Film application device and method for manufacturing decorative member

Abstract

To suppress the deterioration of the design of decorative components. [Solution] The film application device 40 applies the film 15, which has a first surface 15a and a second surface 15b, to the adherend AB by moving the film 15 in a first direction D1, starting from the second surface 15b. The film application device 40 includes a holding device 50 for holding the film 15 and a moving device 42 for moving the holding device 50. The film 15 is applied to the adherend AB with the film 15 protruding in the first direction D1 toward the adherend AB.

Description

[Technical Field]

[0001] This disclosure relates to a film application apparatus and a method for manufacturing decorative members. [Background technology]

[0002] As described in Patent Document 1, a film application device is known for attaching a film to an object. The film application device moves the film in a first direction relative to the object. The object and the film attached to the object constitute a decorative member. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2019-531951 [Overview of the project] [Problems that the invention aims to solve]

[0004] In Patent Document 1, the film is attached to the substrate while being stretched in at least one of the second and third directions. The second direction is perpendicular to the first direction. The third direction is perpendicular to both the first and second directions. The film, stretched in the second or third direction, is attached to the substrate in a wrinkled state. The design of the decorative member, including the film attached in a wrinkled state, deteriorates. This disclosure aims to suppress the deterioration of the design of the decorative member. [Means for solving the problem]

[0005] A first film application apparatus according to one embodiment of the present disclosure is A film application device that applies a film having a first surface and a second surface to an object by moving the film in a first direction, starting from the second surface, A holding device for holding the aforementioned film, A moving device for moving the holding device, and The film is attached to the adherent in a state of protruding in the first direction toward the adherent.

[0006] A second film sticking device according to an embodiment of the present disclosure is A film sticking device that sticks a film having a first surface and a second surface to an adherent from the second surface by moving the film in a first direction, A holding device for holding the film, A pressurizing device for pressurizing a first space included in the first surface, and The pressurizing device projects the film in the first direction toward the adherent.

Advantages of the Invention

[0007] According to the present disclosure, deterioration of the design of the decorative member can be suppressed.

Brief Description of the Drawings

[0008] [Figure 1] FIG. 1 is a diagram of an embodiment and is an exploded perspective view of a decorative moving body. [Figure 2] [[ID='32']]FIG. 2 is a cross-sectional view of a decorative member included in the decorative moving body of FIG. 1. [Figure 3] FIG. 3 is a diagram of a film sticking device included in the decorative moving body of FIG. 1. [Figure 4] FIG. 4 is a diagram of a film sticking device included in the decorative moving body of FIG. 1. [Figure 5] FIG. 5 is a view of the holding device of FIGS. 3 and 4 observed from the second side in the first direction. [Figure 6] FIG. 6 is a diagram for explaining the operation of the fixing member in the holding device of FIG. 5. [Figure 7] FIG. 7 is a diagram for explaining the operation of the fixing member in the holding device of FIG. 5 [Figure 8] FIG. 8 is a perspective view of the suction device, the holding device, and the film. [Figure 9]Figure 9 is a cross-sectional view taken along the line IX-IX in Figure 8. [Figure 10] Figure 10 shows the adherends in Figures 3 and 4 as observed from the first side in the first direction. [Figure 11] Figure 11 shows the adherend, film, and holding device from Figures 3 and 4, as observed from the first side in the first direction. [Figure 12] Figure 12 shows the internal space of the holding device under pressure, observed from the second side in the third direction. [Figure 13] Figure 13 shows the internal space of the holding device under pressure, observed from the second side in the second direction. [Figure 14] Figure 14 is a view of the holding device shown in Figure 12, after it has been moved toward the object to be attached by the moving device, as observed from the second side in the third direction. [Figure 15] Figure 15 shows a film partially attached to an object and separated from the holding device, observed from the first side in the first direction. [Figure 16] Figure 16 is a perspective view of the film forming apparatus and the edge of the film. [Figure 17] Figure 17 is a perspective view of the first type of film molding apparatus shown in Figure 16. [Figure 18] Figure 18 is a perspective view of the second type of film forming apparatus shown in Figure 16. [Figure 19] Figure 19 is a view of the film forming apparatus shown in Figure 16, observed from the Y direction. [Figure 20] Figure 20 is a view of the film forming apparatus shown in Figure 16, observed from the Z direction. [Figure 21] Figure 21 is a perspective view of a film formed by a film forming machine. [Figure 22] Figure 22 is a side view of the object to be adhered to, as shown in Figure 21. [Figure 23] Figure 23 is a plan view of the object to be adhered to, as shown in Figure 21. [Figure 24] Figure 24 is a cross-sectional view of one modified example of the decorative member shown in Figure 2. [Modes for carrying out the invention]

[0009] One embodiment of the present disclosure relates to the following [1] to

[36] .

[0010] [1] A film application device for applying a film having a first surface and a second surface to an object by moving the film in a first direction, starting from the second surface, A holding device for holding the aforementioned film, The device comprises a moving device for moving the aforementioned holding device, A film application device wherein the film is attached to the adherend in a state where it protrudes toward the adherend in a first direction toward the adherend.

[0011] [2] The film application apparatus of [1], further comprising a pressing device for pressing the first space facing the first surface when the holding device is holding the film.

[0012] [3] A film application device for applying a film having a first surface and a second surface to an object by moving the film in a first direction, starting from the second surface, A holding device for holding the aforementioned film, The device comprises a pressurizing device for pressurizing the first space having the first surface, The pressurizing device is a film application device that causes the film to protrude toward the object to be adhered in the first direction.

[0013] [4] The film is a decorative film, and the film application apparatus is one of [1] to [3].

[0014] [5] A film application device according to any of [1] to [4], wherein the holding device holds both side edges of the film in a second direction nonparallel to the first direction, and both side edges of the film in a third direction nonparallel to both the first and second directions.

[0015] [6] The film application device of [5], wherein the film is joined to the holding device from the second surface at both side edges in the second direction and both side edges in the third direction.

[0016] [7] The film includes a bonding layer that constitutes the second surface, The film application device according to [2] or [3], wherein the pressurizing device increases the pressure in the first space when the film partially contacts the adherend compared to before contact.

[0017] [8] A film application device according to any of [1] to [7], further comprising a cutting device for cutting the film.

[0018] [9] The holding device includes a circumferential frame opening to the first and second sides in the first direction, and a cover that closes the opening from either the first or second side in the first direction, The film is applied by any of the film application devices [1] to [8], which close the opening of the frame from the other of the first and second sides.

[0019]

[10] Further comprising a cutting device that cuts the film by emitting light, The film application device [9] wherein the cover is positioned between the cutting device and the film and is transparent.

[0020]

[11] A film application device from any of [1] to

[10] , further comprising an imaging device for acquiring an image of the film.

[0021]

[12] Further comprising an imaging device for acquiring an image of the film, The cover is disposed between the imaging device and the film and is transparent, and is a film application device of [9] or

[10] .

[0022]

[13] A film application device according to any of [2] to

[12] , further comprising a control device for controlling the operation of the pressurizing device.

[0023]

[14] Further comprising an imaging device for acquiring an image of the film, The control device controls the operation of the pressurizing device based on the image, the film application device

[13] .

[0024]

[15] An imaging device that acquires an image of the film and an image of the adherend, A cutting device for cutting the aforementioned film, A film application device, any one of [1] to

[14] , further comprising a control device that controls the operation of the cutting device based on at least one of the aforementioned images.

[0025]

[16] A film application device according to any of [1] to

[15] , further comprising a control device for controlling the operation of the moving device.

[0026]

[17] The imaging device further comprises an imaging device that acquires an image of the object to be adhered to, The control device controls the operation of the moving device based on the image,

[16] of the film application device.

[0027]

[18] The control device stores the number of times the film is applied by the film application device, and is one of the film application devices from

[13] to

[17] .

[0028]

[19] The suction device further comprises a device for sucking the film from the first or second surface, The holding device is a film application device, one of [1] to

[18] , that holds the film in the state where it has been sucked by the suction device.

[0029]

[20] The film includes a substrate layer, The aforementioned base layer comprises thermoplastic polyurethane, and is a film application apparatus according to any of [1] to

[19] .

[0030]

[21] The film includes a bonding layer that constitutes the second surface, The peeling force of the film attached from the second surface is 3N / 25mm or more. A film application device from [1] to

[20] .

[0031]

[22] A film application apparatus according to any of [1] to

[21] , wherein the 3% strain tensile stress of the film is 1 N / 10 mm or more and 40 N / 10 mm or less in an environment of 25°C.

[0032]

[23] The adherend has a three-dimensional shape and protrudes toward the film in a first direction, and is a film application device according to any of [1] to

[22] .

[0033]

[24] The object to be attached and A method for manufacturing a decorative member comprising a film attached to the adherend, A method for manufacturing a decorative member, comprising the step of attaching the film to the adherend using one of the film attachment devices [1] to

[23] .

[0034]

[25] Equipped with Type 1 and Type 2, A film forming apparatus that forms the edge portion sandwiched between the first mold and the second mold by heating the edge portion of a film partially attached to a substrate.

[0035]

[26] A film forming apparatus of

[25] in which at least one of the first type and the second type heats the edge.

[0036]

[27] Equipped with Type 1 and Type 2, A film forming apparatus that forms the edge of a film sandwiched between the first and second molds by heating the edge of the film with at least one of the first and second molds.

[0037]

[28] The film includes a bonding layer that bonds the film to the adherend, A film molding apparatus according to

[26] or

[27] , wherein the material of at least one of the molds is one of a fluororesin, a silicone resin, and an olefin resin in the portion that contacts the bonding layer.

[0038]

[29] The film includes corners where multiple edges are connected to each other, A film forming apparatus, one of

[25] to

[28] , for forming the corner portion sandwiched between the first and second types.

[0039]

[30] One of the first and second molds is provided with a recess for accommodating the other of the first and second molds, The edge portion is bent in the recess, in any of the film forming apparatuses

[25] to

[29] .

[0040]

[31] The first and second types are pivotably connected to each other, and the film forming apparatus is one of the

[25] to

[30] .

[0041]

[32] The adherend is a film forming apparatus having a three-dimensional shape, one of the

[25] to

[31] .

[0042]

[33] A first application step of partially attaching the film to the substrate, A molding step of forming the edge of the film using one of the film molding apparatuses

[25] to

[32] , A method for manufacturing a decorative member, comprising a second attachment step of attaching the edge portion to the adherend.

[0043]

[34] The method for manufacturing the decorative member of

[33] , wherein the film includes a positioning portion for positioning at least one of the first type and the second type at the edge.

[0044]

[35] The film includes a substrate layer, A method for manufacturing a decorative member

[33] or

[34] , wherein the base layer comprises thermoplastic polyurethane.

[0045]

[36] A method for manufacturing a decorative member according to any of

[33] to

[35] , wherein the 3% strain tensile stress of the film is 1 N / 10 mm or more and 40 N / 10 mm or less in an environment of 25°C.

[0046] An implementation of this disclosure will be described with reference to the drawings. For ease of illustration and understanding, dimensional ratios in the drawings may be modified from those of the actual object. Shapes, terms used to specify geometric conditions such as "parallel" and "orthogonal," lengths, and angle values ​​should not be interpreted strictly, but rather within a range that allows for the expectation of similar functionality. Components shown in one drawing may be omitted in other drawings.

[0047] Directions common to multiple drawings are indicated by arrows with a common reference numeral in each drawing. In each illustrated direction, the tip of the arrow is the first side, and the opposite side, i.e., the base of the arrow, is the second side. The first side in a direction perpendicular to the drawing is indicated by a symbol of a circle with a dot inside. The second side in a direction perpendicular to the drawing is indicated by a symbol of a circle with an X inside.

[0048] Multiple candidates for the lower limit of a certain parameter and multiple candidates for the upper limit of that parameter may be listed. The candidate numerical range of the parameter will be a combination of one of the multiple candidates for the lower limit and one of the multiple candidates for the upper limit. For example, B1, B2, and B3 may be listed as multiple candidates for the lower limit of parameter A. B1, B2, and B3 are all different numbers. C1, C2, and C3 may be listed as multiple candidates for the upper limit of parameter A. C1, C2, and C3 are all different numbers. In this example, the candidate numerical ranges of parameter A are B1 or greater and C1 or less, B1 or greater and C2 or less, B1 or greater and C3 or less, B2 or greater and C1 or less, B2 or greater and C2 or less, B2 or greater and C3 or less, B3 or greater and C1 or less, B3 or greater and C2 or less, B3 or greater and C3 or less.

[0049] Figures 1 to 23 are diagrams illustrating one embodiment. Figure 1 is a perspective view of the movable body 100. The movable body 100 includes a decorative member 25. The decorative member 25 displays a design. The decorative member 25 includes an adherend AB and a film 15 attached to the adherend AB. In the decorative member 25, the film 15 may display a design. The film 15 that displays the design may be described as a decorative film 20, as described later. In the decorative member 25, the adherend AB may display a design. The movable body 100 may include a plurality of decorative members 25.

[0050] The mobile body 100 is a movable device or equipment. Examples of the mobile body 100 include automobiles, motorcycles, bicycles, tricycles, trains, aircraft, ships, snowmobiles, industrial robots, drones, etc. Below, one embodiment will be described using an example in which the decorative film 20 is applied to an automobile 1, particularly a passenger car. Examples of automobiles 1 other than passenger cars include trucks, buses, taxis, ambulances, fire trucks, police vehicles, construction vehicles, etc.

[0051] In the example shown in Figure 1, the automobile 1 includes a plurality of exterior members 10. The exterior members 10 are members that form the outer surface of the automobile 1. The exterior members 10 form a part of the outer surface of the moving body 100. The automobile 1 includes a roof 11, pillars 12, and a trunk lid 13 as exterior members 10. The exterior members 10 may also be adherends AB. In the illustrated example, adherends AB are the roof 11. That is, the film 15 is attached to the roof 11. The decorative film 20 may be attached to exterior members 10 other than the roof 11.

[0052] The exterior member 10 may be made of metal such as aluminum or stainless steel. The exterior member 10 may also contain synthetic resin such as fiber-reinforced plastic (FRP). The exterior member 10 may be manufactured by processing sheet material. The exterior member 10 may be formed by various processing methods such as press working. The exterior member 10 may have a three-dimensional shape. "Having a three-dimensional shape" means having a curved surface that is bent around two or more axes that extend non-parallel to each other.

[0053] The exterior member 10 may be coated with paint. The exterior member 10 may display a design by being coated with paint. The exterior member 10 may be colored with paint. The exterior member 10 may be coated with a coating agent. The exterior member 10 may be given a glossy appearance by being coated with a coating agent.

[0054] In the example shown in Figure 1, the roof 11 extends in the longitudinal and lateral directions of the automobile 1. The roof 11 has a front edge and a rear edge, which are edges in the longitudinal direction, and side edges, which are edges in the lateral direction. The front edge and rear edge extend in the lateral direction. The side edges extend in the longitudinal direction.

[0055] The roof 11 in Figure 1 has a three-dimensional shape. In other words, the roof 11 has a curved surface 11R that is bent around two or more axes that extend non-parallel to each other. As described above, the roof 11 is the adherend AB of the film 15. The curved surface 11R may also be described as the adherend surface of the adherend AB. Furthermore, the illustrated roof 11 protrudes upward, i.e., upward in the vertical direction.

