Method for manufacturing a molded body and apparatus for manufacturing a molded body

Abstract

To provide a method for manufacturing molded articles and a molded article manufacturing apparatus that can increase the productivity of the target molded articles. [Solution] A method for manufacturing a molded body, comprising: an ink application step of applying ink to a fiber-containing material; and a first molding step of using a pressurizing mechanism to heat and pressurize the ink-applied deposit to fix the ink and bond the fibers together to produce a first molded body. The method for manufacturing a molded body also comprises a second molding step after the first molding step of processing the first molded body along the pattern formed by the ink to produce a third molded 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 a sheet from fibers. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2006-89896 [Overview of the Initiative] [Problems that the invention aims to solve]

[0004] However, the manufacture of products using sheets produced by the method described in Patent Document 1 had not been given much consideration. [Means for solving the problem]

[0005] A method for manufacturing a molded article according to an application example of the present invention includes an ink application step of applying ink to a material containing fibers, The process includes a first molding step in which a pressurizing mechanism is used to heat and pressurize the deposit to which the ink has been applied, thereby fixing the ink and bonding the fibers together to produce a first molded body.

[0006] An example of a molded article manufacturing apparatus according to the present invention includes an ink application unit for applying ink to a material containing fibers, The device includes a first molding unit having a pressurizing mechanism, which uses the pressurizing mechanism to heat and pressurize the deposit to which the ink has been applied, thereby fixing the ink to the deposit and bonding the fibers together to produce a first molded body. [Brief explanation of the drawing]

[0007] [Figure 1] Figure 1 is a configuration diagram showing an overview of a molded body manufacturing apparatus according to a first embodiment of the present invention. [Figure 2] Figure 2 is a flowchart of a method for manufacturing a molded body according to a first embodiment of the present invention. [Figure 3] Figure 3 is a cross-sectional view showing a primary deposition sheet, a secondary deposition sheet, and a state in which the secondary deposition sheets are stacked. [Figure 4] Figure 4 is a cross-sectional view showing a laminate, a first molded body, and a third molded body, respectively. [Figure 5] Figure 5 is a perspective view of the first molded body. [Figure 6] Figure 6 is a perspective view of the third molded body. [Figure 7] Figure 7 is a cross-sectional view showing a pressing part included in a molded body manufacturing apparatus according to a second embodiment of the present invention, and shows a state in which a transfer sheet is disposed on a laminate. [Figure 8] Figure 8 is a cross-sectional view showing the pressing part shown in Figure 7, and shows a state in which the laminate is being pressed. [Figure 9] Figure 9 is a cross-sectional view showing the pressing part shown in Figure 7, and shows a state in which the pressing of the laminate is released and the transfer sheet is removed. [Figure 10] Figure 10 is a cross-sectional view showing a pressing part included in a molded body manufacturing apparatus according to a third embodiment of the present invention, and shows a state in which a concave portion forming member is disposed on a laminate. [Figure 11] Figure 11 is a cross-sectional view showing the pressing part shown in Figure 10, and shows a state in which the laminate is being pressed. [Figure 12] Figure 12 is a cross-sectional view showing the pressing part shown in Figure 10, and shows a state in which the pressing of the laminate is released and the concave portion forming member is removed.

Embodiments for Carrying Out the Invention

[0008] The method for manufacturing a molded article and the apparatus for manufacturing a molded article of the present invention will be described in detail below based on preferred embodiments shown in the accompanying drawings.

[0009] <First Embodiment> Figure 1 is a schematic diagram showing a molded article manufacturing apparatus according to the first embodiment of the present invention. Figure 2 is a flowchart of the method for manufacturing a molded article according to the first embodiment of the present invention. Figure 3 is a cross-sectional view showing a primary deposited sheet, a secondary deposited sheet, and the state in which the secondary deposited sheets are stacked. Figure 4 is a cross-sectional view showing a laminate, a first molded article, and a third molded article. Figure 5 is a perspective view of the first molded article. Figure 6 is a perspective view of the third molded article.

[0010] In the following, the upper side of Figures 1, 3, 4, 5, and 6 (and similarly for Figures 7, 8, and 9) may be referred to as "up" or "above," and the lower side as "down" or "below." Also, Figure 1 is a schematic diagram, and the positional relationships, orientations, sizes, etc., of the various parts of the molded body manufacturing apparatus 100 are not limited to those shown. Furthermore, in Figure 1, the direction in which the material or molded body is conveyed is also referred to as the conveying direction. In addition, the tip of the arrow in Figure 1 indicating the conveying direction is also referred to as the "downstream side," and the base of the arrow is also referred to as the "upstream side."

[0011] [Molded object manufacturing equipment 100] The molded body manufacturing apparatus 100 shown in Figure 1 is an apparatus for carrying out the molded body manufacturing method of the present invention, and is an apparatus for molding a fiber-containing material M1 to produce a third molded body S5 as a molded body. The molded body manufacturing apparatus 100 comprises a deposition section 1, a fixing section 2, a cutting section 3, a base layer forming section 8, an ink application section 9, a first molding section 4, a cooling section 5, a second molding section 6, a control device 7, and a cutting section 10. Furthermore, as shown in Figure 2, the molded body manufacturing method includes a deposition step, a fixing step, a cutting step, a base layer forming step, an ink application step, a first molding step, a cooling step, a cutting step (second molding step), and a joining step (second molding step). In this embodiment, the case of manufacturing a handbag using the third molded body S5 is used as an example, but the present invention is not limited thereto, and the final product manufactured by the third molded body S5 may be, for example, a mask, gloves, socks, a book cover, a business card case, slippers, etc. Furthermore, the third molded body S5 may be the final product. The following describes in detail each part of the molded body manufacturing apparatus 100 and each step of the manufacturing method for the molded body.

[0012] (Material M1) First, let's describe material M1. Material M1 includes fibers F and a binder P that binds the fibers F together.

[0013] Fiber F is not particularly limited and examples include various cellulose fibers and various chemical fibers.

[0014] The average fiber length of fiber F is not particularly limited, but is preferably 0.1 mm to 10 mm, and more preferably 1 mm to 5 mm. This makes it possible to more reliably increase the strength of the third molded body S5 and to make processing such as the cutting and shaping processes described later easier.

[0015] From a similar viewpoint, the average width (average diameter) of the fiber F is not particularly limited, but 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.

[0016] From a similar viewpoint, the fiber F content in material M1 is not particularly limited, but is preferably, for example, 20% by weight or more and 99% by weight or less, and more preferably 50% by weight or more and 90% by weight or less.

