Method for manufacturing a shaped body and apparatus for manufacturing a shaped body

Abstract

The present invention provides a method for manufacturing a shaped body and a device for manufacturing a shaped body. The method for manufacturing a shaped body is characterized by applying an ink to a material containing fibers, and using a pressurizing mechanism to heat and press the accumulation to which the ink has been applied, thereby causing the ink to solidify and the fibers to bind to each other, thereby generating a first shaped body.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a molded article and an apparatus for manufacturing a molded article. Background Technology

[0002] For example, Patent Document 1 discloses an apparatus for manufacturing sheets from fibers.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2006-89896

[0004] However, no study was conducted on the issue of manufacturing products using sheets produced by the method described in Patent Document 1. Summary of the Invention

[0005] The manufacturing method of the molded body according to an application example of the present invention includes the following steps: an ink application step, which applies ink to a material containing fibers; and a first molding step, which uses a pressure mechanism to heat and pressurize the deposit on which the ink has been applied, thereby fixing the ink and bonding the fibers together to form a first molded body.

[0006] An example of the present invention provides a molded body manufacturing apparatus comprising: an ink application unit that applies ink to a fiber-containing material; and a first molding unit having a pressure mechanism that heats and pressurizes the deposit to which the ink has been applied, thereby fixing the ink to the deposit and bonding the fibers together to form a first molded body. Attached Figure Description

[0007] Figure 1 This is a structural diagram showing a general outline of the molding body manufacturing apparatus according to the first embodiment of the present invention.

[0008] Figure 2 This is a flowchart of a method for manufacturing a molded body according to the first embodiment of the present invention.

[0009] Figure 3 These are cross-sectional views showing the overlapping states of primary stacked sheets, secondary stacked sheets, and secondary stacked sheets, respectively.

[0010] Figure 4 These are cross-sectional views showing the laminate, the first shaped body, and the third shaped body, respectively.

[0011] Figure 5 This is a three-dimensional drawing of the first formed object.

[0012] Figure 6 This is a three-dimensional diagram of the third-order model.

[0013] Figure 7This is a cross-sectional view showing the pressure section of the molding body manufacturing apparatus according to the second embodiment of the present invention, and a diagram showing the state in which the transfer sheet is arranged on the laminate.

[0014] Figure 8 It means Figure 7 The cross-sectional view of the pressurized section shown is a diagram illustrating the state of pressurizing the laminate.

[0015] Figure 9 It means Figure 7 The cross-sectional view of the pressurized section shown is a diagram illustrating the state of releasing the pressure on the laminate and removing the transfer sheet.

[0016] Figure 10 This is a cross-sectional view showing the pressure section of the molding body manufacturing apparatus according to the third embodiment of the present invention, and a diagram showing the state in which the recess forming member is arranged on the laminate.

[0017] Figure 11 It means Figure 10 The cross-sectional view of the pressurized section shown is a diagram illustrating the state of pressurizing the laminate.

[0018] Figure 12 It means Figure 10 The cross-sectional view of the pressurized section shown is a diagram illustrating the state of releasing the pressure on the laminate and removing the recessed part to form the component.

[0019] Label Explanation

[0020] 1…Stacking section; 2…Fixing section; 3…Cutting section; 4…First forming section; 5…Cooling section; 6…Second forming section; 7…Control device; 8…Base layer forming section; 9…Ink application section; 10…Cutting section; 11…Dispersion section; 12…Wire mesh belt; 13…Suction section; 14…Sheet supply section; 21…Heating and pressure roller; 31…Cutting blade; 32…Conveying roller; 40…Transfer sheet; 41…Pressure section; 61…Sewing machine; 71…Control section; 72…Storage section; 73…Communication section; 100…Forming body manufacturing device; 101…Cutting blade; 111…Roller; 112…Outer shell; 121…Tensioning Roller; 131…tube; 132…blower; 141…supply roller; 300…base layer; 301…base agent; 400…printing layer; 400A…pattern; 400B…assembly pattern; 400C…cut pattern; 401…ink; 402…recess; 411…pressurizing component; 412…pressurizing component; 413…recess forming component; F…fiber; M1…material; M2…accumulation; P…bonding material; S…sheet; S1…first-layer stacked sheet; S2…second-layer stacked sheet; S21…laminated body; S3…first-formed body; S4…second-formed body; S5…third-formed body; T M2 …average thickness; T S…average thickness; T S1 …average thickness, T S2 …average thickness, T S3 …average thickness. Detailed Implementation

[0021] Hereinafter, the method for manufacturing a molded article and the apparatus for manufacturing a molded article according to the present invention will be described in detail based on the preferred embodiments shown in the accompanying drawings.

[0022] <First Implementation>

[0023] Figure 1 This is a structural diagram showing a general outline of the molding body manufacturing apparatus according to the first embodiment of the present invention. Figure 2 This is a flowchart of a method for manufacturing a molded body according to the first embodiment of the present invention. Figure 3 These are sectional views showing the overlapping states of primary stacked sheets, secondary stacked sheets, and secondary stacked sheets, respectively. Figure 4 These are cross-sectional views showing the laminate, the first shaped body, and the third shaped body, respectively. Figure 5 This is a three-dimensional drawing of the first formed object. Figure 6 This is a three-dimensional diagram of the third-order model.

[0024] In addition, the following will sometimes be Figure 1 , Figure 3 , Figure 4 , Figure 5 as well as Figure 6 ( Figure 7 , Figure 8 as well as Figure 9 Similarly, the upper side is called "upper" or "above," and the lower side is called "lower" or "below." Furthermore, Figure 1 This is a schematic structural diagram; the positional relationships, orientations, and sizes of the various parts of the molding apparatus 100 are not limited to those shown in the diagram. Furthermore, in Figure 1 In this context, the direction in which materials or shaped bodies are conveyed is also referred to as the conveying direction. Additionally, the conveying direction is also indicated by... Figure 1 The end of the arrow in the diagram is called the "downstream side", and the base of the arrow is called the "upstream side".

[0025] [Molded body manufacturing apparatus 100]

[0026] Figure 1 The molded body manufacturing apparatus 100 shown is an apparatus for performing the molded body manufacturing method of the present invention, and is an apparatus for molding a fiber-containing material M1 to manufacture a third molded body S5 as a molded body. The molded body manufacturing apparatus 100 includes an accumulation section 1, a fixing section 2, a cutting section 3, a base layer forming section 8, an ink application section 9, a first forming section 4, a cooling section 5, a second forming section 6, a control device 7, and a cutting section 10. Furthermore, as... Figure 2 As shown, the method for manufacturing a molded body includes a stacking process, a fixing process, a cutting process, a base layer forming process, an ink application process, a first molding process, a cooling process, a cutting process (second molding process), and a joining process (second molding process). In this embodiment, the manufacturing of a tote bag using the third molded body S5 is described as an example, but the present invention is not limited to this. The final product manufactured by the third molded body S5 may also be, for example, a mask, gloves, socks, book covers, business card holders, slippers, etc. Furthermore, the third molded body S5 may also be a final product. Hereinafter, each part of the molded body manufacturing apparatus 100 and each step of the molded body manufacturing method will be described in detail.

