Intermediate processing method for extruded resin sheet and hot pressing processing method for intermediate resin sheet

Abstract

The present invention relates to an intermediate processing method for an extruded resin sheet and a hot pressing processing method for an intermediate resin sheet subjected to intermediate processing. A process management system (1) equipped with a computer virtually divides a strip-shaped extruded resin sheet (W) after extrusion molding into a plurality of individual regions corresponding to a plurality of resin sheets. Each individual region is further virtually divided into a plurality of segmented regions. Shrinkage rate-related information associated with the shrinkage rate of each segmented region is obtained for each segmented region. When performing intermediate processing, the process management system performs intermediate processing with modified processing conditions on each individual region based on the shrinkage rate-related information of each segmented region and the processing condition information of hot pressing, i.e., the hot pressing processing condition information.

Description

Technical Field

[0001] One aspect of the present invention relates to a method for processing a resin sheet. For example, a resin material is heated and extruded to form a strip-shaped extruded resin sheet. An intermediate resin sheet for hot pressing is produced from the extruded resin sheet. This aspect relates to a method for intermediate processing of an extruded resin sheet, and a method for hot pressing an intermediate resin sheet obtained by subjecting the extruded resin sheet to intermediate processing. Background Art

[0002] For example, resin sheets with a thickness of several millimeters or less are widely used in various fields and devices. For example, in vehicles, transparent resin sheets several millimeters thick are used in various locations, such as rear windows and the roofs of vehicles equipped with sunroofs. However, when using resin sheets for rear windows and roofs, the flat sheet must be formed into a curved shape. Specifically, the resin sheet must be heated and pressurized to form the shape, which is called hot pressing.

[0003] During the manufacture of resin sheets, variations in the batch size of the resin material can lead to changes in residual stress during extrusion, resulting in thermally induced shrinkage. Furthermore, even within the same batch, when extruding flat or strip-shaped resin sheets, the temperature distribution and thickness distribution vary depending on the position of the sheet. Consequently, shrinkage varies depending on the position of the sheet. The dimensional fluctuations caused by these differences in shrinkage can range from approximately 1 to 5%, a relatively large range, and it is desirable to minimize precision deviations.

[0004] For example, Japanese Patent Application Publication No. 2018-34562 discloses a window component. The window component has a substrate formed using a material containing a thermoplastic resin, and a coating provided on at least one side of the substrate. For the substrate, the heat shrinkage rate measured according to the method specified in JIS K6735 is 5% or less. In the manufacturing method of the window component, an extruder is used. The pressure in the extruder is preferably set to 15 to 25 [MPa]. The temperature in the extruder is preferably set to 260 to 280 [°C]. The molten sheet (substrate) from the extruder is flattened by passing through three rollers: a touch roller, a cooling roller, and a rear cooling roller. Then, the sheet is cooled by a plurality of cooling rollers, clamped by two tension rollers, and sent out in the conveying direction. The above-mentioned Publication No. 562 states that through the above-mentioned steps, the heat shrinkage rate of the substrate can be set to 5 [%] or less.

[0005] In the manufacturing method of window components described in Gazette No. 562, the post-processing steps of the substrate performed by an extruder include a coating layer forming step, a printing step, and a molding step. In Gazette No. 562, a coating layer (coating) is formed by a "coating layer forming step" for a substrate having a heat shrinkage rate of 5% or less. In the case where a printed surface is formed on the substrate (in the case of a "printing step"), printing is performed on the coating layer before the molding step to form the printed surface. In the "molding step", a flat plate (substrate) is heated and softened, and then immediately pressed against a mold for molding, and the remaining flat plate along its contour is removed, thereby obtaining a windbreak.

[0006] Specifically, while the heat shrinkage rate is set at 5% or less, it's unclear how the sheet will shrink before hot pressing. Consequently, large flat sheets are hot pressed, and the excess shrinkage is removed, resulting in significant waste of substrate. Furthermore, when applying the coating, it's unknown where the excess begins, so the coating must be applied to the entire large sheet. Consequently, significant waste of coating agent occurs. Furthermore, regarding printing, aside from setting the heat shrinkage rate of the substrate to 5% or less, there's no information regarding how the print position or printed shape should be adjusted for shrinkage. In other words, printing is performed without knowing which areas of the substrate will shrink and how, creating the possibility of print offset after shrinkage.

[0007] Therefore, there is a need for a sheet processing method that can further reduce waste of substrates, coating agents, etc., as well as the occurrence of printing deviations, and can produce products with more stable precision. For example, the sheet processing method is an intermediate processing method for an extruded resin sheet used to produce an intermediate resin sheet used in a hot press process, or a hot press process method for an intermediate resin sheet that has been subjected to intermediate processing on an extruded resin sheet. Summary of the Invention

[0008] One aspect of the present invention is an intermediate processing method for an extruded resin sheet for manufacturing a resin sheet for hot pressing, i.e., an intermediate resin sheet, from a strip-shaped extruded resin sheet that has been heated and extruded. This method uses a process management system equipped with a computer. The process management system virtually divides the strip-shaped extruded resin sheet that has been extruded into a plurality of individual regions corresponding to the plurality of resin sheets. Each of the virtually divided individual regions is further virtually divided into a plurality of segmented regions. Shrinkage rate-related information associated with the shrinkage rate of each segmented region of each individual region is obtained for each of the individual regions and each of the segmented regions. When an intermediate processing is performed on each of the individual regions, which is a processing after the extrusion molding and before the hot pressing, the process management system performs the intermediate processing with the processing conditions corrected on each of the individual regions. The correction is performed on each of the individual regions based on the shrinkage rate-related information of each of the segmented regions and the processing condition information of the hot pressing, i.e., the hot pressing processing condition information of each of the individual regions and each of the segmented regions.

[0009] Therefore, the individual area corresponding to each product is further virtually divided into a plurality of segmented areas. Moreover, based on the shrinkage rate associated information and hot pressing condition information of each individual area and each segmented area, each individual area is subjected to corrected intermediate processing. The individual thermal shrinkage data (shrinkage rate associated information, hot pressing condition information) of each product from the resin sheet whose shrinkage rate varies depending on the position (segmented area) is obtained. Moreover, based on the thermal shrinkage data, each area is subjected to appropriately corrected intermediate processing. In this way, the waste of substrates, coating agents, etc. and the occurrence of printing offsets can be further reduced, and products with more stable precision can be manufactured.

[0010] According to another aspect of the present invention, before performing the intermediate processing, the process management system virtually sets a target contour corresponding to the resin sheet after the intermediate processing and the hot pressing process for each individual region. A contour calculation step is performed to calculate and virtually set a contour before shrinking to the target contour, i.e., a pre-shrinkage contour, for each individual region based on the shrinkage rate-related information for each individual region and each segmented region and the hot pressing condition information for each individual region and each segmented region. Furthermore, the process management system performs a contour storage step to store the target contour and the pre-shrinkage contour in association with the individual region. Furthermore, in the intermediate processing step, which is the intermediate processing step, before performing the intermediate processing, the process management system performs a correction amount acquisition step to determine a correction amount for performing the intermediate processing for each individual region based on the target contour and the pre-shrinkage contour stored in the contour storage step. Furthermore, the process management system performs an intermediate processing implementation step to perform the intermediate processing on each individual region with the corrections determined for each individual region in the correction amount acquisition step.

[0011] Therefore, the target outline (the outline of the resin sheet after intermediate processing and hot pressing) and the pre-shrinkage outline (the outline before shrinking toward the target outline) are calculated and stored. Furthermore, the correction amount for each intermediate processing step is calculated for each individual area based on the pre-shrinkage and target outlines, enabling appropriate corrections to be made for each individual area. Consequently, by performing appropriately corrected intermediate processing on each individual area, waste of substrate, coating agent, and other materials, as well as printing deviation, can be further reduced, enabling the production of products with more stable precision.

[0012] According to another aspect of the present invention, the intermediate processing step includes a coating step for coating the surface of the extruded resin sheet. The process management system calculates a correction amount for each of the individual regions in the correction amount acquisition step corresponding to the coating step. The correction amount is calculated by setting the range of the coating application for each individual region to the range of the pre-shrinkage profile corresponding to the individual region. This reduces unnecessary coating for each individual region.

[0013] According to another aspect of the present invention, the intermediate processing step includes a printing step for printing on the surface of the extruded resin sheet. The process management system calculates a correction amount for each of the individual areas in the correction amount acquisition step corresponding to the printing step. The correction amount is calculated by determining the range, shape, and scale of printing for each individual area based on the pre-shrinkage contour corresponding to the individual area, the target contour, the shrinkage rate-related information for each segmented area, and the hot pressing condition information. Therefore, it is possible to reduce printing offsets, deformations, and the like for each individual area.

[0014] According to another aspect of the present invention, the intermediate processing step includes a trimming step for cutting out a region corresponding to the resin sheet from the strip-shaped extruded resin sheet from the individual regions. In the correction amount acquisition step corresponding to the trimming step, the process management system calculates a correction amount for each of the individual regions. The correction amount is calculated by setting the range cut out from each individual region to the range of the pre-shrinkage contour corresponding to the individual region. Therefore, a range that shrinks toward the target contour can be appropriately cut out from the strip-shaped extruded resin sheet for each individual region.

[0015] According to another aspect of the present invention, the shrinkage-related information includes at least one of the following: the temperature of the extruded resin sheet after the extrusion molding, the temperature of the rollers used in the extrusion molding, the rotational speed of the rollers, the thickness distribution of each of the divided regions, the temperature distribution of each of the divided regions, and the refractive index distribution of each of the divided regions, corresponding to the individual regions. Therefore, appropriate information can be obtained as the shrinkage-related information.

[0016] According to another aspect of the present invention, the hot pressing condition information includes at least one of a heating distribution for each of the divided regions and a pressure distribution for each of the divided regions corresponding to the individual regions. Therefore, appropriate information can be obtained as the hot pressing condition information.

