JP3188281B2 - Vacuum lamination molding method and apparatus - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vacuum laminating method and apparatus, and more particularly to a vacuum laminating method for closely laminating or transferring a synthetic resin sheet on which a pattern or the like is printed on the outer surface of a substrate. It relates to a device used for implementation.

[0002]

2. Description of the Related Art For laminating, hot stamping transfer, etc., a vacuum is used in which a decorative sheet (synthetic resin sheet) made of thermoreversible synthetic resin on which a pattern or the like is printed is closely laminated on the outer surface of a substrate. As one of the lamination molding methods, in an openable and closable airtight container, a base material is placed on a base material mounting table, and a decorative sheet is arranged to face the upper side thereof, and the decorative sheet has a base material side, that is, a lower side. The first chamber on the side and the second chamber on the opposite side, that is, the upper side, are airtightly partitioned from each other. The interior of the room is brought into a substantially vacuum state, and then the pressure in the second chamber is released to give a differential pressure between the two chambers. The differential pressure causes the decorative sheet to be tightly laminated on the outer surface of the substrate by vacuum lamination by the OVL method. A molding method is known, which is described, for example, in Japanese Patent Publication No. 56-4576. No. are shown in Japanese, also a device for implementing the method shown in JP-A-56-99624.

[0003] As another vacuum lamination molding method,
In the vacuum lamination molding method according to the OVL method as described above, the first chamber and the second chamber are preliminarily hermetically separated from each other by a rubber-like elastic film made of rubber or the like. A vacuum lamination molding method in which a sheet is arranged to perform lamination molding equivalent to the above-described vacuum lamination molding method by the OVL method is known, and this is generally called a vacuum press method.

[0004]

In any of the vacuum lamination molding methods as described above, in any case, the moldability is insufficient or extra wrinkles occur at the lower peripheral portion where the substrate abuts on the substrate mounting table. In some cases, appearance defects such as peeling of the sheet occurred. In view of this, a flat mounting table smaller than the base material is provided on the base material mounting table, and the base material is placed on the upper surface of the base material so as to float from the base material mounting table in an overhang state,
That is, the outer peripheral edge portion of the base material protrudes outward from the outer peripheral edge portion of the placing table on the placing table, and in this state, the differential pressure is applied to the first chamber and the second chamber to provide the differential pressure. It is considered that a synthetic resin sheet is adhered to the outer surface of the base material. In this case, since the lower peripheral portion of the base material is away from the base table, the decorative sheet also adheres well to this portion,
In addition, since the decorative sheet wraps around from the lower peripheral portion to the bottom of the base material, no wrinkles are generated on the lower peripheral portion, and the moldability is improved.

However, as illustrated in FIG. 7, the occurrence of wrinkles L generated at the corners C of the substrate W cannot be reduced, and the problem still remains. The occurrence of the wrinkles L is such that when the decorative sheet S in the softened state comes into contact with the base material W, the decorative sheet S is deformed inward in the vicinity of the corner C thereof, and the first chamber and the second chamber are further deformed. Before the decorative sheet S comes into contact with the base material W due to the pressure difference between the decorative sheets S, the decorative sheets S in this portion come into contact with each other and come into close contact with each other. However, it was not possible to prevent the generation of the wrinkles L at the corners C only by providing the above-mentioned table.

The present invention has been made in view of the above-mentioned problems in the conventional vacuum lamination molding method. When a synthetic resin sheet such as a decorative sheet is adhered to the outer surface of a substrate, avoids wrinkle corners synthetic resin sheet throughout including, vacuum lamination molding method is always favorably adhered to the synthetic resin sheet and the base material and the vacuum lamination molding apparatus used in the practice of the method It is intended to provide.

[0007]

According to the present invention, a synthetic resin sheet to be laminated is disposed so as to face a substrate mounted on a substrate mounting table. The synthetic resin sheet is brought into close contact with the outer surface of the base material by applying a pressure difference between the first chamber formed on the base material side and the second chamber formed on the opposite side, and the base In the vacuum lamination molding method of laminating the synthetic resin sheets, a substrate having a planar shape smaller than the substrate is provided on the substrate mounting table, and the substrate is overhanged on the table. A frame member having a height lower than the height of the base material placed on the mounting table is placed at a position spaced apart from the outer peripheral edge of the base material by a predetermined distance outwardly from the mounting table. The first chamber and the second chamber are covered with the synthetic resin sheet. Is accomplished by vacuum lamination molding method, characterized in that on the chamber giving a differential pressure adhering the said synthetic resin sheet to the outer surface of the base material.

