Manufacturing apparatus for decorated product having three-dimensional shape, and manufacturing method for decorated product having three-dimensional shape using manufacturing apparatus

Abstract

To provide a manufacturing apparatus for a decorated product having a three-dimensional shape using a shaping mold and a manufacturing method for the decorated product having the three-dimensional shape using the manufacturing apparatus.SOLUTION: A manufacturing apparatus for a decorated product having a three-dimensional shape includes: a shaping mold that exhibits the three-dimensional shape to mold a decorative sheet into the decorated product that exhibits the three-dimensional shape; a case part having the shaping mold, a bottom part corresponding to a bottom surface of the case, and a wall part that stands upright so as to surround the bottom part; a root suction hole that is arranged so as to surround the shaping mold placed at the bottom part; an upper end suction hole arranged at an upper end of the wall part; a suction blower device that sucks air from the root suction hole and the upper end suction hole; and a fixing frame that fixes the decorative sheet when the decorative sheet is arranged on the case part.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to an apparatus for manufacturing a decorated product having a three-dimensional shape using a mold, and a method for manufacturing a decorated product having a three-dimensional shape using the manufacturing apparatus. [Background technology]

[0002] As a method for manufacturing a decorated product with a three-dimensional shape, Patent No. 5554016 discloses the following: "A decorative panel having a decorative portion formed by plastic press processing technology using a decorative sheet having positioning holes formed through the sheet surface, the panel body being made of a plastic sheet base material and having the sheet base material formed into a three-dimensional shape by molding, and a decorative portion made of ink, paint or fine particles provided on either one or both of the front and back surfaces of the panel body."

[0003] The above invention was invented by the present inventor and has been well received in the market. Using the decorative sheet, a decorative panel having a three-dimensional shape can be created.

[0004] However, the above invention is suitable for decorative sheets having a thickness of approximately 0.5 mm, and is not suitable for sheets having a thickness greater than that.

[0005] Therefore, when creating a decorated product with a three-dimensional shape, a molded product is created by injection molding and a pattern or the like is added to the molded product by insert molding or in-mold molding, which decorates the molded product at the same time as injection molding. In addition, the pattern or the like is added by painting the product after molding. Furthermore, the molded product may be decorated by plating the surface of the molded product with a thin metal film or by printing a part of the surface of the molded product with a name or the like.

[0006] However, when painting with multiple colors, there are many problems in terms of cost and process, such as masking parts, processing for each color after drying, and defects due to foreign matter such as dust in the air. Also, when plating, unnecessary parts may be removed by laser processing after plating. This also requires time and cost. Also, printing is often expressed on a part of a relatively flat part of a molded product, and it is not possible to process it on the entire surface, which has unevenness. [Prior art documents] [Patent documents]

[0007] Patent No. 5554016 DISCLOSURE OF THEINVENTION [Problem to be solved by the invention]

[0008] The present invention has been made with attention to the above-mentioned points, and its object is to provide a manufacturing apparatus for a decorated product having a three-dimensional shape using a shaping mold, and a manufacturing method for a decorated product having a three-dimensional shape using the manufacturing apparatus.

[0009] In order to solve the above-mentioned problems, the manufacturing apparatus for a decorated product having a three-dimensional shape according to a first aspect includes a shaping mold having a three-dimensional shape for molding a decorative sheet into a decorated product having a three-dimensional shape, a case portion having the shaping mold, the case portion having a bottom portion corresponding to the bottom surface of the case and a wall portion erected to surround the bottom portion, the shaping mold being placed on the bottom portion, a base suction hole arranged to surround the shaping mold, the wall portion having an upper end portion at its upper end and an upper end suction hole arranged at the upper end, and further including a suction blow device which sucks air through the base suction hole and the upper end suction hole, and a fixing frame which fixes the decorative sheet when it is placed in the case portion.

[0010] In order to solve the above-mentioned problems, the manufacturing apparatus for a decorated product having a three-dimensional shape of the second aspect includes a shaping mold having a three-dimensional shape for molding a decorative sheet into a decorated product having a three-dimensional shape, a case portion having the shaping mold, the case portion having a bottom portion corresponding to the bottom surface of the case and a wall portion erected to surround the bottom portion, the shaping mold being placed on the bottom portion and a base suction hole arranged to surround the shaping mold, the wall portion having an upper end portion at its upper end and having an upper end suction hole arranged at the upper end and a bottom suction hole arranged at the base of the wall portion, and further including a suction blow device which sucks air through the base suction hole, the upper end suction hole and the bottom suction hole, and a fixing frame which fixes the decorative sheet when it is placed in the case portion.

[0011] In order to solve the above problems, a manufacturing device for a decorated product having a three-dimensional shape according to a third aspect of the present invention includes a shaping mold having a three-dimensional shape, and a case portion having the shaping mold, the case portion having a bottom portion corresponding to the bottom surface of the case and a wall portion erected so as to surround the bottom portion, the shaping mold being placed on the bottom portion, a base suction hole disposed so as to surround the shaping mold, and the wall portion having an upper end portion at its upper end and a base suction hole disposed at the upper end portion. The decorative sheet has an upper suction hole at the base of the wall portion and a bottom suction hole at the base of the wall portion, and the shaping mold has a first shaping mold suction hole which serves as a suction hole and a second shaping mold suction hole, and further has a suction blow device which sucks air from the base suction hole, the upper suction hole, and the bottom suction hole, a first suction blow device which sucks air from the first shaping mold suction hole, a second suction blow device which sucks air from the second shaping mold suction hole, and a fixing frame which fixes the decorative sheet when it is placed in the case portion.