[0017] Another aspect of the present invention is a method for hot pressing an intermediate resin sheet that has been subjected to intermediate processing on a strip-shaped extruded resin sheet that has been heated and extruded. This method uses a process management system equipped with a computer. The process management system virtually divides the strip-shaped extruded resin sheet that has been extruded into a plurality of individual regions corresponding to the plurality of resin sheets. Each of the virtually divided individual regions is further virtually divided into a plurality of divided regions. Shrinkage rate-related information associated with the shrinkage rate of each divided region of each individual region is obtained for each of the individual regions and each of the divided regions. The intermediate processing is processing after the extrusion molding and processing until the hot pressing processing. When the hot pressing processing is performed on each of the resin sheets that has been subjected to the intermediate processing, that is, each of the intermediate resin sheets, the process management system performs the hot pressing processing. The hot pressing processing is implemented based on the shrinkage rate related information of each of the above-mentioned individual areas and each of the above-mentioned divided areas, and the processing condition information of the above-mentioned hot pressing processing of each of the above-mentioned individual areas and each of the above-mentioned divided areas, that is, the hot pressing processing condition information, and the processing condition information of the above-mentioned intermediate processing of each of the above-mentioned individual areas and each of the above-mentioned divided areas, that is, the intermediate processing condition information, which modifies the above-mentioned hot pressing processing condition information for at least a part of the above-mentioned individual areas.

[0018] Therefore, the hot pressing condition information is corrected based on the hot pressing condition information and intermediate processing condition information for each individual region and each segmented region. Hot pressing is performed based on the corrected hot pressing condition information and shrinkage-related information for each individual region and each segmented region. This allows for hot pressing that has been appropriately corrected for each individual region. Furthermore, since the hot pressing condition information used for correction for each individual region is further corrected, products with more stable precision can be manufactured.

[0019] Another aspect of the present invention is a hot pressing method for an intermediate resin sheet that is subjected to intermediate processing on a strip-shaped extruded resin sheet that has been heated and extruded. This method uses a process management system equipped with a computer. The process management system virtually divides the strip-shaped extruded resin sheet that has been extruded into a plurality of individual regions corresponding to the plurality of resin sheets. Each of the virtually divided individual regions is further virtually divided into a plurality of segmented regions. Shrinkage rate-related information associated with the shrinkage rate of each segmented region of each individual region is obtained for each of the individual regions and each of the segmented regions. The intermediate processing is processing after the extrusion molding and before the hot pressing. When the above-mentioned process management system performs the above-mentioned hot pressing processing on each of the above-mentioned resin sheets, i.e., each of the above-mentioned intermediate resin sheets, after the above-mentioned intermediate processing with modified processing conditions is performed on each of the above-mentioned individual areas and each of the above-mentioned divided areas based on the above-mentioned shrinkage rate related information and the above-mentioned processing condition information of the above-mentioned hot pressing processing for each of the above-mentioned individual areas and each of the above-mentioned divided areas, i.e., the above-mentioned hot pressing processing condition information, the above-mentioned process management system is used to perform the above-mentioned hot pressing processing based on the above-mentioned shrinkage rate related information and the above-mentioned processing condition information of the above-mentioned hot pressing processing for each of the above-mentioned individual areas and each of the above-mentioned divided areas, i.e., the above-mentioned hot pressing processing condition information.

[0020] Therefore, instead of modifying the hot pressing condition information for each individual region and each segmented region, complex processing is reduced. Based on the hot pressing condition information and shrinkage-related information for each individual region and each segmented region, appropriately modified hot pressing is performed on each individual region. This provides a method for hot pressing an intermediate resin sheet subjected to intermediate processing on an extruded resin sheet, which can produce a product with more stable precision.

[0021] According to another aspect of the present invention, the shrinkage-related information includes at least one of the following: the temperature of the extruded resin sheet after the extrusion molding, the temperature of the rollers used in the extrusion molding, the rotational speed of the rollers, the thickness distribution of each of the divided regions, the temperature distribution of each of the divided regions, and the refractive index distribution of each of the divided regions, corresponding to the individual regions. Therefore, appropriate information can be obtained as the shrinkage-related information.

[0022] According to another aspect of the present invention, the hot pressing condition information includes at least one of a heating distribution for each of the divided regions and a pressure distribution for each of the divided regions corresponding to the individual regions. Therefore, appropriate information can be obtained as the hot pressing condition information. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1It is a diagram for explaining the overall process of manufacturing the resin sheet according to the first embodiment.

[0024] Figure 2 It is a perspective view illustrating an example of the extrusion molding process.

[0025] Figure 3 It is a perspective view for explaining an example of a virtual segmentation step, a shrinkage-related information acquisition step, a contour calculation step, and a contour storage step.

[0026] Figure 4 yes Figure 3 , which is a top view illustrating examples of individual regions, segmented regions, target contours, and contours before contraction.

[0027] Figure 5 It is a diagram illustrating an example of shrinkage-related information.

[0028] Figure 6 It is a diagram illustrating an example of hot pressing condition information.

[0029] Figure 7 It is a diagram illustrating an example of contour information associated with a target contour and a contour before contraction.

[0030] Figure 8 It is a perspective view illustrating an example of a coating process.

[0031] Figure 9 This is a diagram explaining an example of setting the curvature / maximum allowable coating thickness characteristic according to the curvature of the resin sheet.

[0032] Figure 10 This is a diagram illustrating an example of setting coating thickness information for the maximum allowable coating thickness corresponding to each of the divided regions having various curvatures.

[0033] Figure 11 yes Figure 8 The XI-XI cross-sectional view is a diagram illustrating an example in which coating is applied to a thickness corresponding to each divided region.

[0034] Figure 12 It is a perspective view illustrating an example of a printing process.

[0035] Figure 13 This is a diagram illustrating an example in which printing is performed on the edge portion of the pre-shrinkage outline in consideration of shrinkage.

[0036] Figure 14 This is a diagram illustrating an example of a printed state of the edge portion of a final product after heat pressing and shrinkage.

[0037] Figure 15 It is a perspective view explaining an example of a trimming process.

[0038] Figure 16 This is a diagram illustrating an example of a resin sheet cut out in a pre-shrinkage contour in a trimming step.

[0039] Figure 17 It is a perspective view explaining an example of a hot pressing process and an inspection process.

[0040] Figure 18 This is a diagram illustrating an example of final product inspection information acquired in the inspection process.

[0041] Figure 19 It is a diagram for explaining the overall process of manufacturing the resin sheet according to the second and third embodiments.

[0042] Figure 20 This is a diagram illustrating an example of curvature / target curing degree characteristics in which a target curing degree corresponding to the curvature of a resin sheet is set in the second embodiment.

[0043] Figure 21 This is a diagram illustrating an example of setting curing degree information for target curing degrees corresponding to respective divided regions having various curvatures in the second embodiment.

[0044] Figure 22 This is a diagram illustrating an example of curvature / target coating thickness characteristics in which a target coating thickness corresponding to the curvature of a resin sheet is set in the third embodiment.

[0045] Figure 23 This is a diagram illustrating an example of setting coating thickness information for target coating thicknesses corresponding to respective divided regions having various curvatures in the third embodiment. DETAILED DESCRIPTION

[0046] Hereinafter, the embodiment for implementing one form of the present invention will be described using the accompanying drawings. In addition, in the figure, when the X-axis, Y-axis, and Z-axis are recorded, the Z-axis direction refers to the vertical upward direction, the X-axis direction refers to the extrusion direction of the extruded resin sheet W (approximately horizontal direction), and the Y-axis direction refers to the approximately horizontal direction orthogonal to the X-axis direction. Hereinafter, the first to third embodiments will be described in order regarding the intermediate processing method of an extruded resin sheet of one form of the present invention and the manufacturing process of the resin sheet of the hot pressing processing method of the intermediate resin sheet in which the extruded resin sheet is subjected to intermediate processing. In the first embodiment, the coating process P3 includes a coating curing process P3E (a process for setting the coating to a fully cured state). In the second embodiment, the coating curing process P3E is changed to a coating semi-curing process P3F (a process for setting the coating to a semi-cured state), and a coating full curing process P7 (a process for setting the coating to a fully cured state) is added between the hot pressing process P6 and the inspection process P8.

[0047] [First embodiment ( Figures 1 to 18 )]

[0048] First use Figure 1 The overall outline of the manufacturing process of the resin sheet is described. The manufacturing process of the resin sheet includes an extrusion molding process P1, a shrinkage prediction process P2, a coating process P3, a printing process P4, a trimming process P5, a hot pressing process P6, an inspection process P8, etc. The manufacturing process is managed and controlled by a process management system 1, and the process management system 1 is composed of an overall management device 2 and management devices (10, 20, 30, 40, 50, 60, 80) for each process. In addition, the overall management device 2 and the management devices (10, 20, 30, 40, 50, 60, 80) for each process are connected to a communication line T and can send and receive various information to each other. In addition, the communication line T can be either wired or wireless, or it can be the Internet. In the case of the Internet, the extrusion molding process P1 to the trimming process P5, the hot pressing process P6 and the inspection process P8 can be implemented at different remote locations.

[0049] The overall management device 2 is, for example, a personal computer, and performs startup and shutdown of the management devices (10 to 60, 80) of each process, and transmits and receives various information, thereby centrally managing whether each process is being carried out normally.

[0050] like Figure 1 As shown, in the extrusion molding process P1, an extrusion molding device 11 is used to extrude a strip-shaped extruded resin sheet W from a resin material 13. The strip-shaped extruded resin sheet W is cut into individual intermediate resin sheets Wn (intermediate products) through a shrinkage prediction process P2, a coating process P3, a printing process P4, and a trimming process P5. Moreover, after the hot pressing process P6 (heating implementation process P6B, pressurization implementation process P6D) is completed, each intermediate resin sheet Wn (intermediate product) becomes a resin sheet Wz (finished product) as a finished product. In each process, the intermediate resin sheet Wn (intermediate product) is heated by the heating implementation process P6B in the hot pressing process P6. Then, the intermediate resin sheet Wn is pressurized by the pressurization implementation process P6D. During this period, various regions of the intermediate resin sheet Wn (intermediate product) shrink in various directions. This shrinkage will naturally change when the batch of resin material 13 changes. Even for the same batch, the shrinkage of each region of the extruded resin sheet W changes due to various reasons such as residual stress during extrusion. Therefore, it has been very difficult to stably ensure the accuracy of the resin sheet Wz (finished product) in the past. However, the intermediate processing method for an extruded resin sheet and the hot pressing method for an intermediate resin sheet subjected to intermediate processing described in this embodiment can stably ensure the accuracy of the resin sheet Wz (finished product).