[0027] (Material M1)

[0028] First, let's describe material M1. Material M1 includes fibers F and a bonding material P that binds the fibers F together.

[0029] As for fiber F, it is not specifically limited; for example, various cellulose fibers and various chemical fibers can be listed.

[0030] Although the average fiber length of fiber F is not particularly limited, it is preferably 0.1 mm or more and 10 mm or less, and more preferably 1 mm or more and 5 mm or less. As a result, the strength of the third molded body S5 can be improved more reliably, and the cutting and trimming processes described later can be performed more easily.

[0031] From the same point of view, although the average width (average diameter) of fiber F is not particularly limited, it is preferably 0.5 μm or more and 200 μm or less, and more preferably 1.0 μm or more and 100 μm or less.

[0032] From the same point of view, the content of fiber F in material M1 is not particularly limited, for example, preferably 20% by weight or more and 99% by weight or less, more preferably 50% by weight or more and 90% by weight or less.

[0033] As a binding material P, examples include various polyolefins, acrylic resins, polyvinyl chloride, polyesters, polyamides and other thermoplastic resins, various thermoplastic elastomers, starch, dextrin, glycogen, amylose, hyaluronic acid, kudzu root, konjac, potato starch, etherified starch, esterified starch, natural gum paste, fiber-induced paste, seaweed, animal protein and other components derived from natural sources, and one or more of these substances can be selected and used in combination.

[0034] The bonding material P is in the form of particles or fibers.

[0035] When the bonding material P is in the form of particles, its average particle size (volume basis) is not particularly limited. For example, it is preferably 0.5 μm or more and 200 μm or less, and more preferably 1.0 μm or more and 100 μm or less. As a result, the strength of the third molded body S5 can be improved more reliably, and the cutting and trimming processes described later can be performed more easily.

[0036] From the same point of view, when the bonding material P is fibrous, the average fiber length of the bonding material P is not particularly limited. For example, it is preferably 0.1 mm or more and 10 mm or less, and more preferably 1 mm or more and 10 mm or less.

[0037] From the same point of view, when the bonding material P is fibrous, the average width (average diameter) of the bonding material P is not particularly limited. For example, it is preferably 0.5 μm or more and 200 μm or less, and more preferably 1.0 μm or more and 100 μm or less.

[0038] From the same point of view, the content of the binding material P in material M1 is not particularly limited, for example, preferably 1% or more and 80% or less by weight, more preferably 10% or more and 50% or less by weight.

[0039] In addition, material M1 may also contain other components besides binding material P. Examples of such other components include colorants for coloring fibers, aggregation inhibitors for inhibiting fiber aggregation, and flame retardants for making fibers less flammable. One or more of these components may be used.

[0040] When material M1 contains other components, the content of these other components in material M1 is not particularly limited, but is preferably 0.1% by weight or more and 10% by weight or less, more preferably 0.5% by weight or more and 5% by weight or less. This allows for the achievement of the effects produced by mixing other components, and ensures sufficient amounts of fiber F and binding material P, thereby more effectively improving the strength of the third molded body S5. Furthermore, if the fiber F dissolves or softens itself and bonds with itself, the binding material P may not need to be added in addition to the fiber F.

[0041] (Stacking Section 1, Stacking Process)

[0042] like Figure 1 As shown, the stacking section 1 is the part that performs the stacking process, dispersing material M1 in gas to generate a deposit M2 of material M1. Figure 1 As shown, the stacking section 1 has a dispersing section 11, a mesh belt 12, a suction section 13, and a sheet supply section 14.

[0043] The dispersing section 11 unravels and releases the intertwined fibers F in the material M1. The dispersing section 11 has a roller 111 for introducing and releasing the material M1 and a housing 112 for receiving the roller 111.

[0044] The drum 111 is composed of a cylindrical mesh and is a sieve that rotates around its central axis. As the drum 111 rotates, fibers F and the like, smaller than the mesh size in the material M1, can pass through it. At this time, the material M1 is released along with the air. In other words, the drum 111 functions as a release unit for releasing material M1 containing fibers F.

[0045] The roller 111 is connected to a drive source (not shown) and rotates by a rotational force output from the drive source. This drive source is electrically connected to a control device 7, and its operation is controlled.

[0046] Furthermore, the material M1 released by the roller 111 falls as it disperses in the gas and moves toward the mesh belt 12 located below the roller 111.

[0047] In addition, a material supply unit (not shown) is connected to the roller 111. Examples of material supply units include those in the sheet manufacturing apparatus described in Japanese Patent Application Publication No. 2024-113315, which have a structure including a raw material supply unit, a coarse crushing unit, a defiberizing unit, and a mixing unit, or a supply unit that supplies material M1 in a box-like manner.

[0048] The mesh belt 12 is a mesh component, and in the illustrated structure, it is composed of annular belts. Sheets S are supplied to the mesh belt 12 from the sheet supply section 14 (described later), and material M1 dispersed and released by the dispersion section 11 accumulates on the sheet S, thereby forming a deposit M2. The mesh belt 12 is wound around four tension rollers 121. Driven by the rotation of the tension rollers 121, the deposit M2 on the mesh belt 12 is conveyed downstream.

[0049] Furthermore, although the mesh belt 12, which is an annular belt, is used as an example of a mesh component in the illustrated structure, the present invention is not limited to this. For example, a structure using a flat mesh component may also be used.

[0050] The suction section 13 is a suction mechanism that draws air from below the mesh belt 12. This allows material M1 to be drawn onto the mesh belt 12. Therefore, it promotes the deposition of material M1 onto the sheet S. Furthermore, it enables the generation of a uniformly thick deposit M2.

[0051] A pipe 131 is connected to the suction section 13. Furthermore, a blower 132 is installed midway along the pipe 131. The operation of the blower 132 generates suction force within the suction section 13. The blower 132 is electrically connected to the control device 7, and its operation is controlled.

[0052] The sheet supply unit 14 has a supply roller 141, which functions to feed the sheet S by rotating the supply roller 141. The sheet S fed by the supply roller 141 is fed onto the mesh belt 12. Then, a deposit M2 is formed on the sheet S. Hereinafter, the sheet S and the deposit M2 on the sheet S will be collectively referred to as "one-time deposited sheet S1". However, if the deposit M2 is formed on the mesh belt 12 without using the sheet S, or if the sheet S is peeled off after the deposit M2 is formed, the deposit M2 may be referred to as one-time deposited sheet S1.

[0053] The supply roller 141 is connected to a drive source (not shown) and rotates by a rotational force output from the drive source. This drive source is electrically connected to a control device 7, and its operation is controlled.

[0054] The sheet S is breathable and is made of woven fabric, non-woven fabric, etc. The fibers constituting the sheet S include those exemplified in the aforementioned fiber F. By supplying such a sheet S, the strength of the third molded body S5 can be improved more effectively, and the cutting and trimming processes described later can be performed more easily.

