WO2015019712A1 - 加飾フィルムの部分オーバーレイによる部分真空成形方法 - Google Patents
加飾フィルムの部分オーバーレイによる部分真空成形方法 Download PDFInfo
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- WO2015019712A1 WO2015019712A1 PCT/JP2014/065959 JP2014065959W WO2015019712A1 WO 2015019712 A1 WO2015019712 A1 WO 2015019712A1 JP 2014065959 W JP2014065959 W JP 2014065959W WO 2015019712 A1 WO2015019712 A1 WO 2015019712A1
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- WIPO (PCT)
- Prior art keywords
- space
- adherend
- opening
- decorative film
- receiving jig
- Prior art date
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Classifications
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/001—Joining in special atmospheres
- B29C66/0012—Joining in special atmospheres characterised by the type of environment
- B29C66/0014—Gaseous environments
- B29C66/00145—Vacuum, e.g. partial 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
- 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
- B29C51/10—Forming by pressure difference, e.g. 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
- 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
- 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
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/261—Handling means, e.g. transfer means, feeding means
- B29C51/262—Clamping means for the sheets, e.g. clamping frames
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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
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/30—Moulds
- B29C51/303—Moulds with sealing means or the like
-
- 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
- B29C63/0065—Heat treatment
-
- 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
- B29C63/0091—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor in particular 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
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
-
- 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
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
-
- 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
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- 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
- B29L2031/3005—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
- B29L2031/722—Decorative or ornamental articles
Definitions
- the present invention relates to a vacuum forming machine for depositing and forming a sheet material on an adherend W in a vacuum state, a substrate for a vacuum forming machine used in a vacuum forming process using the vacuum forming machine, or such vacuum forming.
- the present invention relates to a partial vacuum forming method using a machine substrate, and particularly to a partial forming method for forming a partial portion of an adherend W.
- a vacuum forming apparatus that is not easily affected by outside air, it is equipped with a chamber box at the top and bottom, and is a vacuum forming apparatus that molds a molded object in both chamber boxes, and the upper chamber box and the lower chamber box are Disclosed is one in which joining / separation is possible and a heater is incorporated in the upper chamber box, and the molded article is heated by the heater in both joined chamber boxes (see Patent Document 1). .
- the molded object is heated by the heater in the bonded chamber boxes, and the near-infrared heater is used as the heater so that the molded object can be heated and molded in a closed space. Therefore, it is said that it is possible to provide a vacuum forming apparatus that is less susceptible to the influence of outside air during molding than in the past.
- the present invention can form the film in a relatively short time even when the large adherend W is used.
- the task is to do.
- the decorative film F having a size covering both the opening and the containing chamber 21 having the containing space S21 having the upper opening and the upper box 22 having the box space 22S having the lower opening are used.
- the upper and lower box spaces S21 and 22S are combined to form a hermetic space, and the upper and lower sides of the combined space are pressure-controlled to accommodate them in the molding space.
- a receiving chamber 21 in which a receiving jig that covers a portion of the predetermined molding portion WP of the adherend W in a state where the adherend W is accommodated in the box space, can be disposed close to the upper opening;
- An upper box which is arranged to be movable up and down above the upper space of the storage chamber 21 and is combined by bringing the lower opening of the box space into contact with the upper opening of the storage chamber 21 with the decorative film F in the lowermost state.
- Pressure control means for controlling the pressure of the upper space 22S in the upper box 22 and the lower space 11S in the receiving jig arranged and fixed in the storage chamber 21, By placing the upper end of the receiving die of the receiving jig that covers a part of the adherend W in the accommodation chamber 21 close to the upper opening, the lower space 11S and the accommodation space 21S in the receiving chamber are received.
- the lower space 11S11S in the partitioned receiving jig and the upper space 22S in the upper box 22 are hermetically sealed up and down across the decorative film F, By depressurizing each of the sealed internal space 11S and the upper space 22S and then releasing only the upper space 22S, A decorative film F is overlaid on a part of the adherend W covered with a receiving jig.
- the three-dimensional decorative molding is performed by partially enclosing only a part of the adherend W and not the whole, only the size of the molding part WP to be decorated is used regardless of the part shape and part size of the adherend.
- Vacuum forming is performed by enclosing, and the vacuum time is greatly reduced.
- the working environment is greatly improved by performing partial overlay molding of the decorative film F instead of plating or painting.
- the receiving jig includes a bottom frame plate 11 that can be inserted between the plurality of opening forming portions WH of the adherend W, and a side frame plate 312 that is combined around the four sides of the bottom frame plate 11.
- a predetermined molded portion WP of the adherend W is configured. It is preferable that the second set state (SB1) in which the molding die 12 is in contact with the back side of the predetermined molding portion WP can be obtained.
- the receiving jig is formed into a necessary shape of the adherend using the opening forming portion WP of the adherend W. A set state in which the portion WP is partially brought into close contact can be obtained.
- Example 1 which will be described later, a rising portion 11E along the inside of the side frame plate 312 is formed on a pair of parallel side portions of the periphery of the bottom frame plate 11 on the four sides in plan view, and the rising portion 11E is further formed.
- a bent piece is formed on the outer side from the upper rising end (FIG. 2A, etc.).
- the raised portion 11E is disposed along the inside of the side frame plate 312 integrated with the lower frame 31, and the bent piece is stopped so as to be caught on the upper surface of the frame, whereby the bottom frame plate 11 and the side frame plate 312 (FIG. 2C).
- Example 2 the step portion 312D of the side frame plate 312 and the thin plate portion 11B at the end portion of the side frame plate 11 are fitted to each other so that the bottom frame plate 11 is placed on the structure of the lower end of the side frame plate 312.
- a stepped assembly structure is provided (FIG. 4).
