JP2012096416A - Vacuum molding machine, substrate for vacuum molding machine, and vacuum molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve yields of molded products by preventing occurrence of a mold-abutting phenomenon even when a covered film is in a drawdown state, and by securely preventing a mark of the mold abutting from remaining after molding, and preventing generation of air accumulation and wrinkles.SOLUTION: A periphery of a surface of the covered body W set on a table 3 is made into a pressure-reduced environment. The vacuum molding machine molds by making a heated decorative film F3 come close to and attaching the decorative film F3 tightly to the surface of the covered body W. A frame part 11 which is projected in a come-close direction of the decorative film F3 at a projection height higher than the maximum height of the covered body is arranged on an outer side of a periphery of the set covered body W. The frame part 11 is in contact with the decorative film F3 earlier than the covered body W when the decorative film F3 is made to come close, and the decorative film F3 is pushed up and stretched on the outer side of the periphery of the covered body W.

Description

  The present invention relates to a vacuum forming machine for forming a sheet material on a adherend in a vacuum state, a substrate for a vacuum forming machine used in a vacuum forming process using the vacuum forming machine, or such a vacuum forming machine. The present invention relates to a vacuum forming method using an industrial substrate.

  2. Description of the Related Art Conventionally, as a vacuum forming apparatus that is not easily affected by outside air, a vacuum forming apparatus that has a chamber box at the top and bottom and that performs molding of an object to be molded 1 in both chamber boxes, an upper chamber box and a lower chamber box. In addition, a heater is incorporated in the upper chamber box and the object to be molded is heated by the heater in both the joined chamber boxes (see Patent Document 1). ).

  This means that the object to be molded is heated by the heater in both the bonded chamber boxes, and the object to be molded can be heated and molded in a closed space by using a near infrared heater as the heater. Therefore, it is possible to provide a vacuum forming apparatus that is less susceptible to the influence of outside air than before when forming.

Japanese Patent Application Laid-Open No. 2002-079573

  However, in this vacuum forming apparatus, although the protective plastic sheet 22 is not easily affected by fluctuations in the ambient temperature of the outside air, the molded product (plastic sheet) heated by the heater is in a draw-down state that is softened by the material, and the expanded portion May wave and the central part may hang down. When the molded object (plastic sheet) is in this drawdown state, when the part that hangs down or undulates comes into contact with the mold (FRP bathtub shape) before molding, the so-called mold contact (wak) phenomenon occurs. There is a high possibility that the part will remain as a trace per mold after molding, an air pool or a wrinkle will occur. The occurrence of traces, air accumulation, and wrinkles affects the yield of molded products as defective molding, but it is difficult to adjust the distance between the molding object and the mold depending on the shape of the mold or vacuum molding machine. Met. In particular, when a flat mold having a large flat area and a low height was used, the mold contact was likely to occur.

  Further, when molding is performed by vacuum molding in which the pressure between the mold and the molding is lowered, the heated molding (plastic sheet) is instantaneously shaped into a shape of a mold or a trapezoid around the mold at the time of molding. When it stretches along, it may tear or wrinkle. If it is torn or if wrinkles are generated, vacuum forming will fail.

  Therefore, the present invention avoids the so-called die-to-mold (wack) phenomenon even when the film-like sheet to be deposited is in a draw-down state, and the portion of the die-to-die (wak) is a trace per die after molding. To provide a vacuum molding machine, a substrate for a vacuum molding machine, or a vacuum molding method that can reliably avoid the occurrence of residual air, air accumulation, or wrinkles, and improving the yield of molded products. Is an issue.

  Further, when the film-like sheet to be applied is instantaneously stretched along the shape of the mold or the trapezoid around the mold at the time of molding, a vacuum molding machine, a vacuum molding machine substrate or It is an object to provide a vacuum forming method.

In the present invention, the following means (1) to (5) are taken to solve the above problems.

(1) The vacuum molding machine of this invention makes the decoration film contact | adhere to the surface of a to-be-adhered body by making the surface vicinity of the to-be-adhered body set on the table into a pressure-reduced environment, and making the heated decoration film adjoin. In the vacuum forming machine
On the outer periphery of the set adherend, a frame projecting in the proximity direction of the decorative film with a protruding height higher than the maximum height of the adherend is provided,
The frame portion is in contact with the decorative film prior to the adherend when the decorative film is brought close to the frame, and the decorative film is pushed up and spread around the outer periphery of the adherend. A vacuum forming machine that features.