[0055] like Figure 3 As shown, although the average thickness T of sheet S S The thickness is not particularly limited, but is preferably 0.01 mm or more and 20 mm or less, more preferably 0.1 mm or more and 2 mm or less. This allows for a more reliable increase in the strength of the third molded body S5, and makes it easier to perform the cutting and trimming processes described later.

[0056] From the same perspective, the density ρ of material M1 in the accumulation M2... M1 No particular limit is specified, but 0.01 g / cm³ is preferred. 3 Above and 2.0 g / cm 3 The following is more preferably 0.1 g / cm³. 3 Above and 1.0 g / cm 3 the following.

[0057] Starting from the same point of view, such as Figure 3 As shown, the average thickness T of the deposit M2 M2 There are no particular limitations, but it is preferred to be 1 mm or more and 100 mm or less, and more preferably 1.5 mm or more and 50 mm or less.

[0058] From the same perspective, the average thickness T of a single-layer stacked sheet S1 S1 It is not specifically limited, but preferably 1.1 mm or more and 120 mm or less, more preferably 1.3 mm or more and 60 mm or less.

[0059] (Fixing Part 2, Fixing Process)

[0060] like Figure 1 As shown, the fixing unit 2 is a part that performs a fixing process to fix the fibers F of the secondary stacked sheet S2 before the ink application process described later, and fixes the pile M2 of the primary stacked sheet S1 and conveys it downstream. The fixing performed by the fixing unit 2 refers to the process of compressing the primary stacked sheet S1 to reduce the thickness of the pile M2 and increase its density. Such fixing (temporary fixing) is not necessary, but by fixing (temporary fixing), it is possible to more effectively prevent the fibers F from spreading or scattering, thus improving operability.

[0061] The fixing part 2 has a pair of heating and pressurizing rollers 21 disposed on the downstream side of the stacking part 1. Each heating and pressurizing roller 21 is arranged vertically across the conveying path of the primary stacked sheet S1. When the primary stacked sheet S1 passes between the pair of heating and pressurizing rollers 21, the stacked material M2 is heated and pressurized. As a result, a secondary stacked sheet S2 is generated. Then, the secondary stacked sheet S2 is conveyed downstream by means of the rotation of the pair of heating and pressurizing rollers 21.

[0062] A pair of heated pressure rollers 21 are connected to a drive source (not shown) and a heat source, and rotate by the rotational force output from the drive source. The heated pressure rollers 21 are heated by the heat generated by the heat source. The drive source and the heat source are electrically connected to a control device 7, and their operation is controlled.

[0063] By applying pressure and heating simultaneously through the fixing part 2, the bonding material P in the stack M2 can be melted or softened and penetrated between the fibers F. Therefore, the fibers F can be bonded together, restricting accidental movement of the fibers F in the secondary stacked sheet S2, thus facilitating shape maintenance. This improves operability in subsequent processes.

[0064] like Figure 3 As shown, the average thickness T of the secondary stacked sheet S2 S2 While not specifically limited, the thickness is preferably 0.8 mm or more and 100 mm or less, more preferably 1.2 mm or more and 50 mm or less. This improves operability in subsequent processes more effectively.

[0065] The average thickness T of the secondary stacked sheet S2 S2 (mm) and the average thickness T of the single-layer stacked sheet S1 S1 (mm) ratio T S2 / T S1 The pressure is not particularly limited, but is preferably 0.1 or more and 0.9 or less, more preferably 0.2 or more and 0.8 or less. Applying this level of pressure through the fixing part 2 can more effectively improve operability in subsequent processes.

[0066] The density ρ of material M1 in the secondary stacked sheet S2 S2 It is not specifically limited, but is preferably 0.02 g / cm³. 3 Above and 3.0 g / cm 3 The following is more preferably 0.15 g / cm³. 3 Above and 1.5g / cm 3 The following applies pressure by means of the fixing part 2, which can more effectively improve operability in subsequent processes.

[0067] Although the density ρ of the material M1 in the accumulation M2 is M1 (g / cm 3 The density ρ of material M1 in the secondary stacked sheet S2 is... S2 (g / cm 3 The ratio of ρ M1 / ρ S2 While not specifically limited, the pressure is preferably 0.07 or higher and 0.85 or lower, more preferably 0.1 or higher and 0.7 or lower. Applying this level of pressure via the fixing part 2 can more effectively improve operability in subsequent processes.

[0068] The heating temperature T2 of the fixing part 2 is not particularly limited, but is preferably a temperature lower than the heating temperature T4 in the first forming process. Specifically, the heating temperature T2 is preferably 40°C or higher and 200°C or lower, more preferably 45°C or higher and 150°C or lower. This allows the bonding material P in the deposit M2 to be moderately melted or softened. Therefore, the bonding strength between the fibers F can be kept within an appropriate range. Thus, operability can be improved more effectively, and the degree of freedom in subsequent processing steps can be further increased.

[0069] Therefore, the preferred method for manufacturing the molded article includes a fixing step that fixes the fibers F of the secondary stacked sheet S2, which serves as the deposit, before the ink application step. This effectively prevents the fibers F from scattering or flying away, thereby significantly improving operability in subsequent processes.

[0070] In addition, in a fixed process, only pressurization may be performed. Alternatively, the fixed process may be omitted.

[0071] Furthermore, in the fixing process, it is preferable to fix the fibers at a lower temperature (heating temperature T2) or for a shorter time than the heating temperature T4 in the first forming process. The fixing of the fibers F after the fixing process is weaker compared to the fixing of the fibers F after the first forming process. This prevents the fibers F from being over-fixed, thereby further increasing the degree of freedom in subsequent processing steps and saving energy used for heating.

[0072] Alternatively, instead of shortening the heating time, the heating temperature T2 can be the same as the heating temperature T4, or it can be a higher temperature than the heating temperature T4.

[0073] (Cutting section, cutting process)

[0074] like Figure 1 As shown, the cutting section 3 performs a cutting process to cut the secondary stacked sheet S2 into the desired size. The cutting section 3 has a pair of cutting blades 31 located downstream of the fixing section 2. Each cutting blade 31 is arranged vertically across the conveying path of the secondary stacked sheet S2. Each cutting blade 31 is arranged with its blade tips facing each other, configured so that the blade tips can approach and separate. When the blade tips of each cutting blade 31 approach to contact, the secondary stacked sheet S2 passing between them is cut. In addition, by adjusting the timing of the approach and separation of each cutting blade 31, the length of the secondary stacked sheet S2 can be adjusted.

[0075] The cutting blade 31 is connected to a drive source (not shown) and approaches and separates by means of a force output from the drive source. This drive source is electrically connected to a control device 7, whose operation is controlled.

[0076] Furthermore, a pair of conveying rollers 32 are provided downstream of the cutting blade 31. They are arranged vertically across the conveying path of the secondary stacked sheet S2. The conveying rollers 32 rotate while clamping the cut secondary stacked sheet S2, thereby conveying it downstream to the first forming section 4.

