method for manufacturing a sheet-shaped laminate, a mold for molding the sheet-shaped laminate, and a sheet-shaped laminate. |
JP2016-255468 | 2016-12-28 | ||
PCT/IB2017/058160 WO2018122683A1 (en) | 2016-12-28 | 2017-12-19 | Method for manufacturing sheet laminate, mold for molding sheet laminate, and sheet laminate |
US201916470403A | 2019-06-17 | 2019-06-17 | |
US17/698,156 US20220203599A1 (en) | 2016-12-28 | 2022-03-18 | Method for manufacturing sheet laminate, mold for molding sheet laminate, and sheet laminate |
Related Parent Applications (2)
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PCT/IB2017/058160 Division WO2018122683A1 (en) | 2016-12-28 | 2017-12-19 | Method for manufacturing sheet laminate, mold for molding sheet laminate, and sheet laminate |
US16/470,403 Division US11292181B2 (en) | 2016-12-28 | 2017-12-19 | Method for manufacturing sheet laminate |
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US20220203599A1 true US20220203599A1 (en) | 2022-06-30 |
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US16/470,403 Active 2038-04-02 US11292181B2 (en) | 2016-12-28 | 2017-12-19 | Method for manufacturing sheet laminate |
US17/698,156 Pending US20220203599A1 (en) | 2016-12-28 | 2022-03-18 | Method for manufacturing sheet laminate, mold for molding sheet laminate, and sheet laminate |
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US16/470,403 Active 2038-04-02 US11292181B2 (en) | 2016-12-28 | 2017-12-19 | Method for manufacturing sheet laminate |
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US (2) | US11292181B2 (en) |
EP (1) | EP3562668A1 (en) |
JP (1) | JP6914035B2 (en) |
CN (1) | CN110121417B (en) |
WO (1) | WO2018122683A1 (en) |
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CN110520267A (en) * | 2017-04-28 | 2019-11-29 | 株式会社斯巴鲁 | Composite molding fixture, composite material forming method and composite material |
KR20210032916A (en) | 2019-09-17 | 2021-03-25 | 주식회사 엘지화학 | pouch type battery case and apparatus for manufacturing thereof, pouch type secondary battery |
CN112164314B (en) * | 2020-09-30 | 2022-09-23 | 京东方科技集团股份有限公司 | Preparation method of display device and display device |
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JPS58217352A (en) * | 1982-06-10 | 1983-12-17 | 日産自動車株式会社 | Manufacture of various covers for engine |
JP2586550Y2 (en) | 1992-10-16 | 1998-12-09 | 日立工機株式会社 | Anti-vibration structure of hammer drill |
JP3044516B2 (en) | 1993-06-11 | 2000-05-22 | ソニーケミカル株式会社 | Metal plate molding method |
JP2009056605A (en) | 2007-08-30 | 2009-03-19 | Hattori Bankin Kogyo Kk | Thermoplastic resin molding apparatus |
US20110151241A1 (en) * | 2008-09-11 | 2011-06-23 | Sanwa Kogyo Co., Ltd. | Formed material for vehicle interior component |
US10245776B2 (en) * | 2011-09-30 | 2019-04-02 | Apple Inc. | Methods for forming electronic devices with bent display edges |
WO2014153660A1 (en) * | 2013-03-26 | 2014-10-02 | Ferri, Domenico | Decorative panel and method of producing the same |
KR20160014765A (en) * | 2013-06-06 | 2016-02-11 | 쓰리엠 이노베이티브 프로퍼티즈 컴파니 | Method for preparing structured adhesive articles |
CN104598475B (en) | 2013-10-31 | 2018-02-23 | 中国移动通信集团公司 | Storage and indexing means and system based on driving dosage model event |
JP6349932B2 (en) | 2014-05-07 | 2018-07-04 | 東洋製罐株式会社 | Pouch folding method and bending apparatus |
JP6137056B2 (en) | 2014-06-04 | 2017-05-31 | トヨタ自動車株式会社 | Manufacturing method of resin parts for automobile and manufacturing apparatus of resin parts for automobile |
CN205740727U (en) * | 2016-06-15 | 2016-11-30 | 蓝思科技(长沙)有限公司 | A kind of glass bending mould |
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- 2017-12-19 CN CN201780081234.5A patent/CN110121417B/en not_active Expired - Fee Related
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US20200122383A1 (en) | 2020-04-23 |
EP3562668A1 (en) | 2019-11-06 |
CN110121417A (en) | 2019-08-13 |
JP6914035B2 (en) | 2021-08-04 |
US11292181B2 (en) | 2022-04-05 |
WO2018122683A1 (en) | 2018-07-05 |
CN110121417B (en) | 2022-05-10 |
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