  By contacting the frame portion ahead of the decorative film, as shown in FIG. 1 (c1), the amount of deflection and the amount of undulation are reduced with the drawdown film stretched more than before contact. It is possible to prevent the occurrence of traces in the portion of the decorative film due to the so-called “per die contact” phenomenon that occurs when a part of the decorative film comes into contact with the adherend in advance.

(2) The frame portion includes a side frame member 12 fixed by surrounding the outer peripheral portion of the bottom plate 10 on which the adherend is placed in a polygonal shape,
The side frame member 12 preferably has an inner inclined surface 12t inclined toward the center of the polygonal shape on the inner side of the frame at least at all corners constituting the polygonal shape. Durable vacuum molding by easily securing the strength of the frame that is subjected to a high pressure load at the time of molding by inclining the inner surface of the frame at the polygonal corners where stress concentration tends to occur A structure can be obtained.

  In addition, when the film-like sheet to be applied is instantly stretched along the shape of the mold or the trapezoid around the mold at the time of molding, it is difficult to break by forming the side frame portion, and it is difficult for wrinkles to occur It becomes.

(3) Any one of the frame portions includes a side frame member 12 fixed so as to surround an outer peripheral portion of the bottom plate 10 on which the adherend is placed.
The side frame member 12 is configured such that a bent column body having an inner inclined surface 12t inclined toward the housing portion inside the frame is fixed on the bottom plate,
One side has an inclined side by the inner inclined surface 12t, and the other side opposite to the one side has an inclined side or a vertical side inclined in the opposite direction to the one side on the other side. It is preferable to become.
The cross-sectional shape of such a bent column body is an inner / outer inclined shape in which one side is inclined inward and the other side is inclined outwardly over the entire length surrounding the outer periphery. By fixing the column with an inner and outer inclined cross section on the bottom plate, the frame is subjected to a load in the crossing direction from both the inner and outer sides even when the upper surface of the bottom plate is in a high-pressure atmosphere. The durability of the fixed structure can be increased. Moreover, it can avoid over the full length direction of a side frame material extending | stretching that a decorative film extended too much at the boundary of a baseplate and a frame part at the time of vacuum forming by having an inside inclined surface.

(4) The substrate for a vacuum forming machine of the present invention is a substrate for a vacuum forming machine that is detachably installed on the table of the vacuum forming machine described above,
A bottom plate 10 having an accommodating portion on which the adherend can be placed near the center of the upper surface, and a frame height that is fixed along the periphery of the bottom plate and is higher than the maximum height of the adherend accommodated on the bottom plate. The side frame material 12 surrounds the outer periphery of the adherend, and the frame portion is constituted by the side frame material 12.

  A plurality of types of substrates for vacuum forming machines that are detachably installed in the vacuum forming machine have a shape having an accommodating portion / inner inclined surface corresponding to the planar shape and maximum height of the adherend. Thus, it is possible to select and install an appropriate substrate that is not easily torn or wrinkled. In particular, it is possible to use one in which the angle of the inner inclined surface or the width of the flat portion of the bottom plate constituting the housing portion is adjusted in accordance with the shape of the adherend and the extension amount of the decorative film. For example, with respect to the width of the housing portion, the space around the adherend at the maximum height portion where the wrinkles are likely to occur is made wider than the other portions, and the side frame material constituting the outer edge of the housing cavity is provided. It is preferable to form the inclination angle smaller than other portions.

