Classifications

• • 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
  • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
  • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating 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
  • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
  • B29C45/17—Component parts, details or accessories; Auxiliary operations
  • B29C45/76—Measuring, controlling or regulating
• • 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
  • B29C51/04—Combined thermoforming and prestretching, e.g. biaxial stretching
• • 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
  • B29C51/46—Measuring, controlling or regulating
• • G—PHYSICS
  • G06—COMPUTING OR CALCULATING; COUNTING
  • G06F—ELECTRIC DIGITAL DATA PROCESSING
  • G06F2113/00—Details relating to the application field
  • G06F2113/22—Moulding
• • G—PHYSICS
  • G06—COMPUTING OR CALCULATING; COUNTING
  • G06F—ELECTRIC DIGITAL DATA PROCESSING
  • G06F30/00—Computer-aided design [CAD]
  • G06F30/20—Design optimisation, verification or simulation

Definitions

• the present invention relates to an evaluation method for evaluating the elongation of a decorative sheet and a method for manufacturing a decorated molded product.
• decorative molded products in which a decorative sheet is laminated onto the surface of a resin molded product, have been used as interior and exterior parts for automobiles, interior and exterior materials for building materials, and housings for home appliances.
• the decorative sheet is formed into a shape that matches the surface shape of the decorative molded product using a molding die.
• some areas of the decorative sheet may stretch significantly. For example, some areas of the decorative sheet may stretch by 50% to 200%. If some areas of the decorative sheet bearing a pattern stretch by such a large rate, the pattern on the decorative sheet may become noticeably distorted, and the decorated molded product may end up with a design different from the intended design.
• the purpose of an embodiment of the present disclosure is to make it possible to evaluate the elongation of a decorative sheet when producing a decorated molded product without actually producing a mold or a decorated molded product.
• One embodiment of the present disclosure relates to the following [1] to [29].
• a method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding when producing a decorative molded product including the molded decorative sheet comprising: generating or acquiring molded product data representing a three-dimensional shape of the decorated molded product; generating or acquiring pre-molding image data representing the decorative sheet before molding; a step of provisionally determining a molding die to be used for molding the decorative sheet based on the molded product data; generating forming mold data representing the provisionally determined three-dimensional shape of the forming mold; a step of provisionally determining conditions for primary molding for stretching the pre-molded decorative sheet so as to conform to the decorated molded product based on the molded product data or the mold data; a primary elongation data generating step of calculating elongation of each portion of the decorative sheet after the primary molding relative to the decorative sheet before molding based on the provisionally determined conditions of the primary molding, and generating primary elongation data; and a secondary elongation data generation process for calculating the
• the evaluation method according to [1] further comprises a step of generating secondary elongation display image data that visually represents the correspondence between the elongation of each part of the decorative sheet before molding and the elongation of each part of the decorative sheet after the secondary molding, based on the secondary elongation data.
• the decorative sheet has a pattern
• the evaluation method according to [20] wherein the post-molding image data is generated by deforming a pattern of the decorative sheet before molding in accordance with the elongation of each part of the decorative sheet represented by the elongation data.
• the decorative sheet has a color
• a method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding when producing a decorative molded product including the molded decorative sheet comprising: generating or acquiring molded product data representing a three-dimensional shape of the decorated molded product; generating or acquiring pre-molding image data representing the decorative sheet before molding; a step of provisionally determining a molding die to be used for molding the decorative sheet based on the molded product data; generating forming mold data representing the provisionally determined three-dimensional shape of the forming mold; a step of provisionally determining a plurality of bent shapes, which are shapes obtained by bending the decorative sheet before molding so as to fit the decorated molded product, based on the molded product data or the mold data; an elongation data generating step of calculating elongation of each portion of the decorative sheet after molding relative to the decorative sheet before molding, based on each provisionally determined bending shape and the molding die data, to generate a plurality of elongation data, when the bent decorative sheet
• a method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding when producing a decorative molded product including the molded decorative sheet comprising: generating or acquiring molded product data representing a three-dimensional shape of the decorated molded product; generating or acquiring pre-molding image data representing the decorative sheet before molding; a step of provisionally determining a plurality of molding dies to be used for molding the decorative sheet based on the molded product data; generating forming mold data representing the three-dimensional shape of each provisionally determined forming mold; a step of provisionally determining a plurality of bent shapes, which are shapes obtained by bending the decorative sheet before molding so as to fit the decorated molded product, based on the molded product data or the mold data; an elongation data generating step of calculating elongation of each portion of the decorative sheet after molding relative to the decorative sheet before molding, based on each provisionally determined bending shape and each molding die data, to generate a plurality of elongation data;
• the elongation of a decorative sheet when producing a decorated molded product can be evaluated without producing a mold or a decorated molded product.