[0056] The term "front-rear direction" used for the automobile 1, exterior component 10, and film 15 attached to the exterior component 10 is based on the normal direction of travel of the automobile 1 on the driving surface. The term "up-down direction" used for the automobile 1 and exterior component 10 means the direction perpendicular to the driving surface. The term "left-right direction" used for the automobile 1 and exterior component 10 means the direction perpendicular to both the front-rear direction and the up-down direction. The term "front" or "forward" used for the automobile 1 and exterior component 10 means the direction toward the direction of travel in the front-rear direction. The term "rear" or "backward" used for the automobile 1 and exterior component 10 means the direction opposite to the direction of travel in the front-rear direction.

[0057] The film 15 in Figure 2 has a first surface 15a and a second surface 15b opposite to the first surface 15a. The film 15 in Figure 2 is attached to the substrate AB from the second surface 15b. The illustrated film 15 can be observed from the first surface 15a.

[0058] In the film 15, a separator (not shown) may be superimposed on at least one of the first surface 15a and the second surface 15b. The film 15 improves scratch resistance on the surface on which the separator is superimposed. Furthermore, when at least one of the first surface 15a and the second surface 15b is composed of the bonding layer 32 described later, the film 15 can be prevented from unintentionally bonding on the surface on which the separator is superimposed. The separator may be peeled off when the film 15 is attached to the adherend AB.

[0059] As shown in Figure 1, in the decorative member 25, the film 15 may be a decorative film 20. The decorative film 20 displays a design on the surface to which it is applied. When the film 15 is a decorative film 20, the film 15 displays the design in the decorative member 25. In the illustrated decorative member 25, the display of the design by the film 15 eliminates the need for the adherend AB to display the design. In particular, in the illustrated movable body 100, the display of the design by the film 15 eliminates the need to paint the adherend AB, i.e., the exterior member 10. The painting method for the exterior member 10 includes a paint film baking step. The paint film baking step can also be eliminated by the film 15 displaying the design. Therefore, when manufacturing the illustrated decorative member 25, greenhouse gas emissions in the paint film baking step can be suppressed.

[0060] From the viewpoint of stably displaying the design, a lower limit may be set for the thickness of the film 15. The thickness of the film 15 may be 50 μm or more, or 100 μm or more. Furthermore, from the viewpoint of stably maintaining the state in which it is attached to the adherend AB, an upper limit may be set for the thickness of the film 15. The thickness of the film 15 may be 500 μm or less. Note that the thickness of the film 15 is the dimension of the film 15 in the direction in which the first surface 15a and the second surface 15b face each other.

[0061] The thickness of film 15 and the thickness of its constituent elements are determined by observing a cross-sectional image of film 15 using a scanning transmission electron microscope (STEM). The thickness of film 15 and the thickness of its constituent elements are determined as the arithmetic mean of five measurements taken at five different locations.

[0062] The film 15 in Figure 1 includes an edge 15e extending in the front-to-back or left-to-right direction. The illustrated edge 15e includes a first edge 15ea extending in the front-to-back direction and a second edge 15eb extending in the left-to-right direction. The edge 15e includes two first edges 15ea separated from each other in the left-to-right direction. The edge 15e includes two second edges 15eb separated from each other in the front-to-back direction. The film 15 in Figure 1 is curved along the adherend AB at the edge 15e. The edge 15e of the film 15 includes a portion that is curved along the adherend AB.

[0063] The film 15 in Figure 1 includes corners 15r where the ends of the edges 15e are connected to each other. The film 15 in Figure 1 includes four corners 15r. The film 15 is curved along the substrate AB at the corners 15r. The corners 15r of the decorative film 20 include portions that are curved along the substrate AB.

[0064] The decorative film 20 in Figure 1 includes an edge portion 20e extending in the front-to-back direction or the left-to-right direction. The edge portion 20e of the decorative film 20 constitutes the edge portion 15e of the film 15. The illustrated edge portion 20e includes a first edge portion 20ea extending in the front-to-back direction and a second edge portion 20eb extending in the left-to-right direction. The first edge portion 20ea of ​​the decorative film 20 constitutes the first edge portion 15ea of ​​the film 15. The second edge portion 20eb of the decorative film 20 constitutes the second edge portion 15eb of the film 15.

[0065] The decorative film 20 in Figure 1 includes corners 20r where the edges of the border 20e are connected to each other. The corners 20r of the decorative film 20 constitute the corners 15r of the film 15. The decorative film 20 in Figure 1 includes four corners 20r.

[0066] In the film 15, an upper limit may be set for the 3% strain tensile stress at room temperature. Specifically, the 3% strain tensile stress of the film 15 may be 40 N / 10 mm or less, 30 N / 10 mm or less, or 20 N / 10 mm or less in an environment of 25°C. By setting such an upper limit, the film 15 can be stably attached to the adherend AB even at room temperature, according to the shape of the adherend. Furthermore, when the illustrated film 15 is attached to the adherend AB using the film attachment device 40 described later, it can be easily moved in the first direction D1 even at room temperature by applying pressure in the first space S1.

[0067] In film 15, a lower limit may be set for the 3% strain tensile stress at room temperature from the viewpoint of ensuring strength at room temperature. Specifically, the 3% strain tensile stress of film 15 may be 1 N / 10 mm or more, or 3 N / 10 mm or more, in an environment of 25°C.

[0068] The "3% strain tensile stress" in a film is determined using a tensile testing machine compliant with JIS B 7721:2009 by the following method. First, a film sample is prepared that has a length of 120 mm in one direction and a length of 10 mm in the direction perpendicular to that direction. Next, both ends of the sample in the longitudinal direction are clamped in chucks with a distance of 100 mm between the chucks. Then, the sample clamped in the chucks is pulled at a tensile speed of 200 mm / min, and the stress is measured when the strain of the sample reaches 3%. When measuring the 3% strain tensile stress in an environment of 25°C, the sample is pulled in an environment of 25±2°C.

[0069] Five measurements are obtained by measuring the tensile stress in five samples under the above conditions. The 3% strain tensile stress of film 15 is determined as the average of the three measurements, excluding the largest and smallest measurements from the five measurements. The 3% strain tensile stress of film 15 is measured under conditions other than those described above, in accordance with JIS K 7161:1994.

[0070] <<Decorative film 20>> The decorative film 20 may display designs such as colors and geometric patterns. The decorative film 20 may display textures such as metallic and leather-like finishes. The decorative film 20 may have a matte finish. The decorative film 20 in Figure 1 conforms to the shape of the adherend AB.

[0071] The decorative film 20 in Figure 2 includes a first surface 20a and a second surface 20b opposite to the first surface 20a. The first surface 20a of the decorative film 20 constitutes the first surface 15a of the film 15. The second surface 20b of the decorative film 20 constitutes the second surface 15b of the film 15. The decorative film 20 includes a surface layer 34, a design layer 33, a base layer 31, and a bonding layer 32, extending from the first surface 20a to the second surface 20b. The first surface 20a of the decorative film 20 is composed of the surface layer 34. The second surface 20b of the decorative film 20 is composed of the bonding layer 32.

[0072] In the decorative film 20, the above-described separator may be superimposed on at least one of the first surface 20a and the second surface 20b. The separator may be peeled off when the decorative film 20 is attached to the substrate AB.

[0073] <Base material layer 31> The base layer 31 in Figure 2 supports the layers of the decorative film 20 other than the base layer 31. The base layer 31 may be a film. The base layer 31 may contain a synthetic resin. In particular, the base layer 31 may contain a thermoplastic resin. The base layer 31 may contain one or more of the following thermoplastic resins: (meth)acrylic resin, polyvinyl chloride (PVC), acrylonitrile-butadiene-styrene copolymer synthetic resin (ABS resin), polyolefin resin, polyester resin, urethane resin, fluororesin, polycarbonate, and cellulose resin. Note that the urethane resin includes thermoplastic polyurethane (TPU). From the viewpoint of improving conformability to the shape of the adherend AB and the durability of the decorative film 20, the thermoplastic resin contained in the base layer 31 is preferably urethane resin, and particularly thermoplastic polyurethane, among the examples above.

[0074] Polyolefin resins may contain polyethylene and polypropylene. Polyolefin resins may also contain thermoplastic polyolefin (TPO). Polyester resins may contain one or more of polyethylene naphthalate (PEN), polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). Fluorine resins may contain one or more of polyvinylidene fluoride (PVDF), perfluoroalkoxyalkane (PFA), ethylene-tetrafluoroethylene copolymer (ETFE), perfluoroethylene propene copolymer (FEP), and polytetrafluoroethylene (PTFE).

[0075] From the viewpoint of stably supporting layers other than the base layer 31, a lower limit may be set for the thickness of the base layer 31. The thickness of the base layer 31 may be 20 μm or more, 45 μm or more, 70 μm or more, 120 μm or more, or 170 μm or more. From the viewpoint of reducing the thickness of the film 15, the thickness of the base layer 31 may be 550 μm or less, 450 μm or less, or 350 μm or less.

[0076] The substrate layer 31 may be transparent. When the film 15 and its components are "transparent," it means that the total light transmittance of those components is 70% or more. The total light transmittance of transparent components may be 80% or more, or 90% or more.

[0077] As mentioned above, total light transmittance is a numerical value expressed in percentages. A D65 light source is used to measure total light transmittance. The D65 light source is a light source that mimics the spectrum of D65. D65 is a standard illuminant defined by the International Commission on Illumination (CIE). Before measuring total light transmittance, the D65 light source is lit for 15 minutes to stabilize its output. The angle of incidence to the sample when measuring total light transmittance is set to 0°. The test environment when measuring total light transmittance is set to a temperature of 23°C ± 2°C and a relative humidity of 50% ± 5%. The sample is placed in the test environment for 16 hours before the start of the test. Other measurement conditions when measuring total light transmittance follow JIS K7361-1:1997.

[0078] The total light transmittance used to determine that film 15 and its components are transparent is the average of measurements taken at five different locations under the conditions described above.

[0079] <Joining layer 32> The bonding layer 32 in Figure 2 is located between the base material layer 31 and the adherend AB. The bonding layer 32 improves the adhesion of the film 15 to the adherend AB. The bonding layer 32 may contain an adhesive or tack material. The adhesive included in the bonding layer 32 may include one or more of acrylic adhesives, rubber adhesives, urethane adhesives, and silicone adhesives. The tack material included in the bonding layer 32 may include one or more of acrylic adhesives, rubber adhesives, urethane adhesives, and silicone adhesives. The bonding layer 32 may be omitted from the film 15.

[0080] When the film 15 includes the bonding layer 32 that constitutes the second surface 15b, a lower limit may be set for the peeling force of the film 15. The peeling force of the film 15 may be 3N / 25mm or more, 5N / 25mm or more, or 7N / 25mm or more. By setting such a lower limit for the peeling force of the film 15, the peeling of the film 15 from the adherend AB can be suppressed. Furthermore, when the film 15 is bonded to the holding device 50 described later, by setting such a lower limit for the peeling force of the film 15, the peeling of the film 15 from the holding device 50 can also be suppressed. In particular, if the peeling force of the film 15 is 7N / 25mm or more, even if the film 15 moves relative to the holding device 50 due to the pressurization of the first space S1 described later, the peeling of the film 15 from the holding device 50 can also be suppressed.

[0081] When the film 15 includes the bonding layer 32 that constitutes the second surface 15b, an upper limit may be set for the peeling force of the film 15. The peeling force of the film 15 may be 45N / 25mm or less, 35N / 25mm or less, or 25N / 25mm or less. By setting such an upper limit for the peeling force of the film 15, any excess film 15 generated when it is attached to the adherend AB can be easily peeled off from the frame 51.

[0082] The peeling force of film 15 refers to the magnitude of the force required to peel film 15 from the adherend AB. The peeling force of film 15 is measured by the following method. First, a sample of film having a length of 100 mm in one direction and a length of 25 mm in a direction perpendicular to that direction is attached to a painted steel plate having a length of 70 mm from the second side. The sample is attached to a portion of the painted steel plate other than the portion that will be held by the chuck described later. The portion of the sample attached to the painted steel plate has a length of 40 mm in the longitudinal direction. The portion of the sample attached to the painted steel plate includes one end of the sample in the longitudinal direction. Paint (KINO1210TW Clear, manufactured by Kansai Paint Co., Ltd.) is applied to the surface of the painted steel plate that comes into contact with the sample. When attaching the sample to the painted steel plate, the sample is pressed down by moving a roller (SA-1003-B, manufactured by Tester Sangyo Co., Ltd.) back and forth once with a load of 2 kgf.

[0083] Next, 30 minutes after the sample is attached to the painted steel plate, a 180-degree peel strength test is performed as follows: The edge of the painted steel plate is clamped in one chuck. The portion of the sample not attached to the painted steel plate is folded back 180 degrees relative to the portion attached to the painted steel plate. A 24 mm wide cellophane tape (manufactured by Nichiban Co., Ltd.: CT405AP-24) is attached to the folded portion of the sample, and this cellophane tape is clamped in the other chuck. The sample in this state is pulled at a tensile speed of 200 mm / min under 25°C conditions, and the average stress is measured from 10 mm to 30 mm in length as the sample peels off from the painted steel plate. By measuring this average stress for five samples, five measurement values ​​are obtained. The peel force on the second surface 15b of the film 15 is determined as the average of the three measurement values ​​obtained by excluding the largest and smallest measurement values ​​from the five measurement values ​​described above. The peeling force on the second surface 15b of film 15 is measured in accordance with JIS Z 0237:2009 under conditions other than those described above.

[0084] <Design layer 33> The design layer 33 in Figure 2 is located between the base layer 31 and the surface layer 34. The design layer 33 displays the design shown by the decorative film 20. The design displayed by the design layer 33 may include one or more graphic elements such as figures, patterns, designs, colors, pictures, photographs, characters, marks, pictograms, letters, and numbers. The design layer 33 may include a binder resin portion and a colorant held by the binder resin portion. The binder resin portion may include a thermoplastic resin. The colorant may be a dye, a pigment, or a combination of a dye and a pigment. The design layer 33 may be formed by printing. The design layer 33 may be formed by transfer.

[0085] <Surface layer 34> The surface layer 34 in Figure 2 constitutes the outer surface of the decorative film 20, i.e., the first surface 20a. The surface layer 34 may perform functions required for the outer surface of the decorative film 20. For example, the surface layer 34 may be a hard coat layer with scratch resistance. The surface layer 34 may also be an anti-fouling layer that provides anti-fouling functionality. The surface layer 34 may be omitted from the decorative film 20.

[0086] The surface layer 34 may contain a cured resin product. The cured resin product is a cured product of a thermosetting resin composition or a cured product of an ionizing radiation-curable resin composition. The thermosetting resin composition contains a thermosetting resin. The thermosetting resin is usually a resin that crosslinks upon heating. The thermosetting resin composition hardens by crosslinking of the thermosetting resin. The thermosetting resin composition may further contain a curing agent. The curing agent may function as a catalyst to promote the hardening of the thermosetting resin, or it may react with the thermosetting resin. The thermosetting resin may crosslink upon reaction with the curing agent. The curing agent may be included in the cured product of the thermosetting resin composition. In the thermosetting resin composition, the thermosetting resin may be referred to as the main component.