[0012] In order to solve the above problems, a manufacturing method for a decorated product according to a fourth aspect includes a manufacturing apparatus for a decorated product according to the first or second aspect and a heating apparatus for heating a decorative sheet, and includes a decorative sheet arranging step of placing the decorative sheet on an upper end of a case portion in order to manufacture a decorated product having a three-dimensional shape using the manufacturing apparatus and the heating apparatus, and a decorative sheet fixing step of placing a fixing frame on the decorative sheet arranged on the upper end of the case portion in the decorative sheet arranging step. The method includes a decorative sheet heating process in which a heating device is placed on a fixed frame and the decorative sheet is heated, and a decorative sheet suction process in which, when the heated decorative sheet begins to soften through the decorative sheet heating process, a suction blow device is driven to suck the softened decorative sheet through the base suction hole and the upper end suction hole.

[0013] In order to solve the above problems, a manufacturing method for a decorated product according to a fifth aspect includes a manufacturing apparatus for a decorated product according to the first or second aspect, and a cooling apparatus for cooling a decorative sheet, and uses the manufacturing apparatus, the heating apparatus, and the cooling apparatus to manufacture a decorated product having a three-dimensional shape, the manufacturing method including a decorative sheet placement step of placing the decorative sheet on an upper end of the case portion, a decorative sheet fixing step of placing a fixing frame on the decorative sheet placed on the upper end of the case portion in the decorative sheet placement step, and a heating apparatus disposed on the fixing frame to fix the decorative sheet. a decorative sheet suction process in which, when the heated decorative sheet begins to soften through the decorative sheet heating process, a suction blow device is driven to suck the softened decorative sheet through the base suction hole and the upper end suction hole; and a decorative sheet cooling process in which, through the decorative sheet heating process and the decorative sheet suction process, the decorative sheet is molded in a shaping mold, and once the decorative sheet has been molded into a three-dimensional shape, the molded three-dimensional shape of the decorative sheet is cooled by a cooling device.

[0014] In order to solve the above problems, a manufacturing method for a decorated product according to a sixth aspect includes the manufacturing apparatus for a decorated product according to the third aspect and a heating device for heating a decorative sheet having a pattern, and in order to manufacture a decorated product having a pattern and a three-dimensional shape using the manufacturing apparatus and the heating device, the manufacturing method includes a decorative sheet arranging step of placing the decorative sheet having the pattern on an upper end of a case portion, a decorative sheet fixing step of placing a fixing frame on the decorative sheet arranged on the upper end of the case portion in the decorative sheet arranging step, and a decorative sheet fixing step of arranging the heating device on the fixing frame and heating the decorative sheet having the pattern. The method includes a sheet heating process, a high-position decorative sheet shaping suction process in which, when the decorative sheet having the heated pattern begins to soften through the decorative sheet heating process, a first suction blow device is driven to suck air through a shaping suction hole located at a high position, a low-position decorative sheet shaping suction process in which a second suction blow device is driven to suck air through a shaping suction hole located at a lower position than the shaping suction hole, and a decorative sheet shaping suction process in which the suction blow device is driven to suck the decorative sheet that has begun to soften through the base suction hole, the upper end suction hole and the shaping suction hole.

[0015] In order to solve the above problems, a manufacturing method for a decorated product according to a seventh aspect includes the manufacturing apparatus for a decorated product according to the third aspect, a heating device for heating a decorative sheet having a pattern, and a cooling device for cooling the decorative sheet having the pattern, and in order to manufacture a decorated product having a pattern and a three-dimensional shape using the manufacturing apparatus, the heating device, and the cooling device, the manufacturing method includes a decorative sheet arranging step of placing the decorative sheet having the pattern on an upper end of a case portion, a decorative sheet fixing step of placing a fixing frame on the decorative sheet arranged on the upper end of the case portion in the decorative sheet arranging step, a decorative sheet heating step of arranging a heating device on the fixing frame and heating the decorative sheet having the pattern, and a first suction blow device for blowing the decorative sheet having the pattern into the decorative sheet having the pattern in a state in which the heated decorative sheet has begun to soften by the decorative sheet heating step. the high-position decorative sheet shaping suction process in which a first suction blow device is driven to suck air through the shaping suction holes located at a higher position; the low-position decorative sheet shaping suction process in which a second suction blow device is driven to suck air through the shaping suction holes located at a lower position than the shaping suction holes; the decorative sheet shaping suction process in which the suction blow device is driven to suck the softened decorative sheet through the base suction hole, the upper end suction hole and the shaping suction hole; and the decorative sheet heating process, the high-position decorative sheet shaping suction process, the low-position decorative sheet shaping suction process and the decorative sheet shaping suction process in which the decorative sheet is shaped by the shaping mold to form a decorated product with a three-dimensional shape to which a pattern has been added, and then the molded three-dimensional decorated product is cooled by a cooling device. Effect of the Invention

[0016] Since the present invention is configured and operates as described above, it is possible to provide a manufacturing apparatus for a decorated product having a three-dimensional shape using a shaping mold, and a manufacturing method for a decorated product having a three-dimensional shape using the manufacturing apparatus. [Brief description of the drawings]