[0077] The conveyor roller 32 is connected to a drive source (not shown) and rotates by means of a rotational force output from the drive source. This drive source is electrically connected to a control device 7, and its operation is controlled.

[0078] In addition, the cutting part 3 is not limited to the above structure, and may also have a structure in which a cutting roller with a blade is formed on the outer periphery of the roller instead of the cutting blade 31.

[0079] In addition, although not shown in the figure, the cutting part 3 may also have a cutting blade that cuts the two edges of the secondary stacked sheet S2 in the width direction.

[0080] Alternatively, the cutting section 3 can be omitted. In this case, it is preferable to use a structure in which the secondary stacked sheet S2 is bent and overlapped in the thickness direction before forming in the first forming section 4 described later.

[0081] (8. Base layer formation process)

[0082] The substrate forming section 8 is a part that performs a substrate forming process to form a substrate layer 300 on the secondary stacked sheet S2 before the ink application process described later. In this embodiment, the substrate layer 300 is formed on the upper surface of the uppermost secondary stacked sheet S2 while multiple secondary stacked sheets S2 are overlapped. That is, it can be said that a lamination process of overlapping multiple secondary stacked sheets S2 is performed before the substrate forming process.

[0083] Furthermore, by providing a base layer 300 in the laminate S21, higher precision printing can be performed in the ink application process, and the durability of the printed layer 400 formed in the ink application process can be further improved. Hereinafter, the laminate formed by overlapping multiple secondary stacked sheets S2 will also be referred to as the laminate S21.

[0084] The number of secondary stacked sheets S2 in the laminate S21 is not particularly limited, but is preferably 2 or more and 20 or less, more preferably 3 or more and 10 or less. This allows for a more effective increase in the strength of the first molded body S3 (described later) and enables good bonding between adjacent secondary stacked sheets S2.

[0085] In this embodiment, multiple secondary stacked sheets S2 are stacked in a manner where adjacent secondary stacked sheets S2 in the thickness direction are connected to each other, with one sheet S connected to the other stack M2. However, this structure is not limited to this one; the sheets S can also be connected to each other, and the stack M2 can be connected to each other. Alternatively, a stacking sequence combining such a configuration with the configuration shown in the figure can also be used.

[0086] In addition, in this embodiment, the base layer 300 is formed on the uppermost secondary stacked sheet S2 after the laminate S21 is formed. However, it is also possible to form the base layer 300 on the secondary stacked sheet S2 before the laminate S21 is formed and then stacked on the secondary stacked sheet S2 on which the base layer 300 is not formed.

[0087] The substrate forming section 8 can be a structure that sprays the substrate 301 using an inkjet or spray method, or it can be a structure that directly coats the substrate using a simulated coating machine or the like.

[0088] The substrate forming section 8 forms a substrate 300 over the entire area of ​​the upper surface of the secondary stacked sheet S2. However, it is not limited to this structure. For example, the substrate forming section 8 may be a structure in which the substrate 300 is formed only in the area where ink 401 is applied in the ink application process described later, or it may be a structure in which the substrate 300 is formed only in the area where ink 401 is applied and its surrounding area.

[0089] As the base agent 301 constituting the base layer 300, there are no particular limitations as long as it has excellent adhesion to the ink 401. For example, transparent ink, white ink, etc. can be used.

[0090] Thus, the method for manufacturing the molded body according to this embodiment includes a base layer forming step, which forms a base layer 300 on a secondary stacked sheet S2 as a deposit, before the ink application step. By applying ink 401 to the base layer 300, higher precision printing can be performed in the ink application step, and the durability of the printed layer 400 formed in the ink application step can be further improved.

[0091] Alternatively, the base layer formation process can be omitted.

[0092] (Ink application section 9, ink application process)

[0093] The ink application section 9 is the part that performs the ink application process of applying ink 401 to the laminate S21, which is a deposit. For example, the ink application section 9 applies ink 401 to the base layer 300 on the laminate S21 by inkjet printing to form a printed layer 400. Alternatively, other components such as stamps or pens can be used to apply ink 401 to the base layer 300 to form a printed layer 400.

[0094] There are no particular limitations on ink 401; known inkjet inks such as pigment inks and dye inks, or sublimation inks as described in the second embodiment, can be used.

[0095] The printed layer 400 displays a prescribed pattern when viewed from above. The pattern forms graphics, designs, characters, and other designs, represented by lines, dots, and combinations thereof. For example... Figure 4 and Figure 5 As shown, the printed layer 400 has a pattern 400A, an assembly pattern 400B, and a cutting pattern 400C.

[0096] Pattern 400A is used to enhance design flexibility and is formed in a visually perceptible position after the third molded body S5 becomes the final product. In this embodiment, pattern 400A is formed in the center of the laminate S21.

[0097] The assembly pattern 400B serves as an assembly marker in the second molding process described later. After the second molding process, the second molded body S4 overlaps and is hidden. In this embodiment, the assembly pattern 400B consists of two lines. Each assembly pattern 400B is located on both sides, separated by pattern 400A.

[0098] The cutting pattern 400C serves as a cutting mark in the cutting process described later. In this embodiment, the cutting pattern 400C consists of two lines, and each cutting pattern 400C is located on the outer side of the assembly pattern 400B.

[0099] The formation position, shape, and color of pattern 400A, assembly pattern 400B, and cutting pattern 400C are not limited to the structure shown in the illustration.

[0100] The assembly pattern 400B and the cutting pattern 400C preferably differ in at least one of their shape (e.g., line width) and color. Therefore, in the second forming process, the assembly pattern 400B and the cutting pattern 400C can be distinguishably identified. Consequently, the second forming process can be performed more smoothly and accurately.

[0101] After the printing layer 400 is formed, the ink 401 is not yet fused with the laminate S21 and is in a state where it is relatively easy to bleed out.

[0102] (First forming part 4, first forming process)

[0103] like Figure 1 As shown, the first forming section 4 has a pressure section 41 as a pressure mechanism. The pressure section 41 heats and pressurizes the laminate S21, which is a deposit to which ink 401 has been applied, so that the ink 401 is fixed and the fibers of the laminate S21 are bonded together to form a first formed body S3. That is, the first forming process is to heat and pressurize the deposit to which ink 401 has been applied, i.e., the laminate S21, so that the ink 401 is fixed and the fibers of the laminate S21 are bonded together to form a first formed body S3.

[0104] "To fix the ink 401" means to make the colorant of the ink 401 stably adhere to the object and make it difficult to detach. In this embodiment, the "object" refers to the material M1 (fiber F, etc.) contained in the laminate S21 or the secondary stacked sheet S2. Furthermore, when using the base layer 300, this includes situations where the ink is stably adhered to the object via the base layer 300 or its components and is difficult to detach.

[0105] When ink 401 contains thermosetting resin, ink 401 can be more effectively fixed by heating in this process.