[0087] The thermosetting resin contained in the thermosetting resin composition may include one or more of the following: phenolic resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, unsaturated polyester resin, polyurethane resin, epoxy resin, amino alkyd resin, melamine-urea cocondensation resin, and silicon resin. The curing agent contained in the thermosetting resin composition may be an isocyanate compound. The isocyanate compound is a compound containing an isocyanate group. The isocyanate compound may also be a polyisocyanate containing multiple isocyanate groups.

[0088] An ionizing radiation-curable resin composition contains an ionizing radiation-curable resin. An ionizing radiation-curable resin is a resin that crosslinks upon irradiation with ionizing radiation. Ionizing radiation means electromagnetic waves or charged particle beams that have energy quanta capable of polymerizing or crosslinking molecules. Electromagnetic waves may be ultraviolet (UV), X-rays, or gamma rays. Charged particle beams may be electron beams (EB), alpha rays, or ion beams. Among ionizing radiation-curable resins, those that crosslink upon irradiation with ultraviolet radiation may be referred to as ultraviolet-curable resins. Among ionizing radiation-curable resins, those that crosslink upon irradiation with electron beams may be referred to as electron-beam-curable resins.

[0089] In an ionizing radiation-curable resin composition, the ionizing radiation-curable resin may contain functional groups having ethylenically double bonds, such as (meth)acryloyl groups, vinyl groups, and allyl groups. The ionizing radiation-curable resin may also contain one or more epoxy groups and oxetanyl groups. The ionizing radiation-curable resin may also contain ethylenically unsaturated bonding groups. The ionizing radiation-curable resin may also contain siloxane bonds.

[0090] <<Film application device 40>> The film 15 having the above layer structure is attached to the substrate AB by the film application device 40 shown in Figures 3 and 4. The illustrated film application device 40 attaches the decorative film 20 to the substrate AB. The details of the film application device 40 for attaching the decorative film 20 to the substrate AB will be described below, mainly with reference to Figures 3 and 4. However, the film 15 attached to the substrate AB using the film application device 40 is not limited to the decorative film 20.

[0091] In Figures 3 and 4, the automobile 1, including the adherend AB (roof 11), is positioned so that the decorative film 20 can be applied to the adherend AB by the film application device 40. The film application device 40 applies the decorative film 20 to the adherend AB from the second surface 20b by moving the decorative film 20 in a first direction D1 relative to the adherend AB. The illustrated film application device 40 is used to apply the decorative film 20 to the roof 11 of the automobile 1.

[0092] The first direction D1 shown in Figures 3 and 4, etc., is parallel to the vertical direction of the vehicle 1. The first side S11 of the first direction D1 is upward, i.e., the upper side in the vertical direction. The second side S12 of the first direction D1 is downward, i.e., the lower side in the vertical direction. The first direction D1 may not be parallel to the vertical direction, as shown in the figures. The first direction D1 may be parallel to the left-right direction of the vehicle 1, or parallel to the front-rear direction of the vehicle 1. The first direction D1 may be inclined with respect to both the vertical and front-rear directions. An inclined first direction D1 may be located between the vertical and front-rear directions.

[0093] The film application device 40 includes a holding device 50 and at least one of a moving device 42 and a pressurizing device 60. The holding device 50 holds the decorative film 20. The moving device 42 moves the holding device 50, which is holding the decorative film 20, in a first direction D1. That is, the moving device 42 moves the decorative film 20 together with the holding device 50. The pressurizing device 60 pressurizes the first space S1 that the first surface 20a of the decorative film 20 faces, while the holding device 50 is holding the decorative film 20. The first space S1 is also the space that the first surface 15a of the film 15 faces. The pressurizing device 60 makes the pressure in the first space S1 greater than the pressure in the second space S2 that the second surface 20b of the decorative film 20 faces. The second space S2 is also the space that the second surface 15b of the film 15 faces.

[0094] The decorative film 20 may be partially moved in the first direction D1 while being held by the holding device 50 due to the pressure in the first space S1. The film application device 40 may include the holding device 50, the moving device 42, and the pressurizing device 60, as shown in Figures 3 and 4. Contrary to the figures, the film application device 40 may not include the moving device 42 or the pressurizing device 60.

[0095] In the film application device 40, the decorative film 20 moves in a first direction D1 by the operation of at least one of the moving device 42 and the pressing device 60. The illustrated decorative film 20 moves toward the second side S12 in the first direction D1 with respect to the adherend AB and the automobile 1 including the adherend AB. The decorative film 20 moving in the first direction D1 is attached to the adherend AB from the second surface 20b.

[0096] The film application device 40 may include components other than those described above. As shown in Figures 3 and 4, the film application device 40 may include one or more of the following: a first support member 41, a cutting device 43, an imaging device 44, a control device 70, a display device 80, and an input device 90. One or more of these components may be omitted in the film application device 40. Furthermore, as shown in Figures 3 and 4, the film application device 40 may further include a second support member 430 that supports the cutting device 43.

[0097] In Figure 5, the decorative film 20 held by the holding device 50 is spread in a second direction D2 and a third direction D3. The second direction D2 is a direction nonparallel to the first direction D1. In particular, the illustrated second direction D2 is perpendicular to the first direction D1. The third direction D3 is a direction nonparallel to both the first direction D1 and the second direction D2. In particular, the illustrated third direction D3 is perpendicular to both the first direction D1 and the second direction D2.

[0098] In the film application apparatus 40 shown in Figures 3 and 4, the second direction D2 is parallel to the front-rear direction of the automobile 1. The third direction D3 is parallel to the left-right direction of the automobile 1. The first side S21 of the second direction D2 is the rear, i.e., the rear side in the front-rear direction. The second side S22 of the second direction D2 is the front, i.e., the front side in the front-rear direction.

[0099] The decorative film 20 in Figure 5 has a first side edge 21, a second side edge 22, a third side edge 23, and a fourth side edge 24. The first side edge 21 and the second side edge 22 are the side edges of the decorative film 20 in the second direction D2. The third side edge 23 and the fourth side edge 24 are the side edges of the decorative film 20 in the third direction D3. Each of the first side edge 21 and the second side edge 22 extends in the third direction D3. Each of the third side edge 23 and the fourth side edge 24 extends in the second direction D2. The first side edge 21 and the second side edge 22 are separated from each other in the second direction D2. The third side edge 23 and the fourth side edge 24 are separated from each other in the third direction D3. The first side edge 21 and the second side edge 22 are connected to the third side edge 23 or the fourth side edge 24 at both ends in the third direction D3. The third side edge 23 and the fourth side edge 24 are connected to the first side edge 21 or the second side edge 22 at both ends in the second direction D2.

[0100] The holding device 50 in Figures 3 and 4 is positioned between the adherend AB and the cutting device 43 in the first direction D1. The holding device 50 may be movable away from between the adherend AB and the cutting device 43. When the decorative film 20 is being attached to the adherend AB, the holding device 50 may be positioned between the adherend AB and the cutting device 43 with the decorative film 20 attached. The holding device 50 may move away from between the adherend AB and the cutting device 43 when the attachment of the decorative film 20 to the adherend AB is complete.

[0101] The holding device 50 may be fixed between the adherend AB and the cutting device 43. The decorative film 20 may be placed between the adherend AB and the holding device 50. The holding device 50 may hold the decorative film 20 that is placed between the holding device 50 and the adherend AB.

[0102] The holding device 50 in Figure 5 holds the first side edge 21, second side edge 22, third side edge 23, and fourth side edge 24 of the decorative film 20. With these side edges held by the holding device 50, the decorative film 20 is moved in the first direction D1 by at least one of the moving device 42 and the pressurizing device 60.

[0103] The decorative film 20 in Figures 3 and 4 protrudes toward the adherend AB in a first direction D1. The decorative film 20 is attached to the adherend AB while protruding toward the adherend AB in a first direction D1. The adherends AB in Figures 3 and 4 protrude toward the decorative film 20 in a first direction D1. The decorative film 20 may protrude toward the first direction D1 by its own weight. The decorative film 20 may also protrude toward the first direction D1 by pressurizing the first space S1 by a pressurizing device 60, which will be described later.

[0104] The decorative film 20 held by the holding device 50 may be closest to the adherend AB on the center line ML2 in the second direction D2 of the holding device 50, as shown in Figure 4. The decorative film 20 held by the holding device 50 may be closest to the adherend AB on the center line ML3 in the third direction D3 of the holding device 50, as shown in Figure 3.

[0105] The decorative film 20 may be joined to the holding device 50 from the second surface 20b at the first side edge 21, second side edge 22, third side edge 23, and fourth side edge 24. By joining the decorative film 20 to the holding device 50 at these side edges, its movement in the second direction D2 and third direction D3 relative to the holding device 50 may be restricted. As shown in Figure 2, the second surface 20b of the decorative film 20 is composed of a bonding layer 32. The decorative film 20 may also be joined to the holding device 50 from the bonding layer 32.

[0106] The material of the holding device 50 may be selected such that the amount of deformation caused by the pressurized air in the first space S1 is less than that of the decorative film 20. The material of the holding device 50 may be selected from materials having a greater tensile modulus than that of the decorative film 20. The holding device 50 may include any of the following materials: metal, glass, cured resin, or thermoplastic resin. Details of the deformation caused by the pressurized air in the first space S1 will be described later.

[0107] <First support member 41> In Figures 3 and 4, the first support member 41 supports the holding device 50, the moving device 42, and the cutting device 43. As a result, in Figures 3 and 4, the holding device 50, the moving device 42, and the cutting device 43 are positioned on the first side S11 in the first direction D1 relative to the object AB.

[0108] The first support member 41 in Figures 3 and 4 supports the moving device 42 from the second side in the first direction D1. The moving device 42 may be restricted from moving in a direction perpendicular to the first direction D1 while supported by the first support member 41.

[0109] The first support member 41 may include a plurality of legs 412 and a connecting portion 413 that connects the plurality of legs 412, as shown in Figures 3 and 4. The plurality of legs 412 and the connecting portion 413 may be made of metal such as aluminum or stainless steel.

[0110] The multiple legs 412 shown in Figures 3 and 4 extend in a first direction D1. Each of the multiple legs 412 is located outward in a third direction D3 from the automobile 1. The legs 412 are further to the left and right from the centerline of the automobile 1 than the automobile 1.

[0111] The connecting portion 413 shown in Figure 4 extends in the second direction D2. The connecting portion 413 connects two leg portions 412 that are aligned in the second direction D2.

[0112] <Mobile device 42> The moving device 42 may include a stage 421, a drive unit 422 connected to the stage 421, and legs 423 supporting the stage 421, as shown in Figures 3 and 4. The drive unit 422 drives the stage 421. The moving device 42 may include a plurality of drive units 422, as shown in Figures 3 and 4.

[0113] The stage 421 shown in Figures 3 and 4 is a plate extending in a second direction D2 and a third direction D3. The stage 421 is connected to legs 423 at its corners, i.e., at its ends in both the second direction D2 and the third direction D3. The illustrated stage 421 is connected to four legs 423. The illustrated legs 423 extend in a first direction D1. At the end of the second side S12 in the first direction D1, it is connected to a first support member 41.

[0114] The stage 421 in Figures 3 and 4 is movable in a first direction D1 relative to the legs 423. The stage 421 is movable in a first direction D1 relative to the legs 423 by the operation of the drive unit 422. The drive unit 422 may also have a function to restrict the movement of the stage 421 in the first direction D1 relative to the legs 423.

[0115] The stage 421 in Figures 3 and 4 includes a portion positioned between the adherend AB and the holding device 50 in the first direction D1. When the holding device 50 holds the decorative film 20, the stage 421 includes a portion positioned between the adherend AB and the decorative film 20 in the first direction D1. The illustrated moving device 42 supports the holding device 50 and the cutting device 43 from the second side S12 in the first direction D1 on the stage 421. The stage 421 and the legs 423 may be made of metal such as aluminum or stainless steel.

[0116] The stage 421 in Figures 3 and 4 includes an opening 421A. The opening 421A is located between the decorative film 20 and the adherend AB in a first direction D1. In Figures 3 and 4, the dimension of the opening 421A in the direction perpendicular to the first direction D1 is larger than the dimension of the adherend AB in the direction perpendicular to the vertical direction. Specifically, in Figure 3, the dimension of the opening 421A in the third direction D3 is larger than the dimension of the adherend AB in the left-right direction. In Figure 4, the dimension of the opening 421A in the second direction D2 is larger than the dimension of the adherend AB in the front-back direction.

[0117] The drive unit 422 in Figure 4 may be electric. The electric drive unit 422 may include a motor. The drive unit 422 may be able to move the stage 421 relative to the legs 423 by hydraulics. The drive unit 422 may be able to move the stage 421 relative to the legs 423 by compressed air.

[0118] <Holding device 50> The holding device 50 in Figures 5 and 12 to 14 includes a frame 51 and a cover 52. As shown in Figure 5, the holding device 50 may further include a fixing member 53 connected to the frame 51. The fixing member 53 fixes the decorative film 20. The fixing member 53 fixes the decorative film 20 by pressing the decorative film 20 against the frame 51. The fixing member 53 restricts the movement of the decorative film 20 relative to the frame 51.

[0119] The frame 51 in Figure 5 has openings on the first side S11 and the second side S12 in the first direction D1. The frame 51 in Figures 12 to 14 is provided with openings 51h that open on the first side S11 and the second side S12 in the first direction D1. In Figures 12 to 14, the opening 51h is a space that is blocked from the first direction D1 by the cover 52 and the decorative film 20. The opening 51ha of the frame 51 is the contour of the opening 51h when observed from the first side S11 in the first direction D1. The opening 51hb of the frame 51 is the contour of the opening 51h when observed from the second side S12 in the first direction D1.

[0120] The cover 52 shown in Figures 12 to 14 closes the opening 51ha of the frame 51 from the first side S11 in the first direction D1. When we say that the cover 52 "closes" the opening 51ha or opening 51hb of the frame 51 from the first side S11 or second side S12 in the first direction D1, it means that when observed from the first side S11 or second side S12 in the first direction D1, the opening 51ha or opening 51hb of the frame 51 is covered by the cover 52.

[0121] The decorative film 20 shown in Figures 5 and 12-14 covers the opening 51hb of the frame 51 from the second side 12 in the first direction D1. When the decorative film 20 "covers" the opening 51ha or opening 51hb of the frame 51 from the first side S11 or second side S12 in the first direction D1, it means that when observed from the first side S11 or second side S12 in the first direction D1, the opening 51ha or opening 51hb of the frame 51 is covered by the decorative film 20.

[0122] The frame 51 in Figure 5 extends circumferentially. The frame 51 includes a portion extending in a second direction D2 and a portion extending in a third direction D3. The portion of the frame 51 extending in the second direction D2 is connected at both ends to the portion of the frame 51 extending in the third direction D3. The portion of the frame 51 extending in the third direction D3 is connected at both ends to the portion of the frame 51 extending in the second direction D2. The frame 51 may be made of a metal such as aluminum.