[0017] [Figure 1] 2 is a plan view of a shaping mold and a case portion in the manufacturing apparatus for a decorated product. FIG. [Diagram 2]FIG. 2 is a cross-sectional view taken along line II-II in FIG. [Diagram 3] 1A is a schematic plan view of a state in which a decorative sheet is placed in a manufacturing device for a decorated product, and FIG. 1B is a schematic cross-sectional view taken along line IIIB-IIIB in the state of A. [Figure 4] Fig. 1A is a cross-sectional conceptual diagram of a state in which a decorative sheet is placed in a manufacturing device for decorated products and is about to be heated by a heating device. Fig. 1B is a cross-sectional conceptual diagram of a state in which a decorative sheet is placed in a manufacturing device for decorated products and is starting to soften as it is heated by the heating device. [Diagram 5] 1A is a schematic cross-sectional view of the decorative sheet being heated by a heating device, and FIG. 1B is a schematic cross-sectional view of the decorative sheet being heated by a heating device. [Figure 6] 1A is a schematic cross-sectional view of the decorative sheet being cooled by a cooling device, and FIG. 1B is a schematic cross-sectional view of the decorative sheet after being cooled by the cooling device. [Figure 7] 1A is a schematic cross-sectional view of a molded decorative sheet being released from a molding die, and FIG. 1B is a schematic cross-sectional view of a decorated product. [Figure 8] 4A is a plan view of a four-sided decorative sheet and a second case part in which four case parts are integrated, and FIG. 4B is a schematic cross-sectional view taken along line VIIIB-VIIIB of FIG. [Figure 9] FIG. 1A is a schematic plan view of a decorative sheet having patterns X, Y, and Z. FIG. 1B is a schematic cross-sectional view of a state in which a fixing frame is placed on the decorative sheet placed on the upper end of the case part. [Figure 10] FIG. 1 is a schematic cross-sectional view showing a state in which a decorative sheet having patterns X, Y, and Z is placed in a manufacturing device for a decorated product and heated by a heating device. [Figure 11] FIG. 1 is a cross-sectional conceptual diagram of a decorative sheet having patterns X, Y, and Z being cooled by a cooling device. [Figure 12] FIG. 2 is a schematic cross-sectional view of a decorative sheet having molded patterns X, Y, and Z being released from a shaping mold. BEST MODE FOR CARRYING OUT THEINVENTION

[0018] Hereinafter, examples will be described with reference to the illustrated embodiment. The manufacturing apparatus 10 for the decorated product 800 of the first embodiment has a shaping mold 20 having a three-dimensional shape and a case part 60 having the shaping mold 20. The manufacturing apparatus 10 for the decorated product 800 of the first embodiment (see FIG. 7B) may have a fixing frame 80 for fixing the decorative sheet 700 described later to the case part 60 (see FIGS. 3A and 3B). Incidentally, having the shaping mold 20 means that the shaping mold 20 is disposed in the case part 60, and the specific configuration will be described later. Furthermore, the manufacturing apparatus 10 for the decorated product 800 of the first embodiment may have a suction blow device 100 for sucking or blowing air and a heating device 200 for heating the decorative sheet 700 (see FIGS. 4A and 4B).

[0019] The shaping mold 20 is for processing the decorative sheet 700 into a three-dimensional decorated product 800, and it goes without saying that the shape of the shaping mold 20 is processed in advance into a three-dimensional shape that imitates the shape of the decorated product 800. The shaping mold 20 can be made of metals such as aluminum, brass, iron, and stainless steel, as well as resins such as bakelite and chemical wood.

[0020] The case part 60 has a bottom part 61 which serves as the bottom surface and a wall part 66 which stands so as to surround the bottom part 61. The bottom part 61 literally corresponds to the bottom surface of the case part 60, and the above-mentioned shaping mold 20 is disposed on the bottom part 61. The shaping mold 20 and the bottom part 61 may be made separately and attached, or they may be attached integrally.

[0021] The bottom 61 has a plurality of root suction holes 61a for sucking the periphery of the shaping mold 20 (in each drawing, some of the suction holes 61a are marked with a reference symbol). A groove portion 61b can be provided at a position offset, for example, by 5 mm from the root suction hole 61a so as to surround the periphery of the shaping mold 20. The groove portion 61b is disposed so as to surround the root suction hole 61a. The groove portion 61b has a plurality of groove suction holes 61c for sucking the periphery of the shaping mold 20 (in each drawing, some of the groove suction holes 61c are marked with a reference symbol).

[0022] When the decorative sheet 700 is molded, wrinkles may form in the groove 61b from the wall 66 of the case 60 toward the shaping mold 20, which will be described later. When the wrinkles attempting to grow from the wall 66 toward the shaping mold 20 reach the groove 61b, the groove 61b inhibits the growth of the wrinkles, thereby preventing the formation of wrinkles in the molded decorated product 800, which will be described later. In particular, as described above, the groove 61b has groove suction holes 61c for suction, so that the decorative sheet 700 enters the groove 61b by the suction, and the effect of inhibiting the growth of wrinkles can be further expected.

[0023] The wall 66 has an upper end 67, which is the upper end, and has a plurality of upper end suction holes 67a that serve as suction holes for exerting suction force from the suction blow device 100 (in each drawing, some of the upper end suction holes 67a are marked with a reference number). The upper end 67 also has two or three contact portions 69 for positioning the decorative sheet 700 when it is placed on the upper end 67. The contact portions 69 can be positioned relative to the case 60 by placing them on the first side 70a or the second side 70b of the upper end 67. That is, the contact portions 69 are for aligning the shaping mold 20 and the decorative sheet 700 placed on the case 60. If the user can accurately place the decorative sheet 700 on the case 60 to perform registration, the contact portions are not necessarily required.