[0017] Examples of binders P include thermoplastic resins such as various polyolefins, acrylic resins, polyvinyl chloride, polyester, and polyamide, various thermoplastic elastomers, and natural product-derived components such as starch, dextrin, glycogen, amylose, hyaluronic acid, kudzu, konjac, potato starch, etherified starch, esterified starch, natural gum glue, fiber-inducing glue, seaweed, and animal protein. One or more of these can be selected and used in combination.

[0018] The binder P is in the form of parts or fibers. When the binder P is in particulate form, its average particle size (by volume) is not particularly limited, but 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. This makes it possible to more reliably increase the strength of the third molded body S5 and to make processing such as the cutting and shaping processes described later easier.

[0019] From a similar viewpoint, when the binder P is fibrous, the average fiber length of the binder P is not particularly limited, but is preferably 0.1 mm or more and 10 mm or less, and more preferably 1 mm or more and 10 mm or less.

[0020] From a similar viewpoint, when the binder P is fibrous, the average width (average diameter) of the binder P is not particularly limited, but 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.

[0021] From a similar viewpoint, the content of the binder P in material M1 is not particularly limited, but is preferably, for example, 1% by weight or more and 80% by weight or less, and more preferably 10% by weight or more and 50% by weight or less.

[0022] Furthermore, material M1 may contain other components besides the binder P. Examples of these other components include colorants for coloring the fibers, flocculation inhibitors for suppressing fiber aggregation, and flame retardants for making the fibers less flammable. One or more of these can be used in combination.

[0023] If 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, and more preferably 0.5% by weight or more and 5% by weight or less. This allows for the effects of incorporating other components to be obtained, while also ensuring sufficient amounts of fiber F and binder P, thereby more effectively increasing the strength of the third molded body S5. Furthermore, if the fiber F itself dissolves or softens and bonds with other fiber F, it is not necessary to add binder P in addition to the fiber F.

[0024] (Deposition part 1, deposition process) As shown in Figure 1, the deposition section 1 is the part that performs the deposition process, and generates a deposit M2 of material M1 by dispersing material M1 in the air. As shown in Figure 1, the deposition section 1 has a dispersion section 11, a mesh belt 12, a suction section 13, and a sheet supply section 14.

[0025] The dispersion unit 11 loosens and releases the intertwined fibers F in the material M1. The dispersion unit 11 includes a drum 111 for introducing and releasing the material M1, and a housing 112 for housing the drum 111.

[0026] The drum 111 is a sieve composed of a cylindrical mesh body that rotates around its central axis. As the drum 111 rotates, fibers F and other materials in the material M1 that are smaller than the mesh opening can pass through the drum 111. In this process, the material M1 is loosened and released along with the air. In other words, the drum 111 functions as a release unit that releases the material M1 containing the fibers F.

[0027] The drum 111 is connected to a drive source (not shown) and rotates due to the rotational force output from the drive source. The drive source is electrically connected to a control device 7, and its operation is controlled.

[0028] Furthermore, the material M1 released from drum 111 disperses into the air as it falls, heading towards the mesh belt 12 located below drum 111.

[0029] A material supply unit (not shown) is connected to the drum 111. Examples of material supply units include those with a raw material supply unit, a crushing unit, a defibration unit, a mixing unit, etc., as described in Japanese Patent Publication No. 2024-113315, or those that supply material M1 in a cartridge type.

[0030] The mesh belt 12 is a mesh member, and in the illustrated configuration, it is composed of an endless belt. Sheets S are supplied to the mesh belt 12 from a sheet supply unit 14, which will be described later. Material M1 dispersed and released by the dispersion unit 11 accumulates on the sheet S, and deposits M2 are generated. The mesh belt 12 is wrapped around four tension rollers 121. The rotational drive of the tension rollers 121 transports the deposits M2 on the mesh belt 12 downstream.

[0031] In the illustrated configuration, an endless belt, the mesh belt 12, is used as an example of a mesh member. However, the present invention is not limited to this, and a configuration using a flat plate-shaped mesh member may also be used.

[0032] The suction unit 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. As a result, the deposition of material M1 onto the sheet S is promoted. Furthermore, a deposit M2 of uniform thickness can be generated.

[0033] A pipe 131 is connected to the suction unit 13. A blower 132 is installed in the middle of this pipe 131. The operation of this blower 132 generates suction force in the suction unit 13. The blower 132 is electrically connected to the control device 7, and its operation is controlled by the control device 7.

[0034] The sheet supply unit 14 has a supply roller 141, and the function of dispensing the sheet S is achieved by the rotation of the supply roller 141. The sheet S dispensed by the supply roller 141 is supplied onto the mesh belt 12. Then, sediment M2 is formed on the sheet S. The sheet S and the sediment M2 deposited on the sheet S together will be referred to as the "primary sediment sheet S1" below. However, if sediment M2 is formed on the mesh belt 12 without using the sheet S, or if the sheet S is removed after the sediment M2 has been formed, the sediment M2 alone may also be referred to as the primary sediment sheet S1.

[0035] The supply roller 141 is connected to a drive source (not shown) and rotates due to the rotational force output from the drive source. The drive source is electrically connected to a control device 7, and its operation is controlled.

[0036] The sheet S is breathable and is made of woven fabric, nonwoven fabric, etc. The fibers that make up the sheet S include those exemplified by the fiber F mentioned above. By supplying such a sheet S, the strength of the third molded body S5 can be more effectively increased, and processing such as the cutting process and shaping process described later can be made easier.

[0037] As shown in Figure 3, the average thickness T of sheet S S While not particularly limited, the thickness is preferably 0.01 mm to 20 mm, and more preferably 0.1 mm to 2 mm. This makes it possible to more reliably increase the strength of the third molded body S5 and to make processing such as the cutting and shaping processes described later easier.

[0038] From a similar perspective, the density ρ of material M1 in sediment M2M1 This is not particularly limited, but is 0.01 g / cm³. 3 More than 2.0g / cm 3 Preferably, it is 0.1 g / cm³ 3 More than 1.0g / cm 3 The following is more preferable.

[0039] From a similar perspective, as shown in Figure 3, the average thickness T of the sediment M2 M2 While not particularly limited, it is preferably 1 mm to 100 mm, and more preferably 1.5 mm to 50 mm.

[0040] From a similar perspective, the average thickness T of the primary deposition sheet S1 S1 While not particularly limited, it is preferably 1.1 mm to 120 mm, and more preferably 1.3 mm to 60 mm.