[0106] The pressurizing section 41 includes a block-shaped pressurizing component 411 and a pressurizing component 412. The pressurizing components 411 and 412 are metal molds, but are not limited to these; they can also be molds made of ceramic or other materials. The pressurizing component 411 is a component on which a secondary stacked sheet S2 is disposed. The pressurizing component 412 is connected to a drive source (not shown) and is configured to be able to approach and separate from the pressurizing component 411. When the pressurizing component 412 approaches the pressurizing component 411, the secondary stacked sheet S2 on the pressurizing component 411 is heated and pressurized, thereby generating a first molded body S3. When the pressurization is released, the secondary stacked sheet S2 can be disposed on the pressurizing component 411, or the first molded body S3 can be removed from the pressurizing component 411.

[0107] The pressure components 411 and 412 are not limited to being block-shaped; for example, they can also be made of rollers.

[0108] Furthermore, the pressure member 412 is connected to a heat source (not shown) and can be heated by the heat generated by the heat source. That is, the pressure member 412 on the side of the laminate S21 where ink 401 is applied is heated. As a result, the ink 401 can be heated more directly, and the ink 401 can be fixed more effectively.

[0109] The aforementioned drive source and heat source are electrically connected to the control device 7 to control the timing of pressurization, the timing of heating, the degree of pressurization, and the degree of heating. Furthermore, the pressurization component 411 may be connected to the heat source, or only the pressurization component 411 may be connected to the heat source. The pressurization component 411 itself may also be a heat source.

[0110] By applying pressure through the first forming section 4, the fibers F in each of the secondary stacked sheets S2 can be compressed to increase their density, thereby generating a first molded body S3 with higher strength. Furthermore, adjacent secondary stacked sheets S2 can be bonded together more effectively. Additionally, by heating while applying pressure through the first forming section 4, the bonding material P in the secondary stacked sheets S2 can be melted or softened and penetrated between the fibers F. Therefore, the fibers F can be bonded together, thereby more effectively increasing the strength of the first molded body S3, and ensuring good bonding between adjacent secondary stacked sheets S2.

[0111] In this way, in the first forming process, the fixation of the ink 401 and the compression of the deposit (fiber F) described above can be performed simultaneously, that is, repeatedly in time. Therefore, compared to performing the heating and pressurizing process (the forming process) and the ink fixing process separately, one process can be omitted, and the first formed body S3 can be manufactured more efficiently. Furthermore, the productivity of the third formed body S5 can be improved.

[0112] Furthermore, in this embodiment, ink 401 with different functions such as pattern 400A, assembly pattern 400B and cutting pattern 400C can be fixed together, thus enabling more efficient manufacturing of the first molded body S3 and further improving the productivity of the third molded body S5.

[0113] The pressurization in the first forming section 4 is carried out at a higher pressure than that in the fixing section 2, that is, the degree of compression of the fiber F is higher than that of the fiber F in the fixing section 2. Figure 4 As shown, the average thickness T of a secondary stacked sheet S2 of the first formed body S3 is... S3 It is not particularly limited, but preferably 0.7 mm or more and 90 mm or less, more preferably 1.1 mm or more and 40 mm or less. By applying this level of pressure through the first forming part 4, the strength of the first formed body S3 can be improved more effectively, and the ink 401 can be fixed more effectively.

[0114] The density ρ of material M1 in a secondary stacked sheet S2 of the first formed body S3 S3 It is not specifically limited, but is preferably 0.03 g / cm³. 3 Above and 4.0 g / cm 3 The following is more preferably 0.2 g / cm³. 3 Above and 2.5g / cm 3 The following applies pressure to this extent through the first forming part 4, which can more effectively improve the strength of the first formed body S3.

[0115] The density ρ of material M1 in the secondary stacked sheet S2 S2 (g / cm 3 The density ρ of material M1 in a secondary stacked sheet S2 of the first formed body S3 is... S3 (g / cm 3 The ratio of ρ S2 / ρ S3 The value is not particularly limited, but is preferably 0.2 or more and 0.8 or less, more preferably 0.3 or more and 0.7 or less. By applying this level of pressure through the first forming part 4, the strength of the first formed body S3 can be improved more effectively, and the cutting process and other processing described later can be performed more easily.

[0116] The density ρ of material M1 in the accumulation M2 M1 (g / cm 3 The density ρ of material M1 in a secondary stacked sheet S2 of the first formed body S3 is... S3 (g / cm 3 The ratio of ρ M1 / ρ S3The value is not particularly limited, but is preferably 0.05 or more and 0.7 or less, more preferably 0.1 or more and 0.5 or less. Applying this level of pressure through the first forming part 4 can more effectively improve the strength of the first molded body S3.

[0117] The heating temperature T4 in the first forming process is not particularly limited, but is preferably 40°C or higher and 220°C or lower, more preferably 150°C or higher and 190°C or lower. This allows the bonding material P to be melted or softened more effectively, thereby enabling a more robust bonding of the fibers F. Consequently, the strength of the first formed body S3 can be improved more effectively.

[0118] Furthermore, the difference ΔT(T4-T2) between the heating temperature T2 (°C) of the fixing part 2 and the heating temperature T4 (°C) of the first forming part 4 is not particularly limited, but is preferably 10°C or higher and 180°C or lower, more preferably 20°C or higher and 130°C or lower. This allows for more effective melting or softening of the bonding material P, thereby enabling a more secure bonding of the fibers F. Consequently, the strength of the first formed body S3 can be more effectively improved.

[0119] The heating and pressurizing time for the first forming section 4 is not particularly limited, but is preferably 1 second or more and 60 seconds or less, more preferably 2 seconds or more and 45 seconds or less. This allows for more reliable application of the ink 401 and the melting or softening of the bonding material P.

[0120] Furthermore, by printing on the upper surface of the uppermost secondary stacked sheet S2 and the lower surface of the lowermost secondary stacked sheet S2, followed by heating, patterns can also be formed on both sides of the laminate S21. Alternatively, printing can be performed on the sheet S corresponding to the lower surface of the lowermost secondary stacked sheet S2 before fiber stacking, and then fixed by heating. This method can be performed whether a pattern is formed on the upper surface of the uppermost secondary stacked sheet S2 or not.

[0121] (Cooling Section 5, Cooling Process)

[0122] The cooling section 5 is the part that performs the cooling process for cooling the first molded body S3. The cooling performed by the cooling section 5 refers to lowering the temperature of the first molded body S3 immediately after the first molding process is completed. The cooled temperature only needs to be below the melting point of the bonding material P; for example, room temperature is preferred, but it is not limited to this. In this embodiment, a structure is formed in which a cooling block or cooling roller contacts both surfaces of the first molded body S3. However, it is not limited to this structure; the cooling section 5 may also be a structure that blows cold air onto the first molded body S3, or a structure in which the first molded body S3 is placed in a cavity and heats the first molded body S3. Alternatively, it may be a structure where the heating of the pressure member 411 and pressure member 412 is released, and the pressure member 411 and pressure member 412 are brought into contact with the first molded body S3 until the temperature of the pressure member 411 and pressure member 412 cools down, thereby performing cooling.

