WO2007013292A1 - 成形品の製造方法および自動車両 - Google Patents

成形品の製造方法および自動車両 Download PDF

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Publication number
WO2007013292A1
WO2007013292A1 PCT/JP2006/313745 JP2006313745W WO2007013292A1 WO 2007013292 A1 WO2007013292 A1 WO 2007013292A1 JP 2006313745 W JP2006313745 W JP 2006313745W WO 2007013292 A1 WO2007013292 A1 WO 2007013292A1
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WO
WIPO (PCT)
Prior art keywords
sheet
molded product
decorative
adhesive
layer
Prior art date
Application number
PCT/JP2006/313745
Other languages
English (en)
French (fr)
Inventor
Yasuo Suzuki
Naohiro Morozumi
Original Assignee
Yamaha Hatsudoki Kabushiki Kaisha
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Yamaha Hatsudoki Kabushiki Kaisha filed Critical Yamaha Hatsudoki Kabushiki Kaisha
Priority to EP06780966A priority Critical patent/EP1911566A4/en
Priority to JP2007528403A priority patent/JP4448540B2/ja
Priority to US11/718,651 priority patent/US20090114341A1/en
Publication of WO2007013292A1 publication Critical patent/WO2007013292A1/ja

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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
    • B29C51/16—Lining or labelling
    • 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
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/0073—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor of non-flat surfaces, e.g. curved, profiled
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1432—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface direct heating of the surfaces to be joined
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1445—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface heating both sides of the joint
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1464—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface making use of several radiators
    • B29C65/1467—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous welding
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/001—Joining in special atmospheres
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/344—Stretching or tensioning the joint area during joining
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73117—Tg, i.e. glass transition temperature
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/826—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined
    • B29C66/8266—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined using fluid pressure directly acting on the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/826—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined
    • B29C66/8266—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined using fluid pressure directly acting on the parts to be joined
    • B29C66/82661—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined using fluid pressure directly acting on the parts to be joined by means of vacuum
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/001—Shaping in several steps
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • 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
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
    • 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
    • B29C2795/00—Printing on articles made from plastics or substances in a plastic state
    • B29C2795/002—Printing on articles made from plastics or substances in a plastic state before shaping
    • 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
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1412—Infrared [IR] radiation
    • B29C65/1422—Far-infrared radiation [FIR]
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/82—Testing the joint
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    • B29C65/82—Testing the joint
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7232—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer
    • B29C66/72321—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer consisting of metals or their alloys
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29K2305/00—Use of metals, their alloys or their compounds, as reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29K2305/00—Use of metals, their alloys or their compounds, as reinforcement
    • B29K2305/02—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29K2305/00—Use of metals, their alloys or their compounds, as reinforcement
    • B29K2305/08—Transition metals
    • B29K2305/10—Copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29K2305/00—Use of metals, their alloys or their compounds, as reinforcement
    • B29K2305/08—Transition metals
    • B29K2305/14—Noble metals, e.g. silver, gold or platinum
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0022—Bright, glossy or shiny surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29L2009/00—Layered products
    • B29L2009/003—Layered products comprising a metal layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3055—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3067—Ships
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3091—Bicycles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7172—Fuel tanks, jerry cans
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/722—Decorative or ornamental articles

Definitions

  • the present invention relates to a method for manufacturing a decorative molded product having a surface decorated, and particularly relates to a method for manufacturing a molded product suitably used for an exterior member or interior member of a motor vehicle.
  • the decorative sheet 110 shown in FIG. 11 includes a base material 1 made of a resin material, a decorative layer 2 provided on the main surface la of the base material 1, and an adhesive provided on the decorative layer 2.
  • the decorative layer 2 is formed by printing, for example.
  • the adhesive layer is formed, for example, by dry laminating a resin-based adhesive.
  • the decorative sheet 110 is attached to the surface of the molded article main body 121, whereby a decorative molded article 120 having a decorated surface is obtained.
  • a molded product body 121 shown in FIG. 12 (a) has a hemispherical (ridge-shaped) convex portion 121a, and has a undulation on the surface. Therefore, the decorative sheet 110 is spread so as to follow this undulation when being stuck. In order to suitably spread the decorative sheet 110, typically, the decorative sheet 110 is heated and softened to apply the force.
  • a vacuum forming apparatus for manufacturing a decorative molded product 120 as shown in FIG. 12 (c) using a decorative sheet 110 is disclosed in Patent Document 1, for example! Speak.
  • Patent Document 1 JP 2002-79573 A
  • FIG. 13 shows a fender 122 for a motorcycle that is decorated with a decorative sheet 110. As shown in FIG. 13, string-like gloss unevenness 123 appears on a part of the surface of the fender 122, and the aesthetic appearance is degraded.
  • the present invention has been made in view of the above problems, and an object of the present invention is to provide a method capable of suitably producing a decorative molded product using a decorative sheet without deteriorating aesthetic appearance. There is to do.
  • the method for producing a molded product according to the present invention is a method for producing a decorative molded product having a decoration on the surface, the step (A) of preparing a molded product main body, A step (B) of placing the first sheet including the adhesive layer, a step (C) of heating the second sheet including the decorative layer and the base material supporting the decorative layer, and the heated A step (D) of adhering the molded product body and the second sheet by placing the second sheet on the first sheet, thereby achieving the above object. .
  • the first sheet further includes a support layer that supports the adhesive layer
  • the method for producing a decorative molded product according to the present invention includes the step described above.
  • the method further includes a step (E) of peeling the support layer from the adhesive layer.
  • the method for producing a molded product according to the present invention further includes a step (F) of heating the first sheet before the step (B).
  • the step (D) includes the step (D1) of bringing the heated second sheet close to the molded product body, and the step (D1) being close to the molded product body.
  • the first space formed between the second sheet and the molded article main body is more than the second space that extends to the opposite side of the first space with respect to the second sheet.
  • a step of reducing pressure (D2) is a step of reducing pressure (D2).
  • the second sheet is formed along the surface of the molded product body.
  • the melting point of the adhesive layer is 30 ° C or more lower than the glass transition temperature of the substrate.
  • the adhesive layer is 1 X 10 3 Pa or more and 1 X 10 6 Pa or less at 80 ° C and 1 X 10 & 1 or more and 1 X 10 5 Pa or less at 180 ° C. A material force having an elastic modulus is formed.
  • the base material is formed from a thermoplastic resin.
  • the molded product body is deep-drawn and has a shape in which the drawing diameter L and the drawing depth D satisfy L ⁇ 100 mm and DZL ⁇ lZ3.
  • the motor vehicle according to the present invention includes a molded product formed by the above manufacturing method.
  • a first sheet including an adhesive layer is placed on a molded article body, and then a second sheet including a decorative layer is placed on the first sheet. Adhere the molded body and the second sheet by placing them on. For this reason, the uneven distribution of the adhesive and the occurrence of the string-like gloss unevenness is suppressed. Therefore, according to the present invention, a decorative molded product decorated with a decorative sheet can be suitably manufactured without deteriorating the aesthetic appearance.
  • FIG. 1 is a diagram schematically showing a vacuum forming apparatus used in a method for producing a decorative molded product according to the present invention.
  • FIG. 2 (a) and (b) are process cross-sectional views schematically showing a process for producing a decorative molded product.
  • FIG. 3 (a) and (b) are process cross-sectional views schematically showing a production process of a decorative molded product.
  • FIG. 4 (a) and (b) are process cross-sectional views schematically showing a production process of a decorative molded product.
  • FIG. 5 (a) and (b) are process cross-sectional views schematically showing a process for producing a decorative molded product.
  • FIG. 6 (a) and (b) are process cross-sectional views schematically showing a production process of a decorative molded product.
  • FIG. 7 (a) and (b) are process cross-sectional views schematically showing a process for producing a decorative molded product.
  • FIG. 8 is a perspective view showing an example of a decorative sheet used in the method for producing a decorative molded product according to the present invention.
  • FIG. 9 (a) is a perspective view showing an example of a decorative molded product manufactured by the method for manufacturing a decorative molded product according to the present invention, and (b) is a view of 9B-9B ′ in (a). It is sectional drawing along a line.