- the partial vacuum forming method of the present invention is a molding in which the box spaces are connected to each other by combining the accommodation chamber 21 having a box space having an upper opening and the upper box 22 having a box space having a lower opening.
- the space is hermetically sealed and the decorative film F is brought into close contact with the partial surface of the adherend W accommodated in the molding space by controlling the pressure in the molding space.
- a predetermined molding portion WP of a part of the adherend W is formed of a concave-shaped container covering the side periphery from the inside of the portion, and the upper end of the receiving die is opened along the upper opening edge of the accommodation chamber 21.
- Tools consisting of a bottom frame plate 11 and a side frame plate 312;
- An accommodation chamber 21 in which a receiving jig that covers the predetermined molding portion WP of the adherend W in a state where the adherend W is accommodated in the box space can be disposed close to the upper opening;
- An upper box which is arranged to be movable up and down above the upper space of the storage chamber 21 and is combined by bringing the lower opening of the box space into contact with the upper opening of the storage chamber 21 with the decorative film F in the lowermost state.
- a lower frame 31 having a four-sided frame-like plate attached along the opening of the storage chamber 21 and attaching the upper end of the receiving jig along the lower inner edge of the forming frame;
- An upper frame 32 having a four-sided frame-shaped plate attached along the opening of the upper box 22 and capable of contacting the upper surface of the lower frame 31;
- Pressure control means for controlling the pressure of the upper space 22S in the upper box 22 and the lower space 11S in the receiving jig arranged and fixed in the storage chamber 21, -Both the adherend W and the receiving jig that covers a part of the predetermined molding portion WP of the adherend W are accommodated in the accommodating space, and the upper end of the receiving jig abuts the lower frame of the upper opening.
- the receiving jig is fixed, and a second set state (SB1) in which a decorative film F having a size covering the entire opening is disposed between the storage chamber 21 and the upper box 22, From this second set state (SB1), the lower frame 31 of the storage chamber 21 and the upper frame 32 in contact with the upper box 22 sandwich the decorative film F, and the upper box 22 is lowered by the arm 22A until they are pressed against each other.
- SB1 a second set state
- the lower opening of the upper box 22 is sealed with the decorative film F
- the upper end of the receiving mold of the receiving jig is sealed with the decorative film F
- SB1 First pressure reduction in which the inside of the upper box 22 and the inside of the receiving jig covering a part of the adherend W in the storage chamber 21 are decompressed by the pressure adjusting means from the second set state (SB1).
- State (SB2) -From this first reduced pressure state (SB2)
- the pressure adjusting means releases the pressure inside the upper box 22 while the inside of the storage chamber 21 is decompressed, so that the object covered with the receiving jig in the receiving jig is covered.
- SC second reduced pressure state
- the adherend W is three-dimensionally formed by a three-dimensional forming plate having a plurality of opening forming portions, and one of the opening forming portions among these adherends W protrudes outward.
- the protruding portion is decorated (overlay) as the predetermined molding portion WP,
- the receiving jig has a hollow mold 12 that protrudes in a three-dimensional shape corresponding to the three-dimensional shape of the protruding portion, and is formed to protrude from the bottom of the concave shape of the container.
- the molding die 12 contacts the back side of the predetermined molding part WP,
- the hollow mold 12 is connected to the upper opening 10 in the mold by the upper box 22 and the communication pipe 5 so that the pressure in the hollow space 10S between the upper opening and the molded part WP is increased. It is preferable to maintain the same state as the pressure state of the space.
- the same pressure circuit that follows the same pressure is constituted by the upper space 22S and the hollow space 10S in the upper box 22, and the hollow space 10S is depressurized together with the inside of the upper box 22 in the first reduced pressure state (SB2).
- the pressure in the hollow space 10S is released together with the inside of the upper box 22 in the second reduced pressure state (SC).
- the external space S21 in the storage chamber 21 defined by the receiving jig circulates between the pair of chambers C11 and C12 formed to communicate with the separation position of the storage chamber 21 and the chambers C11 and C12.
- a pressurized air cleaning means comprising a communication pipe C2, a blowing means C3 for sending fresh air into the communication pipe, and filters 211F, 212F, C4 for removing dust in the communication pipe; It is preferable that the accommodation space 21S in the first reduced pressure state (SB2) or the molded state SD is always filled with pressurized circulating air by the pressurized air cleaning means. As shown in FIG.
- both sides of the storage chamber 21 are set as a blower chamber C11 and a wind receiving chamber C12, respectively, and the blower chamber C11 and the wind receiving chamber C12 are connected to each other outside the storage chamber 21 via respective filters 211F, 212F, and C4.
- the ventilation piping By performing the ventilation piping, the decorative film can be overlaid while maintaining the cleanliness in the storage chamber 21 and the upper box (C22).
- the three-dimensional decorative molding in a state where the influence of dust in the air is small, mixing of impurities between the decorative film F and the adherend W can be prevented.
- the interior of the accommodating chamber 21 is partitioned into predetermined areas by a receiving jig, and the partitioned space
- a molding space with the upper box 22 it is possible to perform film overlay molding in a relatively short time even when a large adherend W is used.
- FIG. 1st set state (SA) and the 2nd set state (SB1) Each side explanatory drawing of the 1st set state (SA) and the 2nd set state (SB1) in the partial vacuum forming method of Example 1.
- FIG. 1st set state (SA) Each side explanatory drawing of the 2nd pressure_reduction
- FIG. 1B is a front explanatory view showing the configuration of the pressurized air cleaning means in the lower diagram of FIG. 1A (second set state (SB1) to first reduced pressure state (SB2) (SB2)). Side surface explanatory drawing to the 1st set state (SA) in the partial vacuum forming method of Example 2.
- FIG. 1A second set state (SB1) to first reduced pressure state (SB2) (SB2)).