[0123] By performing such a cooling process, the bonding material P of the first molded body S3 can be solidified, thereby strengthening the bond between the fibers F and enabling the ink 401 to adhere more effectively. Therefore, the strength of the first molded body S3 can be improved more effectively, and the second molding process described later can be performed while the ink 401 is more reliably adhered. Furthermore, the operability of the second molding process can be improved.

[0124] Alternatively, if heating is performed in a fixed process, a cooling process can be performed between the fixed process and the first forming process. In this case, the cooling process performed between the fixed process and the first forming process is the first cooling process, and the cooling process performed between the first forming process and the second forming process is the second cooling process. The cooling temperatures of the first cooling process and the second cooling process can be the same or different.

[0125] Alternatively, the first cooling process can be omitted and only the second cooling process can be performed, or the second cooling process can be omitted and only the first cooling process can be performed.

[0126] (Cutting section 10, cutting process)

[0127] like Figure 1 As shown, the cutting section 10 is the part that performs a cutting process (second forming process) to partially cut the first molded body S3 into a specified shape and quality. In the illustrated structure, there is a pair of cutting blades 101. The cutting blades 101 are capable of cutting the first molded body S3 along the cutting pattern 400C, so that the first molded body S3 becomes the desired shape.

[0128] Since the cutting pattern 400C is formed on the first molded body S3, cutting can be performed more easily and accurately. In addition, since the ink 401 at the cutting pattern 400C is in a fixed state, the aforementioned cutting can be performed more easily and accurately.

[0129] Furthermore, the number and shape of the cutting blades 101 are not limited to the structure shown in the figure.

[0130] Additionally, in this process, bending of the first molded body S3 may be performed as needed. In this case, in the ink application process described above, it is preferable to form the bending pattern separately from the pattern 400A, the assembly pattern 400B, and the cutting pattern 400C.

[0131] Thus, the method for manufacturing the molded body includes a cutting step as a second forming step after the first forming step. In this second forming step, the first molded body S3 is processed (cut in this case) along the pattern formed by the ink 401, i.e., the cutting pattern 400C, to generate the third molded body S5. This allows the first molded body S3 to be shaped as desired. Furthermore, since the cutting pattern 400C is formed, cutting can be performed more easily and accurately.

[0132] (Second forming part 6, joining process)

[0133] like Figure 1 As shown, the second forming part 6 is the part that performs the joining process (second forming process). In this joining process, the first forming body S3 and the second forming body S4 are joined (processed) to generate the third forming body S5 while the second forming body S4 is overlapped on at least a portion (in this embodiment, all) of the assembly pattern 400B. That is, the second forming process is the process of joining the first forming body S3 and the second forming body S4 to generate the third forming body S5 while the second forming body S4 is overlapped on the pattern formed by the ink 401, i.e., the assembly pattern 400B. As a result, a third forming body S5 with higher strength can be obtained. Furthermore, as described above, since the assembly pattern 400B is formed on the first forming body S3, it is easier to generate a third forming body S5 with high assembly accuracy of the first forming body S3 and the second forming body S4.

[0134] The second forming part 6 is composed of a sewing machine 61 that joins the first forming body S3 and the second forming body S4 by stitching. There is no particular limitation on the sewing method based on the sewing machine 61, and examples include straight sewing, zigzag sewing, blind sewing, overlock sewing, etc.

[0135] Alternatively, the second forming part 6 can also be a structure that performs joints other than sewing, such as pressure-based joints, heat-based joints, or joints using adhesives.

[0136] like Figure 4 as well as Figure 6As shown, in this embodiment, the second molded body S4 is strip-shaped. The width of the second molded body S4 is preferably greater than the width of the assembly pattern 400B. Therefore, when the first molded body S3 and the second molded body S4 are joined, the assembly pattern 400B can be hidden. This allows for more effective improvement in the design of the third molded body S5.

[0137] Furthermore, the second molded body S4 is not limited to the above structure and may also be in a shape other than a strip. Additionally, the second molded body S4 may be overlapped and joined to the first molded body S3 in a manner that does not conceal part or all of the assembly pattern 400B.

[0138] The second molded body S4 can be made of a fiber-containing material or a non-fiber-containing material, such as a resin material. When the second molded body S4 is made of a fiber-containing material, the fiber of the second molded body S4 can be a material exemplified as a constituent material of material M1.

[0139] Furthermore, when the second molded body S4 is made of a fiber-containing material, it may also include a bonding material that binds the fibers together. This bonding material is not particularly limited, and materials exemplified as constituent materials of the bonding material P can be used.

[0140] Additionally, although not illustrated, a tote bag can be obtained by overlapping and partially joining a pair of third moldings S5 together.

[0141] Furthermore, as an example of the second forming process, the cutting process and the joining process are described in this embodiment, but the present invention is not limited to these. For example, the bending process or the like can also be performed as the second forming process.

[0142] (Control device 7)

[0143] Each part of the molding body manufacturing apparatus 100 is electrically connected to the control device 7. Furthermore, the operation of these parts is controlled by the control device 7.

[0144] like Figure 1 As shown, the control device 7 includes a control unit 71, a storage unit 72, and a communication unit 73.

[0145] The control unit 71 has at least one processor that executes various programs stored in the storage unit 72. For example, a CPU (Central Processing Unit) can be used as the processor. Furthermore, the control unit 71 has various functions, such as controlling the driving of various parts of the apparatus related to the manufacturing of the molded body.

[0146] The storage unit 72 may store, for example, a program for executing the manufacturing method of the molded body according to the present invention. Alternatively, the program for executing the manufacturing method of the molded body according to the present invention may be stored in a storage device other than the storage unit 72, such as a server's storage device or an external storage device that can be attached to or detached from the control device 7.

[0147] The communication unit 73, for example, is composed of an I / O interface, and communicates with various parts of the molding apparatus 100. Additionally, the communication unit 73, for example, has the function of communicating with a computer or server (not shown) via a network.

[0148] The control device 7 can be either built into the molding body manufacturing apparatus 100 or installed in an external device such as a computer. Furthermore, the control unit 71 and the storage unit 72 can be integrated into a single unit, or the control unit 71 can be built into the molding body manufacturing apparatus 100 while the storage unit 72 is installed in an external device such as a computer, or the storage unit 72 can be built into the molding body manufacturing apparatus 100 while the control unit 71 is installed in an external device such as a computer.

[0149] As explained above, the method for manufacturing the molded body of the present invention includes: an ink application step, in which ink 401 is applied to a secondary deposited sheet S2 formed by depositing a material M1 containing fibers F; and a first forming step, in which a pressure unit 41, which serves as a pressure mechanism, heats and pressurizes the secondary deposited sheet S2 to which ink 401 has been applied, thereby fixing the ink 401 and bonding the fibers F together, thereby generating a first molded body S3. Thus, in the first forming step, the forming of the first molded body S3 and the fixing of the ink 401 can be performed simultaneously. Therefore, the first molded body S3 can be manufactured efficiently. As a result, the productivity of the third molded body S5 can be improved.