  • FIG. 10 is a side view schematically showing a motorcycle.
  • FIG. 11 is a perspective view schematically showing a decorative sheet used in a conventional method for producing a decorative molded product.
  • FIG. 12] (a) to (c) are diagrams for explaining a conventional method for producing a decorative molded product.
  • FIG. 13 is a perspective view showing a motorcycle fender manufactured by a conventional method of manufacturing a decorative molded product.
  • FIG. 14 (a) to (c) are diagrams for explaining a conventional method for producing a decorative molded product. Explanation of symbols
  • Figures 14 (a) to 14 (c) show the process for manufacturing decorative molded products using conventional methods.
  • the decorative sheet 110 is fixed to the gripping frame 30 and then heated using the heater 33. At this time, the decorative sheet 110 is heated to such a temperature that the base material 1 is sufficiently softened and the adhesive layer 4 exhibits sufficient adhesiveness.
  • the decorative sheet 110 is pressed against the molded product body 121 by lowering the gripping frame 30. At this time, a part 110a of the decorative sheet 110 is first attached to the molded product body 121 as shown in the drawing.
  • the other part 110b of the decorative sheet 110 is also formed as shown in FIG. It is joined to the main body 121, and the entire molded product main body 121 is covered with the decorative sheet 110. Thereafter, unnecessary parts of the decorative sheet 110 are cut to complete the decorative molded product.
  • the portion 110a of the decorative sheet 110 that comes into contact with the molded product body 121 first is the portion 110b that comes into contact with the molded product body 121 later due to heat conduction to the molded product body 121. Cools faster.
  • the temperature of the portion 110b is in contact with the molded body 121. While the temperature is 150 ° C to 170 ° C, the temperature of the portion 110a in contact with the molded article main body 121 is reduced to 60 ° C to 120 ° C.
  • the fluidity of the adhesive is lower than that of the portion 110b when it is in contact with the portion 110a in contact with the molded article body 121.
  • the base material 1 of the decorative sheet 110 is stretched once along the surface shape of the molded article body 121, and then contracts by being cooled.
  • FIG. 14 (b) shows the direction in which the base material 1 is spread and the direction in which it shrinks. Due to the contraction of the base material 1, the adhesive of the adhesive layer 4 provided on the base material 1 is moved toward the contraction direction of the base material 1.
  • the collected adhesive has an area where the adhesive has high fluidity (part 110b that comes into contact with the molded article body 121) and a low fluidity area (part 110a that comes into contact with the molded article body 121 first). Therefore, as shown in an enlarged view in FIG. 14 (c), the adhesive layer 4 swells near this boundary. For this reason, the decorative layer 2 and the base material 1 positioned on the adhesive layer 4 also rises reflecting the rise of the adhesive layer 4, and this raised force S is observed as a string-like gloss unevenness.
  • a first sheet adheresive sheet
  • a second sheet decorative sheet
  • FIG. 1 is a view schematically showing a vacuum forming apparatus 100 used for manufacturing a decorative molded product
  • FIGS. 2 to 7 are process cross-sectional views schematically showing the manufacturing process.
  • a vacuum forming apparatus 100 shown in FIG. 1 heats the adhesive frame and the decorative sheet, the support frame 31 that supports the molded product body, and the adhesive sheet and the decorative sheet.
  • Heater for example, far-infrared heater
  • a vacuum vessel 34 for storing them.
  • the vacuum container 34 has a main container 34 a that houses the grip frame 30 and the support base 31, and a sub container 34 b that houses the heater 33.
  • the heater 33 is introduced into the main container 34a when the adhesive sheet and the decorative sheet are heated.
  • the support base 31 is formed with a plurality of openings 31a.
  • the air in the main container 34a can be discharged to the outside through the opening 31a.
  • the main container 34a is provided with a mechanism (for example, a hose connected to the outside) for introducing gas into the main container 34a from the outside.
  • the decorative molded article is manufactured using the vacuum forming apparatus 100 described above, for example, as follows.
  • a molded product body 21 is prepared, and this molded product body 21 is placed on a support base 31.
  • the molded product main body 21 may be formed with a resin material force, or may be formed with a metal material force or another material force.
  • the molded product main body 21 can be manufactured by using a known technique, for example, by injection molding using a resin material.
  • the adhesive sheet 40 in the present embodiment includes an adhesive layer 41 and a support layer 42 that supports the adhesive layer 41, as shown in a partially enlarged view in FIG. 2 (b). ing.
  • the adhesive layer 41 is formed from a material (for example, a resin-based adhesive) that exhibits good adhesion to the molded article body 21. Further, since the support layer 42 is peeled off from the adhesive layer 41 later, the support layer 42 is formed of a material exhibiting excellent peelability with respect to the material of the adhesive layer 41.
  • the adhesive sheet 40 is heated using the heater 33.
  • the adhesive sheet 40 may be heated to a temperature 20 ° C. to 30 ° C. higher than the minimum bonding temperature of the adhesive layer 41 in order to ensure good adhesiveness of the adhesive layer 41. preferable.
  • the space 35 formed between the adhesive sheet 40 and the molded product body 21 is decompressed.
  • the adhesive sheet 40 is joined to the molded product body 21 as shown in FIG.
  • the space 35 between the adhesive sheet 40 and the molded product main body 21 is depressurized, the adhesive sheet 40 is pressed against the molded product main body 21 with a uniform pressure, so that bonding is suitably performed.
  • a larger pressure difference is generated by pressurizing the space 36 extending above the adhesive sheet 40.
  • the pressure in the space 35 is reduced by, for example, discharging the air in the space 35 through the opening 31a of the support base 31 using a vacuum pump.
  • the space 36 is pressurized by supplying compressed air using, for example, a compressor.
  • the support layer 42 of the adhesive sheet 40 is peeled from the adhesive layer 41.
  • the support layer 42 is peeled off, for example, by peeling off the end of the support layer 42 with a human hand or a robot.
  • the decorative sheet 10 in this embodiment includes a decorative layer 2 and a base material 1 that supports the decorative layer 2 as shown in a partially enlarged view in FIG.
  • the decorative layer 2 is provided on one main surface (main surface on the molded product main body 21 side) la of the substrate 1.
  • the decorative layer 2 is formed, for example, by printing ink.
  • the adhesive layer is not provided on the surface of the decorative layer 2 on the side of the molded product body 21.
  • the substrate 1 in the present embodiment is formed from a thermoplastic resin.
  • the decorative sheet 10 is heated using the heater 33, thereby softening the decorative sheet 10.
  • the decorative sheet 10 is heated to a temperature within the range of (T ⁇ 40) ° C to (T + 20) ° C, where T is the deflection temperature under load of the substrate 1.
  • the decorative sheet 10 is heated to a temperature equal to or higher than the load deflection temperature T of the substrate 1.
  • the deflection temperature under load is measured at a specified load (eg 0.45 MPa) according to ASTM D648, for example.
  • ASTM D648 is a standard established by the American Society for Testing Materials on the method for measuring the deflection temperature under load. In this standard, the temperature of a specimen is raised under a specified bending load, and the temperature at which the specified deflection amount is reached. The deflection temperature under load.
  • FIG. 6 (a) After the decorative sheet 10 is brought close to the molded product body 21, the space 35 between the decorative sheet 10 and the molded product body 21 is decompressed and decorated. The space 36 extending above the sheet 10 is pressurized, whereby the decorative sheet 10 is joined to the molded product body 21 as shown in FIG. 6 (b). In this step, the decorative sheet 10 is spread and formed along the surface of the molded product body 21. If the decorative sheet 10 becomes too thin, the aesthetics will deteriorate, so this process should be at least 0.4 times the thickness of the attached decorative sheet 10. It is preferable to be performed, and it is more preferable to be performed so that it is 0.5 times or more. Subsequently, as shown in FIG.
  • the unnecessary portion 10 ′ of the decorative sheet 10 is cut (trimmed) using a cutting means such as a rotary blade, and then the molded product body 21 is supported.