- the decorative film F is basically sandwiched between a receiving jig (consisting of the bottom frame plate 11 and the side frame plate 312) and the upper box 22 that are close to or separated from each other.
- a vacuum forming machine capable of forming an upper and lower sealed coupled space
- a decorative film F is applied to the surface of a predetermined molded portion WP that is a part of an adherend W partially surrounded by a receiving jig. Mold it in close contact.
- the partial vacuum forming method of the present invention combines the receiving jig having the lower space 11S having the upper opening and the upper box 22 having the upper space 22S having the lower opening in the vertical direction.
- a coupled space in which the decorative films F are vertically coupled to each other is hermetically formed, and each of the upper and lower spaces constituting the coupled space is subjected to pressure control, so that the covering portion partially accommodated in any of the upper and lower spaces is provided.
- This is a partial overlay molding method for the decorative film F in which the decorative film F is brought into close contact with a partial surface of the body W under reduced pressure.
- a predetermined molding portion WP of a part of the adherend W is formed of a concave-shaped container covering the side periphery from the inside of the portion, and the upper end of the receiving die is opened along the upper opening edge of the accommodation chamber 21.
- Tools consisting of a bottom frame plate 11 and a side frame plate 312;
- An accommodation chamber 21 in which a receiving jig that covers the predetermined molding portion WP of the adherend W in a state where the adherend W is accommodated in the box space can be disposed close to the upper opening;
- An upper box which is arranged to be movable up and down above the upper space of the storage chamber 21 and is combined by bringing the lower opening of the box space into contact with the upper opening of the storage chamber 21 with the decorative film F in the lowermost state.
- a lower frame 31 having a four-sided frame-like plate attached along the opening of the storage chamber 21 and attaching the upper end of the receiving jig along the lower inner edge of the forming frame;
- An upper frame 32 having a four-sided frame-shaped plate attached along the opening of the upper box 22 and capable of contacting the upper surface of the lower frame 31;
- Pressure control means for controlling the pressure of the upper space 22S in the upper box 22 and the lower space 11S in the receiving jig arranged and fixed in the accommodation chamber 21 is provided.
- a protruding portion of the adherend W that protrudes outward from one edge of any opening forming portion WH among the adherend W having a plurality of opening forming portions WH is defined as the predetermined forming portion WP.
- a frame between the opening molding parts WH of the molding part WP is surrounded by a filling frame 13 having a surrounding hole 13H, and the periphery of the frame is hermetically filled (FIG. 2A).
- the protruding portion of the adherend W that protrudes outward from one edge of any opening forming portion WH of the adherend W in the first state is defined as the predetermined forming portion WP.
- the bottom plate frame 11 is inserted between the opening forming portions WH so as to partition, and the rising portions 11E at the front and rear end portions of the bottom plate frame are set in a second state in which the front plate protrudes in the front and rear directions (FIG. 2B).
- the lower frame 31 having the side frame plate 312 is lowered from above the bottom plate frame 11 with both ends projecting back and forth among the adherend W in the second state, and incorporated into the outer surface of the rising portion 11E of the bottom plate frame 11;
- the bottom cover plate 313 attached to the lower portion of the side frame plate 312 so as to be horizontally slidable is slid inward to form a third state in which the side frame plate 11 and the side frame plate 312 are assembled into a container shape having a sealed recess. (FIG. 2C).
- a fixed hook 31C for fixing the assembled state by pressing the bottom cover plate 313 from below is attached to each of the pair of left and right outer surfaces of the side frame plate 312, and the bottom cover plate is operated by operating the fixed hook 31C.
- the third state is maintained by pressing 313.
- the upper end of the receiving jig that covers a part of the predetermined molding portion WP of the adherend W is brought into contact with the lower frame 31 of the upper opening, and the receiving jig in a state surrounding the molding portion WP is 31 is a third state incorporated as a concave receiving tool (FIG. 2C), and the receiving jig and lower frame 31 in this third state are housed in the housing space of the housing chamber 21 together with the adherend W,
- a decorative film F having a size covering the entire opening is disposed between the receiving jig and the accommodating chamber 21 and the upper box 22 to obtain a first set state (SA) (FIG. 1A or 4).
- SA first set state
- the first set state (SA) From the first set state (SA), the upper and lower surfaces of the decorative film F are sandwiched between the lower frame 31 in contact with the storage chamber 21 and the upper frame 32 in contact with the upper box 22, and the upper frame 32 and the lower frame 31.
- the upper box 22 is lowered by the arm 22A until the two come into pressure contact with each other, whereby the lower opening of the upper box 22 is sealed with the decorative film F, and the upper end of the receiving mold of the receiving jig is sealed with the decorative film F.
- the second set state (SB1) is set (the lower diagram in FIG. 1A).
- a first reduced pressure state (SB2) in which the inside of the lower space 11S above the molding portion WP surrounded by the receiving jigs (11, 312) is decompressed is set (lower diagram in FIG. 1A).
- the pressure adjusting means releases the pressure in the upper space 22S in the upper box 22 while the pressure in the lower space 11S is reduced, so that the receiving jig can be used as a receiving jig in the receiving jig.
- a second reduced pressure state (SC) in which the decorative film F is brought into close contact with only the predetermined molding portion WP of the enclosed adherend W, thereby partially overlaying the predetermined molding portion WP of the adherend W. (Upper figure in FIG. 1B).
- the receiving jig is removed from the adherend W in the second reduced pressure state (SC), and the adherend W is taken out from the storage box (SD), and the overhanging film portion FE other than the overlay film F ′ is placed. Remove with a laser cutter (bottom of FIG. 1B).
- the partial vacuum forming method by the partial overlay of the decorative film of the present invention is that the upper and lower sides partitioned by the decorative film F with the decorative film F sandwiched between the lower space having the upper opening and the upper space 22S having the lower opening.