According to a detailed feature of the vacuum lamination molding method according to the present invention, the height of the frame member is 45 to 70% of the height of the base material placed on the table, and the height of the frame member is The distance from the outer peripheral edge of the base material may be 30 to 50 mm. Further, the vacuum lamination molding apparatus according to the present invention has a substrate mounting table, and is formed on the side of the substrate from a synthetic resin sheet as a laminated member disposed opposite to the substrate mounted on the substrate mounting table. The synthetic resin sheet is brought into close contact with the outer surface of the base material by applying a pressure difference to the first chamber and the second chamber formed on the opposite side thereof, and the synthetic resin sheet is attached to the base. In the vacuum lamination molding apparatus for laminating, the base material is formed on the base material mounting table and has a flat shape smaller than the base material, and the base material is overhanging at a position separated by a predetermined amount above the base material mounting table. And a frame member disposed at a position spaced outward by a predetermined distance from an outer peripheral edge of the mounting table of the base material mounting table.

[0009]

According to the vacuum lamination molding method and apparatus of the present invention, the synthetic resin sheet is placed on the mounting table and the lower peripheral portion of the base material is separated from the base mounting table. Because the synthetic resin sheet adheres well to the lower peripheral portion of the base material because it is in close contact with the outer surface, and the synthetic resin sheet wraps from the lower peripheral portion to the bottom of the base material, wrinkles are generated at the lower peripheral portion. Without, further by appropriately determining the separation distance between the outer peripheral edge of the base material and the frame member, the initial sag amount of the synthetic resin sheet from the base material, between the first chamber and the second chamber The pressure difference is balanced, and it is avoided that the synthetic resin sheets at the corners come into contact with each other before the synthetic resin sheet comes into contact with the base material. No wrinkles occur at any point.

[0010]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram of an embodiment of the present invention. FIG. 1 shows an embodiment of a vacuum lamination molding apparatus according to the present invention. The vacuum lamination molding apparatus has a closed container 4 that can be opened and closed by a fixed lower container 2 and a movable upper container 3 on a base 1.

The lower container 2 is constituted by a cup-shaped container having an upper opening, and a substrate mounting table 5 is provided in the lower container 2. The substrate mounting table 5 is fixed to an upper end of a piston rod 7 of a hydraulic cylinder device 6 fixed to the base 1, and is moved up and down in the lower container 2 by the hydraulic cylinder device 6. The upper container 3 is constituted by a cup-shaped container having a lower opening, and is fixed to a lower end of a piston rod 10 of a fluid pressure cylinder device 9 fixed to the upper frame member 8,
The closed casing 4 is opened and closed by being moved up and down by the fluid pressure cylinder device 10. A rubber film 11 is stretched over the lower opening of the upper container 3, thereby closing the lower opening of the upper container 3, and a second chamber B described later is previously defined inside the upper container 3.

A sheet heating heater 12 is attached to the ceiling surface in the upper container 3. The lower container 2 and the upper container 3 are provided with pneumatic ports 13 and 14, respectively.
The pneumatic port 13 of the lower container 2 is connected to a switching valve 16 by a conduit 15, and the switching operation of the switching valve 16 reduces the negative pressure and the atmospheric pressure from the vacuum pump 17 and the conduit 18 to the lower container 2.
It is to be given selectively within.

The pneumatic port 14 of the upper container 3 is connected to the conduit 1
9, the switching operation of the switching valve 20 causes the negative pressure from the vacuum pump 17, the conduits 18 and 21, the air pressure pump 22, and the air pressure and the atmospheric pressure from the conduit 23 to flow into the upper container 3, that is, The second chamber B is selectively provided. As shown in FIGS. 2 and 3 in an enlarged manner,
A jig 24 is exchangeably attached to the substrate mounting table 5. The jig 24 has a floor plate 25, a table 26 and a frame member 27 arranged on the floor plate 25, and has a strength (4 kgf / cm ² ) that is entirely air-permeable and capable of withstanding molding, such as MDF or particle board. Above).

The floor plate 25 is made of a plate having a thickness of about 4 mm. Note that the floor plate 25 may be omitted, and in this case, the placing table 26 and the frame member 27 are directly arranged on the substrate placing table 5. The table 26 has a height of 9-12.
mm, a trapezoidal block having a shape similar to the shape of the bottom surface of the base material W to be laminated and having a smaller flat shape, and the base material W is placed on the upper surface. The W is supported in an overhang state at a position separated from the substrate mounting table 5 above. This overhang amount O
h may be about 5 mm.

The mounting table 26 is prepared in various shapes and sizes according to the shape and size of the base material W to be laminated and formed, and the floor plate 25 may be fixed in a replaceable manner. A plurality of types of jigs 24 having various shapes and sizes of mounting tables 26 and corresponding frame members 27 fixed to the floor plate 25 are prepared, and these are exchangeably attached to the base material mounting table 5. Is also good.