[0123] The frame 51 in Figures 6 and 7 includes a first surface 51a and a second surface 51b that are separated from each other in a first direction D1. Figure 5 is a view of the frame 51 from the side of the second surface 51b. The first surface 51a is located on the first side S11 of the first direction D1 than the second surface 51b. Each of the first surface 51a and the second surface 51b extends in a direction perpendicular to the first direction D1. The first surface 51a and the second surface 51b extend circumferentially.

[0124] The frame 51 may include protrusions 51s for connecting to the fixing member 53, as shown in Figures 6 and 7. The protrusions 51s project outward in a direction perpendicular to the first direction D1. Outward in a direction perpendicular to the first direction D1 means a direction away from the centerline of that direction. As an example, the protrusions 51s shown in Figures 6 and 7 project outward in the third direction D3.

[0125] In the frame 51 shown in Figures 12 to 14, a cover 52 is superimposed from the first side S11 in the first direction D1, and a decorative film 20 is superimposed from the second side S12 in the first direction D1. The illustrated frame 51 is positioned between the cover 52 and the decorative film 20 in the first direction D1. The frame 51 may be in contact with the cover 52 on its first surface 51a. The frame 51 may be in contact with the decorative film 20 on its second surface 51b.

[0126] The cover 52 in Figures 12 to 14 is a plate-shaped member that extends in the second direction D2 and the third direction D3. The cover 52 in Figures 12 to 14 has a first surface 52a and a second surface 52b. The first surface 52a and the second surface 52b are separated from each other in the first direction D1. The illustrated cover 52 is superimposed on the frame 51 from the second surface 52b side. The thickness direction of the cover 52 is parallel to the first direction D1.

[0127] As shown in Figures 12 and 14, the cover 52 may be provided with a through hole 52h that connects to the opening 51h of the frame 51. The illustrated through hole 52h opens to the first surface 52a and the second surface 52b. The hose 61 of the pressurizing device 60 is connected to the illustrated through hole 52h. In this way, the pump 62 of the pressurizing device 60 and the opening 51h are connected to each other via the hose 61 and the through hole. Note that the pump 62 is omitted in Figures 8, 12 and 14. Further details of the hose 61 and pump 62 will be described later.

[0128] The cover 52 may contain one or more of metal, glass, cured resin, or thermoplastic resin. The cover 52 may also be transparent for reasons described later.

[0129] When a component of the film application device 40 is "transparent," it means that the total light transmittance of that component is 70% or more. The total light transmittance of a transparent component may be 80% or more, or 90% or more. The total light transmittance of the components of the film application device 40 is determined by the same method as the total light transmittance of the components of the decorative film 20.

[0130] The decorative film 20 shown in Figures 12 to 14 is superimposed on the frame 51 from the first surface 20a side. As a result, the first space S1 is located between the cover 52 and the decorative film 20 in the first direction D1. In particular, the illustrated first space S1 is formed by the opening 51h of the frame 51. The second space S2 is located between the decorative film 20 and the adherend AB in the first direction D1. In Figures 12 to 14, the first space S1 is closed by the cover 52 from the first side S11 in the first direction D1. The first space S1 is closed by the decorative film 20 from the second side S12 in the first direction D1. The first space S1 is closed by the frame 51 in a direction perpendicular to the first direction D1.

[0131] The holding device 50 in Figure 5 includes a plurality of fixing members 53. Each of the plurality of fixing members 53 is connected to a frame 51. The fixing members 53 are connected to protrusions 51s of the frame 51, as shown in Figures 6 and 7. The fixing members 53 may be pivotably connected to the frame 51, as shown in Figures 6 and 7. The fixing member 53 in Figure 7 pivots counterclockwise about axis AS relative to the fixing member 53 in Figure 6. The illustrated axis AS extends parallel to the second direction D2. The fixing member 53 in Figure 6 may be described as being in the open state. The fixing member 53 in Figure 7 may be described as being in the closed state.

[0132] As shown in Figure 5, the fixing member 53 may press the first side edge 21 and the second side edge 22 of the decorative film 20 against the frame 51 along the entire length in the third direction D3. The fixing member 53 may also press the third side edge 23 and the fourth side edge 24 of the decorative film 20 against the frame 51 along the entire length in the second direction D2. As a result, the holding device 50 may hold the side edges of the decorative film 20 around its entire circumference. By holding the decorative film 20 in this manner, the holding device 50 can effectively suppress the leakage of air from the pressurized first space S1 between the decorative film 20 and the frame 51.

[0133] The fixing member 53 may include a plate portion 531 and a connecting portion 532 connected to the plate portion 531, as shown in Figures 6 and 7. The illustrated fixing member 53 is pivotably connected to the protruding portion 51s of the frame 51 at the connecting portion 532. The fixing member 53 may also be pivotably attached to the frame 51 via a pin.

[0134] The fixing member 53 may be in contact with the decorative film 20 at the plate portion 531, as shown in Figure 7. The decorative film 20 may include a portion located between the frame 51 and the fixing member 53 when its movement relative to the frame 51 is restricted, as shown in Figure 7. The illustrated decorative film 20 is located between the frame 51 and the fixing member 53 at the third side edge 23. Similar to Figure 7, when the decorative film 20 is held by the holding device 50, it may be located between the frame 51 and the fixing member 53 at the first side edge 21, the second side edge 22, and the fourth side edge 24. The illustrated third side edge 23 is located between the frame 51 and the plate portion 531 of the fixing member 53 in the first direction D1.

[0135] When the fixing member 53 restricts the movement of the decorative film 20 relative to the frame 51, it may also restrict the swinging relative to the frame 51 by a bolt 55, as shown in Figure 7. By restricting the swinging relative to the frame 51, the illustrated fixing member 53 can stably restrict the movement of the decorative film 20 on the frame 51. As a result, the holding device 50, including the fixing member 53 and the bolt 55, can stably hold the decorative film 20. The fixing member 53, like the frame 51, may be made of a metal such as aluminum. The bolt 55 may be made of a metal such as aluminum or stainless steel.

[0136] Furthermore, the decorative film 20 may be joined to the fixing member 53 from the second surface 20b at the first side edge 21, second side edge 22, third side edge 23, and fourth side edge 24. The decorative film 20 shown in Figure 7 may be joined to the plate portion 531 of the fixing member 53 from the second surface 20b at the third side edge 23. The decorative film 20 may also be joined to the fixing member 53 from the second surface 20b as a result of the second surface 20b being formed by the bonding layer 32.

[0137] As shown in Figures 6 and 7, the frame 51 may be provided with a threaded hole 51t that engages with the bolt 55. Similarly, the fixing member 53 may be provided with a through hole 53t through which the shaft of the bolt 55 can pass.

[0138] As shown in Figure 6, the fixing member 53 may hold the bolt 55. The illustrated fixing member 53 holds the bolt 55 in the through hole 53t. The illustrated through hole 53t includes a first portion 53ta and a second portion 53tb adjacent to the first portion 53ta. As shown in Figures 6 and 7, the outer diameter of the second portion 53tb is larger than the outer diameter of the first portion 53ta. The illustrated first portion 53ta is provided with a threaded hole. The fixing member 53 holds the bolt 55 in the first portion 53ta of the through hole 53t.

[0139] The bolt 55 in Figures 6 and 7 includes a bolt head 551, a threaded portion 552, and an intermediate portion 553. The intermediate portion 553 is located between the bolt head 551 and the threaded portion 552 in the axial direction of the bolt 55. The outer diameter of the intermediate portion 553 is smaller than the outer diameter of the through hole 53ta. This allows the intermediate portion 553 to pass through the first portion 53ta of the through hole 53. The outer diameter of the intermediate portion 553 may be smaller than the outer diameter of the bolt head 551 and the outer diameter of the threaded portion 552.

[0140] In Figures 6 and 7, the bolt 55 engages with the first portion 53ta of the through hole 53t or the threaded hole 51t at its threaded portion 552. When the bolt 55 engages with the first portion 53ta of the through hole 53t at its threaded portion 552, it is fixed to the fixing member 53. In other words, the fixing member 53 holds the bolt 55 by engaging with the threaded portion 552 at the first portion 53ta of the through hole 53t. When the bolt 55 engages with the threaded hole 51 provided in the frame 51, it is fixed to the frame 51.

[0141] As shown in Figures 6 and 7, the holding device 50 may include a cushioning material 56 connected to the fixing member 53. The illustrated cushioning material 56 is attached to the end of the fixing member 53. The illustrated cushioning material 56 extends along the longitudinal direction in a second direction D2. In Figure 7, the cushioning material 56 is in contact with the decorative film 20. The decorative film 20 is in contact with the cushioning material 56 at the first side edge 21, the second side edge 22, the third side edge 23, and the fourth side edge 24. In Figure 7, contact between the fixing member 53 and the decorative film 20 is avoided. By including the cushioning material 56, the holding device 50 can avoid damage to the decorative film 20 due to contact with the fixing member 53.

[0142] The cushioning material 56 may be deformed by compression between the fixing member 53 and the decorative film 20. The cushioning material 56 may be in contact with the decorative film 20 in a compressed state. This action of the cushioning material 56 improves the airtightness between the fixing member 53 and the decorative film 20. This prevents the air in the first space S1, which is pressurized by the pressurizing device 60, from leaking out between the decorative film 20 and the fixing member 53. The cushioning material 56 may be made of rubber.

[0143] The through hole 53t may accommodate the head of the bolt 55, as shown in Figure 7. The through hole 53t may be enlarged in the portion that accommodates the head of the bolt 55, as shown in Figures 6 and 7. By accommodating the bolt 55 in the through hole 53t, it is possible to prevent the head of the bolt 55 from protruding from the fixing member 53.

[0144] <Pressurizing device 60> The pressurizing device 60 pressurizes the first space S1 described above. The pressurizing device 60 may include a hose 61 and a pump 62 connected to the hose 61, as shown in Figure 4. The first space S1 may be pressurized by compressed air supplied from the pump 62 flowing in through the hose 61. The pressure in the second space S2 may be the same as atmospheric pressure. The pressure in the first space S1 pressurized by the pressurizing device 60 is greater than the pressure in the second space S2. Therefore, the pressurizing device 60 makes the pressure in the first space S1 greater than that in the second space S2 when the holding device 50 is holding the decorative film 20. As will be described later, the pressurizing device 60 moves the decorative film 20 in the first direction D1 relative to the holding device 50 by making the pressure in the first space S1 greater than that in the second space S2.

[0145] Figures 8 to 14 show the operation of the decorative film 20 due to the pressurization of the first space S1. In Figure 8, the first space S1 is not pressurized. In Figures 12 to 14, the first space S1 is pressurized by the pressurizing device 60 to have a greater pressure than the second space S2. In Figure 14, the decorative film 20 is in contact with the adherend AB (roof 11) with the first space S1 pressurized. In Figures 12 and 13, the decorative film 20 is not in contact with the adherend AB (roof 11) at the second surface 20b.

[0146] <Cutting device 43> The cutting device 43 cuts the decorative film 20. The cutting device 43 may cut the decorative film 20 that is in contact with the adherend AB. The cutting device 43 may cut the decorative film 20 that is in partial contact with the adherend AB.

[0147] The cutting device 43 may cut the decorative film 20 by emitting light. The cutting device 43 shown in Figures 3, 4, and 14 cuts the decorative film 20 by emitting light. The light emitted from the cutting device 43 travels toward the decorative film 20 in the second side S12 of the first direction D1. The light emitted from the cutting device 43 may be adjusted to focus on the decorative film 20. By adjusting the position of light focus, it is possible to prevent components other than the decorative film 20, including the holding device 50 and the adherend AB, from being cut.

[0148] The cutting device 43 that emits light may also be a laser light source. The cutting device 43 shown in Figures 3 and 4 is a laser light source. The decorative film 20 is cut by the light emitted from the laser light source and that reaches the decorative film 20. The light emitted from the laser light source may have energy sufficient to cut the decorative film 20. The laser light source may be an Nd:YAG laser emitting light with a wavelength of 1064 nm, a fiber laser, or a CO2 laser.

[0149] Light emitted from the cutting device 43 may pass through the cover 52 before reaching the decorative film 20. The cover 52 may be positioned between the cutting device 43 and the decorative film 20 in the first direction D1, as shown in Figures 3, 4, and 14. From the viewpoint of suppressing the absorption of light before it reaches the decorative film 20, the cover 52 may be transparent. By making the cover 52 transparent, the absorption of light emitted from the cutting device 43 by the cover 52 can be suppressed. As a result, the cutting device 43 can efficiently cut the decorative film 20 even when the cover 52 is positioned between the cutting device 43 and the decorative film 20.

[0150] The film application device 40 may include a second support member 430 that supports the cutting device 43, as shown in Figures 3 and 4. The illustrated second support member 430 is supported by the stage 421 of the moving device 42. The second support member 430 is supported by the stage 421 from the second side S12 in the first direction D1.

[0151] The second support member 430 may include a stage 431 and a plurality of legs 432 connected to the stage 431, as shown in Figures 3 and 4. The illustrated stage 431 extends in a second direction D2 and a third direction D3. The illustrated cutting device 43 is supported on the stage 431 by the second support member 430. The stage 431 is connected to the legs 432 at its corners, i.e., at its ends in both the second direction D2 and the third direction D3. The illustrated stage 431 is connected to four legs 432. The legs 432 extend in a first direction D1.

[0152] The cutting device 43 shown in Figures 3 and 4 is movably supported on the second support member 430. The cutting device 43 is movable relative to the second support member 430 in a direction perpendicular to the first direction D1. The cutting device 43 may also move relative to the second support member 430 in the second direction D2 or in the third direction D3. The cutting device 43 may also be movable relative to the second support member 430 in the first direction D1.

[0153] <Imaging device 44> The imaging device 44 in Figures 3 and 4 is positioned on the first side S11 in the first direction D1 relative to the substrate AB and the decorative film 20. The decorative film 20 is positioned between the substrate AB and the imaging device 44 in the first direction D1. The film application device 40 may include a plurality of imaging devices 44.

[0154] The imaging device 44 acquires one or more images of the object to be adhered AB, the decorative film 20, and the holding device 50. The object to be adhered AB, the decorative film 20, and the holding device 50 can be subjects of the imaging device 44. The imaging device 44 may include a lighting device to illuminate the subjects. The images acquired by the imaging device 44 may be still images or moving images. When images of the decorative film 20, the object to be adhered AB, and the holding device 50 are shown together, the image of the decorative film 20 may be described as the first image, the image of the object to be adhered AB as the second image, and the image of the holding device 50 as the third image.

[0155] As shown in Figures 3 and 4, the cover 52 of the holding device 50 may be positioned between the decorative film 20 and the imaging device 44 in the first direction D1. The imaging device 44 may image the decorative film 20 through the cover 52. The cover 52 positioned between the imaging device 44 and the decorative film 20 may be transparent. By making the cover 52 transparent, the imaging device 44 can acquire a clear image of the decorative film 20 even through the cover 52.

[0156] The imaging device 44 in Figures 3 and 4 is electrically connected to the control device 70. The image acquired by the imaging device 44 may be transmitted to the control device 70 via the electrical connection between the imaging device 44 and the control device 70.

[0157] <Control device 70> The control device 70 in Figures 3 and 4 is electrically connected to the imaging device 44. The control device 70 is electrically connected to one or more of the moving device 42, the cutting device 43, and the pressurizing device 60. The control device 70 may also be electrically connected to the moving device 42, particularly to the drive device 422.