- a predetermined molding portion WP near one end of the adherend W is a molding object, Only the molded part of the adherend W is hermetically sealed with a receiving jig having a concave portion opened upward, An upper box 22 having an upper space with a lower opening is disposed on the upper opening of the receiving jig with a decorative film F sandwiched between the upper opening and the upper opening of the receiving jig. Couple.
- the predetermined molded portion WP from the one end of the adherend is supported by an arm-shaped connecting component (pillar), such as a ceiling portion that is a part of the adherend of the automobile body. Including parts separated from other adherend parts.
- the lower sealed space is formed including the predetermined molding part WP which is a part of the adherend, and the upper and lower sealed spaces are coupled with the upper sealed space with the decorative film F pasted therebetween.
- the receiving jig is a concave-shaped container that covers a predetermined molding portion WP of a part of the adherend W from the inside to the side and the upper end of the receiving die extends along the upper opening edge of the storage chamber 21. Open. Specifically, the bottom frame plate 11 and the side frame plate 312 are combined to be hermetically sealed. As shown in FIG. 2A, the bottom frame plate 11 according to the first embodiment is formed such that the front and rear ends are vertically formed as a raised portion 11E at the same height as the side frame plate, and a protruding piece is extended from the upper end.
- a forming die 12 that protrudes in a three-dimensional shape corresponding to the three-dimensional shape of the protruding portion is formed in a protruding manner in the front and rear directions.
- the molding die 12 contacts the back side of the predetermined molding portion WP.
- the molding die 12 has a rectangular upper opening 10 formed in a plan view, and is set between the lower part of the adherend W and the upper part of the bottom frame plate 11 while being set on the adherend W.
- the hollow space 10S is hermetically formed.
- the bottom hole 50 which penetrates the bottom frame board in opening of this upper opening part 10 up and down is formed.
- the bottom hole 50 has a connection structure that can be detachably connected to the tip portion of the communication hose 52 connected to the tip of the same pressure communication pipe 51.
- the tip portion of the communication hose 52 is connected to the bottom hole 50, and the upper space 22 ⁇ / b> S and the hollow space 10 ⁇ / b> S maintain a pressure guiding state via the pressure guiding communication pipe 51 and the communication hose 52.
- the internal pressure of the hollow space 10S is synchronously released when the pressure of the upper space 22S is released.
- a rising portion 11E that protrudes in the proximity direction of the decorative film F at a protruding height higher than the maximum height of the adherend W is provided on the outer periphery of the set adherend W,
- the raised portion 11E comes into contact with the decorative film F prior to the adherend W, and is brought into a frame contact state in which the decorative film F is pushed up and spread out around the adherend W. Following the contact state, the adherend W adheres to the surface of the stretched decorative film F.
- a rising frame that protrudes in the proximity direction of the decorative film F at a protruding height higher than the maximum height of the adherend W is formed on the outer periphery of the molded portion WP of the set adherend W. Therefore, when the said starting frame makes the decorating film F adjoin, it contacts the decorating film F ahead of the to-be-adhered body W, and pushes up the decorating film F on the outer periphery of the to-be-adhered body W. It becomes a stretched state.
- the accommodation chamber 21 can accommodate all of the adherend W in an internal accommodation space, and a receiving jig that covers a predetermined molding portion WP of the adherend W together with the adherend is contained in an internal accommodation space S21. And the receiving jig can be disposed close to the upper opening.
- the upper box 22 has an upper space 22S as an internal space, and a heater 2H is disposed therein, and is supported by an upper arm 22A that is moved up and down by a pressure cylinder.
- the upper box 22 is arranged to be movable up and down above the upper space of the accommodation chamber 21 by the arm 22, and in the lowest lowered state, the lower opening of the box space is made the upper opening of the accommodation chamber 21 with the decorative film F interposed therebetween. Combined in contact.
- the lower frame 31 has a four-sided frame-like plate attached along the opening of the storage chamber 21, and is attached by attaching the upper end of the receiving jig along the lower inner edge of the forming frame.
- the tool can be fixed at the bottom.
- the upper frame 32 has a four-sided frame-like plate attached along the opening of the upper box 22 and can come into contact with the upper surface of the lower frame 31.
- the upper space 22S in the upper box 22 and the lower space 11S in the receiving jig arranged and fixed in the accommodation chamber 21 are connected to pressure control means for controlling the pressure in each space (not shown).
- the pressure control means can be brought into a reduced pressure state by a vacuum pump, or can be brought to an atmospheric pressure state by releasing the internal pressure of each space in the reduced pressure state.
- the adherend W is three-dimensionally formed by a three-dimensional forming plate having a plurality of opening forming portions WH, and among these, the protruding portion of the adherend W that protrudes outward from one edge of any opening forming portion WH.
- the predetermined molding portion WP is overlaid, and the receiving jig has a three-dimensional shape that corresponds to the three-dimensional shape of the protruding portion. Projectingly formed at the bottom.
- SB1 In the second set state (SB1) in which the receiving jig collectively covers the predetermined molding portion WP within the concave shape, the molding die 12 contacts the back side of the predetermined molding portion WP.
- the upper opening 10 in the mold is connected to the upper box 22 through the communication tube 5 from the opening bottom hole 50 to form a pressure circuit.
- the same pressure circuit automatically controls so that the pressure of the hollow space 10S between the upper opening and the molding part WP keeps following the same state as the pressure state of the upper space.
- the hollow space 10S is decompressed together with the inside of the upper box 22 in the first decompressed state (SB2), and the pressure of the hollow space 10S is released together with the inside of the upper box 22 in the second decompressed state (SC). Is done.
- the receiving jig can be combined by the bottom frame plate 11 that can be inserted between the plurality of opening forming portions of the adherend W and the side frame plate 312 that is combined around the four sides of the bottom frame plate 11.