• FIG. 1 is a diagram illustrating the first embodiment, and is a perspective view of a decorated molded product.
• FIG. 2 is a cross-sectional view for explaining the configuration of the decorated molded product shown in FIG.
• FIG. 3 is a perspective view of a clamp used in manufacturing the decorated molded product shown in FIG.
• FIG. 4 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 5 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 6 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 7 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 1 is a diagram illustrating the first embodiment, and is a perspective view of a decorated molded product.
• FIG. 2 is a cross-sectional view for explaining the configuration of the decorated molded product shown in FIG.
• FIG. 3 is a perspective view
• FIG. 8 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 9 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 10 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 11 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 12 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 13 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 14 is a block diagram showing the configuration of an evaluation device used in the production of the decorated molded product of FIG. FIG.
• FIG. 15A is a flowchart illustrating an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 15B is a flowchart for explaining a modification of the manufacturing method shown in FIG. 15A.
• FIG. 15C is a flowchart for explaining another modification of the manufacturing method shown in FIG. 15A.
• FIG. 16A is a flowchart illustrating another example of the method for manufacturing the decorated molded article of FIG.
• FIG. 16B is a flowchart for explaining a modification of the manufacturing method shown in FIG. 16A.
• FIG. 17A is a flowchart illustrating yet another example of the method for manufacturing the decorated molded article of FIG.
• FIG. 17B is a flowchart for explaining a modification of the manufacturing method shown in FIG. 17A.
• FIG. 18A is a flowchart illustrating yet another example of the method for manufacturing the decorated molded article of FIG.
• FIG. 18B is a flowchart for explaining a modification of the manufacturing method shown in FIG. 18A.
• FIG. 19 is a perspective view of a decorated molded product for explaining the second embodiment.
• FIG. 20 is a perspective view of a clamp used in manufacturing the decorated molded product shown in FIG.
• FIG. 21A is a diagram illustrating an example of a method for manufacturing the decorated molded product of FIG. 19 .
• FIG. 21B is a diagram illustrating an example of a method for manufacturing the decorated molded product of FIG. 19 .
• FIG. 22 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG. FIG.
• FIG. 23 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 24 is a diagram for explaining an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 25 is a block diagram showing the configuration of an evaluation device used in the production of the decorated molded product of FIG.
• FIG. 26A is a flowchart illustrating an example of a method for manufacturing the decorated molded product of FIG.
• FIG. 26B is a flowchart for explaining a modification of the manufacturing method shown in FIG. 26A.
• FIG. 26C is a flowchart for explaining another modification of the manufacturing method shown in FIG. 26A.
• FIG. 27A is a flowchart illustrating another example of the method for manufacturing the decorated molded product of FIG. FIG.
• Fig. 1 is a perspective view of the decorated molded product 1.
• Fig. 2 is a cross-sectional view taken along line F2-F2 of the decorated molded product 1 shown in Fig. 1.
• the decorated molded product 1 is used, for example, as an interior or exterior part for a mobile body, an interior or exterior material for a building, or a housing for a home appliance.
• a mobile body is a movable object.
• a mobile body may be manned or unmanned. Examples of mobile bodies include automobiles, railroad cars, dollies, ships, airplanes, helicopters, drones, and robots.
• the decorated molded product 1 comprises a molded portion 2 and a decorative sheet 3.
• the surface protection layer 6 forms the outermost surface of the decorated molded product 1.
• the surface protection layer 6 may have properties such as scratch resistance.
• the surface protection layer 6 is made of, for example, a resin material. Examples of resin materials that can be used to form the surface protection layer 6 include thermoplastic resins, thermosetting resins, and ionizing radiation curable resins.