[0158] The control device 70 may control the operation of one or more of the moving device 42, cutting device 43, and pressurizing device 60. The control device 70 may control the operation of the moving device 42, in particular the drive device 422. The control device 70 may generate a signal for one or more of the moving device 42, cutting device 43, and pressurizing device 60 to start operation. The control device 70 may generate a signal for one or more of the moving device 42, cutting device 43, and pressurizing device 60 to stop operation. The signals generated by the control device 70 may be transmitted to one or more of the moving device 42, cutting device 43, and pressurizing device 60 via the electrical connections described above.

[0159] The control device 70 may receive electrical signals from the imaging device 44. It may receive electrical signals relating to images acquired by the imaging device 44. The control device 70 may control the operation of one or more of the moving device 42, cutting device 43, and pressurizing device 60 based on the images acquired by the imaging device 44. The control device 70 may control the operation of the moving device 42, in particular the operation of the drive device 422, based on one or more of the first, second, and third images acquired by the imaging device 44. The control device 70 may control the operation of the cutting device 43 based on at least one of the first and second images acquired by the imaging device 44. The control device 70 may control the operation of the pressurizing device 60 based on one or more of the first, second, and third images acquired by the imaging device 44.

[0160] The control device 70 may be a computer. The computer may include a control circuit. The control circuit may include a processor such as a CPU (Central Processing Unit) and an MPU (Micro Processing Unit). The control circuit may include main memory such as RAM (Random Access Memory). The control circuit may also include auxiliary storage devices such as ROM (Read Only Memory) and hard disks.

[0161] The control device 70 may output various judgment results when attaching the decorative film 20 to the substrate AB. The control device 70 may output judgment results based on the image acquired by the imaging device 44. The control device 70 may control one or more operations of the moving device 42, the cutting device 43, and the pressurizing device 60 based on the judgment results. Details of the judgment results will be described later.

[0162] The control device 70 may calculate the number of decorative films 20 attached. The number of decorative films 20 attached is the number of decorative films 20 attached to the substrate AB. The control device 70 may calculate the number of decorative films 20 attached based on the image acquired by the imaging device 44. The control device 70 may calculate the number of decorative films 20 attached based on the determination result.

[0163] <Display device 80> The display device 80 in Figure 4 is electrically connected to the control device 70. The display device 80 may display an image based on electrical signals transmitted from the control device 70. The display device 80 may display the determination result from the control device 70. The display device 80 may display an image acquired by the imaging device 44. The display device 80 may display the number of decorative films 20 applied. The display device 80 may be a display as shown in Figure 4.

[0164] <Input device 90> The input device 90 in Figure 4 is electrically connected to the control device 70. The control device 70 may control one or more operations of the moving device 42, cutting device 43, and pressurizing device 60 based on the operation of the input device 90.

[0165] As shown in Figure 4, the display device 80 and the input device 90 may be the same. The film application device 40 may include a touch panel as the display device 80 and the input device 90.

[0166] The operation of the film application device 40 will be explained with reference to Figures 3 to 21. Specifically, an example of a method for applying the decorative film 20 to the adherend AB using the film application device 40, and an example of a method for manufacturing the decorative member 25 will be explained.

[0167] When the adherend AB is an exterior component 10 of an automobile 1, the application of the decorative film 20 to the adherend AB may be carried out indoors in a factory, car dealership, store, etc. The factory may be a manufacturing plant that produces automobile 1, or a repair shop that services automobile 1. The store may be a retail store that sells automobile-related goods.

[0168] An example of a method for applying the decorative film 20 described below includes a first application step, a molding step, and a second application step. In the first application step, the decorative film 20 is partially applied to the substrate AB by the film application device 40. The first application step includes a placement step and a moving step in that order. The placement step is the step of placing the decorative film 20, held by the holding device 50, onto the substrate AB. The moving step is the step of moving the decorative film 20 in a first direction D1. The molding step is the step of molding the decorative film 20 that has been partially applied to the substrate AB. The second application step is the step of applying the molded portion of the decorative film 20.

[0169] The moving process is performed by the operation of at least one of the moving device 42 and the pressurizing device 60. "Placing" the decorative film 20 held by the holding device 50 on the adherend AB means placing the decorative film 20 held by the holding device 50 on the first side S11 or the second side S12 in the first direction D1 relative to the adherend AB. In the moving process, the decorative film 20 is partially attached to the adherend AB. Therefore, in the placement process, the decorative film 20 is positioned in a location where it can be at least partially attached to the adherend AB in the moving process.

[0170] <<First pasting process>> The first application process may include processes other than the placement and movement processes described above. The first application process may include at least one of the holding process and the cutting process. The holding process is the process of holding the decorative film 20 with the holding device 50. The cutting process is the process of cutting the decorative film 20 with the cutting device 43. The first application process may include the holding process, placement process, movement process, and cutting process in this order. The steps of the first application process will be described below.

[0171] <Holding process> In the holding process, the holding device 50 holds the decorative film 20. In the holding process, the decorative film 20 placed on the holding device 50 is held by the holding device 50.

[0172] The decorative film 20 placed on the holding device 50 may be a portion of a long decorative film 20 supplied by roll-to-roll. Alternatively, a single sheet of decorative film 20 may be placed on the holding device 50.

[0173] When a separator is placed on at least one of the first surface 20a and the second surface 20b of the decorative film 20, the separator may be peeled off during the holding process. The separator may be partially peeled off from at least one of the surfaces in the portion where the decorative film 20 and the holding device 50 overlap. The separator may be peeled off from at least one of the surfaces in the portion where the decorative film 20 and the holding device 50 overlap, and in the portion where the decorative film 20 is attached to the adherend AB.

[0174] The decorative film 20 may be placed on the holding device 50 by a suction device 56 during the holding process, as shown in Figures 8 and 9. The film application device 40 may include a suction device 56. The suction device 56 sucks the decorative film 20 from the first surface 20a or the second surface 20b. The illustrated suction device 56 sucks the decorative film 20 from the first surface 20a. In Figure 9, the suction device 56 restricts the movement of the decorative film 20 relative to the holding device 50 by sucking the decorative film 20 from the first surface 20a.

[0175] The holding device 50 may hold the decorative film 20 in a state where its movement relative to the holding device 50 is restricted by the suction device 56. In the holding process, the holding device 50 described with reference to Figures 5 to 7 may be used, as shown in Figures 8 and 9. Note that in Figure 8, the fixing member 53 is omitted from the viewpoint of making it easier to understand the positional relationship between the suction device 56, the holding device 50, and the decorative film 20.

[0176] The suction device 56 in Figures 8 and 9 includes a first surface 56a that supports the holding device 50 and a second surface 56b that supports the decorative film 20. The first surface 56a extends circumferentially. The second surface 56b is surrounded by the circumferential first surface 56a in a plan view, i.e., observed from the direction normal to the second surface 56b.

[0177] The suction device 56 in Figures 8 and 9 is provided with a hole 56h that opens on the second surface 56b. The suction device 56 may be provided with a plurality of holes 56h, as shown in Figures 8 and 9. Each of the plurality of holes 56h is connected to a pump (not shown) that sucks air from the opening of the hole 56h shown in the figure. The pump may suck air between the decorative film 20 and the suction device 56 when the decorative film 20 is placed on the second surface 56b of the suction device 56. The decorative film 20 may be sucked toward the holding device 50 by the pump.

[0178] The decorative film 20 may be held in the holding device 50 while being sucked toward the holding device 50, as shown in Figure 9. In Figure 9, the decorative film 20 is being sucked from the first surface 20a by the suction device 56. In Figure 9, air is being sucked between the suction device 56 and the decorative film 20 through a hole 56h provided in the suction device 56.

[0179] The decorative film 20 may be restricted from moving relative to the holding device 50 by the suction device 56 when the aforementioned fixing member 53 of the holding device 50 is in the open state. The fixing member 53 may swing from the open state to the closed state when the decorative film 20 is restricted from moving relative to the holding device 50. After swinging to the closed state, the fixing member 53 may be restricted from further swinging by the bolt 55. The holding device 50 in Figures 8 and 9 may hold the decorative film 20 by the swinging of a plurality of fixing members 53 and the connection of the bolt 55. The holding process may be completed when the connection of the bolt 55 is completed. The suction device 56 may release the restriction on the movement of the decorative film 20 when the holding process is completed. Specifically, in the suction device 56, the pump connected to the aforementioned hole 56h may stop suction when the holding device 50 has finished holding the decorative film 20.

[0180] <Placement process> In the placement process, the decorative film 20 is placed on the substrate AB while being held by the holding device 50. In the placement process, the decorative film 20 is placed in a position where it can be attached to the substrate AB. The position where it can be attached to the substrate AB may be within the projection of the substrate AB in the first direction D1. In the film application apparatus 40 of Figures 3 and 4, the holding device 50 is fixed on the stage 421 of the moving device 42 while holding the decorative film 20 in the placement process. The holding device 50 may also be manually fixed on the stage 421 of the moving device 42.

[0181] Prior to the placement process, the adherend AB may be positioned in a location where the decorative film 20 can be applied by the film application device 40. In Figures 3, 4, 10, and 11, the adherend AB is positioned within the projection of the opening 421A of the stage 421 into the first direction D1. In these figures, the position where the decorative film 20 can be applied by the film application device 40 is within the projection of the opening 421A of the stage 421 into the first direction D1.

[0182] In Figures 3, 4, 10, and 11, the adherend AB may be positioned so that the decorative film 20 can be applied as the automobile 1 moves in the longitudinal direction. As described above, the illustrated adherend AB is the roof 11. The illustrated roof 11 is positioned within the projection of the opening 421A of the stage 421 into the first direction D1. The automobile 1 may move in the longitudinal direction by self-propulsion. The automobile 1 may also move in the longitudinal direction by the movement of the mounting surface of the automobile 1. The mounting surface of the automobile 1 may move, in particular, in the automobile 1 manufacturing plant.

[0183] The imaging device 44 in Figures 3 and 4 may acquire an image of the object to be attached AB when the object to be attached AB is placed in the position described above. The control device 70 may output a first determination result based on the image of the object to be attached AB. The first determination result means that the object to be attached AB is placed in a position to which the decorative film 20 can be attached (normal determination), or that the object to be attached AB is not placed in a position to which the decorative film 20 can be attached (abnormal determination). The abnormal determination in the first determination result may mean that the projection of the opening 421A of the stage 421 into the first direction D1 is shifted in a direction perpendicular to the first direction D1. The first determination result may be displayed on the display device 80.

[0184] The control device 70 may output a second determination result based on the first determination result. The second determination result indicates whether the placement process can be performed (possible determination) or whether the placement process cannot be performed (impossible determination). The second determination result may be displayed on the display device 80. The placement process may be performed based on the second determination result.

[0185] The imaging device 44 in Figures 3 and 4 may acquire an image of the decorative film 20 during the placement process. The imaging device 44 may also acquire an image of the holding device 50 during the placement process. The control device 70 may output a third determination result based on at least one of the images of the decorative film 20 and the holding device 50. The third determination result means that the decorative film 20 is placed in a position where it can be attached to the substrate AB (normal determination), or that the decorative film 20 is not placed in a position where it can be attached to the substrate AB (abnormal determination). The third determination result may be displayed on the display device 80. The placement process may be completed when a normal determination is output as the third determination result.

[0186] <Moving process> During the moving process, the decorative film 20 moves in the first direction D1 toward the adherend AB. Figures 12 to 14 show the moving process. In the film application apparatus 40 of Figures 3 and 4, the decorative film 20 moves to the second side S12 of the first direction D1 toward the adherend AB. During the moving process, the decorative film 20 moves in the first direction D1 while protruding toward the adherend AB. The decorative film 20 may move while being held by the holding device 50 at its first side edge 21, second side edge 22, third side edge 23 and fourth side edge 24.

[0187] The moving process is carried out by the operation of at least one of the moving device 42 and the pressurizing device 60. The moving process may also be carried out by a combination of the operation of the moving device 42 and the operation of the pressurizing device 60, as shown in Figures 12 to 14.

[0188] During the moving process, the decorative film 20 is attached to the adherend AB by moving from a state where it protrudes toward the adherend AB in the first direction D1 to the adherend AB in the first direction D1. The illustrated decorative film 20 contacts the adherend AB from the second surface 20b. A contact area is created on the decorative film 20 by contact with the adherend AB at the second surface 20b. When the second surface 20b of the decorative film 20 is composed of a bonding layer 32, it may be bonded to the adherend AB at the contact area. The contact area expands as the amount of movement of the decorative film 20 in the first direction D1 increases.

[0189] The moving process may include a pre-application moving process and a post-application moving process in this order. The pre-application moving process is a process of moving the decorative film 20, which does not include the portion attached to the adherend AB, toward the adherend AB in a first direction D1. The post-application moving process is a process of moving the decorative film 20, which includes the portion attached to the adherend AB, toward the adherend AB in a first direction D1. Figures 12 and 13 show the pre-application moving process. Figure 14 shows the post-application moving process. Each of the pre-application moving process and the post-application moving process is performed by the operation of at least one of the moving device 42 and the pressurizing device 60.

[0190] First, the movement process performed by the operation of the moving device 42 will be explained. The moving device 42 moves the holding device 50, which holds the decorative film 20, in a first direction D1 relative to the adherend AB. The decorative film 20 moves together with the holding device 50, with its first side edge 21, second side edge 22, third side edge 23, and fourth side edge 24 being held by the holding device 50. Note that the operation of the moving device 42 in the pre-application movement process may be the same as the operation of the moving device 42 in the post-application movement process.

[0191] In the moving device 42 shown in Figures 3 and 4, the drive device 422 moves the stage 421 along the legs 423 in a first direction D1. This movement of the stage 421 causes the holding device 50, which is fixed on the stage 421, to move in the first direction D1. The holding device 50 moves in the first direction D1 while holding the decorative film 20.

[0192] The operation of the moving device 42 in the moving process may be controlled by the control device 70. In particular, the movement of the stage 421 by the drive device 422 in the moving device 42 may be controlled by the control device 70. The control device 70 may transmit an electrical signal (movement start signal) to the moving device 42 via an electrical connection to the moving device 42 to start operation. The control device 70 may transmit an electrical signal (movement stop signal) to the moving device 42 via an electrical connection to the moving device 42 to stop operation.

[0193] The control device 70 may generate a movement start signal based on the third determination result described above. The control device 70 may generate a movement start signal when the third determination result is a normal determination. The control device 70 does not have to generate a movement start signal when the third determination result is an abnormal determination. The control device 70 may generate a movement start signal based on the third determination result and the input operation from the input device 90.

[0194] The control device 70 may calculate the amount of movement of the holding device 50 in the first direction D1 by the moving device 42. The control device 70 may also calculate the amount of movement of the holding device 50 based on the measurement results of a displacement sensor (not shown) capable of measuring the amount of movement of the holding device 50.

[0195] The control device 70 may generate a movement stop signal based on the amount of movement of the holding device 50. The control device 70 may store a threshold value related to the amount of movement of the holding device 50. The control device 70 may generate a movement stop signal based on a comparison between the threshold value and the amount of movement.