- the predetermined shape portion WP of the adherend W is attached by combining each of the side frame plates 312 with the side portion of the bottom frame plate 11 inserted between the opening forming portions of the adherend W.
- a second set state (SB1) may be obtained in which the body W is covered from the inside and the molding die 12 is in contact with the back side of the predetermined molding part WP.
- the external space S21 in the storage chamber 21 defined by the receiving jig is formed of a pair of chambers C11 and C12 formed in communication with the separation position of the storage chamber 21 and the chambers C11 and C12. It comprises a pressurized air cleaning means comprising a communication pipe C2 that circulates between them, a blowing means C3 that sends fresh air into the communication pipe, and filters 211F, 212F, and C4 that remove dust in the communication pipe. ( Figure 3).
- the pressurized air cleaning means By the pressurized air cleaning means, the interior space 21S in the first reduced pressure state (SB2) or the molded state SD is always filled with pressurized circulating air.
- the pressure adjusting step includes a pressure reducing step for reducing the pressure in the upper and lower molding spaces partitioned by the decorative film F covering the adherend W, and a pressure step for pressurizing only the upper molding space after the pressure reducing step. .
- the heating process heats the decorative film F from the upper molding space in the former decompression step. In the latter pressing step, the decorative film F is placed on the adherend W by raising the table from the lower molding space.
- Pressure-cooling step In the pressure-cooling step, a cooling gas having a predetermined ejection volume is ejected from the nozzle provided in the upper box 22 toward the vacuum forming machine substrate and the adherend W in the molding space.
- the pressure in the upper molding space can be reduced by discharging the air in the upper molding space having the same volume or less than the volume of the cooling gas from the discharge port provided in the upper box 22 to the outside of the upper box 22. Cool while maintaining.
- the cooling gas is jetted from a jet port provided on one of the inner surfaces of the upper box 22 toward the vacuum forming machine substrate and the adherend W in the upper molding space. It is preferable to discharge from a position that is provided in a region of the inner surface of 22 excluding the vicinity of the outlet of the cooling gas and the destination of the cooling gas and that does not hinder the cooling efficiency due to the injection of the cooling gas.
- the heater 2H composed of a plurality of heating elements is arranged and arranged on the inner surface of the upper box 22, so that the vacuum forming apparatus is hardly affected by the outside air.
- the external space S21 in the storage chamber 21 defined by the receiving jig is connected to the pair of chambers C11 and C12 that are formed to communicate with each other at the separation position of the storage chamber 21 and to circulate communication between the chambers C11 and C12.