[0024] Furthermore, the bottom 61 has a bottom suction hole 68a at the base portion 68 of the wall portion 66, which serves as a suction hole for exerting a suction force from the suction blow device 100 (in each drawing, a reference number is written on a portion of the suction hole 68a). It is also preferable that the bottom 61 has a protrusion 62 that protrudes upward. The protrusion 62 is for forming a protrusion on the decorative sheet 700 for positioning during post-processing when the decorative sheet 700 is molded. It is also preferable that the protrusions 62, 62 have protrusion suction holes 62a, 62a, respectively.

[0025] The fixing frame 80 is for fixing the decorative sheet 700 when the decorative sheet 700 is placed on the upper end 67 of the case part 60. The fixing frame 80 also has an opening 81. The opening 81 functions as a window for exposing the decorative sheet 700 when far infrared rays or near infrared rays are irradiated by the heating device 200. That is, a part of the decorative sheet 700 placed on the upper end 67 is heated through the opening 81, and the other part of the decorative sheet 700 covered by the fixing frame 80 is not easily heated because the heat of the heating device 200 is not transmitted thereto. The reason why the other part of the decorative sheet 700 is difficult to heat is to prevent misalignment between the decorative sheet 700 and the case part 60 (see, for example, FIGS. 3A and 3B).

[0026] In addition to the far-infrared heater, it is also preferable to use both the far-infrared heater and a near-infrared heater in the heating device 200. When the decorative sheet 700 is relatively thin, the far-infrared heater is preferable, and when the decorative sheet 700 is relatively thick, it is also preferable to use both the far-infrared heater and the near-infrared heater in combination. For example, a relatively thick decorative sheet 700 may refer to one having a thickness of 3 millimeters or more, and a thin decorative sheet may refer to one having a thickness less than that.

[0027] The suction blow device 100 can be used not only to suck in air but also to blow out air, and is preferably made up of a vacuum pump and a compressor, and is connected to the root suction hole 61a, the groove suction hole 61c, the convex suction hole 62a, the upper end suction hole 67a, and the bottom suction hole 68a. The root suction hole 61a, the groove suction hole 61c, the convex suction hole 62a, the upper end suction hole 67a, and the bottom suction hole 68a are not only for sucking in air, but also for discharging air.

[0028] The decorative sheet 700 is literally in the form of a sheet, and can be processed into a decorated product 800 by using the manufacturing apparatus 10 of the first embodiment. The base sheet of the decorative sheet 700 is preferably a sheet made of PMMA (polymethyl methacrylate resin, acrylic resin), PC (polycarbonate), PET (polyethylene terephthalate), PP (polypropylene), ABS (acryl butadiene styrene) or a polymer alloy, and is preferably a sheet made of such a thermoplastic resin. The thickness of the decorative sheet 700 is preferably 0.1 to 5 mm, or 0.1 to 3 mm.

[0029] Moreover, the decorative sheet 700 can have a picture or pattern added to the front or back of the sheet made of the above-mentioned resins. For example, the front or back of the decorative sheet 700 can have a picture or pattern printed by a printing technique such as screen printing, pad printing, offset printing, gravure printing, seal printing, flexographic printing, or inkjet printing. When adding a metallic color, a so-called stamping die or rubber die or transfer using a hot roll can be used. This foil stamping technique can be applied from either the front or back of the decorative sheet. The foil used for foil stamping can usually be aluminum-vapor-deposited foil, but tin-vapor-deposited foil or indium-vapor-deposited foil may also be used. In this way, the decorative sheet 700 with a picture or pattern added can be created.

[0030] Next, a method for manufacturing a decorated product 800 having a three-dimensional shape will be described using the manufacturing apparatus 10 for a decorated product of the first embodiment described above, a heating apparatus 200 for heating the decorative sheet 700, and a cooling apparatus 300 for cooling the heated decorative sheet 700. First, the decorative sheet 700 is placed on the upper end portion 67 of the case portion 60. At this time, the decorative sheet 700 is placed so as to contact the attachment portion 69 (decorative sheet placing process). However, the decorated product 800 having a three-dimensional shape can be manufactured without necessarily using the cooling apparatus 300.

[0031] Next, after the decorative sheet arrangement step described above, the fixing frame 80 is placed on the decorative sheet 700 arranged on the upper end portion 67 of the case part 60 (decorative sheet fixing step, see Figs. 3A and 3B). As a result, the decorative sheet 700 is fixed so as to be sandwiched between the case part 60 and the fixing frame 80.

[0032] Next, the heating device 200 is placed on the fixed frame 80, and heats the decorative sheet 700 through the openings 81 (decorative sheet heating step, see FIG. 4A). When the heated decorative sheet 700 starts to soften, the suction blow device 100 is driven (suction is turned on) to suck the softened decorative sheet 700 through the base suction hole 61a, groove suction hole 61c, convex suction hole 62a, upper end suction hole 67a, and bottom suction hole 68a (decorative sheet suction step, see FIG. 4B).