• Figure 3 is a perspective view of a clamp 10 used in manufacturing the decorated molded product 1.
• Figures 4 to 13 are diagrams for explaining an example of a method for manufacturing the decorated molded product 1 shown in Figure 1.
• the decorative sheet 3 is preformed.
• the preforming causes the decorative sheet 3 to undergo plastic deformation.
• the decorative sheet 3 has a shape that is close to the shape of the desired decorated molded product 1.
• vacuum forming or pressure forming is used for preforming.
• the stretched decorative sheet 3 is brought face to face with a vacuum forming die 13.
• the vacuum forming die 13 has a main forming portion 14 and a sub-forming portion 15.
• the main forming portion 14 has a surface shape that corresponds to the shape of the decorated molded product 1 (more specifically, corresponds to the shape of the decorative sheet 3 in the decorated molded product 1).
• the sub-forming portion 15 is located around the main forming portion 14.
• An opening 16 is formed in the surface of the sub-forming portion 15.
• the opening 16 leads to a gas flow path 17 formed within the vacuum forming die 13.
• a suction pump (not shown) is connected to the flow path 17.
• the decorative sheet 3 is positioned so as to cover the main forming portion 14 and sub-forming portion 15.
• the gas inside the flow path 17 is sucked out using a suction pump.
• This gradually reduces the pressure in the space between the decorative sheet 3 and the vacuum forming mold 13, and as shown in Figures 7 and 8, the decorative sheet 3 stretches and adheres to the surfaces of the main molding section 14 and the sub-molding section 15.
• the temperature of the decorative sheet 3 is then lowered, causing the decorative sheet 3 to solidify.
• This causes the decorative sheet 3 to be molded into a shape that corresponds to the surface shape of the vacuum forming mold 13.
• the molding of the decorative sheet 3 using the vacuum forming mold 13 will also be referred to as "secondary molding.” Note that the primary molding and secondary molding may be performed in the same device.
• the first mold 21A and the second mold 21B are separated from each other, and the decorated molded product 1, including the decorative sheet 3 and the molded portion 2, is removed from the cavity 22. In this way, the decorated molded product 1 is obtained.
• the injection molding die 21 of the injection molding device 20 may also serve as the vacuum forming die 13.
• the decorated molded product 1 may be produced by a method known as the thermoject method.
• a gas flow path 17 may be formed in the second die 21B of the injection molding die 21.
• the decorative sheet 3 stretched by the blow molding device 12 is placed so as to cover the surface that defines the cavity 22 of the second die 21B, and the gas within the flow path 17 is then sucked out by a suction pump, allowing the decorative sheet 3 to be molded into a shape that corresponds to the definition of the cavity 22 of the second die 21B.
• the primary molding condition determination unit 32 provisionally determines the conditions for primary molding. More specifically, the primary molding condition determination unit 32 provisionally determines the conditions for primary molding so that the decorative sheet 3 after primary molding will have a shape that roughly matches the shape of the decorated molded product 1.
• the primary molding condition determination unit 32 provisionally determines the conditions for primary molding based on the molded product data in the memory unit 31. Of course, the primary molding condition determination unit 32 may also provisionally determine the conditions for primary molding based on mold data generated by the mold data generation unit 34, which will be described later.
• the primary molding conditions provisionally determined by the primary molding condition determination unit 32 include, for example, the length of time for which gas is blown onto the decorative sheet 3 from the blow molding device 12, the flow rate and speed of the gas blown onto the decorative sheet 3 from the blow molding device 12, the temperature of the decorative sheet 3 during primary molding, and the planar shape of the clamp 10.
• the primary elongation data generation unit 33 calculates the elongation of each part of the decorative sheet 3 after primary molding relative to the decorative sheet 3 before molding, based on the primary molding conditions tentatively determined by the primary molding condition determination unit 32.
• the primary elongation data generation unit 33 stores data representing the calculated elongation of each part of the decorative sheet 3 after primary molding as primary elongation data.
• the primary elongation data generation unit 33 generates primary elongation display image data based on the primary elongation data, which visually represents the correspondence between each part of the decorative sheet 3 before molding and the elongation of each part of the decorative sheet 3 after primary molding.
• the primary elongation display image data may represent the elongation of each part of the decorative sheet 3 represented by the primary elongation data with a color corresponding to the magnitude of that elongation.