[0041] (Fixing part 2, fixing process) As shown in Figure 1, the fixing unit 2 is the part that performs a fixing process to fix the fibers F of the secondary deposition sheet S2 before the ink application process described later, and fixes the deposited material M2 of the primary deposition sheet S1 and transports it downstream. The fixing performed by the fixing unit 2 refers to a process that compresses the primary deposition sheet S1, reduces the thickness of the deposited material M2, and increases its density. Although such fixing (temporary fixing) is not essential, by performing fixing (temporary fixing), it is possible to more effectively prevent the fibers F from scattering or breaking apart and to improve handling.

[0042] The fixing section 2 has a pair of heating and pressurizing rollers 21 located downstream of the deposition section 1. Each heating and pressurizing roller 21 is positioned vertically along the transport path of the primary deposition sheet S1. As the primary deposition sheet S1 passes between the pair of heating and pressurizing rollers 21, the deposition material M2 is heated and pressurized. This generates a secondary deposition sheet S2. The secondary deposition sheet S2 is then transported downstream by the rotation of the pair of heating and pressurizing rollers 21.

[0043] The pair of heating and pressing rollers 21 is connected to a drive source and a heat source (not shown). The heating and pressing rollers 21 rotate by the rotational force output from the drive source and are heated by the heat generation of the heat source. The drive source and the heat source are each electrically connected to the control device 7 and their operations are controlled.

[0044] By performing heating while applying pressure by the fixing portion 2, the binder P in the deposit M2 can be melted or softened and infiltrated between the fibers F. Therefore, the fibers F can be bonded to each other, restricting the unintended movement of the fibers F in the secondary deposited sheet S2 and making it easier to maintain the shape. Thus, the handling property in subsequent processes can be enhanced.

[0045] As shown in FIG. 3, the average thickness T of the secondary deposited sheet S2 S2 is not particularly limited, but is preferably 0.8 mm or more and 100 mm or less, and more preferably 1.2 mm or more and 50 mm or less. Thereby, the handling property in subsequent processes can be more effectively enhanced.

[0046] The average thickness T of the secondary deposited sheet S2 S2 (mm) and the average thickness T of the primary deposited sheet S1 S1 (mm), the ratio T S2 / T S1 is not particularly limited, but is preferably 0.1 or more and 0.9 or less, and more preferably 0.2 or more and 0.8 or less. By the fixing portion 2 applying pressure of this degree, the handling property in subsequent processes can be more effectively enhanced.

[0047] The density ρ of the material M1 in the secondary deposited sheet S2 S2 is not particularly limited, but is preferably 0.02 g / cm 3 or more and 3.0 g / cm 3 or less, and more preferably 0.15 g / cm 3 or more and 1.5 g / cm 3 or less. By the fixing portion 2 applying pressure of this degree, the handling property in subsequent processes can be more effectively enhanced.

[0048] Density ρ of material M1 in sediment M2 M1 (g / cm 3 ) and the density ρ of material M1 in the secondary deposition sheet S2 S2 (g / cm 3 ρ M1 / ρ S2 While not particularly limited, the pressure is preferably between 0.07 and 0.85, and more preferably between 0.1 and 0.7. By applying this level of pressure to the fixing part 2, handling in subsequent processes can be more effectively improved.

[0049] The heating temperature T2 by the fixing part 2 is not particularly limited, but is preferably lower than the heating temperature T4 in the first molding step. Specifically, the heating temperature T2 is preferably 40°C to 200°C, and more preferably 45°C to 150°C. This allows the binder P in the deposit M2 to melt or soften to a certain extent. As a result, the bonding strength between the fibers F can be kept within an appropriate range. Thus, handling properties can be more effectively improved while increasing the degree of freedom in processing in subsequent steps.

[0050] Thus, it is preferable that the method for manufacturing the molded body includes a fixing step before the ink application step in which the fibers F of the secondary deposited sheet S2, which is a deposit, are fixed. This makes it possible to more effectively prevent the fibers F from scattering or becoming loose, and effectively improves handling in subsequent steps.

[0051] In addition, the fixing process may involve only applying pressure. Furthermore, the fixing process may be omitted altogether.

[0052] 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 molding process. This suppresses excessive fixing of the fibers F to each other, thereby increasing the degree of freedom in processing in subsequent processes.

[0053] Note that the heating temperature T2 may be the same as the heating temperature T4, or it may be a higher temperature than the heating temperature T4.

[0054] (cutting part, cutting process) As shown in Figure 1, the cutting unit 3 performs the cutting process and cuts the secondary deposited sheet S2 to a desired size. The cutting unit 3 has a pair of cutting blades 31 provided downstream of the fixing unit 2. Each cutting blade 31 is positioned vertically along the transport path of the secondary deposited sheet S2. Each cutting blade 31 is positioned so that its cutting edges face each other, and the cutting edges are configured to move closer together and further apart. When the cutting edges of each cutting blade 31 approach each other until they touch, the secondary deposited sheet S2 passing between them is cut. Furthermore, the length of the secondary deposited sheet S2 can be adjusted by adjusting the timing of the approach and separation of each cutting blade 31.

[0055] The cutting blade 31 is connected to a drive source (not shown) and moves closer to and further away from it by a force output from the drive source. The drive source is electrically connected to a control device 7, and its operation is controlled.

[0056] Furthermore, a pair of transport rollers 32 are provided downstream of the cutting blade 31. They are arranged vertically along the transport path for the secondary deposition sheet S2. The transport rollers 32 rotate while gripping the cut secondary deposition sheet S2, thereby transporting it downstream, i.e., to the first molding section 4.

[0057] The transport roller 32 is connected to a drive source (not shown) and rotates due to the rotational force output from the drive source. The drive source is electrically connected to a control device 7, and its operation is controlled.

[0058] The cutting section 3 is not limited to the above configuration, and may have a cutting roller with blades formed on its outer circumference instead of the cutting blade 31.

[0059] Although not shown in the figures, the cutting section 3 may also have cutting blades that cut both edges of the secondary deposition sheet S2 in the width direction.

[0060] Furthermore, the cut section 3 may be omitted. In this case, it is preferable to fold the secondary deposition sheet S2 and stack them in the thickness direction prior to performing molding in the first molding section 4, which will be described later.

[0061] (Base layer forming section 8, base layer formation process) The base layer formation section 8 is the part that performs a base layer formation process, in which a base layer 300 is formed on the secondary deposition sheet S2, before the ink application process described later. In this embodiment, the base layer 300 is formed on the upper surface of the uppermost secondary deposition sheet S2 when multiple secondary deposition sheets S2 are stacked on top of each other. In other words, it can be said that the stacking process of multiple secondary deposition sheets S2 is performed before the base layer formation process.

[0062] Furthermore, by providing a base layer 300 on the laminate S21, more precise 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 enhanced. Hereinafter, a stack of multiple secondary deposition sheets S2 will also be referred to as the laminate S21.

