Evaluation method for evaluating the elongation of decorative sheets and method for manufacturing decorative molded products

Abstract

An evaluation method for evaluating elongation of a decorative sheet when producing a decorative molded article, the evaluation method comprising: a step for temporarily determining a mold used for molding the decorative sheet; a step for generating mold data representing a three-dimensional shape of the temporarily determined mold; a step for temporarily determining a condition of primary molding for stretching the decorative sheet before molding so as to conform to the decorative molded article; a step for calculating the elongation of each part of the decorative sheet after the primary molding to generate primary elongation data; and a secondary elongation data generation step for calculating the elongation of each part of the decorative sheet by secondary molding, in which the decorative sheet after the primary molding is molded with the temporarily determined mold, to generate secondary elongation data.

Description

Technical Field

[0001] The present invention relates to an evaluation method for evaluating the elongation of a decorative sheet and a method for manufacturing a decorated molded product.

Background Art

[0002] Conventionally, as interior parts and exterior parts of automobiles, interior materials and exterior materials of building materials, and housings of home appliances, decorated molded products in which a decorative sheet is laminated on the surface of a resin molded product have been used. In the manufacturing process of such decorated molded products, the decorative sheet is molded into a shape corresponding to the surface shape of the decorated molded product using a molding die.

[0003] However, depending on the surface shape of the decorated molded product and the shape of the molding die, a part of the decorative sheet is significantly elongated. For example, a part of the decorative sheet is elongated at an elongation rate of 50% to 200%. When a part of the decorative sheet having a pattern is elongated at such a large elongation rate, the pattern of the decorative sheet may be significantly distorted, and a design different from the intended design may be imparted to the decorated molded product.

[0004] Although it is conceivable to produce a plurality of molding dies having different surface shapes and evaluate the elongation of the decorative sheet molded by each molding die, such a method leads to an increase in the time and cost required to complete the decorated molded product.

[0005] Prior art document: Japanese Patent Application Laid-Open No. 2005-103794

Disclosure of the Invention

[0006] An embodiment of the present disclosure aims to enable evaluation of the elongation of a decorative sheet when producing a decorated molded product without actually producing a molding die or a decorated molded product.

[0007] One embodiment of the present disclosure relates to the following [1] to

[29] .

[0008] [1] A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product that includes a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining the mold used for molding the decorative sheet based on the molded product data, A step of generating mold data representing the three-dimensional shape of the provisionally determined mold, A step of provisionally determining the conditions for primary molding to stretch the decorative sheet before molding so that it conforms to the decorative molded product, based on the molded product data or the mold data, A primary elongation data generation step that generates primary elongation data by calculating the elongation of each part of the decorative sheet after primary molding relative to the decorative sheet before molding, based on the provisionally determined primary molding conditions, An evaluation method comprising: a secondary elongation data generation step, which generates secondary elongation data by generating secondary elongation data, which calculates the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding, based on the primary elongation data and the molding die data, in which the decorative sheet after primary molding is molded with the provisionally determined molding die.

[0009] [2] The evaluation method according to [1], further comprising the step of generating secondary elongation display image data that visually represents the correspondence between the elongation of each part of the decorative sheet before molding and the elongation of each part of the decorative sheet after secondary molding, based on the secondary elongation data.

[0010] [3] The evaluation method according to [2], wherein the secondary elongation display image data represents the elongation of each part of the decorative sheet represented by the secondary elongation data, with a color corresponding to the magnitude of the elongation.

[0011] [4] The evaluation method according to [2] or [3], wherein the secondary elongation display image data represents the elongation of each part of the decorative sheet represented by the secondary elongation data, with line distortion corresponding to the magnitude of the elongation.

[0012] [5] The evaluation method according to any one of [1] to [4], further comprising the step of generating primary elongation display image data that visually represents the correspondence between the elongation of each part of the decorative sheet before molding and the elongation of each part of the decorative sheet after primary molding, based on the primary elongation data.

[0013] [6] The evaluation method according to any one of [1] to [5], further comprising a secondary post-molding image data generation step, which generates secondary post-molding image data representing the decorative sheet after secondary molding, based on the secondary elongation data and the pre-molding image data.

[0014] [7] The decorative sheet has a pattern, The evaluation method according to [6], wherein the post-secondary molding image data is generated by deforming the pattern of the decorative sheet before molding in accordance with the elongation of each part of the decorative sheet as represented by the secondary elongation data.

[0015] [8] The aforementioned decorative sheet has color, The evaluation method according to either [6] or [7], wherein the post-secondary molding image data is generated by changing the color of each part of the decorative sheet before molding according to the elongation of each part of the decorative sheet as represented by the secondary elongation data.

[0016] [9] The aforementioned primary molding is blow molding. The evaluation method according to any one of [1] to [8], wherein the secondary molding is vacuum molding using the mold.

[0017]

[10] A method for evaluating the elongation of a decorated sheet after molding with respect to the decorated sheet before molding when producing a decorated molded product including the formed decorated sheet, comprising: generating or obtaining molded product data representing the three-dimensional shape of the decorated molded product; generating or obtaining pre-molding image data representing the decorated sheet before molding; tentatively determining a plurality of molding dies used for molding the decorated sheet based on the molded product data; generating molding die data representing the three-dimensional shape of each tentatively determined molding die; tentatively determining the conditions for primary molding for stretching the decorated sheet before molding along the decorated molded product based on the molded product data or the molding die data; a primary elongation data generation step of calculating the elongation of each part of the decorated sheet after the primary molding with respect to the decorated sheet before molding based on the tentatively determined conditions for the primary molding, and generating primary elongation data; a secondary elongation data generation step of calculating the elongation of each part of the decorated sheet after the secondary molding with respect to the decorated sheet before molding by secondary molding of the decorated sheet after the primary molding using the tentatively determined molding die, based on the primary elongation data and each molding die data, and generating a plurality of secondary elongation data; An evaluation method comprising the above steps.

[0018]

[11] A method for evaluating the elongation of a decorated sheet after molding with respect to the decorated sheet before molding when producing a decorated molded product including the formed decorated sheet, comprising: generating or obtaining molded product data representing the three-dimensional shape of the decorated molded product; generating or obtaining pre-molding image data representing the decorated sheet before molding; tentatively determining a molding die used for molding the decorated sheet based on the molded product data; generating molding die data representing the three-dimensional shape of the tentatively determined molding die; A step of preliminarily determining a plurality of primary molding conditions for stretching the decorative sheet before molding along the decorative molded product based on the molded product data or the mold data; A primary elongation data generation step of calculating the elongation of each part of the decorative sheet after the primary molding with respect to the decorative sheet before molding based on each of the preliminarily determined primary molding conditions, and generating a plurality of primary elongation data; A secondary elongation data generation step of calculating the elongation of each part of the decorative sheet after the secondary molding with respect to the decorative sheet before molding by secondary molding of molding the decorative sheet after the primary molding with the preliminarily determined mold, and generating a plurality of secondary elongation data based on each primary elongation data and the mold data; An evaluation method comprising:

[0019]

[12] A method for evaluating the elongation of the decorative sheet after molding with respect to the decorative sheet before molding when producing a decorative molded product including the molded decorative sheet, comprising: A step of generating or acquiring molded product data representing the three-dimensional shape of the decorative molded product; A step of generating or acquiring pre-molding image data representing the decorative sheet before molding; A step of preliminarily determining a plurality of molds used for molding the decorative sheet based on the molded product data; A step of generating mold data representing the three-dimensional shape of each preliminarily determined mold; A step of preliminarily determining a plurality of primary molding conditions for stretching the decorative sheet before molding along the decorative molded product based on the molded product data or the mold data; A primary elongation data generation step of calculating the elongation of each part of the decorative sheet after the primary molding with respect to the decorative sheet before molding based on each of the preliminarily determined primary molding conditions, and generating a plurality of primary elongation data; A secondary elongation data generation step involves generating a plurality of secondary elongation data by calculating the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding, based on each primary elongation data and each mold data, in which the decorative sheet after primary molding is molded using the provisionally determined mold. An evaluation method comprising the following features.

[0020]

[13] A post-molding image data generation step generates multiple post-molding image data representing the decorative sheet after post-molding, based on each post-molding elongation data and the pre-molding image data, An evaluation method according to any one of

[10] to

[12] , comprising:

[0021]

[14] The process further includes selecting one secondary elongation data from a plurality of secondary elongation data, The evaluation method according to any one of

[10] to

[13] , wherein in the step of selecting the secondary elongation data, the average, deviation, maximum, or ratio of the maximum and minimum values ​​of the elongation of multiple parts of the decorative sheet after secondary molding relative to the decorative sheet before molding is calculated based on each secondary elongation data, and a single secondary elongation data is selected based on the average, deviation, maximum, and ratio of the maximum and minimum values ​​of the elongation.