- a compressed air cleaning means comprising a pipe C2, a blowing means C3 for sending fresh air into the communication pipe, and filters 211F, 212F, C4 for removing dust in the communication pipe;
- the accommodation space 21S in the first reduced pressure state (SB2) or the molded state SD is always filled with pressurized circulating air by the pressurized air cleaning means. Reliable partial overlay that makes it difficult for dust to enter between the molded part WP and the decorative film because the inside of the storage chamber 21 is in the second set state (SB1) while maintaining a predetermined clean state by the pressurized air cleaning means. It can be performed.
- the bottom frame plate 11 is composed of a plate-like body formed in a stepped portion 11 ⁇ / b> E whose front and rear ends are thin, and a three-dimensional projection portion is formed on the plate surface of the bottom frame plate 11.
- a forming die 12 protruding in a three-dimensional shape corresponding to the shape is formed to protrude.
- the molding die 12 contacts the back side of the predetermined molding portion WP.
- the opening bottom hole 50 is vertically connected to the bottoms of the two upper openings 10.
- Other configurations and molding methods not specifically mentioned are the same as those in the first embodiment.
- the present invention is not limited to the above-described embodiments, and within the scope of the present invention, extraction of some elements, replacement with elements or substitutes of other embodiments, deletion, or configurations between the embodiments Various modifications such as a superimposing combination of the above are possible.
Abstract
Description
被着体Wのうち所定の部分成形部分WPを当該部分の内側から側周囲を覆う凹型形状の容体からなると共に、受け型上端が前記収容チャンバー21の上部開口縁に沿って開口した受け治具(底枠板11,側枠板312からなる)と、
被着体Wをボックス空間内に収容した状態で、被着体Wの前記所定の成形部分WP一部分を覆った受け治具を、上部開口に近接配置し得る収容チャンバー21と、
収容チャンバー21の上部空間の上方にて昇降可能に配置され、最下降状態において、ボックス空間の下部開口を、加飾フィルムFを挟んで収容チャンバー21の上部開口に当接させて組み合わされる上ボックス22と、
上ボックス22内の上空間22S、及び、収容チャンバー21内に配置固定した受け治具内の下空間11Sを圧力制御する圧力制御手段と、を具備して構成され、
収容チャンバー21内で、被着体Wの一部を覆う受け治具の受け型上端を上部開口に近接配置させることで、収容チャンバー21内を受け治具内の下空間11Sと収容空間21Sとに区画し、
前記区画した受け治具内の下空間11S11Sと、上ボックス22内の上空間22Sとを、加飾フィルムFを挟んで上下に密閉連成し、
密閉された容体内空間11S、上空間22Sのそれぞれを減圧したのちに上空間22Sのみを圧力開放することで、
受け治具で覆った被着体Wの一部に加飾フィルムFをオーバーレイ成形することを特徴とする。
被着体Wの一部の所定の成形部分WPを当該部分の内側から側周囲を覆う凹型形状の容体からなると共に、受け型上端が前記収容チャンバー21の上部開口縁に沿って開口した受け治具(底枠板11,側枠板312からなる)と、
被着体Wをボックス空間内に収容した状態で、被着体Wの前記所定の成形部分WPを覆った受け治具を、上部開口に近接配置し得る収容チャンバー21と、
収容チャンバー21の上部空間の上方にて昇降可能に配置され、最下降状態において、ボックス空間の下部開口を、加飾フィルムFを挟んで収容チャンバー21の上部開口に当接させて組み合わされる上ボックス22と、
収容チャンバー21の開口に沿って取り付けられた四方枠状の板体を有し、成形枠の下部内縁に沿って受け治具の上端を取り付けることで受け治具を下部固定可能な下枠31と、
上ボックス22の開口に沿って取り付けられた四方枠状の板体を有し、前記下枠31の枠上面に当接可能な上枠32と、
上ボックス22内の上空間22S、及び、収容チャンバー21内に配置固定した受け治具内の下空間11Sを圧力制御する圧力制御手段と、を具備して構成され、
・被着体W、及び被着体Wの前記所定の成形部分WPの一部分を覆った受け治具を、共に収容空間内に収容し、受け治具の上端を上部開口の下枠に当接させて受け治具を固定し、さらに収容チャンバー21と上ボックス22の間に、各開口全体を覆う大きさの加飾フィルムFを配置した第二セット状態(SB1)とし、
・この第二セット状態(SB1)から、収容チャンバー21の下枠31と上ボックス22に接した上枠32とがそれぞれ加飾フィルムFを挟み、互いに圧接するまでアーム22Aによって上ボックス22を下降させ、これによって、上ボックス22の下部開口を加飾フィルムFで密閉し、かつ、受け治具の受け型上端を加飾フィルムFで密閉した第二セット状態(SB1)とし、
・第二セット状態(SB1)から、前記圧力調整手段によって、上ボックス22内、及び、収容チャンバー21内にて被着体Wの一部分を覆った受け治具内をそれぞれ減圧させた第一減圧状態(SB2)とし、