  • a cutting means such as a rotary blade
  • the adhesive sheet 40 is placed on the molded article body 21, and then the heated decorative sheet 10 is placed on the adhesive sheet 40. As a result, the molded body 21 and the decorative sheet 10 are bonded. That is, in the process of attaching the decorative sheet 10, the adhesive layer 41 is provided on the molded product main body 21 that is different from the decorative sheet 10.
  • the adhesive of the adhesive layer 41 is hardly affected by the shrinkage of the base material 1 of the decorative sheet 10 and is not easily wrinkled.
  • the temperature of the adhesive is almost uniform over the entire adhesive layer 41, and the fluidity of the adhesive is also almost uniform throughout the entire adhesive layer 41. Therefore, local bulge of the adhesive as shown in Fig. 14 (c) hardly occurs.
  • the uneven distribution of the adhesive is less likely to occur, so that the occurrence of string-like gloss unevenness is suppressed and the appearance is prevented from deteriorating.
  • the adhesive layer 41 of the adhesive sheet 40 is formed of, for example, urethane or acrylic adhesive such as urethane resin or acrylic urethane resin.
  • the elastic modulus of the adhesive composing the adhesive layer 41 is 1 X 10 3 Pa or more and 1 X 10 6 Pa or less at 80 ° C from the viewpoint of satisfying the rigidity of the product in the temperature range where the product is used. Preferably there is. If the modulus of elasticity is less than 1 X 10 3 Pa at 80 ° C, problems may occur due to the softness of the adhesive when the product becomes hot (for example, when the product is used outdoors in summer) There is.
  • the elastic modulus of the adhesive is preferably 1 X 1C ⁇ Pa or more and 1 X 10 5 Pa or less at 180 ° C. If the modulus of elasticity is less than 1 X lO'Pa at 180 ° C, a pattern that reflects the flow of the adhesive or immediately after molding may appear on the surface of the molded product.
  • the elastic modulus exceeds 1 X 10 5 Pa at 180 ° C, the adhesive When the sheet 40 is attached, bubbles are likely to enter between the adhesive layer 41 and the molded product body 21.
  • the elastic modulus of the adhesive is measured by, for example, solid viscoelasticity measurement according to 3 ⁇ 4 JIS K7244-6 (or IS06721).
  • the thickness of the adhesive layer 41 is preferably 30 ⁇ m or more and 100 ⁇ m or less. If the thickness of the adhesive layer 41 is less than 30 m, the adhesive layer 41 becomes too thin locally due to spreading when the adhesive sheet 40 is applied (for example, it is not suitable as an adhesive layer). 10 m or less). In addition, when the thickness of the adhesive layer 41 exceeds 100 m, a portion where the adhesive layer 41 is not sufficiently extended tends to be uneven due to shrinkage of the adhesive or the like. Since the adhesive layer 41 is also spread and thinned by spreading when the adhesive sheet 40 is applied, the adhesive layer is appropriately selected according to the surface shape (the size of the undulations) of the molded product body 21. It is preferable to make 41 thick.
  • the support layer 42 that supports the adhesive layer 41 is made of a resin such as polypropylene or polyethylene terephthalate (PET).
  • a resin such as polypropylene or polyethylene terephthalate (PET).
  • PET polyethylene terephthalate
  • various films that are commercially available as release films can be suitably used.
  • the peel force of the support layer 42 is preferably 0.02 to 0.10 NZ25 mm wide.
  • the support layer 42 is 300 in both directions parallel to the main surface and perpendicular to each other. It is preferable to show growth of at least%.
  • the support layer 42 is preferably formed of a material force that hardly contains moisture, and is preferably formed of a material cover that is difficult for dust to adhere to.
  • the thickness of the support layer 42 is typically 60 ⁇ m to 200 ⁇ m.
  • the decorative layer 2 of the decorative sheet 10 is formed of, for example, a resin material as a binder and an ink containing a pigment dispersed in the resin material.
  • the material of the decorative layer 2 is preferably excellent in heat resistance and bending resistance.
  • the ink disclosed in Japanese Patent Application Laid-Open No. 2002-275405 has excellent heat resistance and bending resistance, and therefore can be suitably used as a material for the decoration layer 2.
  • the decorative layer 2 may include a plurality of layers that are not necessarily a single layer. Also, as shown in FIG. 8, the decorative layer 2 may include a metal layer 2b in addition to the ink layer 2a. When the decorative layer 2 includes the metal layer 2b, the decorative sheet 10 can exhibit a metallic color (metallic color) having a metal-like texture due to the metallic luster of the metal layer 2b.
  • the metal layer 2b As a material of the metal layer 2b, tin, aluminum, gold, copper, zinc, silver, indium, an alloy thereof, or the like is used. Further, the decorative layer 2 may be configured only by the metal layer 2b without including the ink layer 2a.
  • the metal layer 2b is formed by, for example, a vapor deposition method.
  • the metal layer 2b may be formed by directly depositing a metal on the substrate 1 (or the ink layer 2a), or a metal is deposited on a separately prepared carrier film, and this laminated structure is used as the substrate 1 Alternatively, the metal layer 2b may be formed by bonding to the (ink layer 2a).
  • the material of the base material 1 of the decorative sheet 10 for example, thermoplastic resin such as polycarbonate and acrylic resin can be suitably used. Since the base material 1 is required to have rigidity as a sheet base material, it is preferable to select a material in consideration of this point. In addition, since the base material 1 is positioned on the outermost surface of the molded product after being attached, it is preferable that the base material 1 is excellent in weather resistance, damage resistance, and the like. A protective layer excellent in weather resistance, damage resistance, etc. may be formed on the main surface opposite to the main surface la on which the decorative layer 2 of the substrate 1 is provided.
  • the thickness of the substrate 1 is preferably 50 ⁇ m or more and 1000 ⁇ m or less. If the thickness of the substrate 1 is less than 50 m, it may be difficult to handle as a sheet, or the strength may be insufficient, and the substrate 1 may be torn. Further, when the thickness of the substrate 1 exceeds 1000 m, the followability to the surface of the molded product main body 21 may be deteriorated.
  • the glass transition temperature of the substrate 1 is typically higher than the melting point of the adhesive layer 41.
  • the difference between the glass transition temperature of the substrate 1 and the melting point of the adhesive layer 4 is large (that is, the adhesive layer 4 compared to the glass transition temperature of the substrate 1).
  • the decorative sheet 110 is heated and softened, the fluidity of the adhesive becomes extremely high, and the uneven distribution of the adhesive occurs and the aesthetic appearance is immediately reduced. It was easy to occur.
  • the present invention even if the melting point of the adhesive layer 4 is much lower than the glass transition temperature of the substrate 1 ( Even if it is lower than 30 ° C, for example, a beautiful appearance without uneven gloss can be obtained.
  • the present invention it is possible to suppress the occurrence of string-like gloss unevenness and to prevent deterioration in aesthetic appearance. Therefore, the present invention is suitably used for decoration of a molded product having a large undulation, for example, for decoration of a molded product formed by deep drawing.
  • FIG. 9 An example of a deep-drawn molded product is shown in FIG.
  • the motorcycle fender 22 shown in Fig. 9 has a large ratio DZL (hereinafter referred to as "drawing ratio") to the drawing diameter L of the drawing depth D (width in the cross section along the short direction of the molded product). It has a shape, that is, a deep drawing shape. Since the present invention can prevent a decrease in aesthetic appearance due to uneven distribution of the adhesive, it is possible to suitably decorate a molded product having a drawing diameter L and a drawing ratio DZL that are larger than a certain level.
  • a molded article having such a shape can be suitably decorated without deteriorating its aesthetic appearance.
  • the molded product produced by the production method of the present invention is suitably used as an interior member of an automobile or an exterior member, or an exterior member of a home appliance.
  • it is suitably used as a tank cover 51, a front fender 52, and a tail cowl 53 of a motorcycle 50 shown in FIG.
  • the force “automobile” refers to an automatically propelled vehicle or machine that is used to transport passengers or goods, or to move goods.