[0022]

[15] A method for manufacturing a decorative molded article including a molded decorative sheet, A step of evaluating the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding, when the decorative sheet is primary molded under the provisionally determined primary molding conditions and secondary molded with the provisionally determined molding die, in accordance with the evaluation method described in any of [1] to

[14] , A step of determining the conditions for the decorative sheet and / or the primary molding and / or the molding die based on the elongation evaluation results, A manufacturing method that includes the following features.

[0023]

[16] A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product that includes a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining the mold used for molding the decorative sheet based on the molded product data, A step of generating mold data representing the three-dimensional shape of the provisionally determined mold, A step of provisionally determining the bent shape, which is the shape obtained by bending the decorative sheet before molding so as to conform to the decorative molded product, based on the molded product data or the mold data, A process for generating elongation data, which involves generating elongation data by calculating the elongation of each part of the decorative sheet after molding relative to the decorative sheet before molding, based on the provisionally determined bending shape and mold data, by molding the bent decorative sheet with the provisionally determined mold, An evaluation method comprising the following features.

[0024]

[17] The evaluation method according to

[16] , further comprising the step of generating elongation display image data that visually represents the correspondence between the elongation of each part of the decorative sheet before molding and each part of the decorative sheet after molding, based on the elongation data.

[0025]

[18] The evaluation method according to

[17] , wherein the elongation display image data represents the elongation of each part of the decorative sheet represented by the elongation data, with a color corresponding to the magnitude of the elongation.

[0026]

[19] The evaluation method according to

[17] or

[18] , wherein the elongation display image data represents the elongation of each part of the decorative sheet represented by the elongation data, expressed as line distortion corresponding to the magnitude of the elongation.

[0027]

[20] The evaluation method according to any one of

[16] to

[19] further comprises a post-molding image data generation step, which generates post-molding image data representing the decorated sheet after molding, based on the elongation data and the pre-molding image data.

[0028] [twenty one] The decorative sheet has a pattern, The post-molding image data is generated by deforming the pattern of the decorative sheet before molding according to the elongation of each part of the decorative sheet as represented by the elongation data, according to the evaluation method described in

[20] .

[0029] [twenty two] The aforementioned decorative sheet has color, The post-molding image data is generated by changing the color of each part of the decorative sheet before molding according to the elongation of each part of the decorative sheet as represented by the elongation data, according to the evaluation method described in

[20] or

[21] .

[0030] [twenty three] The molding is vacuum forming using the molding die, the evaluation method according to any one of

[16] to

[22] .

[0031] [twenty four] A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product that includes a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining multiple molds to be used for molding the decorative sheet based on the molded product data, A process to generate mold data representing the three-dimensional shape of each provisionally determined mold, A step of provisionally determining the bent shape, which is the shape obtained by bending the decorative sheet before molding so as to conform to the decorative molded product, based on the molded product data or the mold data, A stretch data generation step that generates multiple stretch data by calculating the elongation of each part of the decorative sheet after molding relative to the decorative sheet before molding, based on the provisionally determined bending shape and each molding die data, by molding the bent decorative sheet with the provisionally determined molding die, An evaluation method comprising the following features.

[0032] [twenty five] A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product that includes a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining the mold used for molding the decorative sheet based on the molded product data, A step of generating mold data representing the three-dimensional shape of the provisionally determined mold, A step of provisionally determining multiple bent shapes, which are the shape obtained by bending the decorative sheet before molding so as to conform to the decorative molded product, based on the molded product data or the mold data, A stretch data generation step that generates multiple stretch data by calculating the elongation of each part of the decorative sheet after molding relative to the decorative sheet before molding, based on the provisionally determined bending shape and the molding die data, by molding the bent decorative sheet with the provisionally determined molding die, An evaluation method comprising the following features.

[0033]

[26] A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product that includes a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining multiple molds to be used for molding the decorative sheet based on the molded product data, A process to generate mold data representing the three-dimensional shape of each provisionally determined mold, A step of provisionally determining multiple bent shapes, which are the shape obtained by bending the decorative sheet before molding so as to conform to the decorative molded product, based on the molded product data or the mold data, A stretch data generation step that generates multiple stretch data by calculating the elongation of each part of the decorative sheet after molding relative to the decorative sheet before molding, based on the provisionally determined bending shape and mold data, by molding the bent decorative sheet with the provisionally determined molding die, An evaluation method comprising the following features.

[0034]

[27] A post-molding image data generation step generates multiple post-molding image data representing the decorative sheet after molding, based on each elongation data and the pre-molding image data. An evaluation method according to any one of

[24] to

[26] , comprising:

[0035]

[28] The process further includes selecting one growth data from a plurality of growth data, The evaluation method according to any one of

[24] to

[27] , wherein in the step of selecting the elongation data, the average, deviation, maximum, and ratio of the maximum and minimum values ​​of the elongation of multiple parts of the decorative sheet after molding relative to the decorative sheet before molding are calculated based on each elongation data, and one elongation data is selected based on the average, deviation, maximum, and ratio of the maximum and minimum values.

[0036]

[29] A method for manufacturing a decorative molded article including a molded decorative sheet, An evaluation step in which, when the decorative sheet is bent into the provisionally determined bending shape and molded with the provisionally determined molding die according to the evaluation method described in any of

[16] to

[28] , the elongation of each part of the decorative sheet after molding relative to the decorative sheet before molding is evaluated, A step of determining the decorative sheet and / or the molding die based on the elongation evaluation results, A manufacturing method that includes [the necessary equipment / features].

[0037] According to the embodiments of this disclosure, the elongation of the decorative sheet when manufacturing a decorative molded product can be evaluated without manufacturing a mold or a decorative molded product. [Brief explanation of the drawing]

[0038] [Figure 1] Figure 1 is a diagram illustrating the first embodiment and is a perspective view of a decorated molded product. [Figure 2] Figure 2 is a cross-sectional view illustrating the structure of the decorated molded product shown in Figure 1. [Figure 3] Figure 3 is a perspective view of the clamp used in the manufacturing of the decorative molded product shown in Figure 1. [Figure 4] Figure 4 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 1. [Figure 5] Figure 5 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 1. [Figure 6] Figure 6 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 1. [Figure 7] Figure 7 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 1. [Figure 8] Figure 8 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 1. [Figure 9] Figure 9 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 1. [Figure 10] Figure 10 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 1. [Figure 11] Figure 11 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 1. [Figure 12] Figure 12 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 1. [Figure 13] Figure 13 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 1. [Figure 14]Figure 14 is a block diagram showing the configuration of the evaluation apparatus used in the manufacturing of the decorated molded product shown in Figure 1. [Figure 15A] Figure 15A is a flowchart illustrating an example of a manufacturing method for the decorated molded product shown in Figure 1. [Figure 15B] Figure 15B is a flowchart illustrating a modified version of the manufacturing method shown in Figure 15A. [Figure 15C] Figure 15C is a flowchart illustrating other variations of the manufacturing method shown in Figure 15A. [Figure 16A] Figure 16A is a flowchart illustrating another example of the manufacturing method for the decorated molded product shown in Figure 1. [Figure 16B] Figure 16B is a flowchart illustrating a modified version of the manufacturing method shown in Figure 16A. [Figure 17A] Figure 17A is a flowchart illustrating yet another example of the manufacturing method for the decorated molded product shown in Figure 1. [Figure 17B] Figure 17B is a flowchart illustrating a modified version of the manufacturing method shown in Figure 17A. [Figure 18A] Figure 18A is a flowchart illustrating yet another example of the manufacturing method for the decorated molded product shown in Figure 1. [Figure 18B] Figure 18B is a flowchart illustrating a modified version of the manufacturing method shown in Figure 18A. [Figure 19] Figure 19 is a diagram illustrating a second embodiment, and is a perspective view of a decorated molded product. [Figure 20] Figure 20 is a perspective view of a clamp used in the manufacture of the decorative molded product shown in Figure 19. [Figure 21A] Figure 21A is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 19. [Figure 21B] Figure 21B is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 19. [Figure 22] Figure 22 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 19. [Figure 23]Figure 23 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 19. [Figure 24] Figure 24 is a diagram illustrating an example of a manufacturing method for the decorated molded product shown in Figure 19. [Figure 25] Figure 25 is a block diagram showing the configuration of the evaluation apparatus used in the manufacturing of the decorated molded product shown in Figure 19. [Figure 26A] Figure 26A is a flowchart illustrating an example of a manufacturing method for the decorated molded product shown in Figure 19. [Figure 26B] Figure 26B is a flowchart illustrating a modified version of the manufacturing method shown in Figure 26A. [Figure 26C] Figure 26C is a flowchart illustrating other variations of the manufacturing method shown in Figure 26A. [Figure 27A] Figure 27A is a flowchart illustrating another example of the manufacturing method for the decorated molded product shown in Figure 19. [Figure 27B] Figure 27B is a flowchart illustrating a modified version of the manufacturing method shown in Figure 27A. [Figure 28A] Figure 28A is a flowchart illustrating yet another example of the manufacturing method for the decorated molded product shown in Figure 19. [Figure 28B] Figure 28B is a flowchart illustrating a modified version of the manufacturing method shown in Figure 28A. [Figure 29A] Figure 29A is a flowchart illustrating yet another example of the manufacturing method for the decorated molded product shown in Figure 19. [Figure 29B] Figure 29B is a flowchart illustrating a modified version of the manufacturing method shown in Figure 29A. [Modes for carrying out the invention]

[0039] Embodiments of this disclosure will be described below with reference to the drawings. Note that, for the sake of illustration and ease of understanding, the scale and aspect ratios of the drawings attached to this specification have been appropriately altered and exaggerated from those of the actual objects.

