JP2007100272A - Method for producing helmet and the helmet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a helmet, capable of simply conducting finishing treatment of an outer surface of a helmet body in a short time, capable of, when desired, conducting small-lot production of a wide variety of products of the helmet bodies having different colors, shapes, patterns, and designs from one another, and capable of enhancing impact resistance and weather resistance of the outer surface of the helmet body, and to provide the helmet produced by the method. <P>SOLUTION: This method for producing the helmet comprises using a coated sheet 1 which is formed by sequentially laminating a colored layer 5, including an unpatterned layer, and a pressure-sensitive adhesive layer 6 on one of surfaces of a protective sheet 4 formed out of a transparent or translucent thermoplastic resin, holding the helmet body 2 on a molding position of a vacuum molding furnace 3, so as to be attachable and detachable, arranging the coated sheet in the vacuum molding furnace by making the pressure-sensitive adhesive layer of the sheet face to an outer surface 2A of the helmet body, adhering the coated sheet to the outer surface of the helmet body by reducing pressure on a side of the pressure-sensitive adhesive layer while heating the sheet, cooling them, and removing an excessive part 8 of the coated sheet by trimming the part. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a helmet having a shell body and a helmet.

  In addition to impact resistance and weather resistance to protect the head, the helmet cap body is required to be lighter and more heat-resistant, and a mixture of fibers such as glass fiber, carbon fiber, polyester fiber, and synthetic resin. It is mainly molded from FRP (fiber reinforced resin). Since a part of fibers appear on the surface of the cap body made of FRP, a lot of minute irregularities are inevitably generated, the surface becomes rough, and the appearance is poor as it is. Therefore, the surface of the cap body is usually finished by applying a paint or clear to form a surface coating layer.

  In Patent Document 1, a liquid or gel-like photo-curing resin or thermosetting resin is sprayed on the surface of a cap body made of polycarbonate resin or ABS resin with a uniform thickness by a sprayer, and cured by irradiation with ultraviolet rays. A helmet with a coating is disclosed. Thus, by forming a film on the surface, the unevenness on the surface of the cap body is filled and leveled, and the cap body is protected from damage from impact and UV deterioration by a hard and durable film.

  Patent Document 2 discloses a helmet in which the entire outer surface of a cap body made of a polycarbonate resin is directly surrounded by a primer layer, and a printing surface for transfer method is provided on the outer surface of the primer layer so that the entire surface is covered with a top coat. ing. Here, as a method of providing the printing surface of the transfer method on the outer surface of the primer layer, a water-soluble thin film such as an oblate was suspended on the liquid surface of the water tank with the printed pattern surface facing upward, and the primer layer was formed from above. The cap body is lowered and the pattern surface is attached to the entire circumference of the cap body by hydraulic pressure. Then, after the water-soluble thin film is removed by washing with water, the top is protected with a top coat.

  Patent Document 3 discloses a helmet in which a pattern is transferred onto the surface of a cap body using transfer paper. The transfer paper is formed by screen printing a pattern on one surface of a thermoplastic resin film, and an adhesive layer is laminated thereon, and the adhesive layer is bonded to the surface of the cap body and pressed from above. If necessary, the film is peeled off after being heated and adhered to the surface of the cap body.

For automotive parts, etc., a sheet (film) is formed into a required shape by vacuum forming or vacuum / pressure forming, and the formed sheet or film is attached to the shell surface by insert molding to produce a coated product. To manufacture. However, when the sheet is vacuum-formed or vacuum-compressed into a required shape using a jig (die), the accuracy of the finished dimensions is low, and the shell cannot be fitted and covered without any gaps. In the case of insert molding, the shape and depth are limited and not suitable for deep objects such as caps. Although it is possible to insert a preform sheet, it is a processing with advanced technology and has a disadvantage in terms of price.
Utility Model Registration No. 3005407 JP 58-163709 A JP 54-56551 A

  As described above, at least the outer surface of the helmet body needs to be subjected to a finishing treatment. In order to produce a desired color cap body, the cap body itself is made of a resin material of a desired color. The outer surface of the cap body is covered with a transparent top coat, or the outer surface of the cap body is coated with a paint of a desired color, and then the outer cover surface is covered with a transparent top coat. However, in any case, in order to produce helmets of multiple colors, prepare molding machines and coating machines for each color, or adjust molding machines and coating machines over a long period of time so that colors do not mix. This is not suitable for the production of a wide variety of products and small lots, which is a recent social requirement. In addition, a drying process is required after the paint or top coat is applied, and if a pattern or a pattern is to be added, an additional transfer process is necessary, so an increase in cost is inevitable.