[0150] Furthermore, in the ink application process, ink 401 is applied to a laminate S21 formed by overlapping secondary stacked sheets S2, which are multiple stacked materials. In the first forming process, the laminate S21 to which ink 401 has been applied is heated and pressurized to generate a first formed body S3. This allows for a more effective increase in the strength of the first formed body S3. Additionally, since ink 401 is applied only to the front side of the laminate S21, it is not necessary to apply ink 401 to each of the secondary stacked sheets S2. Therefore, the first formed body S3 can be manufactured more efficiently.

[0151] Furthermore, the molding body manufacturing apparatus 100 includes: an ink application unit 9, which applies ink 401 to a secondary stacked sheet S2 formed by stacking a material M1 containing fibers F; and a first molding unit 4, which has a pressure unit 41 as a pressure mechanism, which heats and pressurizes the secondary stacked sheet S2 to which ink 401 has been applied, thereby fixing the ink 401 onto the secondary stacked sheet S2 and bonding the fibers F of the secondary stacked sheet S2 together to form a first molded body S3. Thus, the first molding unit 4 can simultaneously perform the molding of the first molded body S3 and the fixing of the ink 401. Therefore, the first molded body S3 can be manufactured efficiently. As a result, the productivity of the third molded body S5 can be improved.

[0152] <Second Implementation>

[0153] Figure 7 This is a cross-sectional view showing the pressure section of the molding body manufacturing apparatus according to the second embodiment of the present invention, and a diagram showing the state in which the transfer sheet is arranged on the laminate. Figure 8 It is shown Figure 7 The cross-sectional view of the pressurization section shown is a diagram illustrating the state of pressurization of the laminate. Figure 9 It is shown Figure 7 The cross-sectional view of the pressurized section shown is a diagram illustrating the state of releasing the pressure on the laminate and removing the transfer sheet.

[0154] The following is for reference Figure 7 , Figure 8 as well as Figure 9 The second embodiment of the method for manufacturing the molded article and the apparatus for manufacturing the molded article of the present invention will be described, but the following description will focus on the differences from the first embodiment, and the same items will be omitted.

[0155] (Transfer sheet 40)

[0156] like Figure 7 , Figure 8 as well as Figure 9 As shown, in this embodiment, a first molded body S3 is generated using a transfer sheet 40. Ink 401 is applied to one side (lower surface side) of the transfer sheet 40. Ink 401 is applied to the transfer sheet 40 in a pattern corresponding to the pattern 400A, the assembly pattern 400B, and the cutting pattern 400C.

[0157] There are no particular limitations on the transfer sheet 40; for example, ordinary paper or other paper, or a recording medium with an ink receiving layer (called inkjet paper, coated paper, etc.) can be used. As a result, bleeding can be prevented more effectively when transferring ink 401.

[0158] In this embodiment, ink 401 is preferably a sublimation ink. As a result, the transfer of ink 401 can be performed better, and the pattern 400A, the assembled pattern 400B, and the cut pattern 400C can be obtained more vividly.

[0159] As a sublimation ink, there are no particular limitations as long as it is the type of ink that vaporizes upon heating; any known ink can be used.

[0160] In addition, inks other than sublimation inks can also be used as ink 401.

[0161] Furthermore, in this embodiment, the base layer 300 is omitted, and the ink 401 is transferred onto the deposit M2. Thus, the bonding material P contained in the deposit M2 effectively helps to improve the adhesion to the ink 401, thereby enabling the ink 401 to adhere more effectively.

[0162] Alternatively, in this embodiment, a base layer 300 may be formed on the secondary deposit M2.

[0163] In the manufacturing method of the molded body in this embodiment, the ink application step and the first molding step described in the first embodiment are performed together, that is, repeated in time.

[0164] (First forming process (ink application process))

[0165] like Figure 7 As shown, in the first forming process, firstly, the transfer sheet 40 as described above is disposed on the laminate S21 such that the surface on which the ink 401 is applied is in contact with the upper surface of the laminate S21.

[0166] Next, as Figure 8 As shown, the laminate S21, together with the transfer sheet 40, is heated and pressurized using pressure members 411 and 412. That is, in this process, heating and pressurization are performed while the transfer sheet 40 is overlapped with the laminate S21. Thus, while the laminate S21 is heated and pressurized, the transfer sheet 40 is pressed against it. At this time, the ink 401 sublimates and is transferred (applied) to the laminate S21. Furthermore, after the transfer, the ink 401 is fixed to the laminate S21 by the aforementioned heating and pressurization. Therefore, in this embodiment, the application (transfer) of ink 401 to the laminate S21 and the fixation of ink 401 can be performed simultaneously while the first molded body S3 is being formed. Therefore, the first molded body S3 can be manufactured efficiently. As a result, the productivity of the third molded body S5 can be further improved.

[0167] In this embodiment, the heating temperature T4' of the pressure section 41 is not particularly limited, but is preferably 40°C or higher and 220°C or lower, and more preferably 130°C or higher and 190°C or lower. This allows for more effective melting or softening of the bonding material P, thereby enabling a more robust bonding of the fibers F together. Consequently, the strength of the first molded body S3 can be improved more effectively.

[0168] Furthermore, the difference ΔT(T4-T2) between the heating temperature T2 (°C) of the fixing part 2 and the heating temperature T4' (°C) of the first forming part 4 is not particularly limited, but is preferably 10°C or higher and 180°C or lower, more preferably 20°C or higher and 130°C or lower. This allows for more effective melting or softening of the bonding material P, thereby enabling a more secure bonding of the fibers F. Consequently, the strength of the first formed body S3 can be more effectively improved.

[0169] The heating and pressurizing time for the first forming section 4 is not particularly limited, but is preferably 1 second or more and 60 seconds or less, more preferably 2 seconds or more and 45 seconds or less. This allows for more reliable application of the ink 401 and the melting or softening of the bonding material P.

[0170] When the transfer of ink 401 is complete, as follows Figure 9 As shown, the transfer sheet 40 is detached. This allows the generation of a first molded body S3 with applied pattern 400A, assembly pattern 400B, and cutting pattern 400C.

[0171] Alternatively, as a transfer method, methods that do not involve heating or pressurization can be used, such as printing on the surface of a transfer sheet coated with paste, transferring by heating as described above, or using paste to fix the ink onto the surface of the laminate S21.

[0172] Furthermore, by placing the transfer sheet 40 on both the upper and lower surfaces of the laminate S21 and heating it, a pattern can also be applied to both the front and back surfaces of the laminate S21 by applying (transferring) ink 401 and fixing ink 401. By placing the transfer sheet (40) only on the lower surface instead of the upper surface and heating it, a pattern can also be applied to only the reverse side of the laminate (S21) by applying (transferring) ink 401 and fixing ink 401.

[0173] Furthermore, the molding body manufacturing apparatus can perform processes such as coating a paste onto a substrate of the transfer sheet 40 to make the transfer sheet 40, and printing on the transfer sheet 40. It can also be a structure that places a printed transfer sheet made by other means onto the molding body manufacturing apparatus 1 for transfer printing.