[0040] <First Embodiment> A first embodiment of the present disclosure will now be described. First, the configuration of the decorated molded product 1 will be described with reference to Figures 1 and 2. Figure 1 is a perspective view of the decorated molded product 1. Figure 2 is a cross-sectional view of the decorated molded product 1 shown in Figure 1 along the line F2-F2.

[0041] The decorated molded product 1 can be used, for example, as interior or exterior parts for mobile bodies, interior or exterior materials for building materials, or as a housing for home appliances. A mobile body is an object that can be moved. A mobile body may be manned or unmanned. Examples of mobile bodies include automobiles, railway vehicles, trolleys, ships, airplanes, helicopters, drones, and robots. As shown in Figure 2, the decorated molded product 1 comprises a molded part 2 and a decorative sheet 3.

[0042] The molded part 2 is manufactured by injection molding a resin material, as described later. The resin material forming the molded part 2 is not particularly limited. Examples of resin materials forming the molded part 2 include polycarbonate resin, acrylic resin such as polymethyl methacrylate, and ABS (acrylonitrile butadiene styrene copolymer). The molded part 2 may be transparent or opaque. The molded part 2 may be colored or uncolored.

[0043] The decorative sheet 3 covers at least a portion of the surface of the molded part 2. In the illustrated example, the decorative sheet 3 is made by laminating a design layer 5, a surface protection layer 6, etc., onto a base sheet 4 made of a resin material. Examples of resin materials that make up the base sheet 4 include acrylic resin such as polymethyl methacrylate, polyethylene terephthalate, vinyl chloride, ABS (acrylonitrile butadiene styrene copolymer), polycarbonate, polyethylene naphthalate, polystyrene, cyclic polyolefin, and polypropylene. Sheets of the exemplified materials may be used as a single layer or in multiple layers; for example, acrylic resin and ABS may be laminated together. The base sheet 4 may be transparent or opaque. The base sheet 4 may be colored or uncolored.

[0044] Design layer 5 may be a layer on which images such as colors, patterns, figures, designs, pictures, photographs, characters, marks, pictograms, letters, and numbers are formed. Design layer 5 may also be a layer that has an internal uneven structure and exhibits a three-dimensional feel with depth. Design layer 5 may represent the texture of materials such as wood, cloth, leather, stone, and metal. Design layer 5 may be formed by printing or by transfer printing.

[0045] The surface protection layer 6 forms the outermost surface of the decorated molded product 1. The surface protection layer 6 may have properties such as scratch resistance. The surface protection layer 6 is made of, for example, a resin material. Examples of resin materials that make up the surface protection layer 6 include thermoplastic resins, thermosetting resins, and ionizing radiation-curable resins.

[0046] The configuration of the decorative sheet 3 is not limited to the examples described above. For example, the decorative sheet 3 may include functional layers such as an ultraviolet absorption layer, an anti-reflective layer, a light-diffusing layer, an adhesive layer, a backer layer, and a light-shielding pattern.

[0047] Next, the method for manufacturing the decorated molded product 1 in the first embodiment will be described with reference to Figures 3 to 13. Figure 3 is a perspective view of the clamp 10 used in the manufacture of the decorated molded product 1. Figures 4 to 13 are diagrams illustrating an example of the method for manufacturing the decorated molded product 1 shown in Figure 1.

[0048] The method shown in Figures 3 to 13 is one method of in-mold decoration. The method shown in Figures 3 to 13 is also called insert molding (or film insert molding). In this specification, in-mold decoration refers to injection molding in which the object to be bonded, such as a decorative sheet, is housed in a cavity. In-mold decoration includes insert molding and in-mold molding. Insert molding allows for the production of a product in which the injection resin and the object to be bonded are integrated. In this insert molding, the object to be bonded may be deformed.

[0049] First, as shown in Figures 4 to 9, the decorative sheet 3 is pre-formed. Pre-formation causes plastic deformation of the decorative sheet 3. After pre-formation, the decorative sheet 3 has a shape close to the shape of the desired decorative molded product 1. In the examples shown in Figures 4 to 9, vacuum forming or pressure forming is performed as pre-formation.

[0050] In the vacuum forming of the illustrated decorative sheet 3, first, as shown in Figure 3, the edges of the decorative sheet 3 are held by a clamp 10. In the example shown in Figure 3, the clamp 10 is formed in an annular shape. This clamp 10 holds all four sides of the decorative sheet 3, but is not limited to this example. For example, the clamp 10 may hold two opposing sides of the decorative sheet 3. In this case, the clamp 10 does not have to be formed in an annular shape.

[0051] Next, as shown in Figure 4, the decorative sheet 3 held by the clamp 10 is heated and softened by the heater 11.

[0052] Next, as shown in Figure 5, the blow molding apparatus 12 blows gas onto one side of the softened decorative sheet 3 to perform blow molding. This stretches and curves the flat decorative sheet 3. In the illustrated example, the decorative sheet 3 is formed into a dome shape. In other words, the decorative sheet 3 is formed so that its cross-section along its normal direction is semicircular. This allows the decorative sheet 3 to roughly conform to the decorative molded product 1 (more specifically, to the shape of the decorative sheet 3 in the decorative molded product 1). Hereafter, the molding of the decorative sheet 3 by the blow molding apparatus 12 will also be referred to as "primary molding".

[0053] Next, as shown in Figure 6, the vacuum forming die 13 is placed facing the stretched decorative sheet 3. The vacuum forming die 13 has a main forming section 14 and a sub-forming section 15. The main forming section 14 has a surface shape corresponding to the shape of the decorative molded product 1 (more specifically, a surface shape corresponding to the shape of the decorative sheet 3 in the decorative molded product 1). The sub-forming section 15 is located around the main forming section 14. An opening 16 is formed on the surface of the sub-forming section 15. The opening 16 leads to a gas flow path 17 formed inside the vacuum forming die 13. A suction pump (not shown) is connected to the flow path 17. The decorative sheet 3 is arranged to cover the main forming section 14 and the sub-forming section 15.

[0054] Next, the gas in the flow path 17 is sucked out by a suction pump. This gradually reduces the pressure in the space between the decorative sheet 3 and the vacuum forming die 13, and as shown in Figures 7 and 8, the decorative sheet 3 stretches and adheres closely to the surfaces of the main forming section 14 and the sub-forming section 15. Subsequently, the temperature of the decorative sheet 3 is lowered to solidify it. As a result, the decorative sheet 3 is formed into a shape corresponding to the surface shape of the vacuum forming die 13. Hereinafter, the molding of the decorative sheet 3 by the vacuum forming die 13 will also be referred to as "secondary molding". Note that primary and secondary molding may be performed in the same apparatus.

[0055] Next, the decorative sheet 3 is removed from the vacuum forming mold 13. Then, as shown in Figure 9, the unnecessary parts are removed from the decorative sheet 3 that has been removed from the vacuum forming mold 13. Through this process, the decorative sheet 3 is pre-formed.

[0056] Next, a decorative molded product 1 is manufactured using a pre-molded decorative sheet 3. First, an injection molding apparatus 20 is prepared as shown in Figure 10. The injection molding apparatus 20 has an injection mold 21. The injection mold 21 includes a first mold 21A and a second mold 21B. The first mold 21A and the second mold 21B can be separated from each other as shown in Figure 10 and can be brought close to each other as shown in Figure 11. As shown in Figure 11, a cavity 22 is formed between the first mold 21A and the second mold 21B in a closed state where the first mold 21A and the second mold 21B are in contact with each other. The injection mold 21 has a gate 23 leading to the cavity 22. The gate 23 is connected to a supply device for injection resin 2a (not shown). Injection resin 2a is supplied into the cavity 22 through the gate 23. The first mold 21A and the second mold 21B are heated and maintained at a high temperature by a heater (not shown).