[0063] The number of secondary deposition sheets S2 in the laminate S21 is not particularly limited, but is preferably 2 to 20 sheets, and more preferably 3 to 10 sheets. This allows for a more effective increase in the strength of the first molded body S3, which will be described later, and enables good bonding of adjacent laminated secondary deposition sheets S2.

[0064] In this embodiment, multiple secondary sediment sheets S2 are stacked such that adjacent secondary sediment sheets S2 in the thickness direction are in contact with one sheet S and the sediment M2 of the other. However, the configuration is not limited to this, and the sheets may be stacked so that one sheet S is in contact with the other sheet S and one sediment M2 is in contact with the other sediment M2, or a stacking order may be a combination of such arrangements and the illustrated arrangement.

[0065] Furthermore, in this embodiment, the base layer 300 is formed on the uppermost secondary deposition sheet S2 after the laminate S21 is generated. However, it is also possible to form the base layer 300 on the secondary deposition sheet S2 before generating the laminate S21, and then laminate it on the secondary deposition sheet S2 where the base layer 300 has not been formed.

[0066] The base layer forming section 8 may be configured to dispense the base material 301 using an inkjet or spray method, or it may be configured to apply the base material directly using an analog coater or the like.

[0067] The base layer forming section 8 forms a base layer 300 over the entire upper surface of the secondary deposition sheet S2. However, the configuration is not limited to this. For example, the base layer forming section 8 may be configured to form a base layer 300 only in the area to which ink 401 is applied in the ink application process described later, or to form a base layer 300 only in the area to which ink 401 is applied and its periphery.

[0068] The primer 301 constituting the base layer 300 is not particularly limited as long as it has excellent adhesion to the ink 401, and for example, clear ink, white ink, etc. can be used.

[0069] Thus, the manufacturing method of the molded body of this embodiment includes a base layer formation step in which a base layer 300 is formed on the secondary deposited sheet S2 as a deposit before the ink application step. By applying ink 401 onto the base layer 300, more precise 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 enhanced. The subsoil formation process may be omitted.

[0070] (Ink application unit 9, ink application process) The ink application unit 9 is the part that performs the ink application process of applying ink 401 to the laminated body S21 as a deposit. The ink application unit 9 applies ink 401 to the base layer 300 on the laminated body S21 by, for example, inkjet printing to form a printed layer 400.

[0071] The ink 401 is not particularly limited, but may include known inkjet inks such as pigment inks and dye inks, or sublimation inks as described in the second embodiment.

[0072] The printed layer 400 forms a predetermined pattern when viewed from above. The pattern consists of figures, pictures, characters, etc., and is represented by lines, dots, or combinations thereof. As shown in Figures 4 and 5, the printed layer 400 has a pattern 400A, an assembly pattern 400B, and a cutting pattern 400C.

[0073] The pattern 400A is intended to enhance the aesthetic appeal and is formed in a visible location after the third molded body S5 becomes the final product. In this embodiment, the pattern 400A is formed in the central part of the laminate S21.

[0074] The assembly pattern 400B serves as an assembly guide in the second molding process described later, and after the second molding process, it is covered by the second molded body S4. In this embodiment, the assembly pattern 400B is composed of two lines. Each assembly pattern 400B is located on both sides via pattern 400A.

[0075] The cutting pattern 400C serves as a cutting guide in the cutting process described later. In this embodiment, the cutting pattern 400C consists of two lines, and each cutting pattern 400C is located outside the assembly pattern 400B.

[0076] The formation positions, shapes, and colors of pattern 400A, assembly pattern 400B, and cutting pattern 400C are not limited to the configuration shown in the illustration.

[0077] Preferably, the assembly pattern 400B and the cutting pattern 400C differ in at least one of their shapes (e.g., line width) and colors. This allows the assembly pattern 400B and the cutting pattern 400C to be distinguished and recognized in the second molding process. Thus, the second molding process can be carried out more smoothly and accurately.

[0078] Immediately after forming such a printed layer 400, the ink 401 has not yet adhered to the laminate S21 and is relatively prone to bleeding.

[0079] (1st molding section 4, 1st molding process) As shown in Figure 1, the first molding unit 4 has a pressurizing unit 41 as a pressurizing mechanism, and uses the pressurizing unit 41 to heat and pressurize the laminate S21, which is a deposit to which ink 401 has been applied, thereby fixing the ink 401 and bonding the fibers of the laminate S21 together to produce the first molded body S3. In other words, the first molding step is a step in which the pressurizing unit 41 is used to heat and pressurize the laminate S21, which is a deposit to which ink 401 has been applied, thereby fixing the ink 401 and bonding the fibers of the laminate S21 together to produce the first molded body S3.

[0080] "Fixing the ink 401" means stably adhering the colorant of the ink 401 to the object so that it is difficult to detach. In this embodiment, "object" refers to the material M1 (fiber F, etc.) contained in the laminate S21 or the secondary deposition sheet S2. If a base layer 300 is used, this also includes stably adhering the ink to the object via the base layer 300 or its components so that it is difficult to detach.

[0081] If the ink 401 contains a thermosetting resin, heating in this process allows the ink 401 to be fixed more effectively.

[0082] The pressurizing section 41 has block-shaped pressurizing members 411 and 412. The pressurizing members 411 and 412 are metal molds, but are not limited to metal molds; they may be made of ceramics or the like. The pressurizing member 411 is the member on which the secondary deposition sheet S2 is placed. The pressurizing member 412 is connected to a drive source (not shown) and is configured to move toward and away from the pressurizing member 411. When the pressurizing member 412 approaches the pressurizing member 411, the secondary deposition sheet S2 on the pressurizing member 411 is heated and pressurized to produce the first molded body S3. When the pressurization is released, the secondary deposition sheet S2 can be placed on the pressurizing member 411, or the first molded body S3 can be removed from the pressurizing member 411.

[0083] The pressurizing members 411 and 412 are not limited to a block shape, but may be composed of rollers, for example.

[0084] Furthermore, the pressurizing member 412 is connected to a heat source (not shown), and can be heated by the heat generated by the heat source. In other words, the pressurizing member 412 on the side of the laminate S1 to which the ink 401 is applied is the one that performs the heating. This allows the ink 401 to be heated more directly, and the ink 401 can be fixed more effectively.

[0085] The above-mentioned drive source and heat source are electrically connected to the control device 7, and the pressurization timing, heating timing, degree of pressurization, and degree of heating are controlled. The pressurizing member 411 may also be connected to the heat source, or only the pressurizing member 411 may be connected to the heat source.