[0196] Next, the movement process carried out by the operation of the pressurizing device 60 will be described. Figures 12 to 14 show the movement of the decorative film 20 during the movement process. In Figures 12 to 14, the movement process is carried out by at least the pressurizing device 60. In the pressurizing device 60, the pump 62 supplies air to the first space S1. The air passes through the hose 61 and the through hole 52h before reaching the first space S1, which is the opening 51h of the frame 51 in Figures 12 to 14. As a result of the supply of air from the pump 62 to the first space S1, the pressure in the first space S1 becomes greater than the pressure in the second space S2.

[0197] When the pressure in the first space S1 becomes greater than the pressure in the second space S2, the components that close the first space S1 are pushed outward by the air inside the first space S1. In other words, the components that close the first space S1 are pushed toward the space outside the first space S1, which includes the second space S2. In Figures 12 to 14, the components that close the first space S1 are the retaining device 50 and the decorative film 20. More specifically, the components that close the first space S1 are the frame 51, the cover 52 and the decorative film 20.

[0198] As described above, the material of the holding device 50 may be selected such that the amount of deformation caused by the pressurized air in the first space S1 is less than that of the decorative film 20. By selecting the material of the holding device 50 in this way, the amount of deformation of the decorative film 20 may be greater than the amount of deformation of the holding device 50, as shown in Figures 12 to 14. In Figures 12 to 14, the decorative film 20 protrudes in the first direction D1 toward the adherend AB due to the pressurized air in the first space S1. That is, the pressurizing device 60 causes the decorative film 20 to protrude in the first direction D1 toward the adherend AB during the moving process. In Figures 12 and 13, the decorative film 20 is curved in a convex shape in the portion that protrudes in the first direction D1 toward the adherend AB. In Figures 12 and 13, the convexly curved portion of the decorative film 20 protrudes in the first direction D1 in the opposite direction to the adherend AB (roof 11).

[0199] In Figures 12 to 14, the decorative film 20 expands toward the adherend AB in the first direction D1, thereby moving at least partially toward the adherend AB in the first direction D1 relative to the holding device 50. In Figures 12 and 13, the amount of movement of the decorative film 20 toward the first direction D1 is greatest at the point where it coincides with the intersection of the center line ML2 of the second direction D2 and the center line ML3 of the third direction D3. In Figure 14, the decorative film 20, in the portion that expands toward the adherend AB in the first direction D1, is in contact with the adherend AB from the second surface 20b.

[0200] As shown in Figures 12 to 14, the adherend AB has a three-dimensional shape and protrudes toward the decorative film 20 in the first direction D1. Specifically, the curved surface 11R of the illustrated roof 11 protrudes toward the first side S11 in the first direction D1. Due to the shape of the adherend AB, the decorative film 20 is adhered to the adherend AB starting from the portion that protrudes the most in the first direction D1. Adhesion of the decorative film 20 to the adherend AB is suppressed from the portion that protrudes the least in the first direction D1. Therefore, the shape of the illustrated adherend AB can suppress unintentional adhesion to the adherend AB during the moving process.

[0201] The control device 70 may control the pressurizing device 60 so that the pressure in the first space S1 during the post-application movement process is different from the pressure in the first space S1 during the pre-application movement process. The pressurizing device 60 may also increase the pressure in the first space S1 during the post-application movement process compared to the pressure in the first space S1 during the pre-application movement process. In other words, the pressurizing device 60 may increase the pressure in the first space S1 in the state shown in Figure 14 compared to the state shown in Figures 12 and 13.

[0202] The operation of the pressurizing device 60 during the transfer process may be controlled by the control device 70. The control device 70 may transmit an electrical signal (pressurizing start signal) to the pressurizing device 60 via an electrical connection to the pressurizing device 60 to initiate operation. The control device 70 may transmit a signal (pressurizing maintenance signal) to the pressurizing device 60 via an electrical connection to the pressurizing device 60 to maintain the pressure in the first space S1 in a pressurized state. The control device 70 may transmit an electrical signal (pressurizing stop signal) to the pressurizing device 60 via an electrical connection to the pressurizing device 60 to stop operation. Upon receiving the pressurizing stop signal, the pressurizing device 60 may become the same as the pressure in the second space S2.

[0203] The control device 70 may generate a pressurization start signal based on the third determination result described above. The control device 70 may generate a pressurization start signal when the third determination result is a normal determination. The control device 70 does not have to generate a pressurization start signal when the third determination result is an abnormal determination. The control device 70 may generate a pressurization start signal based on the third determination result and the input operation from the input device 90.

[0204] The control device 70 may receive an electrical signal relating to the pressure in the first space S1 from a pressure sensor (not shown) installed in the first space S1. The control device 70 may calculate the pressure in the first space S1 based on the measurement results of the pressure sensor. The control device 70 may generate a pressurization maintenance signal based on the pressure in the first space S1. The control device 70 may generate a pressurization stop signal based on the pressure in the first space S1. The control device 70 may store a threshold value relating to the pressure in the first space S1. The control device 70 may generate a pressurization maintenance signal and a pressurization stop signal based on a comparison between the pressure in the first space S1 and the threshold value.

[0205] The control device 70 may transmit a pressure maintenance signal to the pump 62 based on a comparison of the measured pressure in the first space S1 with a threshold. The control device 70 may also control the pressurizing device 60 to stop the pressure increase in the first space S1 when the pressure in the first space S1 reaches a threshold.

[0206] As described above, the movement process is performed by the pressurizing device 60. During the movement process, the control device 70 may calculate the size of the contact area based on the image of the decorative film 20 acquired by the imaging device 44. As shown in Figure 15, the color of the decorative film 20 may change due to contact with the substrate AB. For example, in observation from the imaging device 44, the brightness of the contact area of ​​the decorative film 20 may change as the amount of reflected light from the contact area decreases compared to the amount of reflected light from areas other than the contact area. The control device 70 may calculate the size of the contact area based on the change in the color of the decorative film 20 in the image acquired by the imaging device 44. Based on the calculated size of the contact area, the control device 70 may generate a movement stop signal, a pressurizing maintenance signal, or a pressurizing stop signal.

[0207] The film can be attached to the substrate by moving it in a first direction, even in a conventional film application apparatus as exemplified in JP2019-531951A. The substrate and the film attached to the substrate constitute a decorative member. When a conventional film application apparatus attaches the film to the substrate, it pulls the film in at least one of a second direction and a third direction. The second direction is non-parallel to the first direction. The third direction is non-parallel to both the first and second directions. As a result, the decorative film is pulled so that it spreads out in a plane perpendicular to the first direction.

[0208] The inventors of this case have found that pulling a film in a second or third direction can promote the formation of wrinkles in the film. When a film is pulled in a second or third direction, variations in tension can occur. These variations in tension can increase, in particular, with increasing film size. It was presumed that in conventional film application devices, wrinkles are formed due to variations in tension on the film. In particular, it was presumed that when a film application device is applied to an automobile, more specifically when a large exterior component such as a roof is used as the adherend, the formation of wrinkles becomes more pronounced.

[0209] When a wrinkled film is applied to an object, air pockets may form between the object and the film. Furthermore, the film may bond to itself at the wrinkled areas. As a result, the design of the decorative component formed by the object and the film may be significantly degraded at the wrinkled areas of the film.

[0210] The inventors of this invention have found a method of attaching a film to an adherend in which the film protrudes toward the adherend in a first direction. In the film application device 40 shown in Figures 3 and 4, the film 15 (decorative film 20) protrudes toward the adherend AB in a first direction D1 by its own weight or by the pressure applied in the first space S1 described above. The film 15 (decorative film 20) is attached to the adherend AB in a state where it protrudes toward the adherend AB in a first direction D1 by the operation of at least one of the moving device 42 and the pressurizing device 60 described above. By protruding toward the adherend AB in a first direction D1, the increase in tension in the direction perpendicular to the first direction D1 is suppressed. As a result, the occurrence of wrinkles due to tension variations can be suppressed compared to a decorative film that is pulled in a second or third direction. Therefore, the film application device 40 can suppress deterioration of the design of the decorative member 25.

[0211] Furthermore, when the pressurizing device 60 causes the film 15 (decorative film 20) to protrude in the first direction D1 toward the adherend AB, the pressure in the first space S1 becomes greater than the pressure in the second space S2. The film 15 (decorative film 20) is prevented from deforming toward the opposite side of the adherend AB, i.e., the first side S11 in the first direction D1, by the pressure difference between the first space S1 and the second space S2. As a result, the film 15 (decorative film 20) can be prevented from deforming due to disturbances such as airflow in the installation environment of the film application device 40 and vibrations of the film application device 40. As a result of preventing deformation due to disturbances, the occurrence of wrinkles in the film 15 (decorative film 20) can be effectively suppressed. Therefore, the film application device 40, which includes a pressurizing device 60 that pressurizes the first space S1, can more effectively suppress the deterioration of the design of the decorative member 25, including the film 15.

[0212] As described above, the pressurizing device 60 may further pressurize the first space S1 during the post-application movement process compared to the pre-application movement process. In other words, the pressurizing device 60 may increase the pressure in the first space S1 when the decorative film 20 partially contacts the adherend AB from the second surface 20b. When the decorative film 20 is in partial contact with the adherend AB, it is at least partially supported by the adherend AB from a direction opposite to the direction of movement in the first direction D1 (the second side S12 in Figures 3 and 4). When the decorative film 20 is supported by the adherend AB, even if the first space S1 is further pressurized, the increase in the amount of movement in the first direction D1 is suppressed. As a result, the film application device 40 can press the film 15 (decorative film 20) toward the adherend AB during the post-application movement process. In addition, if the second surface 20b of the decorative film 20 is composed of a bonding layer 32, the film application device 40 can stably bond the decorative film 20 to the adherend AB during the post-application movement process.

[0213] <Cutting process> In the cutting process, the decorative film 20 is cut by the cutting device 43. As described above, the cutting device 43 may cut the decorative film 20 by emitting light. The decorative film 20 cut by the cutting device 43 is separated from the holding device 50. Figure 15 shows the decorative film 20 separated from the holding device 50. In the illustrated film application device 40, the portion of the decorative film 20 separated from the holding device 50 is applied to the substrate AB.

[0214] In the cutting process, the film 15 may have a positioning portion 15f formed thereon for positioning the film forming apparatus 300 described later. The illustrated decorative film 20 has a positioning portion 20f formed thereon for positioning the film forming apparatus 300 described later in the cutting process. The positioning portion 20f of the decorative film 20 constitutes the positioning portion 15f of the film 15. As shown in Figure 15, the positioning portion 20f may also be a through hole penetrating the decorative film 20.

[0215] The control device 70 may increment the number of times the decorative film 20 is applied by the film application device 40 upon completion of the cutting process.

[0216] As described above, in the first application step, the decorative film 20 is applied to the substrate AB using the film application device 40. In the first application step, the decorative film 20 is partially applied to the substrate AB. In the first application step, portions of the decorative film 20 other than the edge portion 20e may also be applied to the substrate AB.

[0217] The control device 70 may store the number of times the decorative film 20 has been applied by the film application device 40. Based on the stored number of times the decorative film 20 has been applied, the timing for maintenance and replacement of the components of the film application device 40 may be determined. By determining the timing for maintenance and replacement in this way, it is possible to avoid a long-term shutdown of the application work due to a failure of any component of the film application device 40. Therefore, by the control device 70 storing the above number of applications, the efficiency of the application work of the decorative film 20 by the film application device 40 can be improved.

[0218] <<Forming process>> The decorative film 20 is then formed in the molding process using the film molding apparatus 300 shown in Figures 16 to 20. The film molding apparatus 300 is not limited to the decorative film 20, but can also form the film 15. The decorative film 20 is formed at the edges 20e by the molding process. The decorative film 20 may also be formed at the corners 20r by the molding process, as shown in Figures 16 and 21. Below, the configuration of the film molding apparatus 300 will be explained with reference to Figures 16 to 20. Next, the molding process will be explained with reference to Figures 16 to 21. Note that the adherends AB are omitted in Figures 16 to 20.

[0219] The film forming apparatus 300 in Figure 16 includes a first mold 310, a second mold 320, and wiring 330 electrically connected to the second mold 320. In Figure 16, the edge 20e of the decorative film 20 is sandwiched between the first mold 310 and the second mold 320.

[0220] In Figure 16, the decorative film 20 is turned inside out at the corner 20r. In the turned-out region, the decorative film 20 is sandwiched between the first mold 310 and the second mold 320. In Figure 16, the first surface 20a of the decorative film 20 faces the first mold 310. The second surface 20b of the decorative film 20 faces the second mold 320.

[0221] The film forming apparatus 300 heats the decorative film 20 using at least one of the first type 310 and the second type 320. In the illustrated film forming apparatus 300, of the first type 310 and the second type 320, the second type 320 heats the decorative film 20. More specifically, the illustrated second type 320 generates heat in the second body 325, which will be described later. The second type 320 may generate heat in the second body 325 due to the current from the wiring 330.

[0222] The decorative film 20 is formed at the edges 20e by heating. As described above, the decorative film 20 may also be formed by the film forming apparatus 300 at the corners 20r where multiple edges 20e connect to each other. In the film forming apparatus 300 of Figure 16, the second mold 320 heats the decorative film 20.

[0223] The film forming apparatus 300 may include a fixing device 350 for fixing the decorative film 20 to the film forming apparatus 300, as shown in Figure 16. The illustrated fixing device 350 fixes the decorative film 20 to the first mold 310. The fixing device 350 may also be a screw, as shown in Figure 16. The illustrated screw passes through the positioning portion 20f provided on the decorative film 20 at its shaft. The decorative film 20 may be positioned relative to the film forming apparatus 300 by the fixing device 350 passing through the positioning portion 20f. Note that the fixing device 350 is not shown in Figure 20.

[0224] Figure 17 shows the first type 310. The second type 320 is omitted in Figure 17. In Figure 17, the decorative film 20 is indicated by a dashed line. The illustrated first type 310 includes a first body 315 and a first pattern 316 connected to the first body 315. The first type 310 may include multiple first patterns 316. The first type 310 in Figure 17 includes two first patterns 316. As shown in Figure 17, in the first type 310, the first body 315 and the first pattern 316 may be integrated. The first type 310 may be made of a metal such as aluminum.

[0225] In the first type 310 of Figure 16, each of the two first patterns 316 extends from the first body 315 in the X direction DX. The first body 315 extends in the X direction DX and the Y direction DY when viewed from the Z direction DZ. The X direction DX, the Y direction DY, and the Z direction DZ are directions used for the film forming apparatus 300 and the decorative film 20 formed by the film forming apparatus 300. The Y direction DY and the Z direction DZ are directions perpendicular to the X direction DX. The Y direction DY and the Z direction DZ are directions perpendicular to each other.

[0226] The first mold 310 in Figure 17 includes a recess 340 in the first body 315 that accommodates the second mold 320. The recess 340 opens in the Z direction DZ and the X direction DX. The decorative film 20 is molded sandwiched between the first mold 310 and the second mold 320 housed in the recess 340 of the first mold 310. The decorative film 20 is molded to have a shape complementary to the recess 340, as described later. The shape of the recess 340 may be determined based on the shape of the adherend AB.