[0051] In the past, Figure 1The intermediate resin sheet Wn (intermediate product) shown is made into a size with a margin so that it shrinks in the hot pressing process P6. Then, the excess part is cut off to form the resin sheet Wz (finished product). That is, the previous method requires a process of cutting off the excess part. In addition, hot pressing is performed in a state where it is not known how it will shrink, so it is necessary to set the intermediate resin sheet Wn to a size with a considerable margin in advance. Therefore, a large amount of resin sheets are wasted by being cut off (and the waste in coating and printing also increases). In addition, since the intermediate resin sheet Wn is hot pressed in a state where it is not known how it will shrink, there is a possibility of printing deviation. In the intermediate processing method of the extruded resin sheet and the hot pressing method of the intermediate resin sheet to which the extruded resin sheet is subjected to intermediate processing described in this embodiment, there is no need for a process of cutting off the excess part after the hot pressing process. Therefore, it is possible to further reduce wasted resin sheets, wasteful coating, and printing, and to suppress the occurrence of printing deviation.

[0052] [About "intermediate processing" and "post-processing"]

[0053] The strip-shaped extruded resin sheet W is formed by heating and extruding the resin material. Below, each process of manufacturing an intermediate resin sheet Wn (intermediate product) as a resin sheet for hot pressing processing from the strip-shaped extruded resin sheet W is described. Each process includes an intermediate processing method for the extruded resin sheet and a hot pressing method for the intermediate resin sheet Wn (intermediate product) on which the extruded resin sheet W is subjected to intermediate processing. In addition, in the description of this embodiment, "intermediate processing" is processing after extrusion molding and processing before (before, near) hot pressing processing. Moreover, in the description of this embodiment, "intermediate processing" is processing after the shrinkage prediction process P2. For example, the intermediate processing includes processing by the coating process P3, the printing process P4, and the trimming process P5, but does not include the hot pressing process P6. Moreover, in the description of this embodiment, "post-processing" is processing after extrusion molding and includes hot pressing processing. Moreover, in the description of this embodiment, "post-processing" is processing after the shrinkage prediction process P2, including the coating process P3, the printing process P4, the trimming process P5, and the hot pressing process P6.

[0054] [Extrusion molding process P1( Figure 2 )]

[0055] like Figure 2As shown, the extrusion molding process P1 is implemented by an extrusion molding process management device 10 (for example, a personal computer), an extrusion molding device 11, etc. The extrusion molding process management device 10 operates the extrusion molding device 11 based on instructions from the overall management device 2 (or input instructions from an operator, etc.). The extrusion molding device 11 is loaded with a resin material 13 such as polycarbonate, and the resin material 13 is heated to a specified temperature to melt it. The resin material 13 in a molten state is discharged from the resin sheet discharge port 11A at a specified pressure and is set to a strip-shaped extruded resin sheet W with a constant width and a constant thickness. The strip-shaped extruded resin sheet W discharged from the resin sheet discharge port 11A is made into a constant thickness by the extrusion molding rollers 12A and 12B and is conveyed at a constant speed.

[0056] Each time the marking roller Rm rotates, a small mark Mk is engraved on the edge of the extruded resin sheet. The mark Mk is used as the boundary of the individual regions in the virtual segmentation step described later. However, if the boundary of the individual regions can be set without the mark Mk, the engraving of the mark Mk can be omitted.

[0057] The extrusion roller 12A (or the extrusion roller 12B) is provided with a rotation detection mechanism 14 (e.g., a rotation sensor) that outputs a detection signal corresponding to the rotation of the extrusion roller 12A. The extrusion process management device 10 can detect the rotation speed (rotational speed) of the extrusion roller 12A based on the detection signal from the rotation detection mechanism 14.

[0058] The extrusion molding device 11 is provided with a roller temperature detection mechanism 15 (for example, a non-contact temperature sensor) that outputs a detection signal corresponding to the temperature of the extrusion molding roller 12A. In addition, the extrusion molding device 11 is provided with an extrusion resin sheet temperature detection mechanism 16 (for example, a non-contact temperature sensor) that outputs a detection signal corresponding to the temperature of the extruded resin sheet W. The extrusion molding process management device 10 can detect the temperature of the roller surface of the extrusion molding roller 12A based on the detection signal from the roller temperature detection mechanism 15. The extrusion molding process management device 10 can detect the temperature of the extruded resin sheet W at its position based on the detection signal from the extrusion resin sheet temperature detection mechanism 16. In addition, the rotation speed of the extrusion molding roller 12A, the temperature of the extrusion molding roller 12A, and the temperature of the extruded resin sheet W are used in the profile calculation process P2C described later.

[0059] The extrusion molding process management device 10 measures the roller rotation speed, roller temperature, and resin sheet temperature in accordance with the position from the front end of the extruded resin sheet W (corresponding to the individual areas W1, W2, etc. described later), and transmits the measured values to the shrinkage prediction process management device 20 via the communication line T. For example, the diameter of the extrusion molding rollers 12A and 12B is approximately 500 to 600 mm, and the thickness of the extruded resin sheet W may vary slightly with each rotation.

[0060] [Shrinkage prediction step P2 (virtual segmentation step P2A, shrinkage-related information acquisition step P2B, outline calculation step P2C, outline storage step P2D) Figures 3 to 7 )]

[0061] Then use Figures 3 to 7 The shrinkage prediction step P2 (virtual segmentation step P2A, shrinkage-related information acquisition step P2B, contour calculation step P2C, contour storage step P2D) will be described. Figure 1 As shown, in the shrinkage prediction process P2, when the resin sheet Wz (finished product) is manufactured by the extruded resin sheet W, how it will shrink is predicted. As mentioned above, even if the extruded resin sheet W is a continuous strip of sheet material from the same batch, the shrinkage rate will vary depending on the position, so it is difficult to predict the overall shrinkage state of the large area corresponding to the resin sheet Wz (finished product). Therefore, the area corresponding to the resin sheet Wz (finished product) is divided into small divided areas for identification. Moreover, the shrinkage state is predicted for each area and each divided area. If it is a small area, the shrinkage state can be fully predicted. Moreover, the shrinkage state predicted for each individual area and each divided area is integrated, and the overall shrinkage state of the area corresponding to the resin sheet Wz (finished product) is predicted for each individual area. The shrinkage prediction process P2 is implemented by the shrinkage prediction process management device 20 before the intermediate processing (in this case, coating, printing, and trimming) and hot pressing (i.e., post-processing) are carried out.

[0062] The shrinkage prediction step P2 includes a virtual segmentation step P2A, a shrinkage-related information acquisition step P2B, a contour calculation step P2C, a contour storage step P2D, etc. Details of these steps will be described below.

[0063] [Virtual division process P2A ( Figure 3 、 Figure 4 )]

[0064] like Figure 3 As shown, the virtual segmentation process P2A is implemented by the shrinkage prediction process management device 20 (such as a personal computer), the area shooting device 21 (such as a camera), etc. before the intermediate processing and hot pressing processing (i.e., post-processing) are carried out. As described above, the marking conveyor roller Rm is used to engrave the mark Mk at a constant interval on the edge of the extruded resin sheet W conveyed at a constant speed. The shrinkage prediction process management device 20 uses the area shooting device 21 based on the instructions from the overall management device 2 (or the input instructions from the operator, etc.) to virtually divide the extruded resin sheet W continuous in a strip into individual areas W1, W2, W3... The individual areas W1, W2, W3, etc. are different from the resin sheet Wz (finished product) cut out from the extruded resin sheet W (refer to Figure 1) corresponds. Specifically, individual areas W1, W2, W3, etc. are slightly wider than the resin sheet Wz (finished product). Figure 3 as well as Figure 4 In the example shown, the position indicated by the one-dot chain line (the position of the marker Mk) is virtually divided into individual areas W1, W2, W3, . . . .

[0065] Furthermore, the shrinkage prediction process management device 20 is as follows Figure 3 as well as Figure 4 As shown by the dotted lines in , each individual area W1, W2, ... is further virtually divided into a plurality of divided areas. Figure 3 as well as Figure 4 In the example shown, the individual region W1 is divided into 16 segments, namely W1(A, 1), W1(A, 2), ...W1(D, 4). The vertical and horizontal dimensions of the segments are, for example, several tens of millimeters by several tens of millimeters. Furthermore, the shrinkage prediction process management device 20 virtually divides the individual regions and segments, and therefore does not actually add lines or the like to the extruded resin sheet W.

[0066] [Shrinkage rate related information acquisition step P2B ( Figures 3 to 5 )]

[0067] like Figure 3 As shown, the shrinkage-related information acquisition step P2B is performed by the shrinkage prediction process management device 20 and shrinkage-related information measuring devices 25A, 25B, 26A, and 26B before intermediate processing and hot pressing (i.e., post-processing). The shrinkage-related information measuring devices 25A, 25B, 26A, and 26B are, for example, a thickness distribution measuring device that measures the thickness distribution, a temperature distribution measuring device that measures the temperature distribution, or a refractive index distribution measuring device that measures the refractive index distribution. The shrinkage prediction process management device 20 uses the shrinkage-related information measuring device to acquire shrinkage-related information associated with the shrinkage rate of each virtually divided region for each individual region and each divided region, and stores the information in a storage device.

[0068] For example, Figure 5 As shown, the shrinkage prediction process management device 20 stores shrinkage rate related information for each individual area W1, W2, ... Figure 5 In the example, the roller temperature TRw1, roller speed RRw1, and sheet temperature TSw1 are stored in the shrinkage rate related information of the individual area W1 (the above is information received from the extrusion molding process management device 10 of the extrusion molding process P1 via the communication line T). The shrinkage prediction process management device 20 receives the roller temperature, roller speed, sheet temperature, etc. corresponding to the individual area from the extrusion molding process management device 10 and stores them in correspondence with the individual area. Figure 5The shrinkage-rate-related information of the individual region W1 shown stores the plate thickness distribution, temperature distribution, refractive index distribution, etc. of each (divided) region (A, 1), (A, 2) ... (D, 4).