(5) The vacuum forming method of the present invention is a vacuum forming method in which a decorative film is brought into close contact with the surface of an adherend using the vacuum forming machine described in any one of (1), (2) and (3). A method,
A placing step for setting a substrate for a vacuum molding machine on a movable table installed in a molding space at a lower portion, and placing an adherend on a housing portion of the substrate for a vacuum molding machine;
A sealing step that partitions the molding space up and down with the decorative film as a boundary, and seals the table, the substrate for the vacuum molding machine, and the adherend in the lower molding space;
A heating step for heating the decorative film;
The lower molding space sealed by the sealing step is depressurized with respect to the upper molding space to generate a pressure difference in the partitioned molding space, and the vicinity of the surface of the adherend set on the table from the surroundings. The pressure adjustment step to make the decompression environment also,
From below the decorative film heated by the heating step, the decorative film is placed on the surface of the adherend by bringing the substrate for vacuum forming placed on the adherend by the placing step and the heated decorative film close to each other. A proximity step for close molding,
In the proximity step,
On the outer periphery of the set adherend, a frame projecting in the proximity direction of the decorative film with a protruding height higher than the maximum height of the adherend is provided,
The frame part comes into contact with the decorative film prior to the adherend, and the frame part is in a contact state where the decorative film is pushed up and stretched outside the adherend,
Next to this frame portion contact state, the adherend adheres to the surface of the stretched decorative film.

  The vacuum molding machine, the substrate for a vacuum molding machine or the vacuum molding method according to the present invention is a process for depositing a molding object by forming a frame portion that comes into contact with the decorative film before the adherend by the above-described means. Even when the decorative sheet is in a draw-down state due to heating, the so-called mold contact (wak) phenomenon is avoided, and the mold contact (wak) portion remains as a trace per mold after molding, or air accumulation It is possible to improve the yield of molded products by reliably avoiding occurrence of wrinkles or wrinkles.

  In addition, when the film-like sheet to be applied is instantly stretched along the shape of the mold or the trapezoid around the mold at the time of molding, it is difficult to break by forming the side frame portion, and it is difficult for wrinkles to occur It became.

The perspective view of the board | substrate for vacuum forming machines of Example 1 used for the vacuum forming machine of Example 1 of this invention. The front view of the board | substrate for vacuum forming machines of Example 1. FIG. The right view of the board | substrate for vacuum forming machines of Example 1. FIG. 1 is a plan view of a vacuum molding machine substrate according to Embodiment 1. FIG. 1 is a bottom view of a vacuum molding machine substrate according to Embodiment 1. FIG. The perspective view of the board | substrate for vacuum forming machines of Example 2 used for the vacuum forming machine of Example 2 of this invention. The front view of the board | substrate for vacuum forming machines of Example 2. FIG. The right view of the board | substrate for vacuum forming machines of Example 1. FIG. 1 is a plan view of a vacuum molding machine substrate according to Embodiment 1. FIG. Each process figure of the vacuum forming method by the vacuum forming machine of Example 1 of this invention. Each state figure of the process in Drawing 10 (c).

  Hereinafter, embodiments of the present invention will be described with reference to FIGS. 1 to 9 shown as substrates for vacuum forming machines of Examples 1 and 2 and FIGS. 10 to 11 shown as vacuum forming machines and vacuum forming methods of Example 1. To do.

  The substrate for a vacuum forming machine according to the first embodiment shown in FIGS. 1 to 5 accommodates the adherend W and is set on a movable table of the vacuum forming machine, and the bottom plate 10 is vacuum formed by a bottom hole 10D. It can be installed on the movable table of the machine and temporarily fixed. Along the side periphery of the rectangular bottom plate 10, there are side portions 11 and 13 whose inner side surfaces are inclined inwardly, and the adherend is accommodated in the accommodating portion inside in plan view by the frame portion.

  The adherend W accommodated in a substrate for a vacuum molding machine and set on a movable table is depressurized / pressurized with a decorative film as a boundary in a sealed molding space in which a decorative film in a heated state is held. The heated sheet material is applied and molded in a vacuum environment along the surface shape of the adherend by setting the environment. At this time, in the middle of vacuum forming, the frame part is in contact with the decorative film earlier, and as shown in FIG. 1 (c1), the drawdown film is bent and stretched more than before contact. Reduce the amount and the amount of undulations. It is possible to prevent the occurrence of traces in the portion of the decorative film due to the so-called “per die contact” phenomenon that occurs when a part of the decorative film comes into contact with the adherend in advance.

  In Example 1, a column having a substantially triangular cross section is used. Thus, the side frame member 12 itself has a substantially triangular cross section, and the top surface is protected by the top frame member, so that the side frame member 12 is compact and has high pressure resistance.