[0057] As shown in Figure 11, the decorative sheet 3 is housed in the cavity 22 within the injection molding die 21. In the illustrated example, the decorative sheet 3 is positioned in the cavity 22 such that the surface protective layer 6 is in contact with the second die 21B and the base sheet 4 is exposed inside the cavity 22. Next, as shown in Figure 12, the molten injection resin 2a is injected into the cavity 22 through the gate 23. The injection resin 2a is cooled inside the cavity 22 and solidifies by welding to the decorative sheet 3. From the solidified injection resin 2a, a molded part 2 is obtained that is bonded to the surface protective layer 6 of the decorative sheet 3.

[0058] Subsequently, as shown in Figure 13, the first mold 21A and the second mold 21B separate from each other, and the decorated molded product 1, including the decorative sheet 3 and the molded part 2, is removed from the cavity 22. In this way, the decorated molded product 1 is obtained.

[0059] Furthermore, the injection molding die 21 of the injection molding apparatus 20 may also serve as the vacuum forming die 13. In other words, the decorative molded product 1 may be manufactured by a method also known as the thermoject method. In this case, a gas flow path 17 may be formed in the second mold 21B of the injection molding die 21. In this case, the decorative sheet 3 stretched by the blow molding apparatus 12 can be placed so as to cover the surface defining the cavity 22 of the second mold 21B, and then the gas in the flow path 17 can be sucked out by a suction pump, thereby molding the decorative sheet 3 into a shape corresponding to the definition of the cavity 22 of the second mold 21B.

[0060] In this method for manufacturing the decorated molded product 1, the decorative sheet 3 is stretched overall by blow molding (primary molding) so that it can roughly conform to the decorated molded product 1, and then molded according to the shape of the decorated molded product 1 by vacuum forming (secondary molding). Therefore, compared to the case where a flat decorative sheet 3 is molded in a vacuum forming die 13, the distance between each part of the decorative sheet 3 and each part of the vacuum forming die 13 at the start of vacuum forming can be reduced. As a result, the difference in stretching of each part of the decorative sheet 3 can be reduced, and the risk of a part of the decorative sheet 3 being stretched excessively is suppressed. Therefore, the risk of the decorative sheet 3 tearing during vacuum forming, a significant change in the color of a part of the decorative sheet 3, or significant distortion of the pattern on the decorative sheet 3 is suppressed.

[0061] However, even with this method of molding the decorative sheet 3, the color of a part of the decorative sheet 3 may change significantly, or the pattern of the decorative sheet 3 may become significantly distorted. If the color of the decorative sheet 3 changes or the pattern becomes distorted due to significant stretching of the decorative sheet 3, it is conceivable that the color change and pattern distortion can be suppressed by modifying the surface shape of the decorative molded product 1 and the shape of the mold (vacuum forming die) 13. This makes it possible to bring the design applied to the decorative molded product 1 closer to the intended design. However, repeatedly remaking the mold 13 until a satisfactory decorative molded product is produced leads to an increase in the time and cost required to complete the decorative molded product 1.

[0062] Taking this into consideration, the manufacturing method of the decorated molded product 1 in this embodiment allows for the evaluation of the elongation of the decorative sheet 3 when producing the decorated molded product 1 without actually producing the mold 13 or the decorated molded product 1, by using the evaluation device 30 shown in Figure 14. The evaluation device 30 shown in Figure 14 comprises a storage unit 31, a primary molding condition determination unit 32, a primary elongation data generation unit 33, a mold data generation unit 34, and a secondary elongation data generation unit 35. In the example shown in Figure 14, the evaluation device 30 further comprises a secondary molding image data generation unit 36 ​​and a display unit 37.

[0063] The memory unit 31 stores molded product data representing the three-dimensional shape of the decorated molded product 1. The molded product data is, for example, three-dimensional CAD data. The molded product data is generated based on, for example, CAD data for designing the decorated molded product, or a model or image data representing the external shape of the decorated molded product. The molded product data may be generated by the person who evaluates the elongation of the decorative sheet 3, or it may be obtained from someone other than the person who performs the evaluation (for example, a customer who requests the manufacture of the decorated molded product 1).

[0064] Furthermore, the memory unit 31 stores image data representing the decorative sheet 3 before molding (hereinafter also referred to as "pre-molding image data"). The decorative sheet 3 represented by the pre-molding image data has a color and a pattern. The pre-molding image data is generated, for example, based on a sample of the decorative sheet 3. The pre-molding image data may be two-dimensional image data including the design of the decorative sheet 3, or it may be three-dimensional image data including the design and surface structure of the decorative sheet 3. The pre-molding image data may be generated by the person evaluating the elongation of the decorative sheet 3, or it may be obtained from a person other than the person performing the evaluation (for example, a supplier of the decorative sheet 3).

[0065] The primary molding condition determination unit 32 provisionally determines the conditions for primary molding. More specifically, the primary molding condition determination unit 32 provisionally determines the conditions for primary molding so that the decorative sheet 3 after primary molding roughly conforms to the shape of the decorative molded product 1. The primary molding condition determination unit 32 provisionally determines the conditions for primary molding based on the molded product data in the storage unit 31. Of course, the primary molding condition determination unit 32 may also provisionally determine the conditions for primary molding based on the mold data generated by the mold data generation unit 34, which will be described later. If the primary molding is blow molding, the conditions for primary molding provisionally determined by the primary molding condition determination unit 32 are, for example, the duration of blowing gas from the blow molding apparatus 12 onto the decorative sheet 3, the flow rate and velocity of the gas blown from the blow molding apparatus 12 onto the decorative sheet 3, the temperature of the decorative sheet 3 during primary molding, the planar shape of the clamp 10, etc.

[0066] The primary elongation data generation unit 33 calculates the elongation of each part of the decorative sheet 3 after primary molding relative to the decorative sheet 3 before molding, based on the primary molding conditions provisionally determined by the primary molding condition determination unit 32. The primary elongation data generation unit 33 stores the data representing the calculated elongation of each part of the decorative sheet 3 after primary molding as primary elongation data.

[0067] In the illustrated example, the primary elongation data generation unit 33 generates primary elongation display image data that visually represents the correspondence between the elongation of each part of the decorative sheet 3 before molding and the elongation of each part of the decorative sheet 3 after primary molding, based on the primary elongation data. The primary elongation display image data may represent the elongation of each part of the decorative sheet 3 represented by the primary elongation data using colors corresponding to the magnitude of the elongation. In this case, the primary elongation display image data may include a chart showing the correspondence between the magnitude of the elongation and the color. Alternatively, the primary elongation display image data may represent the elongation of each part of the decorative sheet 3 represented by the primary elongation data using line distortions corresponding to the magnitude of the elongation.

[0068] The mold data generation unit 34 generates mold data representing the three-dimensional shape of the mold that has been provisionally determined as the vacuum forming mold 13 used for secondary molding of the decorative sheet 3, based on the molded product data stored in the storage unit 31. For example, if the molded product data represents a three-dimensional shape as shown in Figure 1, mold data representing the shape of the mold 13 shown in Figure 6 is generated based on the molded product data. The mold data includes data relating to the area corresponding to the main molding section 14 and data relating to the area corresponding to the sub-molding section 15. As described above, the main molding section 14 is the part of the vacuum forming mold 13 that corresponds to the decorative molded product 1. By including data relating to areas other than the area corresponding to the decorative molded product in the mold data, the elongation of each part of the decorative sheet 3 when molded with the mold represented by the mold data can be evaluated with greater accuracy. The mold data is, for example, three-dimensional CAD data.

[0069] The secondary elongation data generation unit 35 calculates the elongation of each part of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding. The secondary elongation data generation unit 35 stores the calculated data representing the elongation of each part of the decorative sheet 3 after secondary molding as secondary elongation data. The secondary elongation data generation unit 35 calculates the elongation of each part of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding when the decorative sheet 3 after primary molding is secondarily molded with a provisionally determined mold 13. The secondary elongation data generation unit 35 generates secondary elongation data based on the primary elongation data generated by the primary elongation data generation unit 33 and the mold data generated by the mold data generation unit 34.

[0070] In the illustrated example, the secondary elongation data generation unit 35 generates secondary elongation display image data that visually represents the correspondence between the elongation of each part of the decorative sheet 3 before molding and each part of the decorative sheet 3 after secondary molding, based on the secondary elongation data. The secondary elongation display image data may represent the elongation of each part of the decorative sheet 3 represented by the secondary elongation data using colors corresponding to the magnitude of the elongation. In this case, the secondary elongation display image data may include a chart showing the correspondence between the magnitude of the elongation and the color. Alternatively, the secondary elongation display image data may represent the elongation of each part of the decorative sheet 3 represented by the secondary elongation data using line distortion (for example, distortion of lines forming a grid) corresponding to the magnitude of the elongation.