・この第一減圧状態(SB2)から、前記圧力調整手段によって、収容チャンバー21内を減圧したまま上ボックス22内を圧力開放することで、受け治具内にて受け治具に覆われた被着体Wの所定の成形部分WPに、加飾フィルムFを密着させることで、被着体Wの当該所定の成形部分WPのみを部分オーバーレイ成形した第二減圧状態(SC)とすることを特徴とする。
受け治具は、当該突出部分の三次元形状に対応して三次元形状に突出した中空の成形型12が、容体の凹型形状の底部に突出形成されてなり、
受け治具が凹型形状内にて前記所定の成形部分WPを纏めて覆った第二セット状態(SB1)で、前記成形型12が所定の成形部分WPの裏側に当接するものであり、
また、前記中空の成形型12は、型内の上方開口部10が上ボックス22と連通管5によって配管連通されることで、上方開口部と成形部分WPの間の中空空間10Sの圧力が上空間の圧力状態と同状態を維持してなることが好ましい。これによって、上ボックス22内の上空間22Sと中空空間10Sとで同圧追従する同圧力回路が構成され、第一減圧状態(SB2)にて上ボックス22内と共に前記中空空間10Sが減圧されると共に、前記第二減圧状態(SC)にて上ボックス22内と共に前記中空空間10Sが圧力解放される。
加圧空気清浄手段によって、前記第一減圧状態(SB2)ないし成形状態SDの収容空間21S内が、常に加圧された循環空気で満たされることが好ましい。
図3に示すように収容チャンバー21の両側面をそれぞれ送風チャンバーC11,受風チャンバーC12とし、これら送風チャンバーC11,受風チャンバーC12同士を収容チャンバー21外で各フィルター211F,212F,C4を介して送風配管することで、収容チャンバ―21内及び上ボックス内(C22)の清浄度を保ったまま加飾フィルムのオーバーレイを行うことができる。空気中の塵芥による影響が小さい状態で三次元加飾成形を行うことで、加飾フィルムFと被着体Wとの間の不純物の混入を防ぐことができる。
そしていずれの実施例においても、本発明の部分真空成形方法は、上部開口した下空間11Sを有する受け治具と、下部開口した上空間22Sを有する上ボックス22とを上下に組み合わせて、各空間同士が加飾フィルムFを挟んで上下に連成した連成空間を密閉形成し、この連成空間を構成する上下空間それぞれを圧力制御することで、上下空間内のいずれかに部分収容した被着体Wの一部表面に加飾フィルムFを減圧密着させる加飾フィルムFの部分オーバーレイ成形方法である。
そして加飾フィルムFの部分オーバーレイ成形装置の構成として、
被着体Wの一部の所定の成形部分WPを当該部分の内側から側周囲を覆う凹型形状の容体からなると共に、受け型上端が前記収容チャンバー21の上部開口縁に沿って開口した受け治具(底枠板11,側枠板312からなる)と、
被着体Wをボックス空間内に収容した状態で、被着体Wの前記所定の成形部分WPを覆った受け治具を、上部開口に近接配置し得る収容チャンバー21と、
収容チャンバー21の上部空間の上方にて昇降可能に配置され、最下降状態において、ボックス空間の下部開口を、加飾フィルムFを挟んで収容チャンバー21の上部開口に当接させて組み合わされる上ボックス22と、
収容チャンバー21の開口に沿って取り付けられた四方枠状の板体を有し、成形枠の下部内縁に沿って受け治具の上端を取り付けることで受け治具を下部固定可能な下枠31と、
上ボックス22の開口に沿って取り付けられた四方枠状の板体を有し、前記下枠31の枠上面に当接可能な上枠32と、
上ボックス22内の上空間22S、及び、収容チャンバー21内に配置固定した受け治具内の下空間11Sを圧力制御する圧力制御手段と、を具備して構成される。
被着体Wの一端部寄りの所定の成形部分WPを成形対象とし、
被着体Wのうち前記成形部分のみを、上開口した凹部を有する受け治具で密閉して囲い、
下開口した上空間を有する上ボックス22を、受け治具の上開口との間に加飾フィルムFを挟んで、前記受け治具の上開口上に配置することで、前記上下の密閉空間を連成する。ここで、被着体の一端部よりの前記所定の成形部分WPとは、例えば自動車ボディの被着体の一部である天井部分のように、アーム状の接続部品(ピラー)に支持されて他の被着体部分から区分けされた部分を含む。そして被着体の一部である前記所定の成形部分WPを含んで下の密閉空間を構成し、さらに貼設された加飾フィルムFを挟んで上の密閉空間と連成し、上下の密閉空間内とを共に減圧状態とした状態から上の密閉空間内のみを大気解放して急激に常圧化することで、上下の連成された密閉空間の相互に瞬間的な圧力差を生じさせる。これによって前記下空間内の所定の成形部分WPの立体形状に沿って、加飾フィルムFを延伸状態として隙間なく密着させる。以下、実施例の各構成につき詳述する。
受け治具は、被着体Wの一部の所定の成形部分WPを当該部分の内側から側周囲を覆う凹型形状の容体からなると共に、受け型上端が前記収容チャンバー21の上部開口縁に沿って開口する。具体的には、底枠板11,側枠板312とを組み合わせて密閉構成される。図2Aに示すように、実施例1の底枠板11は前後端が立ち上げ部11Eとして側枠板の高さと同じ高さに縦形成され、さらにその上端から張り出し片が張り出し形成された側面視凹状の屈曲板からなり、底枠板11の板面上には、突出部分の三次元形状に対応して三次元形状に突出した成形型12が、前後に分かれて突出形成されてなる。この受け治具が凹型形状内にて前記所定の成形部分WPを纏めて覆った第二セット状態(SB1)で、前記成形型12が所定の成形部分WPの裏側に当接する。また成形型12は平面視内部に方形の上方開口部10が形成され、被着体Wにセットされた状態で、被着体Wの下部と底枠板11の板上部との間に、内部の中空空間10Sが密閉形成されるものとしている。そしてこの上方開口部10の開口内の底枠板を上下貫通する底孔50が形成される。底孔50は、同圧連通管51の先に接続された連通ホース52の先部と取り外し可能に接続可能な接続構造を有している。第二セット状態においてこの底孔50に連通ホース52の先部が接続され、導圧連通管51及び連通ホース52を介して上空間22Sと中空空間10Sとが導圧状態を保つ。この状態のまま第一、第二減圧状態を経ることで、上空間22Sの圧力開放時に中空空間10Sの内圧を同期解放させるものとしている。これにより、被着体Wの成型箇所WPの裏側に形成された中空リブWRがあった場合でも、この中空リブWR全体を中空空間10S内に纏めて囲い、圧力同期させることで、中空リブWRの中空部の圧力変形を防ぐことができる。
なお、成形工程において、セットした被着体Wの周囲外方に、被着体Wの最大高さよりも高い突出高さで加飾フィルムFの近接方向に突出した立ち上げ部11Eが設けられ、前記立ち上げ部11Eが、被着体Wよりも先に加飾フィルムFと接触し、被着体Wの周囲外方にて加飾フィルムFを押し上げて張り拡げた枠接触状態となり、この枠接触状態の次に、被着体Wが前記張り拡げられた加飾フィルムFの表面に密着する。この場合、セットした被着体Wの成形部分WPの周囲外方に、被着体Wの最大高さよりも高い突出高さで加飾フィルムFの近接方向に突出した立ち上げ枠が形成されるため、前記立ち上げ枠が、加飾フィルムFを近接させる際に被着体Wよりも先に加飾フィルムFと接触し、被着体Wの周囲外方にて加飾フィルムFを押し上げて張り拡げた状態となる。
収容チャンバー21は、被着体Wの全部を内部の収容空間に収容可能であり、被着体Wのうち所定の成形部分WPを覆った受け治具を、被着体と共に内部の収容空間S21に収容し、受け治具を上部開口に近接配置し得る。