[0033] The decorative sheet 700 is molded by the shaping mold 20 through the above-mentioned decorative sheet heating process and decorative sheet suction process (see Figs. 5A and 5B), and the decorative sheet 700 molded into the three-dimensional shape is cooled by the cooling device 300, and the decorative sheet 700 is fixed so as to have a three-dimensional shape (decorative sheet cooling process, see Fig. 6A). After that, the fixing frame 80 is opened (see Fig. 6B), and the suction blow device 100 that blows air is driven (blow is turned on), and air is blown onto the decorative sheet 700 molded into the three-dimensional shape from the root suction hole 61a, the groove suction hole 61c, the convex suction hole 62a, the upper end suction hole 67a, and the bottom suction hole 68a, respectively, and the molded decorative sheet 700 is released from the shaping mold 20 (decorative sheet releasing process, see Fig. 7A). In this way, a decorated product 800 can be obtained (see Fig. 7B). It is not essential to use the cooling device 300. The decorated product 800 can be obtained by natural cooling. Therefore, the decorative sheet cooling step described above is not an essential step.

[0034] In this way, in the manufacturing method of the decorated product 800 having a three-dimensional shape, since it is a method that uses only the lower mold and does not use the upper mold, as described above, the thickness of the decorative sheet 700 can be 0.1 to 5 mm, or 0.1 to 3 mm. Therefore, in the conventional molding method using the upper and lower molds, a sheet with a thickness of 0.5 mm or more may wrinkle or the shape may not be accurately formed, but even if a sheet with a thickness of 0.1 to 5 mm, or 0.1 to 3 mm is used, the risk can be reduced as much as possible. Furthermore, by the decorative sheet 700 entering the groove portion 61b, the effect of inhibiting the growth of wrinkles can be further expected.

[0035] In addition, there are cases where four decorated products having a three-dimensional shape (not shown) are produced at one time, so-called multi-faceting. For example, a four-sided decorative sheet 700', four shaping molds 20 for molding the four-sided decorative sheet 700' at once, a second case part 60' in which four case parts 60 each having the shaping molds 20 are integrated, and a second frame part 80' in which four frame parts are integrated are used, but the same components (case part 60, frame part 80) may be designated by the same reference numerals and explanations thereof may be omitted (see Figs. 8A and B).

[0036] Next, the manufacturing apparatus 500 for the decorated product 850 of the second embodiment has a shaping mold 120 having a three-dimensional shape and a case part 160 having the shaping mold 120. The manufacturing apparatus 500 for the decorated product 850 of the second embodiment (see FIG. 12) may have a fixing frame 80 for fixing the decorative sheet 750 (see FIG. 9A) having the pattern X, pattern Y, and pattern Z described later to the case part 160 (see FIG. 9B). The fixing frame 80 is the same as the fixing frame of the first embodiment, and the description thereof may be omitted. Also, having the shaping mold 120 means that the shaping mold 120 is arranged in the case part 160, and the specific configuration of the shaping mold 120 will be described later.

[0037] The manufacturing apparatus 500 for the decorated product 850 of the second embodiment also includes a first suction blow device 601 for sucking or exhausting, a second suction blow device 602, an upper end suction blow device 603, and a bottom suction blow device 604.

[0038] The shaping mold 120 of the second embodiment has a plurality of convex portions 125a, 125b, 125c or a plurality of concave portions 126a, 126b at the boundaries between the convex portions 125a, 125b, 125c, and can be arranged so that the convex portions 125a, 125b, 125c or the plurality of concave portions 126a, 126b match, for example, the pattern X, the pattern Y, and the pattern Z applied to the decorative sheet 750. In order to match them, a contact portion (not shown) is provided. This contact portion is used, so to speak, for registration with the decorative sheet 700, and is preferably the same as the contact portion 69 in the shaping mold 20 of the first embodiment. In the shaping mold 120 of the second embodiment, the contact portion is not shown.

[0039] The contact portion is for aligning the shaping mold 120 arranged in the case portion 160 with the decorative sheet 750. If the user can align the decorative sheet 750 by accurately placing it on the case portion 160, the contact portion is not necessarily required.

[0040] The patterns X, Y, and Z can be printed on the front or back of a sheet made of resin, similarly to the decorative sheet 700 described above, by printing techniques such as screen printing, pad printing, offset printing, gravure printing, seal printing, flexographic printing, and inkjet printing. When adding a metallic color, a so-called stamping die or rubber die or transfer using a hot roll can be used. This foil stamping technique can be applied from either the front or back of the decorative sheet. The foil used for foil stamping can usually be aluminum-vapor-deposited foil, but tin-vapor-deposited foil or indium-vapor-deposited foil may also be used. In this way, for example, a decorative sheet 750 having the patterns X, Y, and Z can be created.

[0041] In this way, the shaping mold 120 having a plurality of convex projections 125a, 125b, 125c or a plurality of concave recesses 126a, 126b has shaping suction holes 121a and shaping suction holes 121b which serve as suction holes for sucking or exhausting air from the first suction blow device 601. In the shaping mold 120 of the second embodiment, the shaping suction holes 121a and shaping suction holes 121b are arranged in the recesses 126a and 126b, respectively, but they can also be provided in the plurality of convex projections 125a, 125b, 125c (not shown). This means that the convex projections 850a, 850b, 850c or the plurality of recesses 856a and 856b of the decorated product 850 molded from the decorative sheet 750 described later can be configured to match, for example, the pattern X, pattern Y, and pattern Z applied to the decorative sheet 750.

[0042] The shaped suction hole 121a can be arranged at a relatively high position in a cross-sectional view, and the shaped suction hole 121b can be arranged at the next highest position, but is not limited to this.