  • the decorative layer 2 is protected by the base material 1, so that a beautiful appearance can be maintained for a long time. Therefore, the molded article produced according to the present invention is particularly suitably used for products used outdoors. For example, ships, outboard motors, water vehicles, four-wheel buggy (ATV), snowmobiles, two-wheeled vehicles, golf It is suitably used for cars.
  • ATV four-wheel buggy
  • snowmobiles snowmobiles
  • two-wheeled vehicles golf It is suitably used for cars.
  • a CPP (unstretched polypropylene) carrier film with a thickness of 50 / zm was used as the support layer, and an adhesive layer with a thickness of 30 ⁇ m was placed on this carrier film with a urethane adhesive (trade name: manufactured by Nippon Bipolymer Co., Ltd.) An UNH790) force was also formed to produce an adhesive sheet.
  • the molded product was decorated in a vacuum forming apparatus. Specifically, the adhesive sheet was first heated and softened, and then attached to the molded product body. Next, the support layer of the adhesive sheet was peeled from the adhesive layer. Subsequently, the decorative sheet was heated and softened, and then attached to the molded product body.
  • Example 1 By using a CPP carrier film with a thickness of 50 m as a support layer and forming an adhesive layer with a thickness of 50 ⁇ m on this carrier film using an adhesive (trade name: Elfan, manufactured by Nippon Matai) An agent sheet was prepared. Further, a decorative sheet was produced in the same manner as in Example 1. Using these adhesive sheets and decorative sheets, the molded products were decorated in a vacuum forming apparatus in the same manner as in Example 1.
  • an adhesive layer with a thickness of 40 m is formed on this carrier film using an adhesive (trade name: UNH785 manufactured by Nippon Polymer Co., Ltd.). By doing so, an adhesive sheet was produced.
  • a decorative sheet was produced in the same manner as in Example 1. Using these adhesive sheets and decorative sheets, the molded products were decorated in a vacuum forming apparatus in the same manner as in Example 1.
  • a 0.8 mm-thick film (trade name: Europin D01 manufactured by Mitsubishi Gas Chemical Co., Ltd.) formed from polycarbonate as the base material
  • printing was performed on this film to form a decorative layer
  • the decorative layer was A urethane adhesive (trade name: UNH790 manufactured by Nippon-Polymer Co., Ltd.)
  • the laminate was ly laminated to form an adhesive layer having a thickness of 30 m.
  • the decorative sheet thus prepared (including the adhesive layer! / Sold) was heated and softened in a vacuum forming apparatus and attached to the molded product body.
  • a 0.5 mm thick film made of polycarbonate was used as a base material, and a 0.1 ⁇ m thick metal layer having a tin strength was formed on this film.
  • the metal layer was formed by vapor-depositing tin on a 50 m thick film formed from an acrylic resin and pasting this film on a substrate.
  • a urethane adhesive (trade name: UNH385 manufactured by Nippon Polymer Co., Ltd.) was dry laminated on the metal layer to form an adhesive layer having a thickness of 30 ⁇ m.
  • the decorative sheet thus prepared was softened by heating in a vacuum forming apparatus and attached to the molded product body.
  • Example 1 The results of evaluating the appearance of Examples 2 and 3 and Comparative Examples 1 and 2 are shown in Table 1 below.
  • Table 1 “ ⁇ ” indicates that a string-like gloss unevenness did not occur and a beautiful appearance was obtained, and “ ⁇ ” indicates that a string-like gloss unevenness occurred and the aesthetics deteriorated. Indicates.
  • “X” indicates that string-like gloss unevenness is conspicuous and the decrease in aesthetics is remarkable.
  • Table 2 shows the glass transition temperature (T) of the substrate, the melting point (T) of the adhesive, and the difference between Examples 1, 2 and 3 where gloss unevenness did not occur. , Glue bullet
  • the melting point of the adhesive is 30 ° C or more lower than the glass transition temperature of the substrate.