[0086] By applying pressure in the first molding section 4, the fibers F in each secondary deposition sheet S2 are compressed to increase their density, thereby producing a first molded body S3 with relatively high strength, and allowing adjacent laminated secondary deposition sheets S2 to be joined more effectively. Furthermore, by applying heat along with pressure in the first molding section 4, the binder P in the secondary deposition sheet S2 can be melted or softened and permeated between the fibers F. As a result, the fibers F can be joined together, more effectively increasing the strength of the first molded body S3, and allowing adjacent laminated secondary deposition sheets S2 to be joined well.

[0087] Thus, in the first molding process, the fixing of the ink 401 and the compression of the deposit (fiber F) can be carried out simultaneously, or overlapping in time. As a result, compared to the case where the heating and pressurizing process (molding process) and the ink fixing process are carried out separately, one process can be omitted, making it possible to manufacture the first molded body S3 more efficiently. Consequently, the productivity of the third molded body S5 can be increased.

[0088] Furthermore, "simultaneous" simply means that the processes are the same. The fixing of the ink 401 by heating and the bonding of the fibers F by pressurization only need to overlap in time. For example, their start times and end times may be staggered. In other words, even if heating is started after pressurization is started in the first molding section 4, the present invention is included as long as the heating and pressurization overlap in time.

[0089] Furthermore, in this embodiment, the inks 401 of the patterns 400A, 400B, and 400C, which have different functions, can be fixed together, making it possible to manufacture the first molded body S3 even more efficiently and further increase the productivity of the third molded body S5.

[0090] The pressurization in the first molding section 4 is performed at a higher pressure than the pressurization in the fixing section 2, that is, so that the degree of compression of the fibers F is higher than the degree of compression of the fibers F in the fixing section 2.

[0091] As shown in Figure 4, the average thickness T of one secondary deposition sheet S2 of the first molded body S3. S3 While not particularly limited, the thickness is preferably 0.7 mm to 90 mm, and more preferably 1.1 mm to 40 mm. By applying this level of pressure to the first molding section 4, the strength of the first molded body S3 can be more effectively increased, and the ink 401 can be fixed more effectively.

[0092] Density ρ of material M1 in one secondary deposition sheet S2 of the first molded body S3 S3 This is not particularly limited to, but is 0.03 g / cm³. 3 More than 4.0g / cm 3 Preferably, it is 0.2 g / cm³. 3 More than 2.5g / cm 3 The following is more preferable: By applying this level of pressure to the first molding section 4, the strength of the first molded body S3 can be more effectively increased.

[0093] Density ρ of material M1 in secondary deposition sheet S2 S2 (g / cm 3 ) and the density ρ of material M1 in one secondary deposition sheet S2 of the first molded body S3 S3 (g / cm 3 ρ S2 / ρ S3 While not particularly limited, the pressure is preferably 0.2 to 0.8, and more preferably 0.3 to 0.7. By applying this level of pressure to the first molding section 4, the strength of the first molded body S3 can be more effectively increased, and processing such as the cutting process described later can be made easier.

[0094] Density ρ of material M1 in sediment M2 M1 (g / cm 3 ) and the density ρ of material M1 in one secondary deposition sheet S2 of the first molded body S3 S3 (g / cm 3 ρ M1 / ρ S3While not particularly limited, it is preferably 0.05 to 0.7, and more preferably 0.1 to 0.5. By applying this level of pressure to the first molding section 4, the strength of the first molded body S3 can be more effectively increased.

[0095] The heating temperature T4 in the first molding step is not particularly limited, but is preferably 40°C to 220°C, and more preferably 150°C to 190°C. This allows the binder P to be melted or softened more effectively, and the bonding between the fibers F to be strengthened. Thus, the strength of the first molded body S3 can be increased more effectively.

[0096] Furthermore, the difference ΔT(T4-T2) between the heating temperature T2(°C) in the fixing part 2 and the heating temperature T4(°C) in the first molding part 4 is not particularly limited, but is preferably between 10°C and 180°C, and more preferably between 20°C and 130°C. This allows the binder P to be melted or softened more effectively, and the bonding between the fibers F to be strengthened. Thus, the strength of the first molded body S3 can be increased more effectively.

[0097] The time for which the first molding section 4 is heated and pressurized is not particularly limited, but is preferably, for example, 1 second or more and 60 seconds or less, and more preferably 2 seconds or more and 45 seconds or less. This ensures that the ink 401 is fixed and the binder P is melted or softened more reliably.

[0098] Furthermore, by printing on the top surface of the uppermost secondary deposition sheet S2 and the bottom surface of the bottommost secondary deposition sheet S2, and then heating, patterns can be formed on both the front and back surfaces of the laminate S21. It is also possible to print on the sheet S that forms the bottom surface of the bottommost secondary deposition sheet S2 before depositing the fibers, and then fix the print by heating. This method can be used whether or not a pattern is formed on the top surface of the uppermost secondary deposition sheet S2.

[0099] (Cooling section 5, cooling process) The cooling unit 5 is the part that performs a cooling process to cool the first molded body S3. Cooling performed by the cooling unit 5 means lowering the temperature of the first molded body S3 immediately after the completion of the first molding process. The temperature after cooling should be below the melting point of the binder P, and is preferably, but not limited to, room temperature. In this embodiment, a cooling block or cooling roller is in contact with both sides of the first molded body S3. However, the configuration is not limited to this, and the cooling unit 5 may be configured to blow cold air onto the first molded body S3, or the first molded body S3 may be placed in a chamber to dissipate heat from the first molded body S3. Alternatively, the heating by the pressurizing members 411 and 412 may be released, and the pressurizing members 411 and 412 may be kept in contact with the first molded body S3 until their temperatures cool down.

[0100] By performing this cooling process, the binder P of the first molded body S3 can be solidified, strengthening the bonds between the fibers F, and the ink 401 can be fixed more effectively. Therefore, the second molding process described later can be performed with the first molded body S3 having a stronger strength and the ink 401 fixed more securely. In addition, handling in the second molding process can be improved.

[0101] Furthermore, if heating is performed during the fixing process, a cooling process may be performed between the fixing process and the first molding process. In this case, the cooling process performed between the fixing process and the first molding process is the first cooling process, and the cooling process performed between the first molding process and the second molding process is the second cooling process. The cooling temperatures of the first cooling process and the second cooling process may be the same or different.

[0102] Furthermore, the first cooling step may be omitted and only the second cooling step may be performed, or the second cooling step may be omitted and only the first cooling step may be performed.

[0103] (Cutting section 10, cutting process) As shown in Figure 1, the cutting section 10 is the part that performs a cutting process (second molding process) to partially cut the first molded body S3 to a predetermined shape and quality. In the illustrated configuration, it has a pair of cutting blades 101. The cutting blades 101 cut the first molded body S3 along the cutting pattern 400C, making the first molded body S3 into the desired shape.