(Vacuum forming machine)
The vacuum molding machine shown in FIGS. 10 and 11 is provided with a lower molding chamber 21 having an upper surface opening on the upper surface side of itself and containing the movable table 3, and a lower surface side of the lower molding chamber 21. An upper molding chamber 22 in which a lower surface opening faces the upper surface opening of the lower molding chamber 21 and forms a molding space in a sealed state or a released state by relative movement with the lower molding chamber 21, an adherend, and the present invention. A movable table 3 capable of moving up and down in the lower molding chamber 21 with the substrate placed on top, and pressure adjusting means for depressurizing and pressurizing the interior of the lower molding chamber and the interior of the upper molding chamber in a sealed molding space, respectively And a holding means for holding the decorative film in the interior of the upper molding chamber, and a heating means for heating the held decorative film.

  The upper chamber box constituting the upper molding chamber 22 and the lower chamber box constituting the lower molding chamber 21 can be joined / separated, and a heater is incorporated in the upper chamber box. The object to be molded is heated by a heater.

A vacuum circuit is provided in the lower chamber box 21, and a vacuum circuit and a pneumatic circuit are provided in the upper chamber box 2, respectively.
A heater 7 is incorporated in the upper chamber box 22, and the object to be molded F (decoratively printed sheet) is heated by the heater 2 in both bonded chamber boxes. A near infrared heater is used as the heater 2. According to this apparatus, stable molding conditions can be maintained by heating the workpiece 1 in an airtight chamber, and energy can be saved by using a near infrared heater.

The substrate placed on the movable table of the vacuum forming machine for depositing and molding the heated sheet material in a vacuum environment on the surface of the adherend W set on the movable table has at least the adherend W mounted thereon. A bottom plate 10 that can be placed;
And a frame portion (11, 13) that protrudes from the four surroundings of the bottom plate 10 at a protrusion height of 1 h or more.
The frame portion has a protruding height 1 h higher than the maximum height Wh of the adherend W placed on the bottom plate 10. The outer periphery of the adherend W is surrounded by a predetermined distance or more. When the sheet material F heated and brought into a draw-down state is brought close to the movable table from above, the frame portion is attached to the adherend W. The sheet material is stretched in contact with the sheet material F before the adherend W outside the periphery of the body W.

(Vacuum molding machine substrate) The vacuum molding machine substrate of the present invention is a vacuum molding machine substrate that is detachably installed on the table of the vacuum molding machine described above,
A bottom plate 10 having an accommodating portion on which the adherend can be placed near the center of the upper surface, and a frame height that is fixed along the periphery of the bottom plate and is higher than the maximum height of the adherend accommodated on the bottom plate. The side frame member 12 surrounds the outer periphery of the adherend, and the frame portion is formed by the side frame member 12 (FIGS. 1 to 8).

  A plurality of types of substrates for vacuum forming machines that are detachably installed in the vacuum forming machine have a shape having an accommodating portion / inner inclined surface corresponding to the planar shape and maximum height of the adherend. Thus, it is possible to select and install an appropriate substrate that is not easily torn or wrinkled. In particular, it is possible to use one in which the angle of the inner inclined surface or the width of the flat portion of the bottom plate constituting the housing portion is adjusted in accordance with the shape of the adherend and the amount of expansion of the decorative film. For example, with respect to the width of the housing portion, the space around the adherend at the maximum height portion where the wrinkles are likely to occur is made wider than the other portions, and the side frame material constituting the outer edge of the housing cavity is provided. It is preferable to form the inclination angle smaller than other portions.

(Vacuum forming machine of the present invention)
The vacuum forming machine according to the present invention forms the adhesive film in close contact with the surface of the adherend by making the vicinity of the surface of the adherend set on the table a reduced pressure environment and bringing the heated decorative film in close proximity. In vacuum forming machine,
On the outer periphery of the set adherend, a frame projecting in the proximity direction of the decorative film with a protruding height higher than the maximum height of the adherend is provided,
The frame portion is in contact with the decorative film prior to the adherend when the decorative film is brought close to the frame, and the decorative film is pushed up and spread around the outer periphery of the adherend. Features.