  • the elastic modulus of the adhesive at 80 ° C is in the range of 1 X 10 3 Pa to 1 X 10 6 Pa, and the adhesive at 180 ° C The elastic modulus is in the range of 1 X 10 & 1 X 10 5 Pa or less.
  • a decorative molded product can be suitably produced by using a decorative sheet without deteriorating aesthetic appearance.
  • the molded product produced by the production method of the present invention has a beautiful appearance, it can be suitably used as an exterior member for various motor vehicles, an interior member, and an exterior member for various home appliances.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Toxicology (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • Thermal Sciences (AREA)
  • Fluid Mechanics (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Description

明 細 書
成形品の製造方法および自動車両
技術分野
[0001] 本発明は、表面に装飾が施された加飾成形品の製造方法に関し、特に、自動車両 の外装部材ゃ内装部材などに好適に用いられる成形品の製造方法に関する。
背景技術
[0002] 近年、各種の成形品を装飾する手法として、成形品の表面に装飾用のシートを貼り 付ける手法が提案されている。装飾用シートを用いると、塗料を用いた塗装に比べ、 成形品のリサイクルが容易になる。また、塗装とは異なる美観を醸し出すこともできる ので、装飾性の向上を図ることもできる。
[0003] 装飾用シートの一例を図 11に示す。図 11に示す装飾用シート 110は、榭脂材料か ら形成された基材 1と、基材 1の主面 la上に設けられた装飾層 2と、装飾層 2上に設 けられた接着剤層 4とを有している。装飾層 2は、例えば、印刷によって形成されてい る。接着剤層は、例えば、榭脂系の接着剤をドライラミネートすることによって形成さ れている。この装飾用シート 110を、図 12 (a)〜（c)に順に示すように、成形品本体 1 21の表面に貼り付けることにより、表面に装飾が施された加飾成形品 120が得られる
[0004] 図 12 (a)に示す成形品本体 121は、半球状 (椀状)の凸部 121aを有しており、表 面に起伏を有している。そのため、装飾用シート 110は、貼り付けられる際にこの起 伏に追従するように展延される。装飾用シート 110の展延を好適に行うため、典型的 には、装飾用シート 110を加熱して軟化させて力も貼り付けが行われる。装飾用シー ト 110を用いて図 12 (c)に示したような加飾成形品 120の製造を行うための真空成 形装置は、例えば特許文献 1に開示されて！ヽる。
特許文献 1：特開 2002— 79573号公報
発明の開示
発明が解決しょうとする課題
[0005] し力しながら、表面に起伏を有する成形品に装飾用シートを貼り付けた場合、得ら れた加飾成形品の表面に光沢むらが発生し、美観が損なわれてしまうことがある。図
13に、装飾用シート 110を用 ヽて装飾された自動二輪車用のフェンダー 122を示す 。図 13に示すように、フェンダー 122の表面の一部に、ひも状の光沢むら 123が現れ ており、美観が低下している。
[0006] 本発明は、上記問題に鑑みてなされたものであり、その目的は、装飾用シートを用 いて美観の低下を伴うことなく加飾成形品を好適に製造することができる方法を提供 することにある。
課題を解決するための手段
[0007] 本発明による成形品の製造方法は、表面に装飾が施された加飾成形品の製造方 法であって、成形品本体を用意する工程 (A)と、前記成形品本体上に、接着剤層を 含む第 1のシートを載置する工程 (B)と、装飾層および前記装飾層を支持する基材 を含む第 2のシートを加熱する工程 (C)と、加熱された前記第 2のシートを前記第 1の シート上に載置することによって前記成形品本体と前記第 2のシートとを接着するェ 程 (D)とを包含し、そのことによって上記目的が達成される。
[0008] ある好適な実施形態にお!ヽて、前記第 1のシートは、前記接着剤層を支持する支 持層をさらに有し、本発明による加飾成形品の製造方法は、前記工程 (D)の前に、 前記接着剤層から前記支持層を剥離する工程 (E)をさらに包含する。
[0009] ある好適な実施形態において、本発明による成形品の製造方法は、前記工程 (B) の前に、前記第 1のシートを加熱する工程 (F)をさらに包含する。
[0010] ある好適な実施形態にぉ 、て、前記工程 (D)は、加熱された前記第 2のシートを前 記成形品本体に近接させる工程 (D1)と、前記成形品本体に近接した前記第 2のシ ートと前記成形品本体との間に形成される第 1の空間を、前記第 2のシートに対して 前記第 1の空間とは反対側に広がる第 2の空間よりも減圧する工程 (D2)とを包含す る。
[0011] ある好適な実施形態において、前記工程 (D)において、前記第 2のシートは、前記 成形品本体の表面に沿うように成形される。
[0012] ある好適な実施形態にぉ ヽて、前記接着剤層の融点は、前記基材のガラス転移温 度よりも 30°C以上低い。 [0013] ある好適な実施形態において、前記接着剤層は、 80°Cにおいて 1 X 103Pa以上 1 X 106Pa以下でかつ 180°Cにおいて 1 X 10 &以上 1 X 105Pa以下の弾性率を有す る材料力 形成されて 、る。
[0014] ある好適な実施形態にぉ ヽて、前記基材は、熱可塑性榭脂から形成されて ヽる。
[0015] ある好適な実施形態にぉ 、て、前記成形品本体は、深絞り成形されており、絞り径 Lおよび絞り深さ Dが L≥ 100mmおよび DZL≥ lZ3を満足する形状を有する。
[0016] 本発明による自動車両は、上記製造方法によって形成された成形品を備えている 発明の効果
[0017] 本発明による成形品の製造方法では、まず、成形品本体上に接着剤層を含む第 1 のシートを載置し、その後、装飾層を含む第 2のシートを第 1のシート上に載置するこ とによって成形品本体と第 2のシートとを接着する。そのため、接着剤の偏在が発生 しにくぐひも状の光沢むらの発生が抑制される。従って、本発明によれば、装飾用シ ートを用いて装飾された加飾成形品を美観の低下を伴うことなく好適に製造すること ができる。
図面の簡単な説明
[0018] [図 1]本発明による加飾成形品の製造方法に用いられる真空成形装置を模式的に示 す図である。
[図 2] (a)および (b)は、加飾成形品の製造工程を模式的に示す工程断面図である。
[図 3] (a)および (b)は、加飾成形品の製造工程を模式的に示す工程断面図である。
[図 4] (a)および (b)は、加飾成形品の製造工程を模式的に示す工程断面図である。
[図 5] (a)および (b)は、加飾成形品の製造工程を模式的に示す工程断面図である。
[図 6] (a)および (b)は、加飾成形品の製造工程を模式的に示す工程断面図である。
[図 7] (a)および (b)は、加飾成形品の製造工程を模式的に示す工程断面図である。
[図 8]本発明による加飾成形品の製造方法に用いられる装飾用シートの例を示す斜 視図である。
[図 9] (a)は、本発明による加飾成形品の製造方法によって製造される加飾成形品の 一例を示す斜視図であり、（b)は、（a)中の 9B— 9B'線に沿った断面図である。 [図 10]自動二輪車を模式的に示す側面図である。
[図 11]従来の加飾成形品の製造方法に用いられる装飾用シートを模式的に示す斜 視図である。
[図 12] (a)〜 (c)は、従来の加飾成形品の製造方法を説明するための図である。
[図 13]従来の加飾成形品の製造方法によって製造された自動二輪車用フェンダー を示す斜視図である。
[図 14] (a)〜 (c)は、従来の加飾成形品の製造方法を説明するための図である。 符号の説明
1 基材
la 基材の主面
2 装飾層
2a インク層
2b 金属層
10 装飾用シート
20 加飾成形品
21 成形品本体
22 自動二輪車用フェンダ'
30 把持枠
31 支持台
31a 開口部
33 ヒーター
34 真空容器
34a 主容器
34b 副容器
35、 36 空間
40 接着剤シート
41 接着剤層 50 自動二輪車
51 タンクカノ一
52 フロントフェンダー
53 テールカウル
100 真空成形装置
発明を実施するための最良の形態
[0020] 以下、図面を参照しながら本発明の実施形態を説明する。なお、本発明は以下の 実施形態に限定されるものではな ヽ。
[0021] まず、従来の手法において光沢むらが発生する理由を説明する。図 14 (a)〜（c) に、従来の手法による加飾成形品の製造工程を示す。