  Therefore, in view of the above-mentioned situation, the present invention intends to solve the problem that the finishing process of the outer surface of the cap body can be easily performed in a short time, and the cap is different in color, shape, pattern, and pattern. To provide a helmet manufacturing method and a helmet manufactured by the method of manufacturing a helmet capable of producing a variety of bodies and small lots as desired, and capable of improving the impact resistance and weather resistance of the outer surface of the cap body is there.

  In order to solve the above-mentioned problems, the present invention uses a covering sheet in which a colored layer containing a non-pattern and an adhesive layer are sequentially laminated on one surface of a protective sheet made of a transparent or translucent thermoplastic resin. After being detachably held at the mold position of the vacuum forming furnace, the pressure-sensitive adhesive layer side of the covering sheet is placed in the vacuum forming furnace facing the outer surface of the cap body and the pressure-sensitive adhesive layer side of the covering sheet is heated while heating. The helmet manufacturing method is characterized in that the pressure is reduced and brought into close contact with the outer surface of the cap body, and after cooling, the surplus portion of the covering sheet is removed by trimming (Claim 1).

  Further, the present invention uses a cover sheet in which a colored layer containing a non-pattern and an adhesive layer are sequentially laminated on one surface of a protective sheet made of a transparent or translucent thermoplastic resin, and the cap body is positioned at the mold position of the pressure forming furnace. After being held in a removable manner, the pressure-sensitive adhesive layer of the covering sheet is placed in a pressure forming furnace facing the outer surface of the cap body, and the protective sheet side of the covering sheet is pressurized while being heated to heat the cap sheet outside the cap body. A method for manufacturing a helmet is characterized in that it is brought into close contact with the surface and, after cooling, an excess portion of the covering sheet is removed by trimming (Claim 2).

  Here, the covering sheet surrounds the collar portion of the cap body, extends along the inner surface, is cut at a position leaving a predetermined width on the inner surface side, and the edge portion of the covering sheet is brought into close contact with the inner surface of the cap body. (Claim 3).

  The covering sheet forms a colored layer having a thickness of 20 to 40 μm on one surface of a transparent polycarbonate protective sheet having a thickness of 0.3 to 0.5 mm, and an adhesive having a thickness of 30 to 50 μm thereon. An agent layer is formed (claim 4).

  Further, the present invention provides a cover sheet in which a colored layer containing a non-pattern and an adhesive layer are sequentially laminated on one surface of a protective sheet made of a transparent or translucent thermoplastic resin, and an adhesive layer on the outer surface of the cap body. A helmet characterized in that it is closely attached and covered with a covering sheet, and a peripheral portion of the covering sheet surrounds the collar portion of the cap body and extends along the inner surface side of the cap body and is in close contact with the inner surface (Claim 5).

  In the helmet manufacturing method of the invention according to claim 1 or 2 as described above, a cover sheet on which an outer surface of the cap body is printed with a desired color, pattern, etc. in advance is removed from the cap body in a vacuum forming furnace or a pressure forming furnace. Since it only covers the surface, the shape of the cap body may be arbitrary, and even if the appearance of the molded cap body has color problems or minute irregularities, it can be used as a fabric. Further, since the outer surface of the cap body is covered with the protective sheet, the colored layer on the lower surface side is not damaged, and the impact resistance and weather resistance of the cap body can be improved. Compared to conventional technologies, it is cheaper and more efficient, and can meet the demands of many varieties and small lots.

  According to claim 3, the covering sheet is cut at a position surrounding the collar portion of the cap body and extending along the inner surface side, and the edge portion of the covering sheet is brought into close contact with the inner surface of the cap body. In addition, there is no fear of falling from the end portion of the covering sheet, and the heel portion of the cap body can be surrounded and protected by the covering sheet.