[0069] [Contour calculation process P2C, contour storage process P2D ( Figures 3 to 7 )]

[0070] like Figure 3 As shown, the contour calculation step P2C and the contour storage step P2D are performed by the shrinkage prediction process management device 20 before the intermediate processing and hot pressing processing (i.e., post-processing) are performed. In the contour calculation step P2C, the shrinkage prediction process management device 20 receives and stores the processing condition information of the post-processing related to shrinkage (in this case, hot pressing), i.e., the hot pressing processing condition information, from the hot pressing process management device 60. Figure 6 An example of hot pressing condition information is shown. Figure 6 The example in FIG. 1 shows an example of setting predetermined processing conditions for hot pressing of individual region W1 for each individual region and each divided region. In the hot pressing processing condition information, the heating distribution (heating temperature distribution, temperature application amount) during heating and the pressure distribution (pressure application amount) during pressing are set for each of the (divided) regions (A, 1), (A, 2) ... (D, 4) of individual region W1.

[0071] Next, the shrinkage prediction process management device 20 virtually sets a target contour Lt (see FIG. 1 ) corresponding to the contour of the resin sheet Wz (finished product) after the intermediate processing and hot pressing processing (i.e., post-processing) for each individual area W1, W2, ... Figure 3 、 Figure 4 ). Figure 3 as well as Figure 4 The example of FIG. 2 shows an example in which the shrinkage prediction process management device 20 virtually sets a target contour Lt for the individual region W1 in the contour calculation step P2C.

[0072] Next, the shrinkage prediction process management device 20 calculates the shrinkage rate related information of each individual region and each divided region (see Figure 5 ) and hot pressing condition information for each individual area and each divided area (refer to Figure 6 ), the contour before shrinkage to the target contour Lt, that is, the pre-shrinkage contour Ls, is calculated (predicted) and virtually set for each individual area. Figure 3 as well as Figure 4 The example shown in FIG. 2 shows an example in which the shrinkage prediction process management device 20 calculates and virtually sets the pre-shrinkage contour Ls corresponding to the target contour Lt for the individual region W1 in the contour calculation step P2C.

[0073] Furthermore, the shrinkage prediction process management device 20 stores information related to the virtually set target contour Lt and the virtually set pre-shrinkage contour Ls in the contour storage step P2D. Figure 7 The outline information shown is stored in the storage device in correspondence with the individual areas W1, W2, ... (in this example, the outline is decomposed into a plurality of position coordinates (a, b) and stored).

[0074] [Coating step P3 (correction amount acquisition step P3A, curvature related information acquisition step P3B, each area coating condition setting step P3C, coating implementation step P3D, coating curing step P3E) Figures 8 to 11 )]

[0075] like Figure 8 As shown, coating step P3 is performed by a coating process management device 30 (e.g., a personal computer), a coating device 31, a curing device 33, and the like. Coating process management device 30 operates coating device 31 and curing device 33 based on instructions from overall management device 2 (or input instructions from an operator, etc.). Coating device 31 sprays a coating agent, for example, using an inkjet method, to form a coating layer of a predetermined thickness (e.g., approximately 10 to 20 μm) on the surface (top surface or top and bottom surfaces) of the extruded resin sheet W. Curing device 33 irradiates ultraviolet light, for example, when the coating agent is a UV-curable paint.

[0076] The coating process P3 includes a correction amount acquisition process P3A, a curvature-related information acquisition process P3B, a region-by-region coating condition setting process P3C, a coating implementation process P3D, and a coating curing process P3E. These processes are described in detail below. Furthermore, the coating process P3 is one of the intermediate processing processes (also one of the post-processing processes). The coating implementation process P3D included in the coating process P3 is also one of the intermediate processing processes.

[0077] [Correction Amount Acquisition Process P3A]

[0078] Before the coating implementation step P3D, the coating process management device 30 determines the correction amount when coating each individual area in the correction amount acquisition step P3A. Specifically, for each individual area, the coating process management device 30 sets the range of the pre-shrinkage contour corresponding to the individual area as the range for coating. In this case, the coating process management device 30 sets the coating range of the individual area W1 to the pre-shrinkage contour Ls corresponding to the individual area W1 (refer to Figure 3 、 Figure 4 ) range.

[0079] [Curvature related information acquisition step P3B ( Figure 10 )]

[0080] Hot pressing process P6 (refer to Figure 1 After the hot pressing, the resin sheet Wz (finished product) is formed into a curved shape with each region being curved at a curvature. A thick coating layer is preferably applied to the surface of the resin sheet. However, if the coating layer is too thick, cracks such as ruptures and fissures may occur when the curvature during hot pressing is large. Therefore, it is desirable to apply the coating layer as thickly as possible to avoid cracks such as ruptures and fissures.

[0081] The storage device 30A of the coating process management device 30 stores Figure 10 In the coating thickness information, a directional target contour Lt is set corresponding to each (divided) area of the individual area (see Figure 3 、 Figure 4 ) when shrinking, and the maximum allowable coating thickness corresponding to the maximum curvature. The maximum allowable coating thickness of each (divided) area in the coating thickness information is determined based on the maximum curvature of the (divided) area (when shrinking toward the target contour Lt) and the curvature / maximum allowable coating thickness characteristic (refer to Figure 9 ) and find out.

[0082] The coating process management device 30 is controlled by the hot pressing process management device 60 (see Figure 1 ) obtains the maximum curvature via the communication line T and stores it in the coating thickness information (refer to Figure 10 ) of each region of the “maximum curvature”. In this case, the maximum curvature is the maximum curvature when shrinking toward the target contour Lt, and is curvature-related information associated with the curvature after the completion of the hot pressing step P6.

[0083] [Each area coating condition setting step P3C ( Figure 9 、 Figure 10 )]

[0084] In the first embodiment, in the per-area coating condition setting step P3C, the coating process management device 30 sets a "coating thickness" for each individual area and each segmented area based on the curvature based on the curvature-related information for each individual area and each segmented area. In other words, the "per-area coating condition" in the first embodiment is the "coating thickness for each individual area and each segmented area."

[0085] The storage device 30A of the coating process management device 30 stores a curvature / maximum allowable coating thickness characteristic (see Figure 9). The coating process management device 30 calculates the maximum allowable coating thickness for each (divided) area associated with the individual area W1 corresponding to the resin sheet based on the maximum curvature corresponding to the (divided) area and the curvature / maximum allowable coating thickness characteristic. The maximum curvature is the maximum curvature based on the curvature association information. Then, the coating process management device 30 stores (sets) the calculated maximum allowable coating thickness in the coating thickness information (refer to Figure 10 ) corresponds to the "maximum allowable coating thickness" of the specified area. The maximum allowable coating thickness obtained is a thickness less than the maximum allowable coating thickness. In the first embodiment, the coating thickness in the segmented area with large curvature is set to be thinner than that in the segmented area with small curvature.

[0086] exist Figure 1 In the hot pressing step P6 shown, the intermediate resin sheet Wn (intermediate product) shrinks. Considering this shrinkage, the above coating thickness information (refer to Figure 10 ), for each individual area and each divided area, a "maximum curvature" when shrinking toward the target contour Lt, and a "maximum allowable coating thickness" corresponding to the maximum curvature are set. Sometimes it is an intermediate resin sheet Wn (intermediate product) with a shrinkage rate of, for example, 1 to 5 [%]. In this case, it is assumed that there is almost no shrinkage in the hot pressing process P6. That is, it is assumed that the intermediate resin sheet Wn (intermediate product) is molded into a resin sheet Wz (finished product) with almost no shrinkage. In this case, the "maximum curvature" and "maximum allowable coating thickness" of each individual area and each divided area of the target contour Lt can also be stored (set) in the coating thickness information (refer to Figure 10 ).

[0087] [Coating step P3D]

[0088] like Figure 8 As shown, in the coating implementation step P3D, the coating process management device 30 controls the coating device 31 to adjust the pre-shrinkage profile Ls (see Figure 3 、 Figure 4 ) range. Therefore, coating is not applied to unnecessary areas, thereby reducing waste of coating agent and time wasted in applying to unnecessary areas. In this way, using the pre-shrinkage profile based on the shrinkage rate-related information for each individual area and each divided area and the hot pressing condition information for each individual area and each divided area, modified coating (intermediate processing and post-processing) is performed on each individual area.

[0089] Figure 8 The coating process management device 30 is based on the coating thickness information (refer to Figure 10 ), coating is performed with the coating thickness set for each (divided) area (refer to Figure 11Sometimes the resin sheet Wz (finished product) is spherical or cylindrical, and the curvature is generally constant. In this case, it is not necessary to set the coating thickness for each divided area, but only to set the coating thickness for each individual area.

[0090] [Coating and curing process P3E]

[0091] In the coating and curing step P3E, the coating step management device 30 controls the curing device 33. The curing device 33 irradiates ultraviolet rays to cure the coating applied to each divided area in the coating application step P3D so that the coating is substantially cured, that is, fully cured.

[0092] [Printing step P4 (correction amount acquisition step P4A, printing implementation step P4B) Figures 12 to 14 )]

[0093] like Figure 12 As shown, the printing process P4 is performed by a printing process management device 40 (e.g., a personal computer), a printing device 41, and the like. The printing process management device 40 operates the printing device 41 based on instructions from the overall management device 2 (or input instructions from an operator, etc.). The printing device 41 sprays a coating material using, for example, an inkjet method to form a printed layer on the surface (or the surface and back) of the extruded resin sheet W.

[0094] Printing step P4 includes a correction amount acquisition step P4A and a printing implementation step P4B. These steps are described in detail below. Printing step P4 is one of the intermediate processing steps (also one of the post-processing steps), and the printing implementation step P4B included in printing step P4 is also one of the intermediate processing steps.