• the primary elongation display image data may include a chart showing the correspondence between the magnitude of elongation and color.
• the primary elongation display image data may also represent the elongation of each part of the decorative sheet 3 represented by the primary elongation data with a line distortion corresponding to the magnitude of that elongation.
• the mold data generation unit 34 generates mold data representing the three-dimensional shape of a mold tentatively determined as the vacuum forming mold 13 to be used for secondary molding of the decorative sheet 3, based on the molded product data stored in the memory unit 31. For example, if the molded product data represents a three-dimensional shape as shown in FIG. 1, mold data representing the shape of the mold 13 shown in FIG. 6 is generated based on the molded product data.
• the mold data includes data relating to the area corresponding to the main molding portion 14 and data relating to the area corresponding to the sub-molding portion 15. As described above, the main molding portion 14 is the portion of the vacuum forming mold 13 that corresponds to the decorated molded product 1.
• the mold data is, for example, three-dimensional CAD data.
• the post-secondary forming image data generation unit 36 generates post-secondary forming image data representing the decorative sheet 3 after secondary forming, based on the secondary elongation data generated by the secondary elongation data generation unit 35 and the pre-forming image data stored in the memory unit 31.
• the post-secondary forming image data may include data relating to the area formed in the main forming section 14 of the provisionally determined forming mold 13 and data relating to the area formed in the sub-forming section 15, or it may include only data relating to the area formed in the main forming section 14.
• the phenomenon of the decorative sheet 3 stretching can also be considered as the film thickness of the decorative sheet 3 becoming thinner.
• the decorative sheet 3 represented by the pre-molding image data is made of a light-transmitting material
• the post-secondary molding image data may be generated so that areas of the decorative sheet 3 that have stretched more appear brighter than areas that have stretched less.
• the primary molding conditions are appropriate. Furthermore, if necessary, the provisionally determined primary molding conditions can be changed taking into account the primary elongation display image data. Furthermore, whether the primary molding conditions are appropriate may also be determined based on the secondary elongation display image data displayed on the display unit 37. Furthermore, if necessary, the provisionally determined primary molding conditions can be changed taking into account the secondary elongation display image data.
• the color change in the decorative sheet after molding compared to the decorative sheet before molding may be easily noticeable in some cases, depending on the color of the decorative sheet. For example, if the color of the decorative sheet before molding is dark and a certain area of the decorative sheet is significantly stretched by molding, an observer will tend to easily notice the color change in that area of the decorative sheet after molding compared to the decorative sheet before molding. On the other hand, if the color of the decorative sheet before molding is light, even if a certain area of the decorative sheet is significantly stretched by molding, an observer will tend not to notice the color change in that area of the decorative sheet after molding compared to the decorative sheet before molding. Therefore, if a color change in the decorative sheet after molding compared to the decorative sheet before molding is noticeable based on the post-secondary molding image data, changing to a decorative sheet 3 with a lighter color may be considered.
• step S7 the elongation of the decorative sheet 3 is evaluated based on the secondary elongation display image data, but this is not limiting.
• the elongation of the decorative sheet 3 may also be evaluated based on secondary elongation data.
• step S9 ⁇ Modification 1-4> 15C
• the process may return to step S2 and provisionally determine the primary molding conditions again.
• the primary molding conditions provisionally determined in step S2 may be changed or modified.
• the pre-molding image data in step S1 may be changed or modified.
• molded product data and pre-molded image data are generated or acquired and stored in the memory unit 31 (step S11).
• the primary molding condition determination unit 32 provisionally determines the conditions for primary molding based on the molded product data in the memory unit 31 (step S12).
• condition A specifies that the time length for blowing gas from the blow molding device 12 onto the decorative sheet 3 is A1 seconds, and the flow rate of the gas blown onto the decorative sheet 3 from the blow molding device 12 is A2 m3 /s.
• the primary elongation data generation unit 33 generates primary elongation data based on the provisionally determined primary forming conditions (step S13).
• the mold data generation unit 34 generates mold data representing the three-dimensional shape of each provisionally determined mold 13 (step S15).
• step S15 multiple mold data are generated.
• mold data 13CD representing the three-dimensional shape of mold 13C
• mold data 13DD representing the three-dimensional shape of mold 13D are generated.