The frame member 27 is arranged so as to surround the outer periphery of the placing stand 26 at a predetermined distance outward from the outer periphery. The separation distance of the frame member 27 from the outer peripheral edge of the mounting table 26 may be a distance that is about 30 to 50 mm away from the outer peripheral edge of the base material W placed on the mounting table 26. The frame member 27 is made of a square bar, and its height is
6 plus the height of the substrate W, ie, the table 2
The substrate placed on 6 may have a height of 45% to 70% of the height of W and a width of about 30 mm.

Next, the operation of the vacuum lamination molding apparatus having the above-described configuration will be described. First, the upper container 3 is moved upward by the fluid pressure cylinder device 9 and the jig 24 on the substrate mounting table 5 in the lower container 2 in a state where the closed container 4 is opened.
The substrate W is placed on the table 26 with its center aligned. As a result, the base material W is horizontally arranged in a state of being floated above the floor plate 25 in an overhang state in which the entire outer peripheral portion protrudes outward from the placing table 26.

Then, a decorative sheet S is placed on the upper opening of the lower container 2 so as to close the upper opening of the lower container 2,
Thereafter, the upper container 3 is moved downward by the hydraulic cylinder device 9 to close the closed container 4. As a result, the decorative sheet S faces the substrate W on the placing table 25 in the closed container 4 and defines the first chamber A on the substrate placing table side, that is, on the lower container 2 side.

In this state, the decorative sheet S is heated and softened by the sheet heating heater 12 . Next, switching valve 1
The negative pressure of the vacuum pump 17 is supplied to the pneumatic ports 13 and 14 by the switching operations of the switches 6 and 20, and the pressure in the first chamber A and the second chamber B is reduced. And the fluid pressure cylinder device 6
The base sheet mounting table 5 is lifted by this, so that the decorative sheet S comes into contact with the upper surface of the base material W on the mounting table 26 at the center. At this time, the decorative sheet S rides on the frame member 27 at the peripheral edge thereof and is supported thereby, thereby limiting the amount of the initial sag from the outer peripheral edge of the base material W.

Next, the atmospheric pressure and the air pressure from the air pressure pump 22 are supplied to the air pressure port 14 by the switching operation of the switching valve 20. As a result, the second chamber B is in a pressurized air state, and the decorative sheet S is formed together with the rubber film 11 by the large differential pressure between the first chamber A and the second chamber B, as shown in FIG. It is pressed against the outer surface of the base material W and is laminated in a close contact state.

At this time, the base material W is on the table 26,
Since the lower peripheral portion is located above the bottom plate 25 and is in an overhang state, the decorative sheet S adheres well to the lower peripheral portion of the base material W, and also goes around from the lower peripheral portion to the bottom of the base material W. No wrinkles occur at the lower peripheral edge. Further, since the distance between the outer peripheral edge of the base material W and the frame member 27 is appropriately determined as described above, the amount of initial sag of the softened decorative sheet S from the outer peripheral edge of the base material W, The pressure difference between the first chamber A and the second chamber B is delicately balanced, so that the decorative sheets at the corners of the decorative sheet S do not contact each other before the decorative sheet S comes into contact with the base material W. Thus, the decorative sheet S adheres firmly at the corners C of the base material W, and the decorative sheet S
No wrinkles occur. FIG. 5 shows the laminated state of the decorative sheet in this case. The material of the base material W is ABS
Synthetic resins such as phenolic resins, metals such as aluminum and iron, wood materials such as wood and particle boards, and inorganic ceramic materials such as ceramics, cement, and glass can be used.

Note that the frame member 27 does not necessarily need to be arranged so as to completely surround the entire circumference of the base material W, and may be separately arranged as shown in FIG. As a result, escape of the decorative sheet S at the corner C of the substrate W is ensured, and the decorative sheet S
May surely adhere to each other. The material of the decorative sheet S includes polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate-vinyl chloride copolymer, polyvinyl fluoride,
Vinyl polymers such as polyvinyl butyral and polyvinylidene fluoride; styrene resins such as polystyrene, acrylic styrene and ABS; acrylic resins such as polyethyl methacrylate, polymethyl methacrylate and polyacrylonitrile; polyethylene, polypropylene and polymethylpentene Cellulose derivatives such as polyolefin, cellulose acetate, nitrocellulose, nylon 6, nylon 66
Polyamide resin such as polyethylene terephthalate, polyethylene terephthalate-isophthalate copolymer,
Examples thereof include polyester resins such as polybutylene terephthalate and polyacrylate, rubber resins such as butadiene, chloroprene rubber, and silicone rubber, polyvinyl alcohol resins such as vinylon and polyvinyl alcohol, and polycarbonate. In particular, the thickness is desirably 50 to 100 μm from the viewpoint of moldability.