[0095] [Correction Amount Acquisition Step P4A]

[0096] Prior to the printing implementation step P4B, the printing process management device 40 calculates the correction amount for printing in the correction amount acquisition step P4A. Specifically, the printing process management device 40 calculates the range, shape, and scale to be printed for each individual area based on the pre-shrinkage contour Ls corresponding to the individual area, the target contour Lt, the shrinkage rate-related information for each individual area and each segmented area, and the hot press processing condition information for each individual area and each segmented area, and calculates the correction amount for printing.

[0097] For example, the printed area At (in Figure 14 The area shown by the shaded area in Figure 14 As shown in FIG, sometimes it is the prescribed width of the edge of the resin sheet Wz (finished product). In this case, the printing process management device 40 obtains Figure 13 The printed area As shown by the shadow in FIG. Figure 13 As shown, sometimes the individual area W1 is the target outline Lt and the outline before shrinkage Ls. In this case, the printing process management device 40 is based on the target outline Lt, the outline before shrinkage Ls, and the shrinkage rate related information of each individual area and each divided area (see Figure 5 ) and hot pressing condition information for each individual area and each divided area (refer to Figure 6 ), infer the shrinkage direction and shrinkage amount of each divided area, and calculate the printing area As of each individual area.

[0098] [Printing Implementation Process P4B]

[0099] In the printing implementation step P4B, the printing process management device 40 controls the printing device 41 to print the printing area As (see Figure 13 ) range. Therefore, printing is not performed in an unnecessary range, thereby reducing waste of paint and time wasted printing in unnecessary areas, and reducing deviation and deformation of the printed area upon completion. In this way, based on the shrinkage rate-related information for each individual area and each divided area, as well as the hot press processing condition information, the pre-shrinkage contour, and the target contour for each individual area and each divided area, corrected printing (intermediate processing and post-processing) is performed for each individual area.

[0100] In addition, in the printing process P4, the identification information ID corresponding to the individual area W1 is printed in the form of a QR code, a bar code, etc. on the edge portion within the pre-shrinkage contour Ls. The identification information ID is "YMD-0001" in the example of this embodiment. This identification information is allocated in the shrinkage prediction process P2 and is used to identify individual areas in the coating process P3, the printing process P4, the trimming process P5, the hot pressing process P6, and the inspection process P8. For example, this identification information is used to identify the intermediate resin sheet Wn (intermediate product) and the resin sheet Wz (finished product). For example, until the intermediate resin sheet Wn (intermediate product) is cut out from the extruded resin sheet W in the trimming process P5, each management device (10, 20, 30, 40, 50) determines the individual areas W1, W2, etc. based on the position from the front end of the extruded resin sheet W. In addition, after the intermediate resin sheet Wn (intermediate product) is cut out from the extruded resin sheet W in the trimming process P5, each management device (60, 80) reads the identification information ID through a code reading device, etc., and identifies the intermediate resin sheet Wn (intermediate product) cut out from the individual area W1.

[0101] [Trimming step P5 (correction amount acquisition step P5A, trimming implementation step P5B) Figure 15 、 Figure 16 )]

[0102] like Figure 15As shown, the trimming process P5 is performed by a trimming process management device 50 (e.g., a personal computer), a trimming device 51, etc. The trimming process management device 50 operates the trimming device 51 based on an instruction from the overall management device 2 (or an input instruction from an operator, etc.). The trimming device 51 is, for example, a laser cutter, which irradiates the extruded resin sheet W with laser light La to cut out an intermediate resin sheet Wn (intermediate product) (see FIG. Figure 1 、 Figure 16 ).

[0103] The trimming step P5 includes a correction amount acquisition step P5A, a trimming implementation step P5B, and the like. These steps are described in detail below. The trimming step P5 is one of the intermediate processing steps (also one of the post-processing steps), and the trimming implementation step P5B included in the trimming step P5 is also one of the intermediate processing steps.

[0104] [Correction Amount Acquisition Step P5A]

[0105] Before the trimming implementation step P5B, the trimming process management device 50 sets the range cut out from each individual area as the range of the pre-shrinkage profile Ls corresponding to the individual area in the correction amount acquisition step P5A, thereby obtaining the correction amount for each individual area when performing trimming.

[0106] [Trimming process P5B]

[0107] In the trimming step P5B, the trimming process management device 50 controls the trimming device 51 to cut out the range of the pre-shrinkage contour Ls from the individual regions. This eliminates any wasted area (in the resin sheet Wz (finished product), the pre-shrinkage contour Ls shrinks toward the target contour Lt). In this way, using the pre-shrinkage contour based on the shrinkage rate-related information for each individual region and each divided region, and the hot press processing condition information for each individual region and each divided region, corrected trimming (intermediate and post-processing) is performed on each individual region.

[0108] When the trimming step P5 is completed, the strip-shaped extruded resin sheet W is separated into individual intermediate resin sheets Wn (intermediate products). Therefore, the next steps (hot pressing step P6 and inspection step P8) can be performed at the factory where the trimming step P5 was performed, or the intermediate resin sheets Wn (intermediate products) can be transported to a remote factory and performed there. When the hot pressing step P6 and inspection step P8 are performed at a remote location, for example, the overall management device 2, the hot pressing process management device 60, and the inspection process management device 80 are connected to the Internet.

[0109] [Hot pressing process P6 ( Figure 17 )]

[0110] like Figure 17 As shown, the hot pressing step P6 is performed by a hot pressing process management device 60 (e.g., a personal computer), a heating device 61, a pressurizing device 63, etc. The hot pressing process management device 60 operates the heating device 61 and the pressurizing device 63 based on instructions from the overall management device 2 (or input instructions from an operator, etc.).

[0111] Hot pressing step P6 includes a heating step P6B, a correction amount acquisition step P6A corresponding to heating step P6B, a pressurization step P6D, and a correction amount acquisition step P6C corresponding to pressurization step P6D. These steps are described in detail below. Hot pressing step P6 is one of the post-processing steps.

[0112] [Correction Amount Acquisition Step P6A (Corresponding to Heating Implementation Step P6B)]

[0113] The storage device 60A of the hot pressing process management device 60 stores Figure 6 The hot pressing process management device 60 obtains the correction amount for each region of the "temperature distribution" of the hot pressing process condition information in the correction amount acquisition step P6A before the heating implementation step P6B. Specifically, the hot pressing process management device 60 obtains the correction amount for each region of the "temperature distribution" of the hot pressing process condition information based on the pre-shrinkage profile Ls (refer to Figure 4 ) and target contour Lt (refer to Figure 4 ), each individual area and each divided area shrinkage rate related information (refer to Figure 5 ) and hot pressing condition information for each individual area and each divided area (refer to Figure 6 ), calculate the correction amount for each area of the "temperature distribution" of the hot pressing condition information.

[0114] [Heating step P6B]

[0115] The heating step P6B is performed by a hot pressing process management device 60 and a heating device 61. The heating device 61 is, for example, a heat preservation tank and includes a conveyor device 61A such as a conveyor and a heating table 62 placed on the conveyor device 61A. The heating table 62 is connected to the (divided) areas (A, 1), (A, 2) ... (D, 4) virtually divided in the virtual dividing step P2A (see Figure 4 The heating stage 62 can heat each divided region of the intermediate resin sheet Wn (intermediate product) placed on the heating stage 62 at a different temperature (different temperature distribution) for each divided region.

[0116] The hot pressing process management device 60 is based on the Figure 6The temperature distribution of each (divided) area of the heating stage 62 is adjusted as needed based on the temperature distribution of each (divided) area of the hot pressing condition information shown in FIG6A and the correction amount in the correction amount acquisition step P6A. In this way, based on the shrinkage rate-related information of each individual area and each divided area and the hot pressing condition information of each individual area and each divided area, heating (post-processing) corrected as needed is performed on each individual area.

[0117] [Correction Amount Acquisition Step P6C (Corresponding to Pressurization Implementation Step P6D)]

[0118] The storage device 60A of the hot pressing process management device 60 stores Figure 6 The hot pressing process management device 60 obtains the correction amount for each region of the "pressure distribution" of the hot pressing process condition information in the correction amount acquisition step P6C before the pressing implementation step P6D. Specifically, the hot pressing process management device 60 obtains the correction amount for each region of the "pressure distribution" of the hot pressing process condition information based on the pre-shrinkage profile Ls (refer to Figure 4 ) and target contour Lt (refer to Figure 4 ), shrinkage rate related information of each segmented area (refer to Figure 5 ) and hot pressing condition information (refer to Figure 6 ), calculate the correction amount for each area of the "pressure distribution" of the hot pressing condition information.

[0119] [Pressure application step P6D]

[0120] The pressurizing step P6D is performed by the hot press process management device 60 and the pressurizing device 63. The pressurizing device 63 includes an upper mold 63A and a lower mold 63B. The pressurizing surfaces of the upper mold 63A and the lower mold 63B are aligned with the (divided) areas (A, 1), (A, 2) ... (D, 4) virtually divided in the virtual dividing step P2A (see Figure 4 The pressurizing surface can pressurize each divided area with different pressures (different pressure distributions) for each divided area, thereby molding the placed intermediate resin sheet Wn (intermediate product) by pressing each divided area with its own pressure.

[0121] The hot pressing process management device 60 is based on the Figure 6 The pressure distribution of each (divided) area of the pressurizing device 63 is adjusted as needed based on the pressure distribution of each (divided) area of the hot pressing condition information shown in FIG6 and the correction amount in the correction amount acquisition step P6C. In this way, based on the shrinkage rate-related information of each individual area and each divided area and the hot pressing condition information of each individual area and each divided area, pressurization (post-processing) corrected as needed is performed on each individual area.

[0122] In the above description, although the example of heating each divided region at a different temperature (temperature distribution) in the heating step P6B and pressurizing each divided region at a different pressure (pressure distribution) in the pressurizing step P6D is described, at least one of these steps is sufficient. Furthermore, by performing both the heating step P6B and the pressurizing step P6D, a resin sheet Wz (finished product) can be obtained.

[0123] [Inspection process P8 ( Figure 17 、 Figure 18 )]

[0124] The resin sheet Wz (finished product) is inspected for size, shape, etc. in the inspection process P8, and the inspection results are fed back to the contour calculation process P2C, etc. Figure 17 As shown, the inspection process P8 is performed by an inspection process management device 80 (eg, a personal computer), an inspection device 81, etc. The inspection process management device 80 operates the inspection device 81 based on instructions from the overall management device 2 (or input instructions from an operator, etc.).