[0227] The recess 340 in Figure 17 is composed of a first bottom surface 311 and a first side surface 312 extending from the first bottom surface 311 in the Z direction DZ. The angle θ between the first bottom surface 311 and the first side surface 312 is... 12 This may be set based on the shape of the adherend AB. The illustrated angle θ 12 This may be set based on the shape of the exterior member 10. Note that the angle θ in the recess 340 shown in the figure 12 It is 90°.

[0228] The angle θ between the first base surface 311 and the first side surface 312 12 This is measured from a cross-section of the first type 310 with planes extending in directions perpendicular to the first base surface 311 and perpendicular to the first side surface 312. Angle θ 12 In the illustrated recess 340, the measurement is taken from the cross-section of the first body 315 with respect to a plane extending in the first bending direction DF1 and the Z direction DZ, or a plane extending in the second bending direction DF2 and the Z direction DZ.

[0229] Further, the first side surface 312 in FIG. 17 includes a first portion 312A extending in the Z direction DZ and the first bending direction DF1, and a second portion 312B extending in the Z direction DZ and the second bending direction DF2. Each of the first bending direction DF1 and the second bending direction DF2 is a direction orthogonal to the Z direction DZ as shown in FIG. 20. As a result, the illustrated recess 340 is constituted by the first bottom surface 311, the first portion 312A of the first side surface 312, and the second portion 312B of the first side surface 312.

[0230] In the first side surface 312, the angle θ between the first portion 312A and the second portion 312B AB may be set based on the shape of the adherent AB. The illustrated angle θ AB may be set based on the shape of the exterior member 10.

[0231] The angle θ between the first portion 312A and the second portion 312B in the first side surface 312 AB is measured from a cross-section by a plane extending in the direction orthogonal to the first portion 312A and in the direction orthogonal to the second portion 312B. In the illustrated first side surface 312, both the first portion 312A and the second portion 312B extend in the Z direction DZ from the first bottom surface 311. Therefore, the angle θ AB is measured from a cross-section of the first main body 315 by a plane orthogonal to the Z direction DZ.

[0232] The first mold 310 may be provided with a hole 314 opening in the Z direction DZ. Two holes 314 are provided in the first mold 310 of FIG. 17. The hole 314 in FIG. 17 is provided in the first main body 315. The hole 314 opens on the first side in the Z direction DZ. The hole 314 may be provided with a threaded hole. By engaging a screw with the threaded hole, the fixture 350 may restrict the movement of the decorative film 20 relative to the first mold 310.

[0233] [[ID=2,3]] In the first type 310 shown in Figures 17 and 20, the two first handles 316 are separated from each other in the Y direction DY. The first type 310 may be provided with a first hole 317 that penetrates each of the two first handles 316, as shown in Figures 17 and 20. The first hole 317 extends in the Y direction DY. A pin P, described later, for connecting the first type 310 and the second type 320 may be inserted into the first hole 317.

[0234] The first type 310 in Figures 17 and 20 includes a connecting portion 318 that connects two first handles 316. The connecting portion 318 extends in the Y direction DY. In the illustrated first type 310, the first hole 317 is located between the first body 315 and the second hole 318 in the X direction DX.

[0235] Figure 18 shows the second type 320. The second type 320 in Figure 18 is reversed from the state in Figure 16. In Figure 18, the first type 310 and the decorative film 20 are omitted. The second type 320 shown in Figure 16 and Figures 18 to 20 includes a second body 325 and a second pattern 326 connected to the second body 325. The second pattern 326 extends from the second body 325 in the X direction DX. When observed from the Z direction DZ, the second body 325 extends in the X direction DX and the Y direction DY. In the second type 320, the second body 325 and the second pattern 326 may be separate parts. The second pattern 326 may be made of a metal such as aluminum. Contrary to the illustration, the second body 325 and the second pattern 326 may be a single unit.

[0236] The second body 325 in Figure 18 includes a second bottom surface 321 and a second side surface 322 extending from the second bottom surface 321 in the Z direction DZ. In the second mold 320, the second bottom surface 321 and the second side surface 322 are portions that contact the decorative film 20. The second mold 320 contacts the second surface 20b of the decorative film 20 at the second bottom surface 320 and the second side surface 322. Specifically, the second mold 320 contacts the bonding layer 32 of the decorative film 20 at the second bottom surface 321 and the second side surface 322. The illustrated second side surface 322 also includes a first portion 322A extending in the Z direction DZ and the first bending direction DF1, and a second portion 322B extending in the Z direction DZ and the second bending direction DF2.

[0237] The second body 325 may be made of synthetic resin such as fluororesin, silicone resin, and olefin resin at the second bottom surface 321 and the second side surface 322. In particular, it is preferable that the material of the second body 325 at the second bottom surface 321 and the second side surface 322 be one of fluororesin, silicone resin, and olefin resin. By selecting the material of the second body 325 at the second bottom surface 321 and the second side surface 322 in this way, the decorative film 20 can be easily peeled off from the second body 325, more specifically from the second bottom surface 321 and the second side surface 322. Therefore, the decorative film 20 can be easily removed from the second mold 320 after molding. In the second mold 320, the entire second body 325 may be made of the above-mentioned material. In the second mold 320, the second bottom surface 321 and the second side surface 322 may be made of a coating. The coating that constitutes the second bottom surface 321 and the second side surface 322 may also contain the above-mentioned material.

[0238] In the second type 320, the angle φ between the second bottom surface 321 and the second side surface 322 12 This may be set based on the shape of the adherend AB. The angle φ shown in the diagram. 12 This may be set based on the shape of the exterior member 10. Note that the angle φ shown in the figure is also shown. 12 The angle is 90°. Similarly, on the second side surface 322, the angle φ between the first portion 322A and the second portion 322B is 90°. ABThis may be set based on the shape of the adherend AB. The angle φ shown in the diagram. AB This may be set based on the shape of the exterior component 10.

[0239] As shown in Figures 18 and 19, the second body 325 may include a connecting surface 323 located between the second bottom surface 321 and the second side surface 322. The connecting surface 323 may be rounded, as shown in Figures 18 and 19. The radius (R) of the rounded connecting surface 323 may be set based on the thickness of the decorative film 20 and the 3% strain tensile stress of the decorative film 20 at room temperature. The radius (R) of the rounded connecting surface 323 may be set based on the shape of the adherend AB.

[0240] As described above, wiring 330 may be connected to the second type 320. The wiring 330 may extend from the second bottom surface 321, as shown in Figure 18.

[0241] The second type 320 in Figure 18 is provided with a second hole 327 that penetrates the second handle 326 in the Y direction DY. The second hole 327 extends in the Y direction DY. A pin P, described later, for connecting the first type 310 and the second type 320 may be inserted into the second hole 327.

[0242] The second type 320 in Figure 18 is provided with a housing portion 328 that at least partially accommodates the connecting portion 318 of the first type 310. The housing portion 328 is located on the second handle 326. The second handle 326 opens to the second side in the Y direction DY and the Z direction DZ in the portion where the housing portion 328 is provided.

[0243] The first type 310 and the second type 320 shown in Figures 16 and 19 are connected to each other by a pin P extending in the Y direction DY. The illustrated pin P passes through a first hole 317 provided in the first type 310 and a first hole 327 provided in the second type 320.

[0244] The first mold 310 and the second mold 320 may be connected to each other so as to be pivotable by the pin P described above, as shown in Figure 19. As a result, the film forming apparatus 300 of Figure 16 can switch between a closed state and an open state while the movement of the first mold 310 and the second mold 320 relative to each other is restricted. The closed state is when the second mold 320 is at least partially housed in the first mold 310. The open state is when the second mold 320 is not housed in the first mold 310. In Figures 19 and 20, the first mold 310 and the second mold 320 are pivotable relative to each other about axis AX. Axis AX extends in the Y direction DY.

[0245] The film forming apparatus 300 in Figure 16 is in a closed state. The film forming apparatus 300 in Figure 19 is in an open state. The film forming apparatus 300 heats the decorative film 20 in the closed state. The film forming apparatus 300 forms the decorative film 20 in the closed state. The oscillation of the first mold 310 and the second mold 320 relative to each other may be restricted by the connection part 318 of the first mold 310.

[0246] In the closed-mold film forming apparatus 300, the first bottom surface 311 of the first mold 310 and the second bottom surface 321 of the second mold 320 face each other in the Z direction DZ. In the closed-mold film forming apparatus 300, the first side surface 312 of the first mold 310 and the second side surface 322 of the second mold 320 face each other in a direction perpendicular to the Z direction DZ. In particular, in the film forming apparatus 300 shown in Figure 20, the first portion 312A of the first side surface 312 and the first portion 322A of the second side surface 322 face each other in the second bending direction DF2. Also, the second portion 312B of the first side surface 312 and the second portion 322B of the second side surface 322 face each other in the first bending direction DF1.

[0247] An example of a molding process using the film molding apparatus 300 having the above configuration will be described. In the molding process, first, the film molding apparatus 300 is opened. By opening the film molding apparatus 300, the decorative film 20 can be placed between the first mold 310 and the second mold 320.

[0248] In the forming process, next, the decorative film 20 is disposed between the first mold 310 and the second mold 320. As shown in FIG. 16, the decorative film 20 may be turned over at the portion to be formed. Different from the illustration, the decorative film 20 may not be turned over at the portion to be formed. The decorative film 20 is disposed on the first main body 315 of the first mold 310. As shown in FIG. 17, the decorative film 20 is disposed on the second side in the Z direction DZ of the first main body 315. By disposing the decorative film 20 on the first main body 315, the first surface 20a of the decorative film 20 faces the first main body 315 of the first mold 310. The second surface 2 b of the decorative film 20 faces the second main body 325 of the second mold 320.

[0249] The decorative film 20 may be positioned with respect to the first mold 310 by the positioning portion 20f. The decorative film 20 may be disposed such that the positioning portion 20f and the hole 314 provided in the first main body 315 overlap in the Z direction DZ. The fixture 350 fixes the decorative film 20 in a state of being positioned with respect to the first mold 310 to the first mold 310.

[0250] In the forming process, next, the film forming apparatus 300 is set to the closed mold state. The film forming apparatus 300 is brought into the closed mold state by swinging the second mold 320 with respect to the first mold 310 in the swinging direction DR. By setting the film forming apparatus 300 to the closed mold state, the decorative film 20 is sandwiched between the first mold 310 and the second mold 320 at the edge portion 20e as shown in FIGS. 16 and 20. In particular, the illustrated decorative film 20 is sandwiched between the first mold 310 and the second mold 320 at the corner portion 20r.

[0251] [[ID=1十二]] The film 15 sandwiched between the first type 310 and the second type 320 has a first portion 15X, a second portion 15Y, and a third portion 15Z, as shown in Figure 20. The first portion 15X is the portion sandwiched between the first portion 312A of the first side surface 312 and the first portion 322A of the second side surface 322. The second portion 15Y is the portion sandwiched between the second portion 312B of the first side surface 312 and the second portion 322B of the second side surface 322. The third portion 15Z is the portion sandwiched between the first bottom surface 311 and the second bottom surface 321. The first portion 15X, the second portion 15Y, and the third portion 15Z are all located at the corners 15r of the film 15.

[0252] The decorative film 20 sandwiched between the first type 310 and the second type 320 has a first portion 20X, a second portion 20Y, and a third portion 20Z, as shown in Figure 20. The first portion 20X of the decorative film 20 constitutes the first portion 15X of the film 15. The second portion 20Y of the decorative film 20 constitutes the second portion 15Y of the film 15. The third portion 20Z of the decorative film 20 constitutes the third portion 15Z of the film 15. The first portion 20X, the second portion 20Y, and the third portion 20Z are all located at the corners 20r of the decorative film 20.

[0253] In the decorative film 20 sandwiched between the first type 310 and the second type 320, the first portion 20X is connected to the second portion 20Y at the first end in the first bending direction DF1. The second portion 20Y is connected to the first portion 20X at the second end in the second bending direction DF2. The third portion 20Z is connected to the first portion 20X at the second end in the second bending direction DF2. The third portion 20Z is connected to the second portion 20Y at the first end in the first bending direction DF1. The first portion 20X is bent along the first bending direction DF1 with respect to the third portion 20Z. The second portion 20Y is bent along the second bending direction DF2 with respect to the third portion 20Z.

[0254] In the molding process, the decorative film 20 is then heated. In the film molding apparatus 300 shown in Figure 16, as described above, the second mold 320 heats the decorative film 20. The decorative film 20 is molded by heating. The decorative film 20 is molded so that the first portion 20X is bent relative to the third portion 20Z, and the second portion 20Y is bent relative to the third portion 20Z.

[0255] Contrary to the above description, the decorative film 20 may also be formed in the molding process by being sandwiched between the first mold 310 and the preheated second mold 320. In this example as well, the decorative film 20 can be formed such that the first portion 20X is bent relative to the third portion 20Z, and the second portion 20Y is bent relative to the third portion 20Z.

[0256] In the molding process, after the decorative film 20 is molded, the film molding apparatus 300 is opened again. The decorative film 20 is released from being sandwiched between the first mold 310 and the second mold 320. As shown in Figure 21, the molded decorative film 20 is maintained with the first portion 20X bent relative to the third portion 20Z and the second portion 20Y bent relative to the third portion 20Z. The illustrated decorative film 20 is molded to have a shape complementary to the shape of the recess 340 provided in the first mold 310.

[0257] The molded decorative film 20 may be cooled. The method for applying the decorative film 20 may include a cooling step between the molding step and the second application step. In the cooling step, the decorative film 20 may be cooled by a blower such as a fan. In the cooling step, the decorative film 20 may be cooled by a spot air supply device such as a cold spray. In the cooling step, the mold used to heat the decorative film 20 in the molding step may be cooled. In the above example, the second mold 320 may be cooled in the cooling step. The second mold 320 may be cooled by a fluid flowing from wiring (not shown) connected to the second mold 320. The cooling step is preferably performed in a closed-mold film molding apparatus 300 from the viewpoint of suppressing unintended deformation of the molded decorative film 20.

[0258] As described above, the decorative film 20 is formed using the film forming apparatus 300 during the molding process. The film forming apparatus 300 is then removed from the formed decorative film 20. The portion of the formed decorative film 20 that includes the positioning portion 20f may be removed.

[0259] Films applied to substrates with a three-dimensional shape are prone to wrinkles and sagging as they cannot conform to the shape of the substrate. As described above, if at least one of these wrinkles or sagging is observed from the outside, the design of the decorative member deteriorates.

[0260] Conventionally, films are applied to three-dimensional substrates while stretched in a planar manner. In other words, a film stretched in a planar manner is pulled in the direction of its expansion. However, when a film is stretched in a planar manner, a large area of ​​excess material may be left unattached to the substrate. Films stretched in a planar manner are prone to wrinkles and sagging in the excess areas. Therefore, the design of decorative members may deteriorate even when the film is applied to the substrate while stretched in a planar manner.