[0043] As described above, the shaped suction hole 121a serves as a suction hole for exerting the suction force from the first suction blow device 601, and the shaped suction hole 121b serves as a suction hole for exerting the suction force from the second suction blow device 602. The shaped suction hole 121a and the shaped suction hole 121b serve not only to suck in air but also to exhaust air.

[0044] Further, case part 160 has bottom part 161 which serves as the bottom surface and wall part 166 which stands so as to surround bottom part 161. Bottom part 161 literally corresponds to the bottom surface of case part 160, and the shaping mold 120 and bottom part 161 may be made separately and attached, or they may be attached integrally.

[0045] The bottom 161 has a plurality of root suction holes 161a for sucking air around the shaping mold 120. A groove 161b can be provided at a position offset, for example, by 5 mm from the root suction hole 161a so as to surround the shaping mold 120. The groove 161b is disposed so as to surround the root suction hole 161a. The groove 161b has a plurality of groove suction holes 161c for sucking air. The root suction hole 161a and the groove suction hole 161c are not only for sucking air but also for discharging air.

[0046] The groove 161b is similar to the above-mentioned groove 61a, and is expected to have the effect of preventing wrinkles from occurring in the molded decorated product 850.

[0047] Inside the bottom 161, a first partition 171 is disposed as a space for the passage of air from the shaped suction hole 121a, and the first partition 171 is connected to the first suction blow device 601. Inside the bottom 161, a second partition 172 is disposed as a space for the passage of air from the shaped suction hole 121b, and the second partition 172 is connected to the second suction blow device 602. Inside the bottom 161 and the wall 166, a third partition 173 is disposed as a space for the passage of air from the upper end suction hole 167a, which will be described later, and the third partition 173 is connected to the upper end suction blow device 603, which will be described later. Furthermore, inside the bottom 161, there is arranged a fourth partition 174, which is a space that serves as a passage for air from the above-mentioned root suction hole 161a, the bottom suction hole 168a described below, and the convex suction hole 162a, and the fourth partition 174 is connected to the bottom suction blow device 604 described below.

[0048] Moreover, the wall portion 166 has an upper end portion 167, which is the upper end, and the upper end portion 167 has a plurality of upper end suction holes 167a which serve as suction holes for exerting the suction force from the upper end suction blow device 603. The upper end suction holes 167a are for exhausting air when not only sucking air.

[0049] Furthermore, the upper end portion 167 may have two or three stoppers (not shown) for positioning the decorative sheet 700 when it is placed on the case portion 160. These stoppers may be similar to the stopper 69 described above. However, as described above, if the user can perform registration by accurately placing the decorative sheet 750 on the case portion 160, the stopper is not necessarily required.

[0050] Furthermore, the bottom 161 has a bottom suction hole 168a at the base portion 168 of the wall portion 166, which serves as a suction hole for exerting the suction force from the bottom suction blow device 604. In addition, it is preferable that the bottom 161 has a convex portion 162 protruding upward. The convex portion 162 is for forming a convex portion for positioning the decorative sheet 750 during post-processing when the decorative sheet 750 is molded. It is preferable that the convex portions 162, 162 also have convex suction holes 162a, 162a, which serve as suction holes for exerting the suction force from the bottom suction blow device 604. It is preferable that the convex portions 162, 162 form protrusions 760, 760 protruding upward on the decorative sheet 750 (see FIG. 12). These protrusions 760, 760 can be used for positioning the decorated product 850 in a later process.

[0051] The fixed frame 80 and the heating device 200 are as described above, and the same reference numerals are used to denote them, and the description thereof may be omitted.

[0052] Next, a method for manufacturing a decorated product 850 having a three-dimensional shape will be described, in which a decorative sheet 750 having patterns X, Y, and Z is formed using the manufacturing apparatus 500 for a decorated product of the second embodiment described above, a heating apparatus 200 for heating the decorative sheet 750, and a cooling apparatus 300 for cooling the heated decorative sheet 750.

[0053] The decorative sheet 750 is placed on the upper end 167 of the case part 160. At this time, the decorative sheet 750 is placed so as to contact a backing part (not shown) (second decorative sheet placing step). Note that it is preferable to place a backing part (not shown) on the upper end 167 in advance to position the decorative sheet 750 relative to the case part 160 so that the patterns X, Y, and Z on the decorative sheet 750 and the protrusions 125a, 125b, and 125c on the shaping mold 120 are aligned with each other.

[0054] Next, after the second decorative sheet arrangement step described above, the fixing frame 80 is placed on the decorative sheet 750 arranged on the upper end 167 of the case part 160 (see FIG. 9B, second decorative sheet fixing step). This fixes the decorative sheet 750 so that it is sandwiched between the fixing frame 80 and the upper end 167 of the case part 160. At this time, the upper end suction blow device 603 is driven (ON) to exert suction force and suck from the upper end suction holes 167a, thereby closely adhering the decorative sheet 750 to the upper end 167.

[0055] Next, the heating device 200 heats the decorative sheet 750 through the opening 81 in the fixed frame 80 (second decorative sheet heating process). When the heated decorative sheet 750 starts to soften, the first suction blow device 601 is driven (ON) to suck air from the shaping mold suction hole 121a arranged at a high position (high-position decorative sheet shaping mold suction process). After that, the second suction blow device 602 is driven (ON) to suck air from the shaping mold suction hole 121b arranged at a lower position than the shaping mold suction hole 121a (low-position decorative sheet shaping mold suction process). In this way, the pattern X, pattern Y, and pattern Z applied to the decorative sheet 750 can be closely attached to the convex parts 125a, 125b, and 125c of the shaping mold 120 so as to match each other (see FIG. 10).