• step S17 based on the multiple secondary elongation data or multiple secondary elongation display image data displayed on the display unit 37, the elongation of each decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding is evaluated, and one secondary elongation data or one secondary elongation display image data is selected (step S17).
• one secondary elongation data or one secondary elongation display image data is selected taking into consideration the average, deviation, maximum value, or ratio of the maximum and minimum values of the elongation of each part of the decorative sheet 3.
• step S19 an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding portion 14 of the vacuum forming mold 13) is performed based on the post-secondary molding image data displayed on the display unit 37 (step S19). If the decorative sheet 3 represented by the post-secondary molding image data is approved ("Yes" in step S19), it is decided to produce the decorated molded product 1 using the primary molding conditions and molding mold 13 corresponding to the secondary elongation data or secondary elongation display image data selected in step S17 (step S20). The decided molding mold 13 is then produced. The decorative sheet 3 represented by the pre-molding image data is then primarily molded under the decided primary molding conditions, and the primarily molded decorative sheet 3 is then secondarily molded using the mold 13 that was created, to produce the decorated molded product 1.
• molded product data and pre-molding image data are generated or acquired and stored in the storage unit 31 (step S21).
• the primary elongation data generation unit 33 generates primary elongation data based on the provisionally determined primary molding conditions (step S23).
• the primary elongation data generation unit 33 generates multiple primary elongation data. For example, it generates primary elongation data AD representing the elongation of each portion of the decorative sheet 3 primarily molded under condition A, and primary elongation data BD representing the elongation of each portion of the decorative sheet 3 primarily molded under condition B.
• multiple secondary elongation data and multiple secondary elongation display image data are generated based on the primary elongation data generated in the primary elongation data generation unit 33 and the forming mold data generated in the forming mold data generation unit 34, and the multiple secondary elongation data or multiple secondary elongation display image data are displayed on the display unit 37 (step S26).
• the multiple secondary elongation data or multiple secondary elongation display image data are displayed on the display unit 37 (step S26).
• secondary elongation data or secondary elongation display image data is generated and displayed on the display unit 37.
• secondary elongation data or secondary elongation display image data is generated and displayed on the display unit 37.
• step S27 based on the multiple secondary elongation data or multiple secondary elongation display image data displayed on the display unit 37, the elongation of each decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding is evaluated, and one secondary elongation data or one secondary elongation display image data is selected (step S27).
• one secondary elongation data or one secondary elongation display image data is selected taking into consideration the average, deviation, maximum value, or ratio of the maximum and minimum values of the elongation of each part of the decorative sheet 3.
• the post-secondary forming image data generation unit 36 generates post-secondary forming image data based on the selected secondary elongation data or secondary elongation display image data and the pre-forming image data, and displays it on the display unit 37 (step S28).
• molded product data and pre-molding image data are generated or acquired and stored in the storage unit 31 (step S31).
• multiple molding dies 13 are tentatively determined based on the molded product data (step S34). For example, molding dies 13C and 13D, which have different surface shapes, are tentatively determined.
• multiple secondary elongation data and multiple secondary elongation display image data are generated based on the primary elongation data generated in the primary elongation data generation unit 33 and the forming mold data generated in the forming mold data generation unit 34, and the multiple secondary elongation data or multiple secondary elongation display image data are displayed on the display unit 37 (step S36).
• the multiple secondary elongation data or multiple secondary elongation display image data are displayed on the display unit 37 (step S36).
• secondary elongation data or secondary elongation display image data is generated and displayed on the display unit 37.
• secondary elongation data or secondary elongation display image data is generated and displayed on the display unit 37.
• secondary elongation data or secondary elongation display image data is generated and displayed on the display unit 37.
• secondary elongation data or secondary elongation display image data is generated based on the primary elongation data BD generated in step S33 and the forming die data 13DD generated in step S35, and displayed on the display unit 37.
• step S39 If the post-secondary molding image data is not approved in step S39 ("No" in step S39), the process returns to step S34 and a provisional mold 13 is again selected. For example, a mold with a different surface shape from molds 13C and 13B is provisionally selected as the mold 13 for secondary molding. Then, the process from step S35 onwards is repeated based on the newly provisionally selected mold 13.