  According to the fourth aspect, since the protective sheet made of polycarbonate having a thickness of 0.3 to 0.5 mm is located on the outer surface of the cap body, it is excellent in impact resistance and weather resistance.

  According to claim 5, it is possible to provide a beautiful helmet in which the outer surface of the cap body is covered with a protective sheet, and a desired color or pattern is provided by the colored layer on the lower surface side, and the colored layer is a protective sheet. Since it is covered with, it will not be damaged, and it will be excellent in impact resistance and weather resistance.

  Next, the present invention will be described in more detail based on the embodiments shown in the accompanying drawings. FIG. 1 is a simplified explanatory view showing the steps of a method for manufacturing a helmet according to the present invention, FIG. 2 is a perspective view of the cap body, FIG. 3 is an enlarged cross-sectional view of the heel portion of the cap body, Reference numeral 2 denotes a cap body, and 3 denotes a vacuum forming furnace.

  The outline of the method for manufacturing a helmet according to the present invention is shown in FIG. First, as shown in FIG. 1 (a), a covering sheet 1 is prepared in which a colored layer 5 including a pattern and an adhesive layer 6 are sequentially laminated on one surface of a protective sheet 4 made of a transparent or translucent thermoplastic resin. To do. Next, as shown in FIG. 1 (b), the cap body 2 is detachably held by a holder 7 at the mold position of the vacuum forming furnace 3, and then the adhesive layer 6 of the covering sheet 1 is put on the cap body 2. It arrange | positions in the vacuum forming furnace 3 toward 2 A of outer surfaces. Then, as shown in FIG. 1 (c), the pressure-sensitive adhesive layer 6 side of the covering sheet 1 is depressurized and uniformly adhered to the outer surface 2 </ b> A of the cap body 2 while uniformly heating the entire surface of the covering sheet 1. Finally, as shown in FIG.1 (d), after cooling, the surplus part 8 of the coating sheet 1 is removed by trimming, and the cap body 2 is manufactured (refer FIG.2). In this manner, a helmet is manufactured by attaching a bracket, hammock, headband, chin strap, etc. (not shown) to the cap body 2 having at least the outer surface 2A covered with the covering sheet 1.

  Here, as shown in FIGS. 2 (c) and 3, when the pressure-sensitive adhesive layer 6 side of the covering sheet 1 is depressurized, the covering sheet 1 comes into close contact with the outer surface 2 </ b> A of the cap body 2, and then the cap It surrounds the heel part 9 of the body 2 and extends along the inner surface 2B to be in close contact. Therefore, the covering sheet 1 extending along the inner surface 2B of the cap body 2 is cut by trimming at a position leaving a predetermined width on the inner surface side, and the edge 10 of the covering sheet 1 is cut into the inner surface 2B of the cap body 2. Adhere to.

  The covering sheet 1 forms a colored layer 5 having a thickness of 20 to 40 μm on one surface of a protective sheet 4 made of transparent polycarbonate having a thickness of 0.3 to 0.5 mm, and has a thickness of 30 to 50 μm thereon. The pressure-sensitive adhesive layer 6 is formed. The colored layer 5 and the pressure-sensitive adhesive layer 6 are formed on the protective sheet 4 by a method similar to a normal printing method.

  The vacuum forming used in the present invention is a method for obtaining a predetermined shape by heat-softening a sheet and bringing the space between the sheet and the mold into a vacuum state, thereby bringing the sheet into close contact with the mold. In contrast, in the present invention, the cap body 2 is placed in the vacuum forming furnace 3 instead of the mold, and the covering sheet 1 is brought into close contact with the outer surface 2A of the cap body 2. FIG. 1B shows the vacuum forming furnace 3 in a simplified manner, and the low-pressure side container 11 and the high-pressure side container 12 can be closed in an airtight state. The holder 7 for holding the cap body 2 is provided in the low-pressure side container 11, and the cap body 2 held by the holder 7 is also accommodated in the low-pressure side container 11. The covering sheet 1 is sandwiched between the low-pressure side container 11 and the high-pressure side container 12 in an airtight state, and the periphery is held. Then, the inside of the low-pressure side container 11 is decompressed by a vacuum pump. Moreover, in order to heat the said covering sheet 1, the heater is incorporated in the inside of the said low voltage | pressure side container 11 or the high voltage | pressure side container 12, or both containers.