[0071] The post-secondary molding image data generation unit 36 ​​generates post-secondary molding image data representing the decorative sheet 3 after post-secondary molding, based on the post-secondary elongation data generated by the post-secondary elongation data generation unit 35 and the pre-molding image data stored in the storage unit 31. The post-secondary molding image data may include data relating to the region molded by the main molding unit 14 and data relating to the region molded by the sub-molding unit 15 of the provisionally determined molding die 13, or it may include only data relating to the region molded by the main molding unit 14.

[0072] Image data after secondary molding may be generated, for example, by deforming the pattern of the decorative sheet 3 before molding, as represented by the pre-molding image data, according to the stretch of each part of the decorative sheet 3 represented by the secondary stretch data (for example, by enlarging the pattern of the areas of the decorative sheet 3 that have greater stretch than the pattern of the decorative sheet 3 represented by the pre-molding image data). Alternatively, image data after secondary molding may be generated, for example, by changing the color of the decorative sheet 3 before molding, as represented by the pre-molding image data, according to the stretch of each part of the decorative sheet 3 represented by the secondary stretch data (for example, by changing the color of the areas of the decorative sheet 3 that have greater stretch to a lighter color than the color of the decorative sheet 3 represented by the pre-molding image data).

[0073] Furthermore, if the decorative sheet 3 represented by the pre-molding image data has an embossed surface and a matte texture, or if the decorative sheet 3 is made of a material that reduces the gloss of its surface (for example, a material with a matte texture), the post-secondary molding image data may be generated so that the areas of the decorative sheet 3 with greater elongation appear to have a higher gloss than the areas with less elongation.

[0074] Furthermore, the phenomenon of the decorative sheet 3 stretching can also be understood as the phenomenon of the film thickness of the decorative sheet 3 becoming thinner. For example, if the decorative sheet 3 represented in the pre-molding image data is made of a light-transmitting material, the post-secondary molding image data may be generated so that the areas of the decorative sheet 3 with greater stretch appear brighter than the areas with less stretch.

[0075] Furthermore, if the decorative sheet 3 represented by the pre-molding image data has multiple light-transmitting holes formed at a uniform density in a plan view of the decorative sheet 3, then the opening area of ​​the light-transmitting holes in the highly elongated region of the decorative sheet 3 is considered to be larger than the opening area of ​​the light-transmitting holes in the less elongated region. In this case, the image data after secondary molding may be generated such that the highly elongated region of the decorative sheet 3 appears brighter than the less elongated region.

[0076] Alternatively, if the decorative sheet 3 represented by the pre-molding image data has multiple permeable holes that promote light transmission, formed at a uniform density in a plan view of the decorative sheet 3, then it is conceivable that the density of permeable holes in the highly elongated region of the decorative sheet 3 will be lower than the density of permeable holes in the less elongated region. In this case, the image data after secondary molding may be generated such that the highly elongated region of the decorative sheet 3 appears darker than the less elongated region.

[0077] The display unit 37 receives input from the secondary elongation data generation unit 35 and displays secondary elongation display image data. The display unit 37 also receives input from the secondary molding image data generation unit 36 ​​and displays secondary molding image data. The display unit 37 may also receive input from the primary elongation data generation unit 33 and display primary elongation data.

[0078] The display unit 37 shows secondary elongation display image data, making it easy to evaluate the elongation of each part of the decorative sheet 3 that has been further secondary-molded after primary molding. Furthermore, based on the secondary elongation display image data displayed on the display unit 37, it is possible to determine whether the provisionally determined mold is suitable as a mold (vacuum forming mold) 13 for secondary molding. If necessary, the design of the provisionally determined mold 13 can be modified taking into account the secondary elongation display image data displayed on the display unit 37.

[0079] Furthermore, by displaying primary elongation display image data on the display unit 37, it is possible to determine whether the primary molding conditions are appropriate or not. Also, if necessary, the provisionally determined primary molding conditions can be changed considering the primary elongation display image data. Note that whether the primary molding conditions are appropriate or not may also be determined based on the secondary elongation display image data displayed on the display unit 37. Also, if necessary, the provisionally determined primary molding conditions can be changed considering the secondary elongation display image data.

[0080] Furthermore, since the image data after secondary molding is displayed on the display unit 37, it is easy to understand the changes in the color and pattern of the decorative sheet 3 after secondary molding. Also, if necessary, the design of the provisionally determined mold 13 can be changed, the provisionally determined primary molding conditions can be changed, the color and pattern of the decorative sheet 3 can be changed, and the positional relationship between the decorative sheet 3 and the mold 13 can be changed, taking into account the image data after secondary molding.

[0081] Here, even with decorative sheets molded using the same mold, the color change of the decorative sheet after molding compared to the decorative sheet before molding is more easily perceived than that of the decorative sheet before molding, depending on the color of the decorative sheet. For example, if the color of the decorative sheet before molding is dark, and a part of the decorative sheet is significantly stretched by molding, observers tend to easily notice the color change of that part of the decorative sheet after molding compared to the decorative sheet before molding. On the other hand, if the color of the decorative sheet before molding is light, even if a part of the decorative sheet is significantly stretched by molding, observers tend to be less likely to notice the color change of that part of the decorative sheet after molding compared to the decorative sheet before molding. Therefore, if the color change of the decorative sheet after molding compared to the decorative sheet before molding is perceived by the secondary molding image data, it is advisable to consider changing to a lighter-colored decorative sheet 3.

[0082] Furthermore, even with decorative sheets molded using the same mold, the degree of deformation of the pattern on the decorative sheet after molding relative to the pre-molding sheet varies depending on the pattern of the decorative sheet. For example, if the pre-molding decorative sheet has a pattern composed of a regular two-dimensional arrangement, such as a mesh pattern, observers tend to easily notice the deformation of the pattern on the post-molding decorative sheet relative to the pre-molding sheet if a portion of the decorative sheet is significantly stretched by molding. On the other hand, if the pre-molding decorative sheet has a pattern that is difficult to grasp at first glance, such as a wood grain pattern, observers tend to be less likely to notice the deformation of the pattern on the post-molding decorative sheet relative to the pre-molding sheet, even if a portion of the decorative sheet is significantly stretched by molding. Therefore, if the deformation of the pattern on the post-molding decorative sheet relative to the pre-molding decorative sheet is perceptible from the secondary post-molding image data, it will be considered to change to decorative sheet 3 with a pattern that is difficult to grasp in terms of regularity.

[0083] Furthermore, even with decorative sheets molded using the same mold, the degree of deformation of the pattern on the decorative sheet after molding compared to the pre-molding sheet, as perceived by the observer, may differ depending on the positional relationship between the pattern on the decorative sheet and the mold during molding. For example, consider the case where the pattern on the decorative sheet is a striped pattern composed of multiple lines. In this case, if the lines constituting the striped pattern extend over a significantly stretched area of ​​the decorative sheet, the observer tends to easily notice the deformation of the pattern on the decorative sheet after molding compared to the pre-molding sheet. On the other hand, if the lines constituting the striped pattern do not extend over a significantly stretched area of ​​the decorative sheet, the observer tends to have difficulty noticing the deformation of the pattern on the decorative sheet after molding compared to the pre-molding sheet. Therefore, if the deformation of the pattern on the decorative sheet after molding compared to the pre-molding sheet is perceived by the secondary post-molding image data, it is advisable to consider changing the positional relationship between the decorative sheet 3 and the mold.

[0084] The display unit 37 may display the image data after secondary molding in translation, rotation, enlargement, and / or reduction, according to the request of the person performing the overall evaluation (for example, by operating an input means such as a keyboard or mouse (not shown)). This allows the decorative sheet 3 to be observed in the same way as when actually holding and observing the decorated molded product 1.

[0085] Next, with reference to Figure 15A, a method for evaluating the elongation of the decorative sheet 3 using the evaluation device 30 shown in Figure 14 and a method for manufacturing the decorative molded product 1 will be described.

[0086] First, molded product data and pre-molding image data are generated or acquired and stored in the storage unit 31 (step S1). Next, the primary molding condition determination unit 32 provisionally determines the primary molding conditions based on the molded product data in the storage unit 31 (step S2). Next, the primary elongation data generation unit 33 generates primary elongation data based on the provisionally determined primary molding conditions (step S3).

[0087] Next, the mold 13 is tentatively determined based on the molded product data (step S4). Then, the mold data generation unit 34 generates mold data representing the three-dimensional shape of the tentatively determined mold 13 (step S5).

[0088] Next, the secondary elongation data generation unit 35 generates secondary elongation data and secondary elongation display image data based on the primary elongation data generated by the primary elongation data generation unit 33 and the mold data generated by the mold data generation unit 34, and displays the secondary elongation display image data on the display unit 37 (step S6).