[0056] Next, the bottom suction blow device 604 is operated to suck air from the above-mentioned root suction holes 161a, groove suction holes 161c, bottom suction holes 168a, and protrusion suction holes 162a (second decorative sheet suction process).

[0057] The decorative sheet 750 is molded by the shaping mold 120 through the second decorative sheet heating process and the second decorative sheet suction process, and when the three-dimensional decorative sheet 750 is molded, the molded three-dimensional decorative sheet 750 is cooled by the cooling device 300 (see FIG. 11, second decorated product cooling process). After that, the first suction blow device 601, the second suction blow device 602, the upper end suction blow device 603, and the bottom suction blow device 604 that blow air are driven (blow ON), and the decorative sheet 750 molded by the shaping mold 120 is released from the shaping mold 120 by blowing air in the opposite direction, thereby obtaining the decorated product 850. It is not essential to use the cooling device 300. The decorated product 850 can be obtained by cooling naturally. Therefore, the above-mentioned second decorated product cooling process is not an essential process.

[0058] In this case, the position of the contact portion (not shown) is arranged in advance so that the convex portions 125a, 125b, 125c of the shaping mold 120 match the patterns X, Y, and Z applied to the decorative sheet 750. Therefore, by matching the convex portions 125a, 125b, 125c of the shaping mold 120 with the patterns X, Y, and Z applied to the decorative sheet 750 through the above-mentioned high-position decorative sheet shaping mold suction process and low-position decorative sheet shaping mold suction process, it is possible to obtain a decorated product 850 having convex portions 850a, 850b, 850c that match the patterns X, Y, and Z.

[0059] In this way, in the manufacturing method of the decorated product 850 having a three-dimensional shape, since it is a method that uses only a lower mold and does not use an upper mold, as described above, the thickness of the decorative sheet 750 can be 0.1 to 5 mm, or 0.1 to 3 mm. Therefore, in the conventional molding method that uses an upper and lower mold, a sheet with a thickness of 0.5 mm or more may wrinkle or the shape may not be accurately formed, but as described above, even if a sheet with a thickness of 0.1 to 5 mm, or 0.1 to 3 mm is used, this risk can be reduced as much as possible.

[0060] Furthermore, when producing a decorated product 850 having a three-dimensional shape with multiple protrusions or recesses, the protrusions or recesses in the shaping mold 120 can be matched with the pattern applied to the decorative sheet 750, making it possible to manufacture a decorated product 850 having a complex pattern that matches the complex three-dimensional shape. [Explanation of symbols]

[0061] 10. Manufacturing apparatus for decorated products according to the first embodiment 20 Shaping mold 60 Case part 60' 2nd case section 61 Bottom 61a Root suction hole 61b Groove 61c groove suction hole 62 Convex 62a Convex suction hole 66 Wall 67 Upper end 67a Upper end suction hole 68 Base part 68a Bottom suction hole 69 Backing 70a First side 70b 2nd side 80 Fixed Frame 80' 2nd frame section 81 Opening 100 Suction blower device 120 Shaping mold 121a, 121b Shaped suction part 125a, 125b, 125c convex part 126a, 126b Recess 160 Case part 161 Bottom 161a Root suction part 161b Groove 161c groove suction hole 166 Wall 167 Upper end 167a Upper end suction hole 168 Base portion of wall 166 168a Bottom suction hole 171 First Section 172 Second Section 173 Third Section 174 Section 4 200 Heating device 300 Cooling device 500 Manufacturing apparatus for decorated products according to the second embodiment 601 First suction blower device 602 Second suction blower device 603 Upper end suction blower device 604 Bottom suction blower device 700 Decorative Sheet 700' Decorative Sheet 750 Decorative Sheet 800 Decorative Products 850 Second Example of Decorated Product 850a, 850b, 850c, convex part 856a, 856b, recess XYZ pattern

Claims

1. A forming mold for forming the decorative sheet into a decorative product having a three-dimensional shape; A case portion having the shaping mold; The case portion has a bottom portion corresponding to a bottom surface of the case, and a wall portion standing so as to surround the bottom portion, The shaping mold is placed on the bottom, and a root suction hole is arranged to surround the shaping mold; The wall portion has an upper end at its upper end, and an upper end suction hole disposed at the upper end, and a suction blower device that sucks air from the base suction hole and the upper end suction hole; the decorative sheet is disposed in the case portion, and a fixing frame is provided for fixing the decorative sheet in place.