上ボックス22内の上空間22S、及び、収容チャンバー21内に配置固定した受け治具内の下空間11Sは、各空間内を圧力制御する圧力制御手段に連結される(図視せず)。圧力制御手段は、真空ポンプによって減圧状態とし、或いは減圧状態とした各空間の内部圧を開放して大気圧状態とすることができる。
また受け治具は、前記被着体Wの複数の開口成形部間を挿通可能な底枠板11と、この底枠板11の四方側部を囲って組み合わされる側枠板312とによって組み合わせ可能に構成され、被着体Wの開口成形部間を挿通させた底枠板11の側部へ、側枠板312のそれぞれを組み合わせることで、被着体Wの所定の成形部分WPを被着体Wの内側から覆い、かつ前記成形型12が所定の成形部分WPの裏側に当接した第二セット状態(SB1)と成り得る。
圧力調整工程は、被着体W上を覆う加飾フィルムFによって仕切られた上下の成形空間をそれぞれ減圧する減圧ステップと、減圧ステップの後に上部の成形空間のみを加圧する加圧ステップとを有する。
加熱工程は、前者の減圧ステップにおいて上部の成形空間内から加飾フィルムFを加熱するものである。また成形工程は、後者の加圧ステップにおいて下部の成形空間内からテーブルを上昇させて加飾フィルムFを被着体W上に被せるものである。
加圧空気清浄手段によって、前記第一減圧状態(SB2)ないし成形状態SDの収容空間21S内が、常に加圧された循環空気で満たされるものとなっている。収容チャンバー21内が加圧空気清浄手段によって所定の清浄状態を保ったまま第二セット状態(SB1)となることで、成形部分WPと加飾フィルムの間に粉塵の混入しにくい確実な部分オーバーレイを行うことができる。
F 加飾フィルム
WP 成形部分
W 被着体W
11 底枠板(受け治具)
11S 下空間
12 成形型
21 収容チャンバー
21S 収容空間
22 上ボックス22
22A アーム
31 下枠
32 上枠
(SA) 第一セット状態
(SB1) 第二セット状態
(SB2) 第一減圧状態
(SC) 第二減圧状態
(SD) 取り出し状態
WH,WH1,WH2 開口成形部
50 開口底孔
10 上方開口部
10S 中空空間
Claims (4)
- 上部開口した下空間と下部開口した上空間との間に加飾フィルムを挟んで、加飾フィルムに仕切られた上下の密閉空間を連成し、連成空間の上下を異なる圧力に瞬間制御することで、片側の空間内に収容した所定の成形部分に加飾フィルムを密着させる加飾フィルムの部分オーバーレイによる部分真空成形方法であって、
被着体の一端部寄りの所定の成形部分を成形対象とし、被着体のうち前記成形部分のみを、上開口した凹部を有する受け治具で密閉して囲い、
下開口した上空間を有する上ボックスを、受け治具の上開口との間に加飾フィルムを挟んで、前記受け治具の上開口上に配置することで、
前記上下の密閉空間を連成し、
これによってできた連成空間の上下を異なる圧力に制御することで加飾フィルムの部分オーバーレイを行う、加飾フィルムの部分オーバーレイによる部分真空成形方法。 - 受け治具は、前記被着体の複数の開口成形部間を挿通可能な底枠板と、この底枠板の四方側部を囲って組み合わされる側枠板とによって組み合わせ可能に構成され、被着体の開口成形部間を挿通させた底枠板の側部へ、側枠板のそれぞれを組み合わせることで、被着体の前記所定の成形部分を被着体の内側から覆い、かつ前記成形型が成形部分の裏側に当接した第二セット状態と成り得る請求項1記載の加飾フィルムの部分オーバーレイによる部分真空成形方法。
- 上部開口した下空間を有する受け治具と、下部開口した上空間を有する上ボックスとを上下に組み合わせて、各空間同士が加飾フィルムを挟んで上下に連成した連成空間を密閉形成し、この連成空間を構成する上下空間それぞれを圧力制御することで、上下空間内のいずれかに部分収容した被着体の一部表面に加飾フィルムを減圧密着させる加飾フィルムの部分オーバーレイ成形方法であって、
被着体の一部の所定の成形部分を当該部分の内側から側周囲を覆う凹型形状の容体からなると共に、受け型上端が前記収容チャンバーの上部開口縁に沿って開口した受け治具と、
被着体をボックス空間内に収容した状態で、被着体の前記所定の成形部分を覆った受け治具を、上部開口に近接配置し得る収容チャンバーと、
収容チャンバーの上部空間の上方にて昇降可能に配置され、最下降状態において、ボックス空間の下部開口を、加飾フィルムを挟んで収容チャンバーの上部開口に当接させて組み合わされる上ボックスと、
収容チャンバーの開口に沿って取り付けられた四方枠状の板体を有し、成形枠の下部内縁に沿って受け治具の上端を取り付けることで受け治具を下部固定可能な下枠と、
上ボックスの開口に沿って取り付けられた四方枠状の板体を有し、前記下枠の枠上面に当接可能な上枠と、
上ボックス内の上空間、及び、収容チャンバー内に配置固定した受け治具内の下空間を圧力制御する圧力制御手段と、を具備して構成され、
被着体の前記所定の成形部分の一部分を覆った受け治具の上端を、上部開口の下枠に当接させ、成形部分を囲った状態の受け治具を、下枠内部で凹状の受け具として組み込んだ状態とし、この状態の受け治具及び下枠を、被着体と共に収容チャンバ―の収容空間内に収容し、受け治具と上ボックスの間に、各開口全体を覆う大きさの加飾フィルムを配置したて第一セット状態とし、
第一セット状態から、収容チャンバーに接した下枠と上ボックスに接した上枠とによって加飾フィルムの上下面を挟み、上枠と下枠とが互いに圧接するまでアームによって上ボックスを下降させ、これによって、上ボックスの下部開口を加飾フィルムで密閉し、かつ、受け治具の受け型上端を加飾フィルムで密閉した第二セット状態とし、
第二セット状態から、上ボックス内、受け治具内の圧力を、それぞれ減圧状態ないし圧力解放状態に制御する圧力調整手段によって、上ボックス内の上空間、及び、受け治具内に囲われた成形部分上部の下空間内をそれぞれ減圧させた第一減圧状態とし、
第一減圧状態から、前記圧力調整手段によって、下空間内を減圧したまま上ボックス内の上空間を圧力開放することで、受け治具内にて受け治具に囲われた被着体の所定の成形部分のみに、加飾フィルムを密着させ、これによって被着体の当該所定の成形部分を部分オーバーレイ成形した第二減圧状態とする、請求項1、2、又は3のいずれかに記載の加飾フィルムの部分オーバーレイによる部分真空成形方法。 - 被着体は三次元成形板によって複数の開口成形部を有して立体成形され、このうちいずれかの開口成形部の片縁よりも外方に突出する被着体の突出部分が、前記所定の成形部分としてオーバーレイ成形されるものであり、
受け治具は、当該突出部分の三次元形状に対応して三次元形状に突出した中空の成形型が、容体の凹型形状の底部に突出形成されてなり、
受け治具が凹型形状内にて前記所定の成形部分を纏めて覆った第二セット状態で、前記成形型が所定の成形部分の裏側に当接するものであり、
また、前記中空の成形型は、型内の上方開口部が開口底孔から連通管によって上ボックスと配管連通されることで、上方開口部と成形部分の間の中空空間の圧力が上空間の圧力状態と同状態を維持する、請求項1、2又は3のいずれか記載の加飾フィルムの部分オーバーレイによる部分真空成形方法。
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