• step S39 the process may return to step S32 and provisionally determine the conditions for the first molding again. For example, provisionally determine conditions for the first molding that are different from conditions A and B. Thereafter, the process from step S33 onwards is repeated based on the newly provisionally determined conditions for the first molding.
• the evaluation method according to the first embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorated molded product 1 including the molded decorative sheet 3.
• This method includes the following steps. A process of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. A process of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. A step of provisionally determining the molding die 13 to be used for secondary molding of the decorative sheet 3 based on the molded product data. A process of generating forming mold data representing the provisionally determined three-dimensional shape of the forming mold 13. A step of provisionally determining the conditions for primary molding based on molded product data or mold data.
• the evaluation method according to the modification of the first embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorated molded product 1 including the molded decorative sheet 3.
• This method includes the following steps. A process of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. A process of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. A step of provisionally determining a plurality of forming dies 13 to be used for secondary forming of the decorative sheet 3 based on the formed product data. A process of generating forming die data representing the three-dimensional shape of each provisionally determined forming die 13.
• the secondary elongation data is data calculated based on the primary elongation data and each molding die data, and indicates the elongation of each part of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding.
• the secondary elongation data indicates the elongation of each part of the decorative sheet 3 after secondary molding when the decorative sheet 3 after primary molding is secondarily molded using each provisionally determined molding die 13.
• primary molding is performed to stretch the pre-molded decorative sheet 3 so that it fits the decorated molded product 1.
• the evaluation method according to another modification of the first embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorated molded product 1 including the molded decorative sheet 3.
• This method includes the following steps. A process of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. A process of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. A step of provisionally determining a plurality of forming dies 13 to be used for secondary forming of the decorative sheet 3 based on the formed product data. A process of generating forming die data representing the three-dimensional shape of each provisionally determined forming die 13.
• primary molding is performed to stretch the pre-molded decorative sheet 3 so that it fits the decorated molded product 1.
• the evaluation method according to the first embodiment and its modified example described above further includes the following steps.
• the evaluation method according to the first embodiment and its modified example described above further includes the following steps.
• the clamp 40 shown in Figure 20 is capable of holding the decorative sheet 3 in a bent state. More specifically, the clamp 40 is capable of holding the decorative sheet 3 so that the bent shape roughly follows the shape of the decorative molded product 1 shown in Figure 19 (more specifically, the shape of the decorative sheet 3 in the decorative molded product 1). In other words, the clamp 40 determines the bent shape of the decorative sheet 3 during molding.
• the clamp 40 is formed in a ring shape and holds four sides of the decorative sheet 3, but this is not limited to this.
• the clamp 40 may hold two opposing sides of the decorative sheet 3. In this case, the clamp 40 does not have to be formed in a ring shape.
• the edge of the decorative sheet 3 is held with a clamp 40. This allows the decorative sheet 3 to be held in a bent state so that it can roughly follow the shape of the decorative molded product 1 shown in Figure 19 (more specifically, the shape of the decorative sheet 3 in the decorative molded product 1).
• the decorative sheet 3 is placed facing the vacuum forming mold 13.
• the decorative sheet 3 is positioned so as to cover the main molding portion 14 and sub-molding portion 15 of the vacuum forming mold 13.
• the decorative sheet 3 is removed from the vacuum forming mold 13. After that, as shown in Figure 24, unnecessary portions are removed from the decorative sheet 3 that has been removed from the vacuum forming mold 13. In this way, the decorative sheet 3 is vacuum formed.
• the decorative sheet 3 is bent so that it can roughly fit the shape of the decorated molded product 1, and then vacuum-formed to fit the shape of the decorated molded product 1. Therefore, compared to forming a flat decorative sheet 3 using a vacuum-forming mold 13, the distance between each part of the decorative sheet 3 and each part of the vacuum-forming mold 13 at the start of vacuum forming can be made smaller. As a result, the difference in elongation between each part of the decorative sheet 3 can be made smaller, and the risk of one part of the decorative sheet 3 being stretched excessively is reduced. Therefore, the risk of the decorative sheet 3 tearing during vacuum forming, a noticeable change in the color of one part of the decorative sheet 3, or a noticeable distortion of the pattern on the decorative sheet 3 is reduced.