[0261] In the molding process described above, the film molding apparatus 300 heats the film 15 (decorative film 20) in the portion sandwiched between the first mold 310 and the second mold 320. In the illustrated film molding apparatus 300, the second mold 320 is heating the film 15 (decorative film 20). The film 15 (decorative film 20) deforms by heating in the portion sandwiched between the first mold 310 and the second mold 320, instead of being stretched planarly. When the film molding apparatus 300 is attached to an adherend AB having a three-dimensional shape, it is possible to suppress the occurrence of a wide area of ​​excess material in the film 15 (decorative film 20). In the film 15 (decorative film 20), the reduction of excess material suppresses the occurrence of wrinkles and sagging at the edges 15e (edges 20e). Therefore, the film molding apparatus 300 can suppress deterioration of the design of the decorative member 25.

[0262] <<Second application process>> The decorative film 20 is then attached to the substrate AB in a second attachment step. In the second attachment step, the portion molded in the molding step is attached to the substrate AB. In the second attachment step, the edge portion 20e of the decorative film 20 may be attached to the substrate AB. In the second attachment step, the corner portion 20r of the decorative film 20 may be attached to the substrate AB.

[0263] The adherend AB in Figure 21 includes a first adherend AB1 and a second adherend AB2 that is bent relative to the first adherend AB1. When the adherend AB is an exterior member 10 of an automobile 1, the second adherend AB2 may extend forward, backward, or downward relative to the first adherend AB1.

[0264] Angle ψ between the first adhered portion AB1 and the second adhered portion AB2 12 This is the angle θ between the first bottom surface 311 and the first side surface 312 in the first type 310. 12 It may be 0.9 times or more and 1.1 times or less. Angle ψ between the first adherend AB1 and the second adherend AB2 12 This is the angle φ between the second bottom surface 321 and the second side surface 322 in the second type 320. 12It may be 0.9 times or more and 1.1 times or less. Note that the angle ψ between the first adhered part AB1 and the second adhered part AB2 12 As shown in Figure 22, the angle θ is measured from the cross-section of the adherend AB by planes extending in directions perpendicular to the first adherend AB1 and perpendicular to the second adherend AB2. 12 and angle φ 12 An angle ψ for at least one of the values ​​of 12 By setting the multiplier of the value as described above within the numerical range, the film forming apparatus 300 can bring the shape of the formed decorative film 20 closer to the shape of the adherend AB. This makes it possible to more effectively reduce the excess portion of the decorative film 20.

[0265] As shown in Figure 21, the second adherend AB2 may include a first portion AB21 and a second portion AB22 that is curved relative to the first portion AB21. In the second adherend AB2, the angle ψ between the first portion AB21 and the second portion AB22 22 This is the angle θ between the first portion 312A and the second portion 312B on the first side surface 312 of the first type 310. AB It may be 0.9 times or more and 1.1 times or less. Angle ψ between the first part AB21 and the second part AB22 22 This is the angle φ between the first portion 322A and the second portion 322B on the second side surface 322 of the second type 320. AB It may be 0.9 times or more and 1.1 times or less. The angle φ between the first part AB21 and the second part AB22 is also acceptable. 22 As shown in Figure 23, the angle θ is measured from the cross-section of the adherend AB by planes extending in directions perpendicular to the first adherend AB1 and perpendicular to the second adherend AB2. AB and angle φ AB An angle ψ for at least one of the values ​​of 22 By setting the multiplier of the value as described above within the numerical range, the film forming apparatus 300 can bring the shape of the formed decorative film 20 closer to the shape of the adherend AB. This makes it possible to more effectively reduce the excess portion of the decorative film 20.

[0266] The corner portion 20r of the decorative film 20 is turned over from the state shown in Figure 21. Of the corner portion 20r formed in the molding process, the third portion 20Z is attached to the first adherend AB1. The first portion 20X is attached to the first portion AB21 of the second adherend AB2. The second portion 20Y is attached to the second portion AB22 of the second adherend AB2.

[0267] In this manner, the film 15 (decorative film 20) is attached to the substrate AB. The completion of the second attachment step completes the method of attaching the film 15 (decorative film 20) described above. By attaching the decorative film 20 to the substrate AB, the decorative member 25, including the film 15 (decorative film 20) and the substrate AB, is manufactured.

[0268] In the embodiment described above, the film application device 40 applies the film 15, which has a first surface 15a and a second surface 15b, to the adherend AB by moving the film 15 in a first direction D1, starting from the second surface 15b. The film application device 40 includes a holding device 50 for holding the film 15 and a moving device 42 for moving the holding device 50. The film 15 is applied to the adherend AB with the film 15 protruding toward the adherend AB in the first direction D1.

[0269] In the embodiment described above, the film application device 40 applies the film 15, which has a first surface 15a and a second surface 15b, to the adherend AB by moving the film 15 in a first direction D1, starting from the second surface 15b. The film application device 40 includes a holding device 50 for holding the film 15 and a pressing device 60 for applying pressure to the first space S1 that the first surface 15a faces. The pressing device 60 causes the film 15 to protrude in the first direction D1 toward the adherend AB.

[0270] According to these forms, when the film 15 is attached to the adherent AB, it is suppressed from being pulled in a direction orthogonal to the first direction D1. Thereby, when being attached to the adherent AB, it is possible to suppress the occurrence of wrinkles in the film 15. Therefore, the film attaching device 40 can suppress the deterioration of the design of the decorative member 25 constituted by the adherent AB and the film 15.

[0271] Also, in one embodiment described above, the film forming device 300 includes a first mold 310 and a second mold 320. The film 15 is sandwiched between the first mold 310 and the second mold 320 at the edge 15e. The film forming device 300 forms the edge 15e of the film 15 by heating the edge 15e of the film 15 partially attached to the adherent AB.

[0272] Furthermore, in one embodiment described above, the film forming device 300 includes a first mold 310 and a second mold 320. The film 15 is sandwiched between the first mold 310 and the second mold 320 at the edge 15e. In the film forming device 300, at least one of the first mold 310 and the second mold 320 heats the edge 15e. Thereby, the film forming device 300 forms the edge 15e of the film 15.

[0273] According to these forms, by heating the film 15, in the forming of the film 15, it is possible to reduce the surplus portion generated at the edge 15e. Thereby, the occurrence of wrinkles and sagging at the edge 15e is suppressed. Therefore, the film forming device 300 can suppress the deterioration of the design of the decorative member 25.

[0274] Although one embodiment has been described while referring to specific examples, the above-described specific examples do not limit one embodiment. The one embodiment described above can be implemented with various other specific examples, and various omissions, replacements, changes, additions, etc. can be made without departing from the gist thereof.

[0275] In the arrangement process described above, the adherends AB were positioned so that the decorative film 20 could be attached by moving the automobile 1 in the front-rear direction. The direction of movement of the automobile 1 is not limited to the front-rear direction. The direction of movement of the automobile 1 may also be the left-right direction.

[0276] In the moving process described above, the control device 70 calculated the size of the contact area based on the image of the decorative film 20 acquired by the imaging device 44. Based on the calculated size of the contact area, the control device 70 generated one of the following signals: a movement stop signal, a pressure maintenance signal, or a pressure stop signal. Alternatively, the control device 70 may generate one of the above signals based on the reaction force from the adherend AB to the holding device 50 instead of the size of the contact area. The reaction force from the adherend AB to the holding device 50 increases with increasing contact area. The film application device 40 may include a sensor capable of measuring the reaction force from the adherend AB to the holding device 50. For example, the film application device 40 may include a load cell capable of measuring the reaction force from the adherend AB to the holding device 50.

[0277] The decorative film 20 described above included a surface layer 34, a design layer 33, a base layer 31, and a bonding layer 32 in this order, from the first surface 15a to the second surface 15b. The design layer 33 was located between the surface layer 34 and the base layer 31. The design layer 33 was located on the first surface 15a side of the base layer 31. The layer configuration of the decorative film 20 is not limited to the example described above. As another example, the decorative film 20 may include a surface layer 34, a base layer 31, a design layer 33, and a bonding layer 32 in this order, from the first surface 15a to the second surface 15b. In this example, the design layer 33 is located between the base layer 31 and the bonding layer 32. The base layer 31 is located on the first surface 15a side of the design layer 33.

[0278] In the decorative member 25 described above, the film 15 was a decorative film 20. In the decorative member 25 described above, the film 15 displayed the design. However, it is not limited to this, and in the decorative member 25, the adherend AB may display the design, as shown in Figure 24. As shown in Figure 24, the film 15 does not have to include the design layer 33 described above. The film 15 may have a function to protect the adherend AB. From the viewpoint of clearly displaying the design displayed by the adherend AB, the film 15 may be transparent. The film 15 shown in Figure 24 may be attached to the adherend AB by the film application device 40 shown in Figures 3 and 4, etc. [Explanation of Symbols]

[0279] 1: Automobile, 10: Exterior component, 11: Roof, 15: Film, 15a: First surface, 15b: Second surface, 15e: Edge, 15r: Corner, 20: Decorative film, 21: First side edge, 22: Second side edge, 23: Third side edge, 24: Fourth side edge, 31: Base material layer, 32: Bonding layer, 33: Design layer, 40: Film application device, 42: Moving device, 43: Cutting device, 44: Imaging device, 50: Holding device, 51: Frame, 52: Cover, 56: Suction device, 60: Pressurizing device, 70: Control device, 80: Display device, 90: Input device, 100: Moving body, D1: First direction, D2: Second direction, D3: Third direction, S1: First space, S2: Second space

Claims

1. A film application device that applies a film having a first surface and a second surface to an object by moving the film in a first direction, starting from the second surface, A holding device for holding the aforementioned film, The device comprises a moving device for moving the aforementioned holding device, The film is attached to the adherend in a state that it protrudes toward the adherend in a first direction, The holding device further comprises a pressurizing device that pressurizes the first space facing the first surface while the holding device is holding the film, The holding device includes a circumferential frame that opens to the first and second sides in the first direction, and a cover that closes the opening from either the first or second side in the first direction. A film application device that seals the opening of the frame from the other of the first and second sides.

2. A film application device that applies a film having a first surface and a second surface to an object by moving the film in a first direction, starting from the second surface, A holding device for holding the aforementioned film, The device comprises a moving device for moving the aforementioned holding device, The film is attached to the adherend in a state that it protrudes toward the adherend in a first direction, A film application device that holds the side edges of the film in a second direction nonparallel to the first direction, and the side edges of the film in a third direction nonparallel to both the first and second directions.

3. A film application device that applies a film having a first surface and a second surface to an object by moving the film in a first direction, starting from the second surface, A holding device for holding the aforementioned film, The device comprises a moving device for moving the aforementioned holding device, The film is attached to the adherend in a state that it protrudes toward the adherend in a first direction, The holding device includes a circumferential frame that opens to the first and second sides in the first direction, and a cover that closes the opening from either the first or second side in the first direction. A film application device that seals the opening of the frame from the other of the first and second sides.

4. A film application device that applies a film having a first surface and a second surface to an object by moving the film in a first direction, starting from the second surface, A holding device for holding the aforementioned film, The device comprises a moving device for moving the aforementioned holding device, The film is attached to the adherend in a state that it protrudes toward the adherend in a first direction, The device further comprises a suction device for sucking the film from the first or second surface, The holding device is a film application device that holds the film in a state where it has been sucked by the suction device.

5. A film application device that applies a film having a first surface and a second surface to an object by moving the film in a first direction, starting from the second surface, A holding device for holding the aforementioned film, The device comprises a pressurizing device that pressurizes the first space to which the first surface faces, The pressurizing device causes the film to protrude in the first direction toward the object to be adhered. The holding device includes a circumferential frame that opens to the first and second sides in the first direction, and a cover that closes the opening from either the first or second side in the first direction. A film application device that seals the opening of the frame from the other of the first and second sides.

6. The film application apparatus according to any one of claims 1 to 5, wherein the film is a decorative film.

7. A film application device for applying a film having a first surface and a second surface to an object by moving the film in a first direction, starting from the second surface, A holding device for holding the aforementioned film, The device comprises a pressurizing device that pressurizes the first space to which the first surface faces, The pressurizing device causes the film to protrude in the first direction toward the object to be adhered. A film application device that holds the side edges of the film in a second direction nonparallel to the first direction, and the side edges of the film in a third direction nonparallel to both the first and second directions.

8. The film application device according to claim 2 or 7, wherein the film is joined to the holding device from the second surface at both side edges in the second direction and both side edges in the third direction.

9. The film includes a bonding layer that constitutes the second surface, The film application apparatus according to claim 1 or 5, wherein the pressurizing device increases the pressure in the first space to a level greater than before contact when the film partially contacts the adherend.

10. The film application apparatus according to any one of claims 1 to 5, further comprising a cutting device for cutting the aforementioned film.

11. The device further comprises a cutting device that cuts the film by emitting light, The film application apparatus according to any one of claims 1, 3, or 5, wherein the cover is disposed between the cutting device and the film and is transparent.

12. The film application apparatus according to any one of claims 1 to 5, 7, further comprising an imaging device that acquires at least one image of the film and an image of the holding device.

13. The device further includes an imaging device for acquiring an image of the aforementioned film, The film application device according to any one of claims 1, 3, or 5, wherein the cover is disposed between the imaging device and the film and is transparent.

14. The film application apparatus according to any one of claims 1, 5, or 7, further comprising a control device for controlling the operation of the pressurizing device.

15. The imaging device further comprises an imaging device that acquires at least one image of the film and an image of the holding device. The film application apparatus according to claim 14, wherein the control device controls the operation of the pressurizing device based on at least one of the images.

16. An imaging device that acquires at least one image of the film and an image of the adherend, A cutting device for cutting the aforementioned film, The film application apparatus according to any one of claims 1 to 5, 7, further comprising a control device for controlling the operation of the cutting apparatus based on at least one of the aforementioned images.

17. The film application apparatus according to any one of claims 1 to 4, further comprising a control device for controlling the operation of the moving device.

18. The device further includes an imaging device that acquires an image of the object to be adhered to, The film application apparatus according to claim 17, wherein the control device controls the operation of the moving device based on the image.

19. The film application device according to claim 14, wherein the control device stores the number of times the film is applied by the film application device.

20. A film application device for applying a film having a first surface and a second surface to an object by moving the film in a first direction, starting from the second surface, A holding device for holding the aforementioned film, The device comprises a pressurizing device that pressurizes the first space to which the first surface faces, The pressurizing device causes the film to protrude in the first direction toward the object to be adhered. The device further comprises a suction device for sucking the film from the first or second surface, The holding device is a film application device that holds the film in a state where it has been sucked by the suction device.

21. The film includes a substrate layer, The film application apparatus according to any one of claims 1 to 5, 7, or 20, wherein the base layer comprises thermoplastic polyurethane.

22. The film includes a bonding layer that constitutes the second surface, The film application apparatus according to any one of claims 1 to 5, 7, or 20, wherein the peeling force of the film applied from the second surface is 3 N / 25 mm or more.

23. The film application apparatus according to any one of claims 1 to 5, 7, or 20, wherein the 3% strain tensile stress of the film is 1 N / 10 mm or more and 40 N / 10 mm or less in an environment of 25°C.

24. The film application apparatus according to any one of claims 1 to 5, 7, or 20, wherein the adherend has a three-dimensional shape and protrudes toward the film in the first direction.

25. The object to be adhered to, A method for manufacturing a decorative member comprising a film attached to the adherend, A method for manufacturing a decorative member, comprising the step of attaching the film to the adherend using a film attachment device according to any one of claims 1 to 5, 7, or 20.

Images