In addition to vacuum forming, pressure forming can also be used. Here, compressed air molding is a method in which a sheet is heated and softened, and the sheet is brought into close contact with a mold with compressed air of 3 to 5 kg / cm ² to obtain a predetermined shape. In the present invention, the cap body 2 is placed in a pressure forming furnace instead of the mold, and the covering sheet 1 is brought into close contact with the outer surface 2A of the cap body 2. Although not shown, the pressure forming furnace has basically the same structure as the vacuum forming furnace 3 described above. The compressed air is fed into the inside of the high-pressure side container 12 from a compressor or a pressure pump and pressurized. That is, the principle is the same in that a pressure difference is provided on both surfaces of the covering sheet 1 and the pressure is changed from the high pressure side to the low pressure side so as to be in close contact with the outer surface 2A of the cap body 2.

  It is also possible to use a compressed air vacuum forming furnace in which the vacuum forming furnace 3 and the compressed air forming furnace are combined. In this compressed air vacuum forming furnace, compressed air is sent into the high pressure side container 12 to pressurize it, and the inside of the low pressure side container 11 is evacuated to reduce the pressure.

The process of the manufacturing method of a helmet is shown, (a) is a perspective view of a covering sheet, (b) is a layout view in a state where a cap body and a covering sheet are set in a vacuum forming furnace, and (c) is in the middle of vacuum forming. A simplified sectional view in a state, (d) shows a simplified sectional view in a state where an excess portion of the covering sheet is cut by trimming. It is a perspective view of the state where the outer surface of the cap body was covered with a covering sheet. It is an expanded sectional view of the collar part of a cap body.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Cover sheet 2 Cap body 2A Outer surface 2B Inner surface 3 Vacuum forming furnace 4 Protective sheet 5 Colored layer 6 Adhesive layer 7 Holder 8 Surplus part 9 Girder part 10 Edge part 11 Low pressure side container 12 High pressure side container

Claims (5)

  Using a cover sheet in which a colored layer containing no pattern and an adhesive layer were sequentially laminated on one surface of a protective sheet made of a transparent or translucent thermoplastic resin, the cap body was detachably held at the mold position of the vacuum forming furnace. Thereafter, the pressure-sensitive adhesive layer of the covering sheet is placed in a vacuum forming furnace facing the outer surface of the cap body, and the pressure-sensitive adhesive layer side of the covering sheet is depressurized while being heated to adhere to the outer surface of the cap body, After cooling, the manufacturing method of the helmet characterized by removing the excess part of a coating sheet by trimming.   Using a cover sheet in which a colored layer and a pressure-sensitive adhesive layer containing a non-pattern are sequentially laminated on one side of a protective sheet made of a transparent or translucent thermoplastic resin, the cap body is detachably held at the mold position of the pressure forming furnace. Thereafter, the pressure-sensitive adhesive layer of the covering sheet is placed in a pressure forming furnace facing the outer surface of the cap body, and the protective sheet side of the covering sheet is pressed while being heated to adhere to the outer surface of the cap body, and then cooled. Then, the manufacturing method of the helmet characterized by removing the excess part of a coating sheet by trimming.   The covering sheet surrounds the collar portion of the cap body, extends along the inner surface, is cut at a position leaving a predetermined width on the inner surface side, and the edge portion of the covering sheet is in close contact with the inner surface of the cap body. Item 3. A method for manufacturing a helmet according to Item 1 or 2.   The covering sheet forms a colored layer having a thickness of 20 to 40 μm on one surface of a transparent polycarbonate protective sheet having a thickness of 0.3 to 0.5 mm, and an adhesive layer having a thickness of 30 to 50 μm thereon. The method for manufacturing a helmet according to claim 1, wherein the helmet is formed. A cover sheet in which a colored layer containing a pattern and an adhesive layer are sequentially laminated on one surface of a protective sheet made of a transparent or translucent thermoplastic resin, and the adhesive layer is adhered to the outer surface of the cap body. A helmet characterized in that the outer peripheral portion of the covering sheet surrounds the collar portion of the cap body, extends along the inner surface side of the cap body, and is in close contact with the inner surface.

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