[0125] The inspection device 81 is a three-dimensional data acquisition device composed of two imaging devices 81A and 81B arranged at a predetermined interval. The inspection process management device 80 uses the two imaging devices 81A and 81B to capture images of the resin sheet Wz (finished product) from various directions and measure the three-dimensional shape of the resin sheet Wz (finished product). Figure 18 As shown in the example of the final product inspection information, for individual areas (W1, W2, ...), the contour error (size error), curvature error (shape error), etc. of each divided area are calculated and stored.

[0126] Furthermore, for example, the inspection process management device 80 transmits the final product inspection information (see Figure 18 ) via the communication line T to the shrinkage prediction process management device 20 (refer to Figure 1 ), the hot pressing process management device 60 sends it. The shrinkage prediction process management device 20, having received the final product inspection information, corrects the correction amount when calculating the pre-shrinkage profile Ls in the profile calculation step P2C based on the final product inspection information in a manner that reduces errors in the final product inspection information.

[0127] Furthermore, based on the final product inspection information, the correction amount for correcting the mechanical error (individual difference) of the heating device 61 and the pressurizing device 63 can be calculated, and the control amount of the heating device 61 and the pressurizing device 63 from the hot pressing process management device 60 can be corrected. In this way, the hot pressing processing conditions of each heating device and the pressurizing device having individual differences can be made consistent with the representative conditions (in this case, the hot pressing processing condition information), so that the hot pressing processing condition information (see Figure 6 ) under processing (hot pressing), it is possible to more accurately perform corrections in each intermediate processing and hot pressing processing (ie, each post-processing).

[0128] In addition, the post-hot pressing contour, which is the contour after hot pressing, can be inferred based on shrinkage rate related information, trimming shape (contour before shrinkage Ls), hot pressing condition information before correction, etc., and the hot pressing condition information can be corrected according to the difference between the inferred post-hot pressing contour and the target contour Lt.

[0129] [Other methods for calculating the pre-shrinkage profile Ls, etc.]

[0130] In the example described above, in the shrinkage prediction step P2, when calculating the pre-shrinkage contour Ls corresponding to the target contour Lt, the shrinkage rate related information (see Figure 5 )、Hot pressing condition information (refer to Figure 6 ) Calculate (predict) the pre-shrinkage profile Ls for each individual region. Furthermore, the hot press processing condition information is modified as needed, based on the modification of the intermediate processing condition information described below. Alternatively, as shown in [Alternative Examples 1] to [Alternative Examples 3] below, the intermediate processing condition information described below is modified as needed, based on the modification of the hot press processing condition information.

[0131] [Other example 1]

[0132] In Other Example 1, the shrinkage prediction process management device 20 corrects at least a portion of the hot press working condition information in the order of (1-1) to (1-3) below, and calculates the final pre-shrinkage profile Ls.

[0133] (1-1) The shrinkage prediction process management device 20 estimates the (temporary) pre-shrinkage profile based on the shrinkage rate related information and the (pre-correction) hot pressing condition information. The shrinkage rate related information is set for each individual area and each divided area (see Figure 5 ), the hot pressing condition information is set for each individual area and each divided area (refer to Figure 6 ).

[0134] (1-2) When the estimated (temporary) pre-shrinkage contour does not converge within the individual region, the shrinkage prediction process management device 20 corrects at least a portion of the hot pressing condition information by reducing the shrinkage amount so that the (temporary) pre-shrinkage contour converges within the individual region. When correcting at least a portion of the hot pressing condition information, first, based on the hot pressing condition information for each individual region and each divided region, and the intermediate processing condition information for each individual region and each divided region, corrected hot pressing condition information that corrects the hot pressing condition information is obtained, and the obtained corrected hot pressing condition information is updated (overwritten) as the hot pressing condition information. In addition, in the intermediate processing condition information, various processing conditions for performing intermediate processing (in this case, coating, printing, and trimming) are set for each individual region and each divided region.

[0135] (1-3) The shrinkage prediction process management device 20 calculates the final pre-shrinkage profile Ls based on the shrinkage rate related information of each individual area and each divided area, and the (corrected and updated (overwritten)) hot pressing condition information of each individual area and each divided area (equivalent to the corrected hot pressing condition information).

[0136] When the hot pressing condition information is used in subsequent intermediate processing and hot pressing processing (ie, post-processing), the corrected and updated (overwritten) hot pressing condition information is used.

[0137] [Other example 2]

[0138] In other example 2, the shrinkage prediction process management device 20 calculates the final pre-shrinkage contour Ls by correcting at least a part of the hot pressing condition information in a manner that reduces the shrinkage amount (or reduces the deformation caused by shrinkage) in the following order of (2-1) to (2-3) even when the (temporary) pre-shrinkage contour converges within an individual area in the above-mentioned "other example 1".

[0139] (2-1) The shrinkage prediction process management device 20 estimates the (temporary) pre-shrinkage profile based on the shrinkage rate related information and the (pre-correction) hot pressing condition information. The shrinkage rate related information is set for each individual area and each divided area (see Figure 5 ), the hot pressing condition information is set for each individual area and each divided area (refer to Figure 6 ).

[0140] (2-2) The shrinkage prediction process management device 20 corrects at least a portion of the hot pressing condition information to reduce the amount of shrinkage (or to reduce deformation caused by shrinkage), regardless of whether the estimated (temporary) pre-shrinkage contour converges or does not converge within the individual regions. When correcting at least a portion of the hot pressing condition information, the device 20 uses the same process as described in (1-2) above to obtain corrected hot pressing condition information that corrects the hot pressing condition information, and updates (overwrites) the obtained corrected hot pressing condition information as the hot pressing condition information. Furthermore, the intermediate processing condition information includes various processing conditions for intermediate processing (in this case, coating, printing, and trimming) set for each individual region and each divided region.

[0141] (2-3) Shrinkage Prediction The process management device 20 calculates the final pre-shrinkage profile Ls based on the shrinkage rate-related information for each individual region and each divided region and the (corrected and updated (overwritten)) hot pressing condition information for each individual region and each divided region.

[0142] When the hot pressing condition information is used in subsequent intermediate processing and hot pressing processing (ie, post-processing), the updated (overwritten) hot pressing condition information is used.

[0143] [Other example 3]

[0144] In Other Example 3, the shrinkage prediction process management device 20 corrects at least a portion of the hot pressing condition information, for example, in a manner that reduces (adjusts) the shrinkage and deformation, such that the pre-shrinkage contour becomes a predetermined set pre-shrinkage contour (pre-set to a contour slightly larger than the target contour Lt), following the procedure described in Other Example 2. Furthermore, hot pressing is performed using the hot pressing condition information that has been corrected for each individual region and each segmented region. Furthermore, in post-processing other than hot pressing, or intermediate processing (in this case, coating, printing, and finishing), processing corresponding to the set pre-shrinkage contour is performed without individual corrections, particularly without individual corrections.

[0145] [Second embodiment ( Figures 19 to 21 )]

[0146] Next, use Figures 19 to 21 The production process of the resin sheet according to the second embodiment will be described. Figure 19 An overview of the entire process of producing a resin sheet according to the second embodiment is shown. Figure 19 The manufacturing process of the resin sheet of the second embodiment shown is relatively Figure 1In the manufacturing process of the resin sheet of the first embodiment shown, the coating curing process P3E (a process for setting the coating to a fully cured state) in the coating process P3 is changed to a coating semi-curing process P3F for setting the coating to a semi-cured state. Moreover, a coating full curing process P7 for setting the coating to a fully cured state is added between the hot pressing process P6 and the inspection process P8. In addition, accompanying this, the setting contents in the coating condition setting process P3C for each area in the coating process P3 are different. Figure 19 In the manufacturing process shown, the process management system 1 is composed of an overall management device 2 and process-specific management devices 10, 20, 30, 40, 50, 60, 70, and 80. The following mainly describes the differences from the first embodiment, and descriptions of the same points as the first embodiment are omitted. Furthermore, "fully cured" refers to a state in which the coating is substantially completely cured, and "semi-cured" refers to a state of curing that is halfway to a fully cured state.

[0147] [Each area coating condition setting step P3C ( Figure 20 、 Figure 21 )]

[0148] In the second embodiment, in the per-area coating condition setting step P3C, the coating process management device 30 sets the "curing degree of the semi-cured coating" for each individual area and each segmented area based on the curvature based on the curvature-related information for each individual area and each segmented area. In other words, the "per-area coating condition" in the second embodiment is the "curing degree of the coating for each individual area and each segmented area."

[0149] The storage device 30A of the coating process management device 30 stores a curvature / target curing degree characteristic (see Figure 20 ). The coating process management device 30 calculates the target curing degree for each (divided) area associated with the individual area W1 corresponding to the resin sheet based on the maximum curvature corresponding to the (divided) area (maximum curvature based on curvature association information) and the curvature / target curing degree characteristic. Furthermore, the coating process management device 30 stores (sets) the calculated target curing degree in the curing degree information (refer to Figure 21 In the second embodiment, the curvature of the divided area is large, and the curvature degree set to be lower than that of the divided area with a small curvature.

[0150] In the above curing degree information (refer to Figure 21), the shrinkage of the intermediate resin sheet Wn (intermediate product) caused by the hot pressing process P6 is taken into consideration, and the "maximum curvature" when shrinking to the target contour Lt and the "target degree of curing" corresponding to the maximum curvature are set for each individual area and each divided area. However, in the case of an intermediate resin sheet Wn (intermediate product) with a shrinkage rate of, for example, about 1 to 5 [%], it can also be assumed that there is almost no shrinkage caused by the hot pressing process P6 (assuming that the intermediate resin sheet Wn (intermediate product) is formed into a resin sheet Wz (finished product) with almost no shrinkage), and the "maximum curvature" and "target degree of curing" of each individual area and each divided area of the target contour Lt are stored (set) in the degree of curing information (refer to Figure 21 ) Alternatively, instead of setting a different target curing degree for each individual region and each divided region, the lowest target curing degree among the target curing degrees obtained for each individual region and each divided region may be applied to all divided regions within the individual region.