• the color of that portion of the decorative sheet 3 may change significantly, or the pattern on the decorative sheet 3 may become significantly distorted. If the color of the decorative sheet 3 changes or the pattern becomes distorted due to significant stretching of the decorative sheet 3, it is possible to suppress the color change or pattern distortion by modifying the surface shape of the decorated molded product 1 or the shape of the molding die (vacuum forming die) 13. This makes it possible to bring the design imparted to the decorated molded product 1 closer to the intended design. However, repeatedly remaking the molding die 13 until a satisfactory decorated molded product 1 is produced increases the time and cost required to complete the decorated molded product 1.
• the memory unit 51 stores molded product data that represents the three-dimensional shape of the decorated molded product 1.
• the molded product data is, for example, three-dimensional CAD data.
• the molded product data is generated, for example, based on CAD data for designing the decorated molded product, or a model or image data that represents the external shape of the decorated molded product.
• the molded product data may be generated by the person who evaluates the elongation of the decorative sheet 3, or may be obtained from a party other than the person who performs the evaluation (for example, a customer who requests the production of the decorated molded product 1).
• the mold data generation unit 52 generates mold data representing the three-dimensional shape of a mold tentatively determined as the vacuum forming mold 13 to be used to form the decorative sheet 3, based on the molded product data stored in the memory unit 51. For example, if the molded product data represents a three-dimensional shape as shown in FIG. 19, mold data representing the shape of the mold 13 shown in FIG. 22 is generated based on the molded product data.
• the mold data includes data relating to the area corresponding to the main molding portion 14 and data relating to the area corresponding to the sub-molding portion 15. As described above, the main molding portion 14 is the portion of the vacuum forming mold 13 that corresponds to the decorative molded product 1.
• the mold data is, for example, three-dimensional CAD data.
• the clamp data generation unit 53 provisionally determines the clamp 40 based on the mold data generated by the mold data generation unit 52, and generates clamp data representing the three-dimensional shape of the provisionally determined clamp 40. For example, if the mold data represents the three-dimensional shape of the mold 13 shown in Figure 22, clamp data representing the shape of the clamp 40 shown in Figure 20 is generated based on the mold data.
• the clamp data is, for example, three-dimensional CAD data.
• the elongation data generation unit 54 calculates the elongation of each part of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding.
• the elongation data generation unit 54 stores data representing the calculated elongation of each part of the decorative sheet 3 after molding as elongation data.
• the elongation data generation unit 54 calculates the elongation of each part of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when the decorative sheet 3 held and bent by the clamps 40 is molded using the provisionally determined molding die 13.
• the elongation data generation unit 54 generates elongation data based on the clamp data generated by the clamp data generation unit 53 and the molding die data generated by the molding die data generation unit 52.
• the stretch data generation unit 54 generates stretch display image data based on the stretch data, visually representing the correspondence between the stretch of each part of the decorative sheet 3 before molding and the stretch of each part of the decorative sheet 3 after molding.
• the stretch display image data may represent the stretch of each part of the decorative sheet 3 represented by the stretch data with a color corresponding to the magnitude of the stretch.
• the stretch display image data may include a chart showing the correspondence between the magnitude of the stretch and the color.
• the stretch display image data may also represent the stretch of each part of the decorative sheet 3 represented by the stretch data with line distortion corresponding to the magnitude of the stretch (for example, distortion of lines forming a grid).
• the post-molding image data may be generated, for example, by modifying the pattern of the pre-molding decorative sheet 3 represented by the pre-molding image data in accordance with the elongation of each part of the decorative sheet 3 represented by the elongation data (for example, by enlarging the pattern of the decorative sheet 3 in the areas with greater elongation than the pattern of the decorative sheet 3 represented by the pre-molding image data).
• the post-secondary molding image data may be generated so that areas of the decorative sheet 3 with greater elongation appear to have a higher gloss than areas with less elongation.
• the post-secondary molding image data may be generated so that areas of the decorative sheet 3 with greater elongation appear brighter than areas with less elongation.
• the post-molding image data can be taken into consideration to change the provisionally determined design of the molding die 13 and clamps 40, change the color and pattern of the decorative sheet 3, or change the positional relationship between the decorative sheet 3 and the molding die.