[0089] Next, the elongation of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding is evaluated based on the secondary elongation display image data displayed on the display unit 37 (step S7). In step S7, if the elongation of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding is below a threshold (YES), the secondary molding image data generation unit 36 ​​generates secondary molding image data representing the decorative sheet 3 after secondary molding based on the secondary elongation data and the pre-molding image data, and displays it on the display unit 37 (step S8).

[0090] Next, based on the image data after secondary molding displayed on the display unit 37, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding section 14 of the vacuum forming die 13) is performed (step S9). The overall evaluation includes an evaluation of the color change and pattern deformation of the decorative sheet 3 in each part of the decorative sheet 3. The overall evaluation may be performed by someone other than the person who evaluated the elongation of the decorative sheet 3 in step S7 (for example, the customer who requested the production of the decorative molded product 1). If the decorative sheet 3 represented by the image data after secondary molding is approved ("Yes" in step S9), it is decided to produce the decorative molded product 1 by adopting the primary molding conditions provisionally determined in step S2 and the mold 13 provisionally determined in step S4 (step S10). Then, the determined mold 13 is produced. After that, the decorative sheet 3 represented by the image data before molding is primary molded under the determined primary molding conditions, and the primary molded decorative sheet 3 is secondary molded using the produced mold 13 to produce the decorative molded product 1.

[0091] If, in step S7, the elongation of any part of the decorative sheet 3 after secondary molding is greater than the threshold ("No" in step S7), or if, in step S9, the image data after secondary molding is not approved ("No" in step S9), the process returns to step S4 to perform a provisional determination of the mold 13 again. Specifically, the shape of the mold 13 that was provisionally determined in step S4 is changed or modified. Then, based on the changed or modified mold 13, the process from step S5 onward is repeated.

[0092] Furthermore, various modifications can be made to the embodiment described above.

[0093] <Variation 1-1> For example, in the example shown in Figure 15A, the elongation of the decorative sheet 3 is evaluated in step S7 based on secondary elongation display image data, but this is not limited to this. The elongation of the decorative sheet 3 may also be evaluated based on secondary elongation data.

[0094] <Variation 1-2> Furthermore, the evaluation of the elongation of the decorative sheet 3 in step S7 may be performed by considering the average, deviation, maximum, or ratio of the maximum and minimum elongations of each part of the decorative sheet 3. For example, in step S7, if the deviation of the elongation of the decorative sheet 3 after secondary molding compared to the decorative sheet 3 before molding is below a threshold, the process may proceed to step S8 to generate image data after secondary molding. Alternatively, in step S7, if the deviation of the elongation of the decorative sheet 3 after secondary molding compared to the decorative sheet 3 before molding is greater than a threshold, the process may return to step S4 to perform a preliminary determination of the molding die again.

[0095] <Variation 1-3> Furthermore, as shown in Figure 15B, if the elongation of the decorative sheet 3 in step S7 is greater than the threshold ("No" in step S7), the process may return to step S2 to re-determine the conditions for primary molding. Specifically, the conditions for primary molding that were tentatively determined in step S2 may be changed or modified. Alternatively, if the result in step S7 is "No", the pre-molding image data from step S1 may be changed or modified. For example, the color of the decorative sheet 3 represented by the pre-molding image data may be changed to a lighter color, or the pattern may be changed to a pattern that is difficult to grasp the regularity of at a glance.

[0096] <Variation 1-4> Furthermore, as shown in Figure 15C, if the image data after secondary molding is not approved in step S9 ("No" in step S9), the process may return to step S2 and perform a provisional determination of the primary molding conditions again. Specifically, the primary molding conditions that were provisionally determined in step S2 may be changed or modified. Alternatively, if the answer in step S9 is "No", the pre-molding image data in step S1 may be changed or modified.

[0097] In the example shown in Figure 15C, if the elongation of the decorative sheet 3 is greater than the threshold in step S7 ("No" in step S7), the process returns to step S2 to re-determine the conditions for primary molding. In another modified example, if the elongation of the decorative sheet 3 is greater than the threshold in step S7 ("No" in step S7), the process returns to step S4 to re-determine the molding die, and if the image data after secondary molding is not approved in step S9 ("No" in step S9), the process returns to step S2 to re-determine the conditions for primary molding.

[0098] <Variation 1-5> The examples shown in Figures 15A to 15C describe a case where one secondary elongation data is generated for one pre-molding image data in step S8, but the method is not limited to this.

[0099] <Variation 1-5-1> In the manufacturing method shown in Figure 16A, first, molded product data and pre-molding image data are generated or acquired and stored in the storage unit 31 (step S11). Next, the primary molding condition determination unit 32 provisionally determines the primary molding conditions based on the molded product data in the storage unit 31 (step S12). For example, the primary molding condition determination unit 32 provisionally determines condition A as the primary molding condition. For example, condition A is defined as the time duration for blowing gas from the blow molding apparatus 12 onto the decorative sheet 3 being A1 seconds, and the flow rate of the gas blown from the blow molding apparatus 12 onto the decorative sheet 3 being A2 m 3 This is what is meant by / s.

[0100] Next, the primary elongation data generation unit 33 generates primary elongation data based on the provisionally determined primary molding conditions (step S13).

[0101] Next, multiple molds 13 are tentatively determined based on the molded product data (step S14). For example, molds 13C and 13D, which have different surface shapes, are tentatively determined.

[0102] Next, the mold data generation unit 34 generates mold data representing the three-dimensional shape of each provisionally determined mold 13 (step S15). In step S15, multiple mold data sets are generated. For example, mold data set 13CD representing the three-dimensional shape of mold 13C and mold data set 13DD representing the three-dimensional shape of mold 13D are generated.

[0103] Next, the secondary elongation data generation unit 35 generates multiple secondary elongation data and multiple secondary elongation display image data based on the primary elongation data generated in the primary elongation data generation unit 33 and the mold data generated in the mold data generation unit 34, and displays the multiple secondary elongation data or multiple secondary elongation display image data on the display unit 37 (step S16). For example, secondary elongation data and multiple secondary elongation display image data are generated based on the primary elongation data generated in step S13 and the mold data 13CD generated in step S15. Alternatively, secondary elongation data and multiple secondary elongation display image data are generated based on the primary elongation data generated in step S13 and the mold data 13DD generated in step S15.

[0104] Next, based on the multiple secondary elongation data or secondary elongation display image data displayed on the display unit 37, the elongation of each decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding is evaluated, and one secondary elongation data or one secondary elongation display image data is selected (step S17). In step S17, one secondary elongation data or one secondary elongation display image data is selected by considering the average, deviation, maximum, or ratio of the maximum and minimum elongation of each part of the decorative sheet 3.

[0105] Next, the post-secondary molding image data generation unit 36 ​​generates post-secondary molding image data based on the selected post-secondary elongation data or post-secondary elongation display image data and pre-molding image data, and displays it on the display unit 37 (step S18).

[0106] Next, based on the image data after secondary molding displayed on the display unit 37, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding section 14 of the vacuum forming die 13) is performed (step S19). If the decorative sheet 3 represented by the image data after secondary molding is approved ("Yes" in step S19), it is decided to produce the decorative molded product 1 by adopting the primary molding conditions and mold 13 corresponding to the secondary elongation data or secondary elongation display image data selected in step S17 (step S20). Then, the determined mold 13 is manufactured. After that, the decorative sheet 3 represented by the image data before molding is primary molded under the determined primary molding conditions, and the primary molded decorative sheet 3 is secondary molded using the manufactured mold 13 to produce the decorative molded product 1.

[0107] If the image data after secondary molding is not approved in step S19 ("No" in step S19), the process returns to step S14 to perform a provisional determination of the mold 13 again. For example, a mold with a different shape from molds 13C and 13D is provisionally determined as the mold 13 for secondary molding. Then, the process from step S15 onwards is repeated based on the newly provisionally determined mold 13.

[0108] If the image data after secondary molding is not approved in step S19 ("No" in step S19), the process may return to step S12 and tentatively determine the conditions for one molding again, as shown in Figure 16B. For example, a condition B different from condition A may be tentatively determined as the conditions for one molding. For example, condition B is defined as the time duration for blowing gas from the blow molding apparatus 12 onto the decorative sheet 3 being B1 seconds, and the flow rate of the gas blown from the blow molding apparatus 12 onto the decorative sheet 3 being B2 m 3 This is set to / s. After that, the process from step S13 onwards is repeated based on the newly determined primary molding conditions. If the decorative sheet 3 is primary molded under different conditions, the shape of the decorative sheet 3 after primary molding will be different, and the elongation of each part of the decorative sheet 3 after secondary molding will also be different.

[0109] <Variation 1-5-2> In the manufacturing method shown in Figure 17A, first, molded product data and pre-molding image data are generated or acquired and stored in the storage unit 31 (step S21).