[0022] 従来の手法では、まず、図 14 (a)に示すように、装飾用シート 110を把持枠 30に固 定した後、ヒーター 33を用いて加熱する。このとき、装飾用シート 110は、基材 1が十 分に軟化し、かつ、接着剤層 4が十分な接着性を示すような温度に加熱される。
[0023] 次に、図 14 (b)に示すように、把持枠 30を下降させることによって、装飾用シート 1 10を成形品本体 121に押し付ける。このとき、装飾用シート 110は、図示しているよう にまずその一部 110aが成形品本体 121に貼り付けられる。
[0024] 続いて、圧縮空気を装飾用シート 110の上方の空間に導入して加圧を行うと、図 1 4 (c)に示すように、装飾用シート 110の他の部分 110bも成形品本体 121に接合さ れ、成形品本体 121全体が装飾用シート 110によって覆われる。その後、装飾用シ ート 110の不要な部分を切断することによって、加飾成形品が完成する。
[0025] 上述した一連の工程において、装飾用シート 110のうち先に成形品本体 121に接 触する部分 110aは、成形品本体 121への熱伝導によって、成形品本体 121に後に 接触する部分 110bよりも早く冷却される。例えば、 180°C〜190°Cに加熱された装 飾用シート 110を貼り付ける場合、図 14 (b)に示す状態では、成形品本体 121に接 触して 、な 、部分 110bの温度が 150°C〜 170°Cであるのに対し、成形品本体 121 に接触している部分 110aの温度は 60°C〜120°Cまで低下する。従って、成形品本 体 121に接触して 、る部分 110aでは接触して 、な 、部分 110bよりも接着剤の流動 性が低い。 [0026] また、上述した一連の工程において、装飾用シート 110の基材 1は、成形品本体 12 1の表面形状に沿うように一且展延された後、冷却されることによって収縮する。図 1 4 (b)には、基材 1が展延される方向と収縮する方向とを示している。この基材 1の収 縮により、基材 1上に設けられた接着剤層 4の接着剤が基材 1の収縮方向に寄せら れてしまう。寄せられた接着剤は、接着剤の流動性が高い領域 (成形品本体 121〖こ 後に接触する部分 110b)と流動性が低 、領域 (成形品本体 121に先に接触する部 分 110a)との境界近傍に溜まるので、図 14 (c)中に拡大して示すように、この境界近 傍において接着剤層 4が盛り上がってしまう。そのため、接着剤層 4の上に位置する 装飾層 2および基材 1も、接着剤層 4の盛り上がりを反映して盛り上がり、この盛り上 力 Sりがひも状の光沢むらとして観察されてしまう。
[0027] 上述したように、従来の手法では、接着剤の偏在によって光沢むらが発生し、美観 が低下してしまう。これに対し、本願発明による加飾成形品の製造方法では、接着剤 層を含む第 1のシート (接着剤シート）と、装飾層を含む第 2のシート (装飾用シート）と を用いることによって、上述したような美観の低下を防止する。
[0028] 以下、本実施形態における製造方法を、図 1〜図 7を参照しながら具体的に説明す る。図 1は、加飾成形品の製造に用いられる真空成形装置 100を模式的に示す図で あり、図 2〜図 7は、製造工程を模式的に示す工程断面図である。
[0029] 図 1に示す真空成形装置 100は、接着剤シートや装飾用シートを把持する把持枠 30と、成形品本体を支持する支持台 31と、接着剤シートや装飾用シートを加熱する ためのヒーター（例えば遠赤外線ヒーター） 33と、これらを収容する真空容器 34とを 備えている。
[0030] 真空容器 34は、把持枠 30や支持台 31を収容する主容器 34aと、ヒーター 33を収 容する副容器 34bとを有している。ヒーター 33は、接着剤シートや装飾用シートをカロ 熱する際に主容器 34a内に導入される。
[0031] 支持台 31には、複数の開口部 31aが形成されている。開口部 31aを通じて、主容 器 34a内の空気を外部に排出することができる。また、ここでは図示していないが、主 容器 34aには、外部から主容器 34a内に気体を導入するための機構 (例えば外部に 接続されたホース）が設けられて 、る。 [0032] 加飾成形品の製造は、上述した真空成形装置 100を用いて例えば以下のようにし て行われる。
[0033] まず、図 2 (a)に示すように、成形品本体 21を用意し、この成形品本体 21を支持台 31上に載置する。成形品本体 21は、榭脂材料力も形成されたものであってもよいし 、金属材料力も形成されたものであってもよぐ他の材料力も形成されたものであって もよい。成形品本体 21は、公知の手法を用いて作製することができ、例えば、榭脂材 料を用いて射出成形により作製することができる。
[0034] 次に、図 2 (b)に示すように、接着剤シート 40を用意し、この接着剤シート 40を成形 品本体 21の上方に位置する把持枠 30に固定する。本実施形態における接着剤シ ート 40は、図 2 (b)中に一部を拡大して示すように、接着剤層 41と、接着剤層 41を支 持する支持層 42とを有している。接着剤層 41は、成形品本体 21に対して良好な接 着性を示す材料 (例えば榭脂系の接着剤)から形成されている。また、支持層 42は、 後に接着剤層 41から剥離されるため、接着剤層 41の材料に対して優れた剥離性を 示す材料から形成されて 、る。
[0035] 続 、て、図 3 (a)に示すように、接着剤シート 40をヒーター 33を用いて加熱する。こ のとき、接着剤シート 40は、接着剤層 41の良好な接着性を確保するために、接着剤 層 41の最低接着温度よりも 20°C〜30°C高い温度に加熱されることが好ましい。
[0036] その後、図 3 (b)に示すように、接着剤シート 40を成形品本体 21に近接させた後に 、接着剤シート 40と成形品本体 21との間に形成される空間 35を減圧し、それによつ て図 4 (a)に示すように接着剤シート 40を成形品本体 21に接合する。接着剤シート 4 0と成形品本体 21との間の空間 35を減圧すると、接着剤シート 40が均一な圧力で成 形品本体 21に押し付けられるので、接合が好適に行われる。本実施形態では、さら に、接着剤シート 40の上方に広がる空間 36を加圧することによって、より大きな圧力 差を生じさせる。これにより、接着剤シート 40の接合をいつそう速やかに行うことがで きる。空間 35の減圧は、例えば、真空ポンプを用い、支持台 31の開口部 31aを通じ て空間 35の空気を排出することによって行われる。また、空間 36の加圧は、例えば 圧縮機 (コンプレッサ)を用いて圧縮空気を供給することによって行われる。
[0037] 次に、図 4 (b)に示すように、接着剤シート 40の支持層 42を接着剤層 41から剥離 する。支持層 42の剥離は、例えば、支持層 42の端部を人間の手やロボットで引き剥 がすことによって行われる。
[0038] 続いて、図 5 (a)に示すように、装飾用シート 10を用意し、この装飾用シート 10を把 持枠 30に固定する。本実施形態における装飾用シート 10は、図 5 (a)中に一部を拡 大して示すように、装飾層 2と、装飾層 2を支持する基材 1とを有している。装飾層 2は 、基材 1の一方の主面 (成形品本体 21側の主面） la上に設けられている。装飾層 2 は、例えばインクを印刷することによって形成されている。図示しているように、装飾 層 2の成形品本体 21側の表面には、接着剤層は設けられていない。また、本実施形 態における基材 1は、熱可塑性榭脂から形成されている。
[0039] 続、て、図 5 (b)に示すように、装飾用シート 10をヒーター 33を用いて加熱し、それ によって装飾用シート 10を軟ィ匕させる。このとき、装飾用シート 10は、基材 1の荷重 たわみ温度を Tとしたとき、（T—40) °C〜（T + 20) °Cの範囲内の温度に加熱され
A A A
ることが好ましい。 (T— 40) °C
A を下回る温度では、基材 1が変形しにくぐ貼り付けに よる成形の際に割れたり、成形そのものができなくなったりすることがある。また、 (τ A
+ 20) °Cを上回る温度では、加熱時のシートの垂れが著しぐ成形ができなくなること がある。典型的には、装飾用シート 10は、基材 1の荷重たわみ温度 T以上の温度に
A
加熱される。荷重たわみ温度は、例えば ASTM D648に準拠して規定の荷重 (例 えば 0. 45MPa)で測定される。「ASTM D648」は、荷重たわみ温度の測定方法 について米国材料試験協会が制定する規格であり、この規格では、試験片を規定の 曲げ荷重下で昇温させ、規定のたわみ量に達した温度を荷重たわみ温度とする。
[0040] その後、図 6 (a)に示すように、装飾用シート 10を成形品本体 21に近接させた後に 、装飾用シート 10と成形品本体 21との間の空間 35の減圧および装飾用シート 10の 上方に広がる空間 36の加圧を行い、それによつて図 6 (b)に示すように装飾用シート 10を成形品本体 21に接合する。この工程において、装飾用シート 10は、成形品本 体 21の表面に沿うように展延 '成形される。装飾用シート 10が薄くなりすぎると、美観 の低下を招いてしまうので、この工程は、貼り付けられた装飾用シート 10の厚さ力 も との厚さの 0. 4倍以上となるように行われることが好ましぐ 0. 5倍以上となるように行 われることがより好ましい。 [0041] 続いて、図 7 (a)に示すように、装飾用シート 10の不要な部分 10'を回転刃などの 切断手段を用いて切断 (トリミング)し、その後、成形品本体 21を支持台 30から取り外 すことによって、図 7 (b)に示すように、表面に装飾が施された加飾成形品 20が完成 する。