The decorative sheet S may be subjected to coloring, printing of various patterns, metal deposition, etc., to impart a design property. Further, in order to improve the adhesiveness between the decorative sheet S and the base material W, the sheet surface may be subjected to corona discharge treatment, various known primer coating, and the like. Further, the decorative sheet S is a known transfer sheet that may be a transfer sheet, and is formed of a synthetic resin sheet (a release layer is formed as necessary) and a release sheet formed thereon. Release protection layer,
One or both of the picture layers and, if necessary, an adhesive layer is provided. After laminating and bonding so that the base material W and the picture layer of the transfer sheet face each other, only the sheet is released and removed. Just do it.

[0024]

As apparent from the above description, according to the vacuum laminating apparatus and method according to the present invention, the base material is placed on the table and the lower peripheral portion of the substrate is separated from the substrate table. Since the synthetic resin sheet such as a decorative sheet is closely adhered to the outer surface of the base material in the state, the synthetic resin sheet also adheres well to the lower peripheral portion of the base material, and the synthetic resin sheet extends from the lower peripheral portion to the bottom of the base material. Since the wrap around, wrinkles do not occur in the lower peripheral portion, further by appropriately determining the separation distance between the outer peripheral portion of the base material and the frame member, the initial sag amount of the synthetic resin sheet from the base material and The pressure difference between the first chamber and the second chamber is balanced, and the synthetic resin sheets at the corners are prevented from coming into contact with each other before the synthetic resin sheet comes into contact with the base material. Synthetic tree attached to the outer surface of the substrate Without wrinkles occurs in any part of the sheet, a synthetic resin sheet and the close contact between the base always good, high quality vacuum lamination molded article comes to be produced stably.

[Brief description of the drawings]

FIG. 1 is a schematic configuration diagram showing an embodiment of a vacuum lamination molding apparatus according to the present invention.

FIG. 2 is an enlarged elevation view of a main part of the vacuum lamination molding apparatus according to the present invention shown in FIG.

FIG. 3 is an enlarged plan view of a main part of the vacuum lamination molding apparatus according to the present invention shown in FIG.

FIG. 4 is an explanatory view showing one step in the vacuum lamination molding method according to the present invention.

FIG. 5 is a perspective view showing a laminated state example of a vacuum laminated molded product obtained by the vacuum laminated molding method according to the present invention.

FIG. 6 is an enlarged plan view of a main part showing a modified example of the vacuum lamination molding apparatus according to the present invention.

FIG. 7 is a perspective view showing an example of a state in which a decorative sheet is closely laminated on an outer surface of a base material by a conventional vacuum lamination molding method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base 2 Lower container 3 Upper container 4 Closed container 5 Substrate mounting table 17 Vacuum pump 22 Pneumatic pump 24 Jig 25 Laying plate 26 Placement table 27 Frame member

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 63/00-63/48 B29C 51/00-51/46

Claims (3)

(57) [Claims] 1. A synthetic resin sheet to be laminated is disposed facing a substrate placed on a substrate placing table, and a first chamber formed on the substrate side from the synthetic resin sheet and a side opposite to the first chamber. It said synthetic resin sheet is adhered to the outer surface of the base material by applying a pressure difference and a second chamber formed, the substrate
In the vacuum lamination molding method of laminating the synthetic resin sheet on a mounting table, a mounting table having a planar shape smaller than the base material is provided on the substrate mounting table, and the base material is overhanged on the mounting table. A frame member having a height lower than the height of the base material mounted on the mounting table at a position spaced apart from the outer peripheral edge of the base material by a predetermined distance and placed above the base material mounting table. Arranged, characterized in that the synthetic resin sheet is brought into close contact with the outer surface of the base material by applying a differential pressure to the first chamber and the second chamber in a state where the synthetic resin sheet covers the synthetic resin sheet. Vacuum lamination molding method. 2. The height of the frame member is 45 to 70% of the height of the substrate placed on the table, and the distance between the frame member and the outer peripheral edge of the substrate is The vacuum lamination molding method according to claim 1, wherein the thickness is 30 to 50 mm. 3. A first substrate having a substrate mounting table and formed on the substrate side from a synthetic resin sheet as a laminated member disposed opposite to the substrate mounted on the substrate mounting table. By applying a pressure difference between the chamber and the second chamber formed on the opposite side, the synthetic resin sheet is brought into close contact with the outer surface of the base material, and the vacuum is applied to stack the synthetic resin sheet on the base material mounting table. In the laminating apparatus, the base material provided in the base material mounting table has a smaller planar shape than the base material, and the base material is overhanged at a position separated by a predetermined amount above the base material mounting table. A vacuum lamination molding apparatus comprising: a mounting table to be mounted; and a frame member disposed at a position spaced outward by a predetermined distance from an outer peripheral edge of the mounting table of the substrate mounting table.