• step S57 if the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding is equal to or less than the threshold value (YES), the post-molding image data generation unit 55 generates post-molding image data representing the decorative sheet 3 after molding based on the elongation data and pre-molding image data, and displays it on the display unit 56 (step S58).
• the mold data generation unit 52 generates clamp data representing the tentatively determined three-dimensional shape of the clamp 40 (step S65). For example, clamp data 40GD representing the three-dimensional shape of clamp 40G is generated.
• multiple molding dies 13 are provisionally determined based on the molded product data (step S82). For example, molding dies 13E and 13F, which have different surface shapes, are provisionally determined.
• the extension data generation unit 54 generates multiple extension data and multiple extension display image data based on the clamp data generated by the clamp data generation unit 53 and the mold data generated by the mold data generation unit 52, and displays the multiple extension data or multiple extension display image data on the display unit 56 (step S86).
• extension data and extension display image data are generated based on clamp data 40GD and mold data 13ED.
• extension data and extension display image data are generated based on clamp data 40GD and mold data 13FD.
• extension data and extension display image data are generated based on clamp data 40HD and mold data 13ED.
• extension data and extension display image data are generated based on clamp data 40HD and mold data 13FD.
• step S89 an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding portion 14 of the vacuum forming mold 13) is performed based on the post-molding image data displayed on the display unit 56 (step S89). If the decorative sheet 3 represented by the post-molding image data is approved ("Yes" in step S89), it is decided to use the clamps 40 and mold 13 corresponding to the elongation data or elongation display image data selected in step S87 to produce the decorated molded product 1 (step S90). The decided mold 13 is then produced. The decorative sheet 3 represented by the pre-molding image data is then held in a bent state using the decided clamps 40, and the bent decorative sheet 3 is molded using the prepared mold 13 to produce the decorated molded product 1.
• step S89 the process may return to step S84 and provisionally determine the clamp 40 again.
• a clamp 40 having a shape different from clamps 40G and 40H may be provisionally determined as the clamp 40. Thereafter, the process from step S85 onwards is repeated based on the newly provisionally determined clamp 40.
• the evaluation method according to the second embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorated molded product 1 including the molded decorative sheet 3.
• This method includes the following steps. A process of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. A process of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. A step of provisionally determining the molding die 13 to be used for molding the decorative sheet 3 based on the molded product data. A process of generating forming mold data representing the provisionally determined three-dimensional shape of the forming mold 13.
• a process of provisionally determining the bent shape of the decorative sheet 3 before molding so as to conform to the decorated molded product 1 based on molded product data or mold data (a process of provisionally determining the clamps 40).
• An elongation data generating step of generating elongation data is calculated based on the provisionally determined bent shape and the mold data of the provisionally determined mold 13, and indicates the elongation of each part of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding, when the bent decorative sheet 3 is molded with the provisionally determined mold 13.
• the evaluation method according to the modification of the second embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorated molded product 1 including the molded decorative sheet 3.
• This method includes the following steps. A process of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. A process of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. A step of provisionally determining a plurality of molding dies 13 to be used for molding the decorative sheet 3 based on the molded product data. A process of generating forming die data representing the three-dimensional shape of each provisionally determined forming die 13.
• a process of provisionally determining multiple bent shapes which are shapes obtained by bending the pre-molded decorative sheet 3 to fit the decorated molded product 1, based on molded product data or mold data (a process of provisionally determining multiple clamps 40).
• the evaluation method according to another modification of the second embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorated molded product 1 including the molded decorative sheet 3.
• This method includes the following steps. A process of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. A process of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. A step of provisionally determining a plurality of molding dies to be used for molding the decorative sheet 3 based on the molded product data. A process of generating forming die data representing the three-dimensional shape of each provisionally determined forming die 13.
• a process of provisionally determining multiple bent shapes which are shapes obtained by bending the pre-molded decorative sheet 3 to fit the decorated molded product 1, based on molded product data or mold data (a process of provisionally determining multiple clamps 40).

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• 2025
  • 2025-02-14 JP JP2026500947A patent/JPWO2025173791A1/ja active Pending
  • 2025-02-14 WO PCT/JP2025/005044 patent/WO2025173791A1/ja active Pending

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