  By contacting the frame portion ahead of the decorative film, as shown in FIG. 1 (c1), the amount of deflection and the amount of undulation are reduced with the drawdown film stretched more than before contact. It is possible to prevent the occurrence of traces in the portion of the decorative film due to the so-called “per die contact” phenomenon that occurs when a part of the decorative film comes into contact with the adherend in advance.

(Frame part)
The frame part of Example 1 comprises a side frame material 12 fixed by surrounding the outer peripheral part of the bottom plate 10 on which the adherend is placed in a polygonal shape,
The side frame member 12 is configured such that a bent column body having an inner inclined surface 12t inclined toward the housing portion inside the frame is fixed on the bottom plate,
One side has an inclined side by the inner inclined surface 12t, and the other side opposite to the one side has an inclined side or a vertical side inclined in the opposite direction to the one side on the other side. Become.
The cross-sectional shape of such a bent column body is an inner / outer inclined shape in which one side is inclined inward and the other side is inclined outwardly over the entire length surrounding the outer periphery. By fixing the column with an inner and outer inclined cross section on the bottom plate, the frame is subjected to a load in the crossing direction from both the inner and outer sides even when the upper surface of the bottom plate is in a high-pressure atmosphere. The durability of the fixed structure can be increased. Moreover, it can avoid that the decorating film which extended too much at the boundary of a baseplate and a frame part at the time of vacuum forming will be torn by having an inside inclined surface.

The frame part of Examples 1 and 2 comprises a side frame member 12 fixed by surrounding the outer peripheral part of the bottom plate 10 on which the adherend is placed in a polygonal shape,
The side frame member 12 has an inner inclined surface 12t that is inclined toward the center of the polygonal shape on the inner side of the frame at least at all corners constituting the polygonal shape. Durable vacuum molding by easily securing the strength of the frame that is subjected to a high pressure load at the time of molding by inclining the inner surface of the frame at the polygonal corners where stress concentration tends to occur A structure can be obtained.

  The frame portion of the second embodiment has an inner inclined surface 12t at a square corner by sticking a corner material made of a triangular prism to four corners of a plate-like side frame material.

(Vacuum forming method) The vacuum forming method of the present invention is a vacuum forming method in which a decorative film is brought into close contact with the surface of an adherend using the vacuum forming machine described above, and is shown in FIG. It has the following steps shown.
A placing step for setting a substrate for a vacuum molding machine on a movable table to be installed in a lower molding space and placing an adherend on a housing portion of the substrate for a vacuum molding machine (FIG. 10A ))
A sealing step that partitions the molding space up and down with the decorative film as a boundary, and seals the table, the substrate for the vacuum molding machine, and the adherend in the molding space below (FIG. 10B)
-Heating step for heating the decorative film (FIG. 10 (b))
-The lower molding space sealed by the sealing step is decompressed with respect to the upper molding space to generate a pressure difference in the partitioned molding space, and the vicinity of the surface of the adherend set on the table is surrounded by Pressure adjustment step for reducing the pressure (Figure 10 (b))
-From below the decorative film heated by the heating step, the decorative film is placed on the surface of the adherend by bringing the substrate for vacuum forming placed on the adherend by the placing step and the heated decorative film close to each other. Proximity step for close molding (Fig. 10 (c))
-After the decorative film is tightly molded by the proximity step, the pressure difference in the pressure adjustment step and the sealed state by the sealing step are released sequentially or simultaneously, and the decorative film and the adherend integrally molded product taken out are taken out. Release step to enable (FIG. 10 (d))
・ Removal step (not shown) to cut off the excess protruding part of the decorative film from the integrally molded decorative film and adherend
(Proximity step)
Especially in the proximity step among the above, by providing a frame portion protruding in the proximity direction of the decorative film at a protruding height higher than the maximum height of the adherend on the outer periphery of the set adherend. The decorative film is closely molded through the following two states shown in FIG.
・ The frame part is in contact with the decorative film before the adherend, and the frame part is in contact with the decorative film by pushing up the decorative film outside the adherend. Close contact molding on the surface of the decorative film Especially when using a flat mold with a large flat area and a low height, the distance between the mold and the mold is close and the mold contact is likely to occur. It was. Therefore, the vacuum forming diameter or the vacuum forming method is effectively used for a flat-shaped adherend having a height of 15 mm or less.