[0151] [Coating step P3D]

[0152] In the coating process P3D, the coating process management device 30 controls the coating device 31 to form the pre-shrinkage profile Ls (see Figure 3 、 Figure 4 In this way, using the pre-shrinkage profile based on the shrinkage rate-related information for each individual area and each divided area and the hot pressing condition information for each individual area and each divided area, a modified coating (intermediate processing and post-processing) is applied to each individual area.

[0153] Furthermore, when applying the coating, the coating process management device 30 applies the coating to each divided area so as to achieve a preset coating thickness.

[0154] [Coating semi-curing process P3F]

[0155] In the semi-curing coating step P3F, the coating process management device 30 controls the curing device 33 based on the curing degree information so that each individual area and each divided area has a different curing degree. For example, the curing device 33 may be a device that irradiates ultraviolet light. In this case, the coating process management device 30 controls the curing device 33 for each individual area and each divided area, using shielding plates corresponding to the divided areas, for a time corresponding to the target curing degree and an irradiation intensity corresponding to the target curing degree.

[0156] In addition, if Figure 20As shown in the curvature / target curing degree characteristics, the curing degree set to a semi-cured state in the segmented area with greater curvature is lower than that in the segmented area with less curvature. In other words, during hot pressing, the coating in the segmented area with greater curvature is set to a lower curing degree, increasing the elastic force and thus suppressing the occurrence of cracks such as splits and crazing.

[0157] [Coating full curing process P7 ( Figure 19 )]

[0158] like Figure 19 As shown, the coating and curing process P7 is performed by a coating and curing process management device 70 (e.g., a personal computer) and a curing device 73. The coating and curing process management device 70 is connected to a communication line T and operates the curing device 73 based on instructions from the overall management device 2 (or input instructions from an operator, etc.). For example, if the coating agent is a UV-curable paint, the curing device 73 is a device that irradiates ultraviolet light. Furthermore, the coating and curing process P7 is performed after the hot pressing process P6 and before the inspection process P8.

[0159] After the hot pressing step P6, the intermediate resin sheet Wn (intermediate product) remains in a semi-cured coating state. In the coating full curing step P7, the coating full curing step management device 70 controls the curing device 73 to cure the semi-cured coating to a fully cured state.

[0160] [Third embodiment ( Figure 19 、 Figure 22 , Figure 23 )]

[0161] Next, use Figure 19 、 Figure 22 、 Figure 23 The manufacturing process of the resin sheet of the third embodiment will be described. Figure 19 The second embodiment shown is the same as the third embodiment, but differs from the second embodiment in the following aspects. The manufacturing process of the resin sheet of the third embodiment differs from the manufacturing process of the resin sheet of the second embodiment in the coating process P3, with respect to the setting contents of the coating condition setting process P3C for each region, the implementation contents of the coating implementation process P3D, and the implementation contents of the coating semi-curing process P3F. These differences from the second embodiment will be mainly described, and the description of the same points as the second embodiment will be omitted. In addition, "fully cured state" refers to a state in which the coating is almost completely cured, and "semi-cured state" refers to a cured state halfway to reaching the fully cured state, which is the same as the second embodiment.

[0162] [Each area coating condition setting step P3C ( Figure 20 、 Figure 21 )]

[0163] In the third embodiment, in the per-area coating condition setting step P3C, the coating process management device 30 sets the "coating thickness" for each individual area and each segmented area based on the curvature based on the curvature association information for each individual area and each segmented area. In other words, the "per-area coating condition" in the third embodiment is the "coating thickness for each individual area and each segmented area."

[0164] In addition, in the first embodiment, the "coating condition for each area" is also the "coating thickness for each individual area and each divided area", but it is different from the first embodiment in the following aspects. In the third embodiment, the coating is set to a semi-cured state and hot pressing is performed. On the other hand, in the first embodiment, the coating is set to a fully cured state and hot pressing is performed. In the first embodiment, the coating thickness in the divided area with a large curvature is made thinner than that in the divided area with a small curvature in such a way that the coating in the fully cured state does not produce cracks in the area with a large curvature. In contrast, in the third embodiment, the coating having elasticity in the semi-cured state does not produce cracks even by hot pressing. Therefore, in the divided area with a large curvature, it is anticipated that the coating will become thinner as it extends with a large curvature, and is applied thicker in advance.

[0165] The storage device 30A of the coating process management device 30 stores a curvature / target coating thickness characteristic (see Figure 22 ). The coating process management device 30 calculates the target coating thickness for each (divided) area associated with the individual area W1 corresponding to the resin sheet based on the maximum curvature corresponding to the (divided) area (maximum curvature based on curvature association information) and the curvature / target coating thickness characteristic. Furthermore, the coating process management device 30 stores (sets) the calculated target coating thickness in the coating thickness information (refer to Figure 23 ) in the corresponding area of the "target coating thickness". In the third embodiment, the coating thickness in the divided area with a large curvature is set to be thicker than that in the divided area with a small curvature.

[0166] In the hot pressing step P6, the intermediate resin sheet Wn (intermediate product) shrinks. Considering this shrinkage, the coating thickness information (see Figure 23), for each individual area and each divided area, the "maximum curvature" when shrinking to the target contour Lt and the "target coating thickness" corresponding to the maximum curvature are set. However, sometimes it is an intermediate resin sheet Wn (intermediate product) with a shrinkage rate of about 1 to 5 [%]. In this case, it is assumed that there is almost no shrinkage caused by the hot pressing process P6. That is, it is assumed that the intermediate resin sheet Wn (intermediate product) is molded into a resin sheet Wz (finished product) with almost no shrinkage. In this case, the "maximum curvature" and "target coating thickness" of each individual area and each divided area of the target contour Lt can also be stored (set) in the coating thickness information (refer to Figure 23 ). In addition, instead of setting a different target coating thickness for each individual region and each divided region, the thickest target coating thickness among the target coating thicknesses calculated for each individual region and each divided region may be applied to all divided regions within the individual region.

[0167] [Coating step P3D]

[0168] In the coating process P3D, the coating process management device 30 controls the coating device 31 to form the pre-shrinkage profile Ls (see Figure 3 、 Figure 4 In this way, using the pre-shrinkage profile based on the shrinkage rate-related information for each individual area and each divided area and the hot pressing condition information for each individual area and each divided area, a modified coating (intermediate processing and post-processing) is applied to each individual area.

[0169] In addition, when coating is performed, the coating process management device 30 calculates the coating thickness based on the coating thickness information (see Figure 23 ) to apply coating to the coating thickness set for each (divided) area.

[0170] [Coating semi-curing process P3F]

[0171] In the coating semi-curing step P3F, the coating step management device 30 controls the curing device 33. Specifically, the coating step management device 30 controls the curing device 33 so that all divided regions within the individual region have substantially the same degree of curing based on a preset degree of curing in the semi-cured state.

[0172] During hot pressing, the semi-cured coating with elasticity can suppress the occurrence of cracks such as cracks and crazing even when bent. In the segmented area with large curvature, the coating extends along the curved shape and becomes thinner, but in the coating thickness information (see Figure 23 ) is set thicker in advance. Thus, the thickness of the coating can be made roughly the same at the part with large curvature and at other parts.

[0173] [Coating full curing process P7 ( Figure 19 )]

[0174] The coating and full curing step P7 of the third embodiment is the same as the coating and full curing step P7 of the second embodiment. Figure 19 As shown, the coating and curing process P7 is performed by a coating and curing process management device 70 (e.g., a personal computer) and a curing device 73. The coating and curing process management device 70 activates the curing device 73 based on instructions from the overall management device 2 (or input instructions from an operator, etc.). For example, if the coating agent is a UV-curable paint, the curing device 73 irradiates ultraviolet light. Furthermore, the coating and curing process P7 is performed after the hot pressing process P6 and before the inspection process P8.

[0175] After the hot pressing step P6, the intermediate resin sheet Wn (intermediate product) remains in a semi-cured coating state. In the coating full curing step P7, the coating full curing step management device 70 controls the curing device 73 to cure the semi-cured coating to a fully cured state.

[0176] As described above, in the intermediate processing method of the extruded resin sheet and the hot pressing method of the intermediate resin sheet Wn (intermediate manufactured product) on which the extruded resin sheet has been subjected to intermediate processing, the extruded resin sheet is virtually divided into a plurality of regions (individual regions, divided regions). Moreover, the different shrinkage rates of each region are obtained, and the corrections of the intermediate processing and hot pressing (i.e., post-processing) are appropriately corrected for each region (each individual region, each divided region). In this way, the waste of the extruded resin sheet (equivalent to the substrate), the coating agent, etc., and the occurrence of printing offset can be further reduced, and products with more stable precision can be manufactured. In addition, by feeding back the inspection results of the size, shape, etc. of the resin sheet Wz (finished product), the precision can be further improved.

[0177] Furthermore, for example, in the factory of Company A Figure 1 as well as Figure 19 The intermediate resin sheet Wn (intermediate product) is produced by performing the extrusion molding process P1 to the trimming process P5 shown. In addition, the hot pressing process P6 to the inspection process P8 can also be carried out in the factory of Company B. In this case, the overall management device 2, the hot pressing process management device 60, (the coating and full curing process management device 70), and the inspection process management device 80 are connected to the Internet. In this case, the hot pressing processing condition information for the hot pressing process P6 can also be produced in the shrinkage prediction process management device 20 (refer to Figure 6), and transmits it to the hot pressing process management device 60 via the communication line T, the overall management device 2 and the Internet. In addition, not only does Company A provide hot pressing processing condition information to Company B, but Company A can also prepare Figure 1 The hot pressing process management device 60, heating device 61, and pressurizing device 63 shown are provided to Company B.

[0178] Furthermore, the manufacturing processes described in the first to third embodiments include intermediate processing steps such as an intermediate processing step and a hot pressing step. Furthermore, the step for modifying processing conditions (for each individual area or each divided area) may be at least one of a coating step, a printing step, a trimming step, and a hot pressing step.