[0104] Since the first molded body S3 has a cutting pattern 400C formed on it, cutting can be performed more easily and accurately. Furthermore, since the ink 401 in the cutting pattern 400C is fixed, the above cutting can be performed even more easily and accurately. Note that the number and shape of the cutting blades 101 are not limited to the configuration shown in the illustration.

[0105] Furthermore, in this process, if necessary, a bending process may be performed to bend the first molded body S3. In this case, it is preferable to form a bending pattern separately from the pattern 400A, assembly pattern 400B, and cutting pattern 400C in the ink application process described above.

[0106] Thus, the method for manufacturing a molded body includes a cutting step as a second molding step, in which the first molded body S3 is processed (in this case, cut) along the cutting pattern 400C, which is a pattern formed by the ink 401, after the first molding step, to produce a third molded body S5. This makes it possible to shape the first molded body S3 into a desired shape. Furthermore, because the cutting pattern 400C is formed, cutting can be performed more easily and accurately.

[0107] (Second molding section 6, joining process) As shown in Figure 1, the second molding section 6 is the part that performs a joining process (second molding process) to produce a third molded body S5 by joining (processing) the first molded body S3 and the second molded body S4 while the second molded body S4 is superimposed on at least a part (in this embodiment, all) of the assembly pattern 400B. In other words, the second molding process is a process in which the first molded body S3 and the second molded body S4 are joined to produce a third molded body S5 while the second molded body S4 is superimposed on the assembly pattern 400B, which is a pattern formed by the ink 401. This makes it possible to obtain a third molded body S5 with higher strength. Furthermore, as mentioned above, since the assembly pattern 400B is formed on the first molded body S3, it is possible to produce a third molded body S5 with high assembly accuracy of the first molded body S3 and the second molded body S4 more easily.

[0108] The second molding section 6 is composed of a sewing machine 61 that joins the first molded body S3 and the second molded body S4 by suturing. The sewing method used by the sewing machine 61 is not particularly limited and includes, for example, straight stitching, zigzag stitching, blind stitching, overcast stitching, etc.

[0109] The second molded section 6 may also be configured to perform joining other than suturing, such as joining by pressure, joining by heat, or joining using an adhesive.

[0110] As shown in Figures 4 and 6, the second molded body S4 is strip-shaped in this embodiment. Preferably, the width of the second molded body S4 is greater than the width of the assembly pattern 400B. This allows the assembly pattern 400B to be hidden when the first molded body S3 and the second molded body S4 are joined together. This makes it possible to more effectively enhance the aesthetic appeal of the third molded body S5.

[0111] The above configuration is not limited to the above, and the second molded body S4 may have a shape other than a strip. Furthermore, the second molded body S4 may be joined to the first molded body S3 by overlapping it so that part or all of the assembly pattern 400B is not hidden.

[0112] The second molded body S4 may be made of a material containing fibers, or it may be made of a material that does not contain fibers, such as a resin material. If the second molded body S4 is made of a material containing fibers, the fibers of the second molded body S4 may be those exemplified as constituent materials of material M1.

[0113] Furthermore, if the second molded body S4 is composed of a material containing fibers, it may also contain a binder for bonding the fibers together. The binder is not particularly limited, and any materials exemplified as constituent materials of the binder P can be used.

[0114] Although not shown in the diagram, a tote bag can be obtained by overlapping and partially joining a pair of third molded bodies S5.

[0115] In this embodiment, a cutting process and a joining process were described as examples of the second molding process. However, the present invention is not limited to these, and for example, a bending process or the like may be performed as the second molding process.

[0116] (Control device 7) Each component of the molded body manufacturing apparatus 100 is electrically connected to the control device 7. The operation of each component is controlled by the control device 7.

[0117] As shown in Figure 1, the control device 7 includes a control unit 71, a storage unit 72, and a communication unit 73.

[0118] The control unit 71 has at least one processor and executes various programs stored in the storage unit 72. For example, a CPU (Central Processing Unit) can be used as the processor. The control unit 71 also has various functions, such as controlling the drive of various parts of the apparatus related to molded body manufacturing.

[0119] The memory unit 72 stores, for example, a program for executing the method for manufacturing the molded article of the present invention. The program for executing the method for manufacturing the molded article of the present invention may also be stored in a storage device other than the memory unit 72, such as the storage device of a server or an external storage device that can be attached to or removed from the control device 7.

[0120] The communication unit 73 is, for example, composed of an I / O interface and communicates with various parts of the molded body manufacturing apparatus 100. The communication unit 73 also has the function of communicating with a computer or server (not shown) via a network.

[0121] The control device 7 may be built into the molded body manufacturing apparatus 100, or it may be provided in an external device such as an external computer. Furthermore, the control unit 71 and the storage unit 72 may, for example, be integrated and configured as a single unit, or the control unit 71 may be built into the molded body manufacturing apparatus 100 and the storage unit 72 may be provided in an external device such as an external computer, or the storage unit 72 may be built into the molded body manufacturing apparatus 100 and the control unit 71 may be provided in an external device such as an external computer.

[0122] As described above, the method for manufacturing a molded article of the present invention comprises an ink application step of applying ink 401 to a secondary deposited sheet S2, which is a deposited material M1 containing fibers F, and a first molding step of heating and pressurizing the secondary deposited sheet S2 to which the ink 401 has been applied using a pressurizing unit 41, which is a pressurizing mechanism, to fix the ink 401 and bond the fibers F together to produce a first molded article S3. As a result, the molding of the first molded article S3 and the fixing of the ink 401 can be performed in one step in the first molding step. Therefore, the first molded article S3 can be manufactured efficiently. As a result, the productivity of the third molded article S5 can be increased.

[0123] Furthermore, in the ink application process, ink 401 is applied to a laminate S21 formed by stacking multiple secondary deposition sheets S2 as deposits. In the first molding process, the laminate S21 to which the ink 401 has been applied is heated and pressurized to produce a first molded body S3. This makes it possible to more effectively increase the strength of the first molded body S3. In addition, since the ink 401 is applied only to the surface of the laminate S21, it is not necessary to apply ink 401 to each of the secondary deposition sheets S2. Therefore, the first molded body S3 can be manufactured even more efficiently.