[0042] 上述した本実施形態における製造方法では、まず、成形品本体 21上に接着剤シ ート 40を載置し、その後、加熱された装飾用シート 10を接着剤シート 40上に載置す ることによって、成形品本体 21と装飾用シート 10とを接着する。つまり、装飾用シート 10の貼り付けを行う工程では、接着剤層 41は、装飾用シート 10にではなぐ成形品 本体 21上に設けられている。
[0043] そのため、接着剤層 41の接着剤は、装飾用シート 10の基材 1の収縮の影響を受け にくぐしわができにくい。また、装飾用シート 10の貼り付けを行う際、接着剤の温度 は接着剤層 41の全体に亘つてほぼ均一であり、接着剤の流動性も接着剤層 41の全 体に亘つてほぼ均一であるので、図 14 (c)に示したような接着剤の局所的な盛り上が りも発生しにくい。このように、本実施形態における製造方法では、接着剤の偏在が 発生しにくいため、ひも状の光沢むらの発生が抑制され、美観の低下が防止される。
[0044] 続いて、接着剤シート 40および装飾用シート 10のより具体的な構造や好ましい構 成を説明する。
[0045] 接着剤シート 40の接着剤層 41は、例えば、ウレタン榭脂ゃアクリルウレタン榭脂な どのウレタン系、アクリル系の接着剤カゝら形成されている。接着剤層 41を構成する接 着剤の弾性率は、製品が利用される温度域での製品の剛性を満足させる観点から、 80°Cで 1 X 103Pa以上 1 X 106Pa以下であることが好ましい。弾性率が 80°Cで 1 X 1 03Pa未満であると、製品が高温となったとき (例えば製品が夏季に屋外で使用された とき）に接着剤の軟ィ匕による不具合が生じることがある。一方、弾性率が 80°Cで 1 X 1 06Paを超えると、接着剤として硬すぎるために衝撃に弱くなる。また、成形品の 3次元 形状に沿ったオーバーレイを容易に行う観点からは、接着剤の弾性率は、 180°Cで 1 X lC^Pa以上 1 X 105Pa以下であることが好ましい。弾性率が 180°Cで 1 X lO'Pa 未満であると、成形時に接着剤が流れやすぐ接着剤の流れを反映した模様が成形 品の表面に現れることがある。また、弾性率が 180°Cで 1 X 105Paを超えると、接着剤 シート 40の貼り付けの際に接着剤層 41と成形品本体 21との間に泡が入りやすい。 接着剤の弾性率は、例え ¾JIS K7244— 6 (あるいは IS06721)に準拠した固体 粘弾性測定によって測定される。
[0046] 接着剤層 41の厚さは、 30 μ m以上 100 μ m以下であることが好ましい。接着剤層 4 1の厚さが 30 m未満であると、接着剤シート 40の貼り付けの際の展延によって接 着剤層 41が局所的に薄くなりすぎる (例えば接着剤層として不適当な 10 m以下と なる）ことがある。また、接着剤層 41の厚さが 100 mを超えると、接着剤層 41の十 分に延びな力 た部分が接着剤の収縮等によって凹凸となりやすい。なお、接着剤 シート 40の貼り付けの際の展延によって接着剤層 41も展延されて薄くなるので、成 形品本体 21の表面形状 (起伏の大きさ）に応じて、適宜接着剤層 41を厚くすることが 好ましい。
[0047] 接着剤層 41を支持する支持層 42は、例えば、ポリプロピレンやポリエチレンテレフ タレート（PET)などの榭脂から形成されている。支持層 42としては、離型フィルム (キ ャリアフィルムと呼ばれることもある）として市販されている種々のフィルムを好適に用 いることがでさる。
[0048] 支持層 42の接着剤層 41からの剥離を好適に行うためには、支持層 42の剥離力は 、 0. 02〜0. 10NZ25mm幅であることが好ましい。また、接着剤シート 40の貼り付 けの際、接着剤シート 40の展延を好適に行うためには、支持層 42は、その主面に平 行で互いに直交する 2方向のいずれについても 300%以上の伸びを示すことが好ま しい。さらに、支持層 42は、水分を含みにくい材料力も形成されていることが好ましく 、ごみが付着しにくい材料カゝら形成されていることが好ましい。支持層 42の厚さは、 典型的には、 60 μ m〜200 μ mである。
[0049] 装飾用シート 10の装飾層 2は、例えば、バインダとしての榭脂材料および榭脂材料 中に分散された顔料を含むインクから形成されている。装飾層 2の材料は、耐熱性、 耐屈曲性に優れて 、ることが好まし 、。特開 2002— 275405号公報に開示されて ヽ るようなインクは、優れた耐熱性、耐屈曲性を有しているので、装飾層 2の材料として 好適に用いることができる。
[0050] 装飾層 2は、必ずしも単層である必要はなぐ複数の層を含んでいてもよい。また、 装飾層 2は、図 8に示すように、インク層 2aに加えて、金属層 2bを含んでいてもよい。 装飾層 2が金属層 2bを含んでいると、金属層 2bの金属光沢により、装飾用シート 10 は金属のような質感を有する金属調の色彩 (メタリックカラー）を呈することができる。
[0051] 金属層 2bの材料としては、錫、アルミニウム、金、銅、亜鉛、銀、インジウムやこれら の合金などが用いられる。また、インク層 2aを含まず、金属層 2bのみで装飾層 2が構 成されていてもよい。金属層 2bは、例えば蒸着法により形成される。基材 1 (あるいは インク層 2a)上に直接金属を蒸着することによって金属層 2bを形成してもよいし、別 途用意したキャリアフィルム上に金属を蒸着し、この積層構造体を基材 1 (あるいはィ ンク層 2a)に貼り合せることによって金属層 2bを形成してもよ 、。
[0052] なお、従来の手法では、金属層を含む装飾用シートを用いると、ひも状の光沢むら がいつそう目立ち、美観の低下が著しかった。そのため、本発明は、金属層 2bを含 む装飾用シート 10を用いる場合に 、つそう顕著な効果が得られる。
[0053] 装飾用シート 10の基材 1の材料としては、例えば、ポリカーボネートやアクリル榭脂 などの熱可塑性榭脂を好適に用いることができる。基材 1には、シート基材としての剛 性が要求されるので、その点を考慮して材料を選択することが好ましい。また、基材 1 は、貼り付け後には成形品の最表面に位置するので、耐候性、耐損傷性などに優れ ていることが好ましい。基材 1の装飾層 2が設けられている主面 laとは反対側の主面 に、耐候性ゃ耐損傷性などに優れた保護層を形成してもよ ヽ。
[0054] 基材 1の厚さは、 50 μ m以上 1000 μ m以下であることが好ましい。基材 1の厚さが 50 m未満であると、シートとして取り扱いにくかったり、強度が不足して貼り付けの 際に破れたりするおそれがある。また、基材 1の厚さが 1000 mを超えると、成形品 本体 21の表面に対する追従性が悪くなることがある。
[0055] 基材 1のガラス転移温度は、典型的には、接着剤層 41の融点よりも高い。図 14 (a) 〜(c)に示す従来の手法では、基材 1のガラス転移温度と接着剤層 4の融点との差が 大きい（つまり基材 1のガラス転移温度に比べ接着剤層 4の融点が力なり低い）と、装 飾用シート 110を加熱して軟化させたときに、接着剤の流動性が著しく高くなつてしま うため、接着剤の偏在が起こりやすぐ美観の低下が発生しやすかつた。これに対し、 本発明によれば、接着剤層 4の融点が基材 1のガラス転移温度よりもカゝなり低くても（ 例えば 30°C以上低くても）、光沢むらのない美しい外観が得られる。
[0056] 上述したように、本発明によれば、ひも状の光沢むらの発生を抑制でき、美観の低 下を防止できる。そのため、本発明は、大きな起伏を有する成形品の装飾に好適に 用いられ、例えば、深絞り成形された成形品の装飾に好適に用いられる。
[0057] 深絞り成形された成形品の一例を図 9に示す。図 9に示す自動二輪車用フェンダ 一 22は、絞り深さ Dの絞り径 L (成形品の短手方向に沿った断面における幅）に対す る比 DZL (以下「絞り比」と呼ぶ）が大きな形状、すなわち深絞り形状を有して 、る。 本発明は、接着剤の偏在による美観の低下を防止できるので、絞り径 Lと絞り比 DZ Lとがある程度以上大きな成形品にも好適に装飾を施すことができる。例えば、従来 の手法では、絞り径レ絞り深さ Dが L≥100mmおよび DZL≥lZ3を満足する形 状を有する成形品に対して装飾を施すと、美観の著しい低下が見られたが、本発明 により、このような形状の成形品にも美観の低下を伴うことなく好適に装飾を施すこと ができる。
[0058] 本発明の製造方法により製造された成形品は、自動車両の内装部材ゃ外装部材、 あるいは家電製品の外装部材として好適に用いられる。例えば、図 10に示す自動二 輪車 50のタンクカバー 51やフロントフェンダー 52、テールカウル 53として好適に用 いられる。なお、言うまでもないことである力 「自動車両」は、自動推進式の乗物また は機械で、旅客や品物の輸送あるいは物の移動のために用いられるものを広く指し 、乗用車、オートバイ、バス、トラック、トラクター、飛行機、モーターボート、土木車両 などを指す。勿論、ガソリンエンジンなどの内燃機関を備えたものだけでなぐ電動機 を備えたものも含む。