[0110] Next, the primary molding condition determination unit 32 provisionally determines multiple primary molding conditions based on the molded product data in the storage unit 31 (step S22). For example, the primary molding condition determination unit 32 provisionally determines two different conditions, A and B.

[0111] Next, the primary elongation data generation unit 33 generates primary elongation data based on the provisionally determined primary molding conditions (step S23). The primary elongation data generation unit 33 generates multiple primary elongation data sets. For example, it generates primary elongation data AD representing the elongation of each part of the decorative sheet 3 that was primary molded under condition A, and primary elongation data BD representing the elongation of each part of the decorative sheet 3 that was primary molded under condition B.

[0112] Next, the mold 13 is tentatively determined based on the molded product data (step S24). In the example shown in Figure 17, a single mold 13 is tentatively determined. For example, mold 13C is tentatively determined as the mold for secondary molding. Next, the mold data generation unit 34 generates mold data representing the three-dimensional shape of the tentatively determined mold 13 (step S25).

[0113] Next, the secondary elongation data generation unit 35 generates a plurality of secondary elongation data and a plurality of secondary elongation display image data based on the primary elongation data generated in the primary elongation data generation unit 33 and the mold data generated in the mold data generation unit 34, and displays the plurality of secondary elongation data or the plurality of secondary elongation display image data on the display unit 37 (step S26). For example, secondary elongation data or secondary elongation display image data is generated and displayed on the display unit 37 based on the primary elongation data AD generated in step S23 and the mold data generated in step S25. Alternatively, secondary elongation data or secondary elongation display image data is generated and displayed on the display unit 37 based on the primary elongation data BD generated in step S23 and the mold data generated in step S25.

[0114] Next, based on the multiple secondary elongation data or secondary elongation display image data displayed on the display unit 37, the elongation of each decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding is evaluated, and one secondary elongation data or one secondary elongation display image data is selected (step S27). In step S27, one secondary elongation data or one secondary elongation display image data is selected by considering the average, deviation, maximum, or ratio of the maximum and minimum elongations of each part of the decorative sheet 3.

[0115] Next, the post-secondary molding image data generation unit 36 ​​generates post-secondary molding image data based on the selected post-secondary elongation data or post-secondary elongation display image data and pre-molding image data, and displays it on the display unit 37 (step S28).

[0116] Next, based on the image data after secondary molding displayed on the display unit 37, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding section 14 of the vacuum forming die 13) is performed (step S29). If the decorative sheet 3 represented by the image data after secondary molding is approved ("Yes" in step S29), it is decided to produce the decorative molded product 1 by adopting the primary molding conditions and mold 13 corresponding to the secondary elongation data or secondary elongation display image data selected in step S27 (step S30). Then, the determined mold 13 is manufactured. After that, the decorative sheet 3 represented by the image data before molding is primary molded under the determined primary molding conditions, and the primary molded decorative sheet 3 is secondary molded using the manufactured mold 13 to produce the decorative molded product 1.

[0117] If the image data after secondary molding is not approved in step S29 ("No" in step S29), the process returns to step S24 to perform a provisional determination of the mold 13 again. For example, mold 13D is provisionally determined as the mold 13 for secondary molding. Then, the process from step S25 onwards is repeated based on the newly provisionally determined mold 13D.

[0118] If the image data after secondary molding is not approved in step S29 ("No" in step S29), the process may return to step S22 and perform a provisional determination of the molding conditions again, as shown in Figure 17B. For example, different conditions from conditions A and B may be provisionally determined as the conditions for one molding. After that, the process from step S23 onwards is repeated based on the newly provisionally determined primary molding conditions.

[0119] <Modified example 1-5-3> In the manufacturing method shown in Figure 18A, first, molded product data and pre-molding image data are generated or acquired and stored in the storage unit 31 (step S31).

[0120] Next, the primary molding condition determination unit 32 provisionally determines multiple primary molding conditions based on the molded product data in the storage unit 31 (step S32). For example, the primary molding condition determination unit 32 provisionally determines two different conditions, A and B.

[0121] Next, the primary elongation data generation unit 33 generates primary elongation data based on the provisionally determined primary molding conditions (step S33). The primary elongation data generation unit 33 generates multiple primary elongation data sets. For example, it generates primary elongation data AD representing the elongation of each part of the decorative sheet 3 that was primary molded under condition A, and primary elongation data BD representing the elongation of each part of the decorative sheet 3 that was primary molded under condition B.

[0122] Next, multiple molds 13 are tentatively determined based on the molded product data (step S34). For example, molds 13C and 13D, which have different surface shapes, are tentatively determined.

[0123] Next, the mold data generation unit 34 generates mold data representing the three-dimensional shape of each provisionally determined mold 13 (step S35). In step S35, multiple mold data sets are generated. For example, mold data set 13CD representing the three-dimensional shape of mold 13C and mold data set 13DD representing the three-dimensional shape of mold 13D are generated.

[0124] Next, the secondary elongation data generation unit 35 generates a plurality of secondary elongation data and a plurality of secondary elongation display image data based on the primary elongation data generated in the primary elongation data generation unit 33 and the mold data generated in the mold data generation unit 34, and displays the plurality of secondary elongation data or the plurality of secondary elongation display image data on the display unit 37 (step S36). For example, secondary elongation data or secondary elongation display image data is generated and displayed on the display unit 37 based on the primary elongation data AD generated in step S33 and the mold data 13CD generated in step S35. Also, secondary elongation data or secondary elongation display image data is generated and displayed on the display unit 37 based on the primary elongation data AD generated in step S33 and the mold data 13DD generated in step S35. Also, secondary elongation data or secondary elongation display image data is generated and displayed on the display unit 37 based on the primary elongation data BD generated in step S33 and the mold data 13CD generated in step S35. Furthermore, based on the primary elongation data BD generated in step S33 and the mold data 13DD generated in step S35, secondary elongation data or secondary elongation display image data is generated and displayed on the display unit 37.

[0125] Next, based on the multiple secondary elongation data or secondary elongation display image data displayed on the display unit 37, the elongation of each decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding is evaluated, and one secondary elongation data or one secondary elongation display image data is selected (step S37). In step S37, one secondary elongation data or one secondary elongation display image data is selected by considering the average, deviation, maximum, or ratio of the maximum and minimum elongations of each part of the decorative sheet 3.

[0126] Next, the post-secondary molding image data generation unit 36 ​​generates post-secondary molding image data based on the selected post-secondary elongation data or post-secondary elongation display image data and pre-molding image data, and displays it on the display unit 37 (step S38).

[0127] Next, based on the post-secondary molding image data displayed on the display unit 37, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding section 14 of the vacuum forming die 13) is performed (step S39). If the decorative sheet 3 represented by the post-secondary molding image data is approved ("Yes" in step S39), it is decided to produce the decorative molded product 1 by adopting the primary molding conditions and mold 13 corresponding to the secondary elongation data or secondary elongation display image data selected in step S37 (step S40). Then, the determined mold 13 is manufactured. After that, the decorative sheet 3 represented by the pre-molding image data is primary molded under the determined primary molding conditions, and the primary molded decorative sheet 3 is secondary molded using the manufactured mold 13 to produce the decorative molded product 1.

[0128] If the image data after secondary molding is not approved in step S39 ("No" in step S39), the process returns to step S34 to perform a provisional determination of the mold 13 again. For example, a mold 13 with a different surface shape from molds 13C and 13B is provisionally determined as the mold 13 for secondary molding. Then, the process from step S35 onwards is repeated based on the newly provisionally determined mold 13.

[0129] If the image data after secondary molding is not approved in step S39 ("No" in step S39), the process may return to step S32 and perform a provisional determination of the molding conditions again, as shown in Figure 18B. For example, conditions different from conditions A and B may be provisionally determined as the conditions for one molding. After that, the process from step S33 onwards is repeated based on the newly provisionally determined primary molding conditions.

[0130] The evaluation method according to the first embodiment described above is a method for evaluating the elongation of the molded decorative sheet 3 relative to the molded decorative sheet 3 when manufacturing a decorative molded product 1 including the molded decorative sheet 3. This method comprises the following steps. • A process for generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. • A step of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. • A step of provisionally determining the mold 13 to be used for secondary molding of the decorative sheet 3 based on the molded product data. • A process for generating mold data representing the three-dimensional shape of the provisionally determined mold 13. • A step in which the conditions for primary molding are provisionally determined based on molded product data or mold data. Here, primary molding is performed to stretch the decorative sheet 3 before molding so that it conforms to the decorative molded product 1. • Primary elongation data generation process for generating primary elongation data. Here, primary elongation data is data that shows the elongation of each part of the decorative sheet 3 after primary molding relative to the decorative sheet 3 before molding, calculated based on the provisionally determined primary molding conditions. • A secondary elongation data generation process for generating secondary elongation data. Here, secondary elongation data is data that shows the elongation of each part of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding, calculated based on primary elongation data and molding die data. The secondary elongation data shows the elongation of each part of the decorative sheet 3 after secondary molding when the decorative sheet 3 after primary molding is secondarily molded using a provisionally determined molding die 13.