[0124] Furthermore, the molded body manufacturing apparatus 100 uses material M1 containing fiber F. The apparatus includes an ink application unit 9 that applies ink 401 to a secondary deposited sheet S2, which is a deposited material, and a first molding unit 4 which has a pressurizing unit 41 as a pressurizing mechanism and uses the pressurizing unit 41 to heat and pressurize the secondary deposited sheet S2 to which the ink 401 has been applied, thereby fixing the ink 401 to the secondary deposited sheet S2 and bonding the fibers F of the secondary deposited sheet S2 together to produce a first molded body S3. As a result, the first molding unit 4 can perform the molding of the first molded body S3 and the fixing of the ink 401 in one step. Therefore, the first molded body S3 can be manufactured efficiently. As a result, the productivity of the third molded body S5 can be increased.

[0125] <Second Embodiment> Figure 7 is a cross-sectional view showing a pressurizing section of a molded body manufacturing apparatus according to a second embodiment of the present invention, showing a state in which a transfer sheet is placed on a laminate. Figure 8 is a cross-sectional view showing the pressurizing section shown in Figure 7, showing a state in which the laminate is being pressurized. Figure 9 is a cross-sectional view showing the pressurizing section shown in Figure 7, showing a state in which the pressurization of the laminate is released and the transfer sheet is removed.

[0126] The following description will focus on the differences from the first embodiment, and will omit explanations of similar matters.

[0127] (Transfer sheet 40) As shown in Figures 7, 8, and 9, in this embodiment, a first molded body S3 is produced using a transfer sheet 40. The transfer sheet 40 has ink 401 applied to one side (the bottom side). The ink 401 is applied to the transfer sheet 40 in patterns corresponding to the pattern 400A, the assembly pattern 400B, and the cutting pattern 400C.

[0128] The transfer sheet 40 is not particularly limited, but for example, it can be made of paper such as plain paper, or a recording medium provided with an ink-receiving layer (referred to as inkjet-specific paper, coated paper, etc.). This makes it possible to more effectively prevent bleeding when transferring the ink 401.

[0129] In this embodiment, it is preferable that the ink 401 is a sublimation ink. This allows for better transfer of the ink 401, and enables the creation of clearer patterns 400A, assembly patterns 400B, and cutting patterns 400C.

[0130] As for the sublimation ink, there are no particular limitations, and any known ink that vaporizes when heat is applied can be used. Note that inks other than dye-sublimation inks may be used as ink 401.

[0131] Furthermore, in this embodiment, the underlayer 300 is omitted, and the ink 401 is transferred to the sediment M2. As a result, the binder P contained in the sediment M2 effectively contributes to improving adhesion with the ink 401, and the ink 401 can be fixed more effectively. In this embodiment, the underlying layer 300 may be formed in the secondary sediment M2.

[0132] In the manufacturing method of the molded article of this embodiment, the ink application step and the first molding step described in the first embodiment are performed together, that is, they overlap in time.

[0133] (First molding process (ink application process)) As shown in Figure 7, in the first molding step, the transfer sheet 40 described above is first placed on the laminate S21 such that the side to which the ink 401 is applied is in contact with the upper surface of the laminate S21.

[0134] Next, as shown in Figure 8, the laminate S21 is heated and pressurized together with the transfer sheet 40 using pressurizing members 411 and 412. That is, in this step, heating and pressurizing are performed with the transfer sheet 40 stacked on top of the laminate S21. As a result, the transfer sheet 40 is pressed against the laminate S21 along with the heating and pressurizing of the laminate S21. At this time, the ink 401 sublimes and is transferred (applied) to the laminate S21. Furthermore, after the transfer, the ink 401 is fixed to the laminate S21 by the heating and pressurizing described above. In this way, in this embodiment, the production of the first molded body S3, the application (transfer) of the ink 401 to the laminate S21, and the fixing of the ink 401 can be performed all at once. Therefore, the first molded body S3 can be manufactured efficiently. As a result, the productivity of the third molded body S5 can be further increased.

[0135] In this embodiment, the heating temperature T4' by the pressurizing section 41 is not particularly limited, but is preferably 40°C to 220°C, and more preferably 130°C to 190°C. This allows the binder P to be melted or softened more effectively, and the bonding between the fibers F to be strengthened. Thus, the strength of the first molded body S3 can be increased more effectively.

[0136] Furthermore, the difference ΔT(T4-T2) between the heating temperature T2(°C) in the fixing part 2 and the heating temperature T4'(°C) in the first molding part 4 is not particularly limited, but is preferably between 10°C and 180°C, and more preferably between 20°C and 130°C. This allows the binder P to be melted or softened more effectively, and the bonding between the fibers F to be strengthened. Thus, the strength of the first molded body S3 can be increased more effectively.

[0137] The time for which the first molding section 4 is heated and pressurized is not particularly limited, but is preferably, for example, 1 second or more and 60 seconds or less, and more preferably 2 seconds or more and 45 seconds or less. This ensures that the ink 401 is fixed and the binder P is melted or softened more reliably.

[0138] Once the transfer of ink 401 is complete, the transfer sheet 40 is removed as shown in Figure 9. This makes it possible to produce a first molded body S3 with pattern 400A, assembly pattern 400B, and cutting pattern 400C applied to it.

[0139] Furthermore, as a transfer method, methods that do not involve heating or pressurizing may be used, such as printing on the surface of a transfer sheet coated with adhesive, transferring the image by heating as described above, and fixing the ink to the surface of the laminate S21 with the adhesive.

[0140] Furthermore, by placing transfer sheets 40 on both the upper and lower surfaces of the laminate S21 and heating it, it is possible to apply (transfer) ink 401 to both the front and back surfaces of the laminate S21 and fix the ink 401 to create a pattern. Alternatively, by placing the transfer sheet 40 only on the bottom surface and heating it, it is also possible to apply (transfer) ink 401 to only the back surface of the laminate S21 and fix the ink 401 to create a pattern.

[0141] Furthermore, the molded body manufacturing apparatus may perform steps such as applying adhesive to the base material of the transfer sheet 40 to create the transfer sheet 40, and printing on the transfer sheet 40. Alternatively, a pre-printed transfer sheet created elsewhere may be set in the molded body manufacturing apparatus 1 and the transfer may be performed.

[0142] Thus, in this embodiment, during the ink application process, one side (the bottom side in the figure) of the transfer sheet 40, on which ink 401 has been applied, is brought into contact with the laminated body S21, which is a deposit. This makes it easy to apply the ink 401.

[0143] Furthermore, in the first molding process, the transfer sheet 40 is placed on top of the laminated body S21, which is the deposited material, and then heating and pressurizing are performed. After that, the transfer sheet 40 is detached from the first molded body S3. This allows the formation of the first molded body S3, the application (transfer) of the ink 401 to the laminated body S21, and the fixing of the ink 401 to the laminated body S21 to be performed all at once. Therefore, the first molded body S3 can be manufactured efficiently. As a result, the productivity of the third molded body S5 can be further increased.