[0059] また、本発明により製造された成形品では、装飾層 2が基材 1によって保護されるの で、美しい外観を長期に亘つて保持することができる。そのため、本発明により製造さ れた成形品は、屋外で使用される製品に特に好適に用いられ、例えば、船舶、船外 機、ウォータービークル、四輪バギー（ATV)、スノーモービル、二輪車、ゴルフカー に好適に用いられる。
[0060] 続いて、本実施形態の製造方法により実際に加飾成形品を製造してその外観を評 価した結果を説明する。また、比較のため、従来の手法により加飾成形品を製造して その外観を評価した結果も説明する。
[0061] (実施例 1)
支持層として厚さ 50 /z mの CPP (無延伸ポリプロピレン）キャリアフィルムを用い、こ のキャリアフィルム上に厚さ 30 μ mの接着剤層をウレタン系接着剤（商品名：日本ュ 二ポリマー社製 UNH790)力も形成することによって、接着剤シートを作製した。
[0062] また、基材としてポリカーボネートから形成された厚さ 0. 8mmのフィルム（商品名： 三菱ガス化学社製ユーピロン D01)を用い、このフィルム上にインクを印刷して装飾 層を形成することによって、装飾用シートを作製した。
[0063] このようにして作製した接着剤シートおよび装飾用シートを用い、真空成形装置内 で成形品に装飾を行った。具体的には、まず、接着剤シートを加熱して軟化させた後 に成形品本体に貼り付けた。次に、接着剤シートの支持層を接着剤層から剥離した 。続いて、装飾用シートを加熱して軟化させた後、成形品本体に貼り付けた。
[0064] (実施例 2)
支持層として厚さ 50 mの CPPキャリアフィルムを用い、このキャリアフィルム上に 接着剤 (商品名：日本マタイ社製エルフアン)を用いて厚さ 50 μ mの接着剤層を形成 することによって、接着剤シートを作製した。また、実施例 1と同様に装飾用シートを 作製した。これらの接着剤シートおよび装飾用シートを用い、実施例 1と同様に真空 成形装置内で成形品の装飾を行った。
[0065] (実施例 3)
支持層として PET力 形成された厚さ 60 mのキャリアフィルムを用い、このキヤリ ァフィルム上に接着剤（商品名：日本ュ-ポリマー社製 UNH785)を用いて厚さ 40 mの接着剤層を形成することによって、接着剤シートを作製した。また、実施例 1と 同様に装飾用シートを作製した。これらの接着剤シートおよび装飾用シートを用い、 実施例 1と同様に真空成形装置内で成形品の装飾を行った。
[0066] (比較例 1)
基材としてポリカーボネートから形成された厚さ 0. 8mmのフィルム（商品名：三菱ガ ス化学社製ユーロピン D01)を用い、このフィルム上に印刷を行って装飾層を形成し た後、装飾層上にウレタン系接着剤（商品名：日本ュ-ポリマー社製 UNH790)をド ライラミネートして厚さ 30 mの接着剤層を形成した。このようにして作製した装飾用 シート (接着剤層を含んで!/ヽる)を真空成形装置内で加熱して軟化させ、成形品本体 に貼り付けた。
[0067] (比較例 2)
基材としてポリカーボネートから形成された厚さ 0. 5mmのフィルムを用い、このフィ ルム上に錫力 なる厚さ 0. 1 μ mの金属層を形成した。金属層の形成は、アクリル榭 脂から形成された厚さ 50 mのフィルム上に錫を蒸着し、このフィルムを基材上に貼 り付けることによって行った。金属層上にウレタン系接着剤（商品名：日本ュ-ポリマ 一社製 UNH385)をドライラミネートして厚さ 30 μ mの接着剤層を形成した。このよう にして作製した装飾用シート (接着剤層を含んで ヽる）を真空成形装置内で加熱して 軟化させ、成形品本体に貼り付けた。
[0068] (外観評価の結果）
実施例 2および 3と比較例 1および 2の外観を評価した結果を下記表 1に示す。 なお、表 1中、「〇」は、ひも状の光沢むらが発生せず、美しい外観が得られたことを 示し、「△」は、ひも状の光沢むらが発生し、美観が低下したことを示す。また、「X」は 、ひも状の光沢むらが目立ち、美観の低下が著し力つたことを示す。
[0069] [表 1]
Figure imgf000016_0001
[0070] 表 1に示すように、実施例 1、 2および 3のいずれについても、ひも状の光沢むらが 発生せず、美しい外観が得られた。これに対し、比較例 1では、ひも状の光沢むらが 発生し、美観が低下した。さらに、金属層を装飾層として含む比較例 2では、ひも状 の光沢むらが目立ち、美観の低下が著し力つた。このように、本発明によれば、装飾 用シートを用いて美観の低下を伴うことなく加飾成形品を好適に製造し得ることが確 f*i¾ れ 。
[0071] また、表 2に、光沢むらが発生しな力つた実施例 1、 2および 3のそれぞれについて 、基材のガラス転移温度 (T )、接着剤の融点 (T )およびこれらの差と、接着剤の弾
g m 性率とを示す。
[0072] [表 2]
Figure imgf000017_0001
[0073] 表 2からわ力るように、実施例 1、 2および 3のいずれについても、接着剤の融点は 基材のガラス転移温度よりも 30°C以上低い。また、実施例 1、 2および 3のいずれに ついても、 80°Cにおける接着剤の弾性率は 1 X 103Pa以上 1 X 106Pa以下の範囲内 にあり、 180°Cにおける接着剤の弾性率は 1 X 10 &以上 1 X 105Pa以下の範囲内 にある。
[0074] このように、接着剤の弾性率を上記の数値範囲内に設定することにより、基材のガ ラス転移温度と接着剤の融点との差が大きい場合 (つまり従来の手法を用いると接着 剤の偏在が起こりやす 、場合)であっても、光沢むらのな ヽ美 、外観が得られるこ とが確認された。
産業上の利用可能性
[0075] 本発明の製造方法によれば、装飾用シートを用いて美観の低下を伴うことなく加飾 成形品を好適に製造することができる。
[0076] 本発明の製造方法により製造された成形品は、美しい外観を有しているので、各種 自動車両の外装部材ゃ内装部材、各種家電製品の外装部材などに好適に用いられ る。

Claims

請求の範囲
[1] 表面に装飾が施された加飾成形品の製造方法であって、
成形品本体を用意する工程 (A)と、
前記成形品本体上に、接着剤層を含む第 1のシートを載置する工程 (B)と、 装飾層および前記装飾層を支持する基材を含む第 2のシートを加熱する工程 (C) と、
加熱された前記第 2のシートを前記第 1のシート上に載置することによって前記成 形品本体と前記第 2のシートとを接着する工程 (D)と、
を包含する成形品の製造方法。
[2] 前記第 1のシートは、前記接着剤層を支持する支持層をさらに有し、
前記工程 (D)の前に、前記接着剤層から前記支持層を剥離する工程 (E)をさらに 包含する請求項 1に記載の成形品の製造方法。
[3] 前記工程 (B)の前に、前記第 1のシートを加熱する工程 (F)をさらに包含する請求 項 1または 2に記載の成形品の製造方法。
[4] 前記工程 (D)は、加熱された前記第 2のシートを前記成形品本体に近接させるェ 程 (D1)と、前記成形品本体に近接した前記第 2のシートと前記成形品本体との間に 形成される第 1の空間を、前記第 2のシートに対して前記第 1の空間とは反対側に広 力 ¾第 2の空間よりも減圧する工程 (D2)と、を包含する請求項 1から 3のいずれかに 記載の成形品の製造方法。
[5] 前記工程 (D)において、前記第 2のシートは、前記成形品本体の表面に沿うように 成形される請求項 1から 4のいずれかに記載の成形品の製造方法。
[6] 前記接着剤層の融点が、前記基材のガラス転移温度よりも 30°C以上低!ヽ請求項 1 力 5のいずれかに記載の成形品の製造方法。
[7] 前記接着剤層は、 80°Cにおいて 1 X 103Pa以上 1 X 106Pa以下でかつ 180°Cにお いて 1 X 10 &以上 1 X 105Pa以下の弾性率を有する材料カゝら形成されている請求 項 1から 6のいずれかに記載の成形品の製造方法。
[8] 前記基材は、熱可塑性榭脂から形成されて ヽる請求項 1から 7の ヽずれかに記載 の成形品の製造方法。
[9] 前記成形品本体は、深絞り成形されており、絞り径 Lおよび絞り深さ Dが L≥ 100m mおよび DZL≥1Z3を満足する形状を有する請求項 1から 8のいずれかに記載の 成形品の製造方法。
[10] 請求項 1から 9の 、ずれかに記載の製造方法によって形成された成形品を備えた 自動車両。
PCT/JP2006/313745 2005-07-25 2006-07-11 成形品の製造方法および自動車両 WO2007013292A1 (ja)

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US11/718,651 US20090114341A1 (en) 2005-07-25 2006-07-11 Process for production of moldings and motor vehicles

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