2. A forming mold for forming the decorative sheet into a decorative product having a three-dimensional shape; A case portion having the shaping mold; The case portion has a bottom portion corresponding to a bottom surface of the case, and a wall portion standing so as to surround the bottom portion, The shaping mold is placed on the bottom, and a root suction hole is arranged to surround the shaping mold; The wall portion has an upper end portion at an upper end thereof, and an upper end suction hole disposed at the upper end portion; a bottom suction hole disposed at the base of the wall portion; A suction blower device that sucks air from the root suction hole, the top end suction hole, and the bottom suction hole; a fixing frame that fixes the decorative sheet when the decorative sheet is placed on the case portion; The manufacturing apparatus for a decorated product further comprises:

3. A forming mold for forming a decorative sheet having a pattern into a decorated product having a three-dimensional shape; A case portion having the shaping mold; The case portion has a bottom portion corresponding to a bottom surface of the case, and a wall portion standing so as to surround the bottom portion, The shaping mold is placed on the bottom, and a root suction hole is arranged to surround the shaping mold; The wall portion has an upper end portion at an upper end thereof, and an upper end suction hole disposed at the upper end portion; A bottom suction hole is disposed at the base of the wall portion; The shaping mold has a first shaping mold suction hole and a second shaping mold suction hole which are suction holes, A suction blower device that sucks air from the root suction hole, the upper end suction hole, and the bottom suction hole; A first suction blow device that sucks air through the first shaping mold suction hole; A second suction blow device that sucks air from the second shaping mold suction hole; a fixing frame that fixes the decorative sheet when the decorative sheet is placed on the case portion; The manufacturing apparatus for a decorated product further comprises:

4. The manufacturing apparatus for a decorated product according to claim 1 or 2, A heating device for heating the decorative sheet, In order to manufacture a decorated product having a three-dimensional shape using the manufacturing apparatus and the heating apparatus, a decorative sheet placement step of placing the decorative sheet on an upper end of the case portion; a decorative sheet fixing step of placing the fixing frame on the decorative sheet arranged at the upper end of the case portion in the decorative sheet arrangement step; a decorative sheet heating step of disposing the heating device on the fixing frame and heating the decorative sheet; a decorative sheet suction process in which, when the heated decorative sheet begins to soften through the decorative sheet heating process, the suction blow device is driven to suck the softened decorative sheet through the base suction hole and the upper end suction hole.

5. The manufacturing apparatus for a decorated product according to claim 1 or 2, A heating device for heating the decorative sheet; A cooling device for cooling the decorative sheet, In order to manufacture a decorated product having a three-dimensional shape using the manufacturing apparatus, the heating apparatus, and the cooling apparatus, a decorative sheet placement step of placing the decorative sheet on an upper end of the case portion; a decorative sheet fixing step of placing the fixing frame on the decorative sheet arranged at the upper end of the case portion in the decorative sheet arrangement step; a decorative sheet heating step of disposing the heating device on the fixing frame and heating the decorative sheet; a decorative sheet suction step in which, in a state in which the heated decorative sheet begins to soften in the decorative sheet heating step, the suction blow device is driven to suck the softened decorative sheet through the base suction hole and the upper end suction hole; a decorative sheet heating process and a decorative sheet suction process in which the decorative sheet is molded by the shaping mold into a three-dimensional shape, and a decorative sheet cooling process in which the molded three-dimensional shape of the decorative sheet is cooled by the cooling device after the decorative sheet has been molded into a three-dimensional shape.

6. The manufacturing apparatus for a decorated product according to claim 3 ; A heating device for heating the decorative sheet having the pattern, In order to manufacture a decorated product having a pattern and a three-dimensional shape using the manufacturing apparatus and the heating apparatus, a decorative sheet placement step of placing a decorative sheet having the pattern on an upper end of the case portion; a decorative sheet fixing step of placing the fixing frame on the decorative sheet arranged at the upper end of the case portion in the decorative sheet arrangement step; a decorative sheet heating step of disposing the heating device on the fixed frame and heating the decorative sheet having the pattern; A high-position decorative sheet shaping suction process in which the first suction blow device is driven in a state in which the heated decorative sheet having the pattern begins to soften due to the decorative sheet heating process, and air is sucked through the shaping suction hole arranged at a high position; A low-position decorative sheet shaping mold suction process in which the second suction blow device is driven to suck air from a shaping mold suction hole arranged at a position lower than the shaping mold suction hole; a decorative sheet shaping suction process in which the suction blow device is driven to suck the decorative sheet that has begun to soften through the base suction hole, the upper end suction hole, and the shaping suction hole.

7. The manufacturing apparatus for a decorated product according to claim 3 ; a heating device for heating the decorative sheet having the pattern; A cooling device for cooling the decorative sheet having the pattern, In order to manufacture a decorated product having a pattern and a three-dimensional shape by using the manufacturing apparatus, the heating apparatus, and the cooling apparatus, a decorative sheet placement step of placing a decorative sheet having the pattern on an upper end of the case portion; a decorative sheet fixing step of placing the fixing frame on the decorative sheet arranged at the upper end of the case portion in the decorative sheet arrangement step; a decorative sheet heating step of disposing the heating device on the fixed frame and heating the decorative sheet having the pattern; A high-position decorative sheet shaping suction process in which the first suction blow device is driven in a state in which the heated decorative sheet having the pattern begins to soften due to the decorative sheet heating process, and air is sucked through the shaping suction hole arranged at a high position; A low-position decorative sheet shaping mold suction process in which the second suction blow device is driven to suck air from a shaping mold suction hole arranged at a position lower than the shaping mold suction hole; a decorative sheet shaping mold suction step in which the suction blow device is driven to suck the decorative sheet that has begun to soften through the base suction hole, the upper end suction hole, and the shaping mold suction hole; A method for manufacturing a decorated product having a three-dimensional shape and a pattern, comprising the steps of: molding the decorative sheet with the shaping mold through the decorative sheet heating step, the high position decorative sheet shaping mold suction step, the low position decorative sheet shaping mold suction step, and the decorative sheet shaping mold suction step to form a decorated product having a three-dimensional shape with a pattern added thereto; and cooling the decorated product with the three-dimensional shape formed by the cooling device.

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