[0144] <Third Embodiment> Figure 10 is a cross-sectional view showing a pressurizing section of a molded body manufacturing apparatus according to a third embodiment of the present invention, showing a state in which a recess-forming member is placed on a laminate. Figure 11 is a cross-sectional view showing the pressurizing section shown in Figure 10, showing a state in which the laminate is being pressurized. Figure 12 is a cross-sectional view showing the pressurizing section shown in Figure 10, showing a state in which the pressurization of the laminate is released and the recess-forming member is removed.

[0145] The following description will focus on the differences from the first embodiment, and will omit explanations of similar matters.

[0146] As shown in Figures 10 to 12, in this embodiment, in the first molding step, a first molded body S3 having a recess 402 is generated using a recess-forming member 413. Specifically, first, as shown in Figure 10, two rigid rod-shaped recess-forming members 413 are placed on the laminate S21. In this embodiment, each recess-forming member 413 is placed on the assembly pattern 400B.

[0147] Next, as shown in Figure 11, heating and pressurization are performed using the pressurizing unit 41. At this time, the recess-forming member 413 enters the first molded body S3 from above, and the recess-forming member 413 becomes embedded in the first molded body S3.

[0148] Next, as shown in Figure 12, the heating and pressurizing are released and the recess-forming member 413 is removed. As a result, a recess 402 is formed in the region of the first molded body S3 where the recess-forming member 413 was located.

[0149] The recess 402 visually and tactilely indicates the assembly position. The shape of the recess 402 is groove-like, corresponding to the shape of the recess-forming member 413. By placing the recess-forming member 413 on the assembly pattern 400B, the assembly pattern 400B is formed at the bottom of the recess 402.

[0150] Although not shown in the diagram, in the joining process, the second molded body S4 is inserted into the recess 402, and the first molded body S3 and the second molded body S4 are joined in this inserted state. During this joining operation, the second molded body S4 is restricted from excessive movement 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.

[0151] According to this embodiment, the recess 402 visually and tactilely indicates the assembly position, and the assembly pattern 400B provided at the bottom of the recess 402 further visually indicates the assembly position clearly. Therefore, the joining of the first molded body S3 and the second molded body S4 can be performed more easily and accurately.

[0152] Although the present invention has been described in detail in the illustrated embodiments of the method for manufacturing a molded article and the molded article manufacturing apparatus, the present invention is not limited to these embodiments. Each part and each process constituting the method for manufacturing a molded article and the molded article manufacturing apparatus of the present invention can be replaced with any structure or process that can perform similar functions. Furthermore, any additional components or processes may be added to the method for manufacturing a molded article and the molded article manufacturing apparatus of the present invention. Moreover, the method for manufacturing a molded article and the molded article manufacturing apparatus of the present invention may be a combination of the features of each embodiment.

[0153] Furthermore, the first embodiment and the second embodiment may be combined, the first embodiment and the third embodiment may be combined, the second embodiment and the third embodiment may be combined, and the first embodiment, the second embodiment and the third embodiment may be combined.

[0154] For example, it is also possible to form a pattern on the surface of the laminate S21 using the method of the first embodiment and the method of the third embodiment, and to form a pattern on the back surface of the laminate S21 using ink using the method of the second embodiment.

[0155] Furthermore, in each process, all steps may be performed automatically by machines, or at least some steps may be performed by humans. [Explanation of Symbols]

[0156] 1...Deposit section, 2...Fixing section, 3...Cutting section, 4...First molding section, 5...Cooling section, 6...Second molding section, 7...Control device, 8...Base layer formation section, 9...Ink application section, 10...Cutting section, 11...Dispersion section, 12...Mesh belt, 13...Suction section, 14...Sheet supply section, 21...Heating and pressurizing roller, 31...Cutting blade, 32...Conveying roller, 40...Transfer sheet, 41...Pressing section, 61...Sewing machine, 71...Control unit, 72...Storage section, 73...Communication section, 100...Molded body manufacturing device, 101...Cutting blade, 111...Drum, 112...Housing, 1 21...Tensioning roller, 131...Tube, 132...Blower, 141...Supply roller, 300...Base layer, 301...Primer, 400...Printing layer, 400A...Pattern, 400B...Assembly pattern, 400C...Cutting pattern, 401...Ink, 402...Recess, 411...Pressure member, 412...Pressure member, 413...Recess forming member, F...Fiber, M1...Material, M2...Deposits, P...Binding agent, S...Sheet, S1...Primary deposited sheet, S2...Secondary deposited sheet, S21...Laminate, S3...First molded body, S4...Second molded body, S5...Third molded body, T M2 ...average thickness, T S ...average thickness, T S1 ...average thickness, T S2 ...average thickness, T S3 ...average thickness

Claims

1. An ink application process for applying ink to a fiber-containing material, A method for manufacturing a molded body, comprising: a first molding step of heating and pressurizing the deposit to which the ink has been applied using a pressurizing mechanism to fix the ink and bond the fibers together to produce a first molded body.

2. A method for manufacturing a molded article according to claim 1, comprising a base layer formation step of forming a base layer on the deposit before the ink application step.

3. In the ink application step, the ink is applied to a laminate formed by stacking multiple deposits. The method for producing a molded article according to claim 1, wherein the first molding step involves heating and pressurizing the laminate to which the ink has been applied, thereby producing the first molded article.

4. A method for manufacturing a molded article according to any one of claims 1 to 3, further comprising a fixing step of fixing the fibers of the deposit before the ink application step.

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

6. A method for manufacturing a molded article according to any one of claims 1 to 3, wherein the heating temperature in the first molding step is 150°C or more and 190°C or less.

7. A method for manufacturing a molded body according to any one of claims 1 to 3, further comprising a second molding step of processing the first molded body along the pattern formed by the ink after the first molding step to produce a third molded body.

8. The method for manufacturing a molded body according to claim 7, wherein in the second molding step, the first molded body and the second molded body are joined together with the second molded body superimposed on the pattern formed by the ink to produce a third molded body.

9. The method for manufacturing a molded article according to any one of claims 1 to 3, wherein in the ink application step, the one surface of the transfer sheet on which the ink has been applied is brought into contact with the deposit.

10. The method for manufacturing a molded body according to claim 9, wherein in the first molding step, the transfer sheet is placed on top of the deposit and then heated and pressurized, and the transfer sheet is subsequently 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. An ink application unit that applies ink to a material containing fibers, A molded body manufacturing apparatus comprising: a first molding unit having a pressurizing mechanism, which uses the pressurizing mechanism to heat and pressurize the deposit to which the ink has been applied, thereby fixing the ink to the deposit and bonding the fibers together to produce a first molded body.

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