[0174] Thus, in this embodiment, during the ink application process, one side (lower surface in the figure) of the transfer sheet 40 on which ink 401 has been applied is brought into contact with the laminate S21, which serves as the deposit. As a result, the application of ink 401 can be easily performed.

[0175] Furthermore, in the first forming process, heat and pressure are applied while the transfer sheet 40 is superimposed on the laminate S21, which serves as a deposit, and then the transfer sheet 40 is detached from the first formed body S3. This allows for the simultaneous application (transfer) of ink 401 to the laminate S21 and the fixation of ink 401 during the formation of the first formed body S3. Therefore, the first formed body S3 can be manufactured efficiently. As a result, the productivity of the third formed body S5 can be further improved.

[0176] <Third Implementation Method>

[0177] Figure 10 This is a cross-sectional view showing the pressure section of the molding body manufacturing apparatus according to the third embodiment of the present invention, and a diagram showing the state in which the recess forming member is arranged on the laminate. Figure 11 It is shown Figure 10 The cross-sectional view of the pressurization section shown is a diagram illustrating the state of pressurization of the laminate. Figure 12 It is shown Figure 10 The cross-sectional view of the pressurized section shown is a diagram illustrating the state of releasing the pressure on the laminate and removing the recessed forming component.

[0178] The following is for reference Figure 10 , Figure 11 as well as Figure 12 The third embodiment of the method for manufacturing the molded article and the apparatus for manufacturing the molded article of the present invention will be described, but the following description will focus on the differences from the first embodiment, and the same items will be omitted.

[0179] like Figures 10-12 As shown, in this embodiment, in the first forming process, a first molded body S3 having a recess 402 is generated using a recess forming member 413. Specifically, firstly, as... Figure 10 As shown, two rigid, rod-shaped recess-forming members 413 are disposed on the laminate S21. In this embodiment, the recess-forming members 413 are disposed on the assembly pattern 400B.

[0180] Next, as Figure 11 As shown, the pressure section 41 is used for heating and pressurization. At this time, the recess forming member 413 enters the first molding body S3 from the top, and the recess forming member 413 is embedded in the first molding body S3.

[0181] Next, as Figure 12As shown, the heating and pressurization are released, and the recess forming member 413 is removed. As a result, a recess 402 is formed in the region in the first molded body S3 where the recess forming member 413 was present.

[0182] The recess 402 visually and tactilely indicates the assembly position. The shape of the recess 402 is a groove corresponding to the shape of the recess forming member 413. By arranging the recess forming member 413 on the assembly pattern 400B, the assembly pattern 400B is formed at the bottom of the recess 402.

[0183] Furthermore, although not illustrated, in the joining process, the second molded body S4 is inserted into the recess 402, and the first molded body S3 is joined to the second molded body S4 in this inserted state. During this joining operation, excessive movement of the second molded body S4 is restricted by the inner surface of the recess 402. Therefore, the joining of the first molded body S3 and the second molded body S4 can be performed more easily and accurately.

[0184] According to this embodiment, the recess 402 can visually and tactilely indicate the assembly position, and the assembly pattern 400B provided at the bottom of the recess 402 can visually and clearly indicate the assembly position. Therefore, the joining of the first molded body S3 and the second molded body S4 can be performed more easily and accurately.

[0185] While the method for manufacturing a molded article and the apparatus for manufacturing a molded article according to the present invention have been described above through the illustrated embodiments, the present invention is not limited thereto. Each part and each process constituting the method for manufacturing a molded article and the apparatus for manufacturing a molded article according to the present invention can be replaced with any structure or process that can perform the same function. Furthermore, any structure or process may be added to the method for manufacturing a molded article and the apparatus for manufacturing a molded article according to the present invention. Moreover, the method for manufacturing a molded article and the apparatus for manufacturing a molded article according to the present invention can also combine features from each embodiment.

[0186] Alternatively, the first and second embodiments can be combined, the first and third embodiments can be combined, the second and third embodiments can be combined, or the first, second and third embodiments can be combined.

[0187] For example, the surface of the laminate S21 can also be formed with a pattern of ink and recess 402 by the method of the first embodiment and the method of the third embodiment, and a pattern formed with ink can be formed on the reverse side of the laminate S21 by the method of the second embodiment.

[0188] In addition, in each process, all processes can be carried out automatically by machinery, or at least some processes can be carried out by humans.

[0189] Furthermore, "simultaneously" simply means within the same stroke. The fixing of ink 401 and the bonding of fibers F can also not be exactly synchronized in time. For example, the start times can be staggered, and the end times can also be staggered. Even if ink 401 fixes during the period of heating to a high temperature, and fibers F bond midway through the cooling process after heating, it can still be called "simultaneous" because the operation is performed within the same stroke, thus it can be said that the ink is fixed and the fibers are bonded together.

Claims

1. A method for manufacturing a shaped article, characterized in that, Apply ink to materials containing fibers. The ink-filled deposit is heated and pressurized using a pressurizing mechanism, thereby fixing the ink and binding the fibers together to form a first shaped body.

2. The method for manufacturing a molded article according to claim 1, wherein, A base layer is formed on the deposit before ink is applied.

3. The method for manufacturing a molded article according to claim 1, wherein, The ink is applied to a laminate formed by overlapping multiple of the aforementioned deposits. The laminate to which the ink has been applied is heated and pressurized to generate the first shaped body.

4. The method for manufacturing a molded article according to any one of claims 1-3, wherein, Before applying ink, the fibers of the deposit are fixed.

5. The method for manufacturing a molded article according to claim 4, wherein, The fixing is performed at a temperature lower than the heating temperature in the first forming process.

6. The method for manufacturing a molded article according to any one of claims 1-3, wherein, The heating temperature during the formation of the first molded body is above 150°C and below 190°C.

7. The method for manufacturing a molded article according to any one of claims 1-3, wherein, After the first molded body is generated, the first molded body is processed along the pattern formed by the ink to generate the third molded body.

8. The method for manufacturing a molded article according to claim 7, wherein, With the second molded body superimposed on the pattern formed by the ink, the first molded body and the second molded body are joined together to generate the third molded body.

9. The method for manufacturing a molded article according to any one of claims 1-3, wherein, Ink is applied by bringing one side of a transfer sheet on which the ink has been applied to a surface into contact with the deposit.

10. The method for manufacturing a molded article according to claim 9, wherein, The transfer sheet is heated and pressurized while it is stacked on the pile, and then the transfer sheet is detached from the first molded body.

11. The method for manufacturing a molded article according to claim 9, wherein, The ink is a sublimation ink.

12. A molding body manufacturing apparatus, characterized in that, have: The ink application unit applies ink to a material containing fibers; A first forming section has a pressurizing mechanism that heats and pressurizes an accumulation to which the ink has been applied, thereby fixing the ink onto the accumulation and binding the fibers together to form a first shaped body.

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