  Further, the inclination angle 11θ of the inner inclined surface is preferably at most 80 degrees or less, and particularly in relation to the strength and the fit of the frame portion, it is 60 degrees plus or minus 5 degrees as in the first embodiment (FIG. 3). It is preferable that the side frame portion 11 is formed of a bent column having a substantially right triangle cross section. In the case of molding by vacuum molding in which the pressure between the moldings is lowered in such a side frame portion, the heated molding (plastic sheet) is instantaneously shaped or deformed at the time of molding. Less likely to break or wrinkle when stretched along the surrounding trapezoidal shape.

  Moreover, since the present invention includes the heater 2, it is a vacuum forming apparatus that is not easily affected by the outside air. In addition, the present invention is not limited to the above-described embodiments, and within the scope of the present invention, extraction of some elements, replacement with elements or substitutes of other embodiments, deletion, or configurations between the embodiments Various modifications such as a superimposing combination of the above are possible.

3 movable table W adherend F1, F2, F3 maximum height Wh of decorative film adherend
Projection height 1h
Bottom plate 10
Side frame material 12
Top frame 13
12t Inclined surface

Claims (5)

In the vacuum forming machine that molds the decorative film in close contact with the surface of the adherend by making the vicinity of the surface of the adherend set on the table a reduced pressure environment and bringing the heated decorative film close to the surface.
On the outer periphery of the set adherend, a frame projecting in the proximity direction of the decorative film with a protruding height higher than the maximum height of the adherend is provided,
The frame portion is in contact with the decorative film prior to the adherend when the decorative film is brought close to the frame, and the decorative film is pushed up and spread around the outer periphery of the adherend. A vacuum forming machine that features. The frame portion comprises a side frame member 12 fixed by surrounding the outer peripheral portion of the bottom plate 10 on which the adherend is placed in a polygonal shape,
2. The vacuum forming machine according to claim 1, wherein the side frame member 12 has an inner inclined surface 12t inclined toward the center of the polygonal shape on the inner side of the frame at least at all corners constituting the polygonal shape. The frame portion comprises a side frame member 12 fixed around the outer periphery of the bottom plate 10 on which the adherend is placed,
The side frame member 12 is configured such that a bent column body having an inner inclined surface 12t inclined toward the housing portion inside the frame is fixed on the bottom plate,
One side has an inclined side by the inner inclined surface 12t, and the other side opposite to the one side has an inclined side or a vertical side inclined in the opposite direction to the one side on the other side. The vacuum forming machine according to claim 1 or 2. A vacuum molding machine substrate removably installed on the table of the vacuum molding machine according to claim 1,
A bottom plate 10 having an accommodating portion on which the adherend can be placed near the center of the upper surface, and a frame height that is fixed along the periphery of the bottom plate and is higher than the maximum height of the adherend accommodated on the bottom plate. And a side frame member 12 surrounding the outer periphery of the adherend, and the frame portion is constituted by the side frame member 12. A vacuum forming method in which a decorative film is closely attached to the surface of an adherend using the vacuum forming machine according to claim 1,
A placing step for setting a substrate for a vacuum molding machine on a movable table installed in a molding space at a lower portion, and placing an adherend on a housing portion of the substrate for a vacuum molding machine;
A sealing step that partitions the molding space up and down with the decorative film as a boundary, and seals the table, the substrate for the vacuum molding machine, and the adherend in the lower molding space;
A heating step for heating the decorative film;
The lower molding space sealed by the sealing step is depressurized with respect to the upper molding space to generate a pressure difference in the partitioned molding space, and the vicinity of the surface of the adherend set on the table from the surroundings. The pressure adjustment step to make the decompression environment also,
From below the decorative film heated by the heating step, the decorative film is placed on the surface of the adherend by bringing the substrate for vacuum forming placed on the adherend by the placing step and the heated decorative film close to each other. A proximity step for close molding,
In the proximity step, a frame portion protruding in the proximity direction of the decorative film at a protruding height higher than the maximum height of the adherend is provided on the outer periphery of the set adherend,
The frame part comes into contact with the decorative film prior to the adherend, and the frame part is in a contact state where the decorative film is pushed up and stretched outside the adherend,
A vacuum forming method characterized in that the adherend adheres closely to the surface of the stretched decorative film after the frame portion contact state.

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