[0179] The intermediate processing method for an extruded resin sheet and the hot pressing method for an intermediate resin sheet subjected to intermediate processing, according to one embodiment of the present invention, are not limited to the processing methods described in this embodiment. Various modifications, additions, and deletions can be made without altering the purpose of one embodiment of the present invention. Furthermore, while the thickness of the resin sheet described in this embodiment is, for example, several millimeters, the thickness of the intended resin sheet is not particularly limited, and a resin panel having a thickness of several tens of millimeters is also possible. Furthermore, the material of the resin sheet is not particularly limited.

[0180] The shrinkage-related information described in this embodiment (see Figure 5 )、Hot pressing condition information (refer to Figure 6 ), outline information (refer to Figure 7 ), curvature / maximum allowable coating thickness characteristics (refer to Figure 9 ), coating thickness information (refer to Figure 10 )、Final product inspection information (refer to Figure 18 ), curing degree information (refer to Figure 21 ), coating thickness information (refer to Figure 23 ) is merely an example and is not limited to the above-mentioned items and forms. Furthermore, the shrinkage-related information only needs to store at least one of the following: the temperature of the extruded resin sheet after extrusion molding, the temperature of the rollers used in extrusion molding, the rotational speed of the rollers, the thickness distribution of each segmented area, the temperature distribution of each segmented area, and the refractive index distribution of each segmented area, corresponding to each region. Furthermore, the hot pressing condition information only needs to store at least one of the heating distribution of each segmented area and the pressure distribution of each segmented area, corresponding to each region.

[0181] In this embodiment, an inkjet coating device, an inkjet printing device, and a laser cutter are described as examples of a finishing device. However, the present invention is not limited to these. Furthermore, there are no particular limitations on the coating agent, printed coating, etc.

[0182] Furthermore, above (≥), below (≤), greater than (>), less than (<), etc. may or may not include an equal sign. The numerical values used in the description of the present embodiment are merely examples and are not intended to be limiting.

[0183] The management devices 10, 20, 30, 40, 50, 60, and 80 described above include at least one programmed electronic processor. The management device includes a memory storing commands or software executed by the electronic processor to implement at least one of the functions of the management device described herein. For example, depending on the embodiment, the management device may be implemented as a microprocessor with a separate memory.

[0184] The above-mentioned storage device can include volatile or non-volatile memory. Examples of suitable storage devices include RAM (random access memory), flash memory, ROM (read-only memory), PROM (programmable read-only memory), EPROM (erasable programmable read-only memory), EEPROM (erasable programmable read-only memory), registers, magnetic disks, optical disks, hard drives, other suitable storage media, or combinations thereof.

[0185] Software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions.

Claims

1. A method for intermediate processing of an extruded resin sheet, wherein the method is for producing a resin sheet for hot pressing, i.e., an intermediate resin sheet, from a strip-shaped extruded resin sheet that has been heated and extruded, wherein: Using a process management system equipped with a computer, the process management system virtually divides the extruded resin sheet in the form of a strip after extrusion molding into a plurality of individual regions corresponding to the plurality of resin sheets, further virtually divides each of the virtually divided individual regions into a plurality of segmented regions, and obtains shrinkage rate-related information associated with the shrinkage rate of each segmented region for each of the individual regions. When performing intermediate processing as processing after the extrusion molding and before the hot pressing processing for each of the individual regions, the process management system is used based on the shrinkage rate-related information for each of the individual regions and each of the divided regions, and The processing condition information of the hot pressing process for each of the individual regions and each of the divided regions, i.e., the hot pressing process condition information, The intermediate processing is performed with modified processing conditions for each of the individual regions.

2. The intermediate processing method of an extruded resin sheet according to claim 1, wherein: Before implementing the above-mentioned intermediate processing, the following steps are carried out: a contour calculating step of virtually setting, using the process management system, a contour corresponding to the resin sheet after completion of the intermediate processing and the hot pressing processing, i.e., a target contour, for each of the individual regions; and calculating and virtually setting, for each of the individual regions, a contour before shrinkage toward the target contour, i.e., a pre-shrinkage contour, based on the shrinkage rate-related information for each of the individual regions and each of the divided regions and the hot pressing condition information for each of the individual regions and each of the divided regions; and The contour storage step uses the process management system to store the target contour and the contour before shrinkage in correspondence with the individual areas. The intermediate processing steps as the above-mentioned intermediate processing steps include: a correction amount obtaining step of obtaining, before performing the intermediate processing, a correction amount for each of the individual regions based on the target contour and the pre-shrinkage contour stored in the contour storing step using the process management system; and The intermediate processing performing step uses the process management system to perform the intermediate processing corrected for each of the individual regions based on the correction amount for each of the individual regions determined in the correction amount acquiring step.

3. The intermediate processing method of an extruded resin sheet according to claim 2, wherein: The intermediate processing step includes a coating step of coating the surface of the extruded resin sheet. Using the above-mentioned process management system, in the above-mentioned correction amount acquisition process corresponding to the above-mentioned coating implementation process, for each of the above-mentioned individual areas, the range of implementing the above-mentioned coating on the individual area is set to the range of the above-mentioned pre-shrinkage contour corresponding to the individual area, thereby calculating the above-mentioned correction amount for each of the above-mentioned individual areas.

4. The intermediate processing method of an extruded resin sheet according to claim 2, wherein: The intermediate processing step includes a printing step of printing on the surface of the extruded resin sheet. Using the above-mentioned process management system, in the above-mentioned correction amount acquisition process corresponding to the above-mentioned printing implementation process, for each of the above-mentioned individual areas, based on the above-mentioned pre-shrinkage contour corresponding to the individual area, the above-mentioned target contour and the above-mentioned shrinkage rate related information of each of the above-mentioned divided areas and the above-mentioned hot pressing processing condition information, the range, shape and scale of printing on the individual area are calculated, thereby calculating the above-mentioned correction amount for each of the above-mentioned individual areas.

5. The intermediate processing method of an extruded resin sheet according to any one of claims 2 to 4, wherein: The intermediate processing step includes a trimming step of cutting out a region corresponding to the resin sheet from the individual region from the strip-shaped extruded resin sheet. Using the above-mentioned process management system, in the above-mentioned correction amount acquisition process corresponding to the above-mentioned trimming implementation process, for each of the above-mentioned individual areas, the range cut out from the individual area is set as the range of the above-mentioned pre-shrinkage contour corresponding to the individual area, thereby calculating the above-mentioned correction amount for each of the above-mentioned individual areas.

6. The intermediate processing method of an extruded resin sheet according to any one of claims 1 to 4, wherein: The above shrinkage-related information includes: Corresponding to the above individual areas, The temperature of the extruded resin sheet after the extrusion molding, The temperature of the rollers used in the above extrusion molding, The speed of the rollers, The plate thickness distribution of each of the above-mentioned divided areas, The temperature distribution of each of the above-mentioned divided areas, and At least one of the refractive index distributions of each of the above-mentioned divided regions.

7. The intermediate processing method of an extruded resin sheet according to any one of claims 1 to 4, wherein: The above hot pressing condition information includes: Corresponding to the above individual areas, The heating distribution of each of the above divided areas, and At least one of the pressure distributions of each of the above-mentioned divided areas.

8. A method for hot pressing an intermediate resin sheet subjected to intermediate processing on an extruded resin sheet, wherein the method comprises: Using a process management system equipped with a computer, the process management system virtually divides the extruded resin sheet in the form of a strip after extrusion molding into a plurality of individual regions corresponding to the plurality of resin sheets, further virtually divides each of the virtually divided individual regions into a plurality of segmented regions, and obtains shrinkage rate-related information associated with the shrinkage rate of each segmented region for each of the individual regions. The intermediate processing is the processing after the extrusion molding and before the hot pressing process. When the heat pressing process is performed on each of the resin sheets that have undergone the intermediate processing, that is, each of the intermediate resin sheets, the process management system is used based on the shrinkage rate-related information for each of the individual regions and each of the divided regions, and The hot pressing condition information is obtained by correcting the hot pressing condition information for at least a portion of the individual region based on the processing condition information for the hot pressing process for each of the individual regions and each of the divided regions, i.e., the hot pressing condition information, and the processing condition information for the intermediate process for each of the individual regions and each of the divided regions, i.e., the intermediate processing condition information. To implement the above-mentioned hot pressing process.

9. A method for hot pressing an intermediate resin sheet subjected to intermediate processing on an extruded resin sheet, wherein the method comprises: Using a process management system equipped with a computer, the process management system virtually divides the extruded resin sheet in the form of a strip after extrusion molding into a plurality of individual regions corresponding to the plurality of resin sheets, further virtually divides each of the virtually divided individual regions into a plurality of segmented regions, and obtains shrinkage rate-related information associated with the shrinkage rate of each segmented region for each of the individual regions. The intermediate processing is the processing after the extrusion molding and before the hot pressing process. Using the above process management system, the shrinkage rate-related information for each of the individual regions and each of the divided regions, and The processing condition information of the hot pressing process for each of the individual regions and each of the divided regions, i.e., the hot pressing process condition information, When the heat pressing is performed on each of the resin sheets after the intermediate processing with the modified processing conditions for each of the individual regions, that is, each of the intermediate resin sheets, the process management system is used based on the shrinkage rate-related information for each of the individual regions and each of the divided regions, and The hot pressing is performed for each of the individual regions and each of the divided regions using the processing condition information of the hot pressing, that is, the hot pressing condition information.

10. The method for hot pressing an intermediate resin sheet obtained by performing intermediate processing on an extruded resin sheet according to claim 8 or 9, wherein: The above shrinkage-related information includes: Corresponding to the above individual areas, The temperature of the extruded resin sheet after the extrusion molding, The temperature of the rollers used in the above extrusion molding, The speed of the rollers, The plate thickness distribution of each of the above-mentioned divided areas, The temperature distribution of each of the above-mentioned divided areas, and At least one of the refractive index distributions of each of the above-mentioned divided regions.

11. The method for hot pressing an intermediate resin sheet obtained by performing intermediate processing on an extruded resin sheet according to claim 8 or 9, wherein: The above hot pressing processing condition information includes: Corresponding to the above individual areas, The heating distribution of each of the above divided areas, and At least one of the pressure distributions of each of the above-mentioned divided areas.

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