[0131] The evaluation method according to the modified version of the first embodiment described above is a method for evaluating the elongation of the molded decorative sheet 3 relative to the molded decorative sheet 3 when manufacturing a decorative molded product 1 including the molded decorative sheet 3. This method comprises the following steps. • A process for generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. • A step of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. A process of provisionally determining multiple molds 13 to be used for secondary molding of the decorative sheet 3 based on the molded product data. • A process for generating mold data representing the three-dimensional shape of each of the tentatively determined molds 13. • A step in which the conditions for primary molding are provisionally determined based on molded product data or mold data. Here, primary molding is performed to stretch the decorative sheet 3 before molding so that it conforms to the decorative molded product 1. • Primary elongation data generation process for generating primary elongation data. Here, primary elongation data is data that shows the elongation of each part of the decorative sheet 3 after primary molding relative to the decorative sheet 3 before molding, calculated based on the provisionally determined primary molding conditions. • A secondary elongation data generation process that generates multiple secondary elongation data. Here, the secondary elongation data is data that shows the elongation of each part of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding, calculated based on the primary elongation data and each molding die data. The secondary elongation data shows the elongation of each part of the decorative sheet 3 after secondary molding when the decorative sheet 3 after primary molding is secondarily molded using each of the provisionally determined molding dies 13.

[0132] An evaluation method based on other modifications of the first embodiment described above is a method for evaluating the elongation of the molded decorative sheet 3 relative to the molded decorative sheet 3 when manufacturing a decorative molded product 1 including the molded decorative sheet 3. This method comprises the following steps. • A process for generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. • A step of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. • A step of provisionally determining the mold 13 to be used for secondary molding of the decorative sheet 3 based on the molded product data. • A process for generating mold data representing the three-dimensional shape of the provisionally determined mold 13. • A step in which multiple conditions for primary molding are tentatively determined based on molded product data or mold data. Here, primary molding is performed to stretch the decorative sheet 3 before molding so that it conforms to the decorative molded product 1. • A primary elongation data generation process that generates multiple primary elongation data. Here, each primary elongation data is data that shows the elongation of each part of the decorative sheet 3 after primary molding relative to the decorative sheet 3 before molding, calculated based on each of the provisionally determined primary molding conditions. • A secondary elongation data generation process that generates multiple secondary elongation data. Here, each secondary elongation data is calculated based on each primary elongation data and molding die data, and shows the elongation of each part of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding. The secondary elongation data shows the elongation of each part of the decorative sheet 3 after secondary molding when the decorative sheet 3 after primary molding is secondarily molded with the provisionally determined molding die 13 under each provisionally determined condition.

[0133] An evaluation method based on other modifications of the first embodiment described above is a method for evaluating the elongation of the molded decorative sheet 3 relative to the molded decorative sheet 3 when manufacturing a decorative molded product 1 including the molded decorative sheet 3. This method comprises the following steps. • A process for generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. • A step of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. A process of provisionally determining multiple molds 13 to be used for secondary molding of the decorative sheet 3 based on the molded product data. • A process for generating mold data representing the three-dimensional shape of each of the tentatively determined molds 13. • A step in which multiple conditions for primary molding are tentatively determined based on molded product data or mold data. Here, primary molding is performed to stretch the decorative sheet 3 before molding so that it conforms to the decorative molded product 1. • A primary elongation data generation process that generates multiple primary elongation data. Here, each primary elongation data is data that shows the elongation of each part of the decorative sheet 3 after primary molding relative to the decorative sheet 3 before molding, calculated based on each of the provisionally determined primary molding conditions. • A secondary elongation data generation process that generates multiple secondary elongation data. Here, each secondary elongation data is data that shows the elongation of each part of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding, calculated based on each primary elongation data and each molding die data. The secondary elongation data shows the elongation of each part of the decorative sheet 3 after secondary molding when the decorative sheet 3 after primary molding is secondarily molded with each of the provisionally determined molding dies 13 under each provisionally determined condition.

[0134] These evaluation methods allow for efficient design of the mold 13, determination of primary molding conditions, and determination of the color and pattern of the decorative sheet 3. In other words, these evaluation methods allow for evaluation of the elongation of each part of the decorative sheet 3 when producing the decorative molded product 1, without actually manufacturing the mold 13 or performing primary or secondary molding of the decorative sheet 3. Therefore, the effort required for prototyping the decorative molded product 1 is significantly reduced, and the time and cost required to complete the decorative molded product 1 are significantly reduced.

[0135] The evaluation method according to the first embodiment and its modified form described above further comprises the following steps. A process for generating secondary elongation display image data that visually represents the correspondence between the elongation of each part of the decorative sheet 3 before molding and each part of the decorative sheet 3 after secondary molding, based on secondary elongation data.

[0136] In this case, the correspondence between the elongation of each part of the decorative sheet 3 before molding and each part of the decorative sheet 3 after secondary molding can be easily understood.

[0137] The evaluation method according to the first embodiment and its modified form described above further comprises the following steps. A process for generating primary elongation display image data that visually represents the correspondence between the elongation of each part of the decorative sheet 3 before molding and the elongation of each part of the decorative sheet 3 after primary molding, based on primary elongation data.

[0138] In this case, the correspondence between the elongation of each part of the decorative sheet 3 before molding and each part of the decorative sheet 3 after primary molding can be easily grasped, making it easy to determine whether the primary molding conditions are appropriate.

[0139] The evaluation method according to the first embodiment and its modified form described above further comprises the following steps. A post-secondary molding image data generation process that generates post-secondary molding image data representing the decorative sheet 3 after secondary molding, based on secondary elongation data and pre-molding image data.

[0140] In this case, it is easy to perform an overall evaluation of the decorative sheet 3 after secondary molding. In particular, it is easy to grasp the color and pattern of the decorative sheet 3 after secondary molding.

[0141] <Second Embodiment> Next, a second embodiment of the present disclosure will be described. Figure 19 is a perspective view of a decorated molded product 1 according to the second embodiment. Figure 20 is a perspective view of a clamp 40 used in the manufacture of the decorated molded product 1 shown in Figure 19. Figures 21 to 24 are diagrams illustrating an example of a method for molding the decorative sheet 3 of the decorated molded product 1 shown in Figure 19. In the description of the second embodiment, parts similar to those in the first embodiment shown in Figures 1 to 18 are denoted by the same reference numerals, and detailed descriptions are omitted.

[0142] The decorated molded product 1 according to the second embodiment has a bent molded portion 2 and a decorative sheet 3 that covers the bent surface of the molded portion 2. The decorative sheet 3 is bent along the bent surface of the molded portion 2.

[0143] The clamp 40 shown in Figure 20 can hold the decorative sheet 3 in a bent state. More specifically, the clamp 40 can hold the decorative sheet 3 so that it bends to roughly conform to the shape of the decorative molded product 1 shown in Figure 19 (more specifically, to the shape of the decorative sheet 3 in the decorative molded product 1). In other words, the clamp 40 determines the bent shape of the decorative sheet 3 during molding. In the example shown in Figure 19, the clamp 40 is formed in an annular shape and holds the four sides of the decorative sheet 3, but it is not limited to this. For example, the clamp 40 may hold two opposing sides of the decorative sheet 3. In this case, the clamp 40 does not have to be formed in an annular shape.

[0144] Next, a method for pre-forming the decorative sheet 3 according to the second embodiment will be described. First, as shown in Figure 20, the edge of the decorative sheet 3 is held by the clamp 40. This holds the decorative sheet 3 in a bent state so that it can roughly conform to the decorative molded product 1 shown in Figure 19 (more specifically, to the shape of the decorative sheet 3 in the decorative molded product 1).

[0145] Next, as shown in Figure 21A or Figure 21B, the decorative sheet 3 held by the clamp 40 is heated and softened by the heater 11. The shape of the heater 11 may be flat, as shown in Figure 21A, or it may be curved to correspond to the curved shape of the decorative sheet 3, as shown in Figure 21B. If the heater 11 is flat, as shown in Figure 21A, the temperature of each part of the heater 11 may be adjusted according to the distance between the part of the heater 11 and the decorative sheet 3 so that the decorative sheet 3 reaches a uniform temperature throughout.

[0146] Next, as shown in Figure 22, the decorative sheet 3 is placed facing the vacuum forming die 13. The decorative sheet 3 is positioned to cover the main molding section 14 and the sub-molding section 15 of the vacuum forming die 13.

[0147] Next, the gas in the flow path 17 is sucked out by a suction pump. As a result, the space between the decorative sheet 3 and the vacuum forming die 13 is gradually depressurized, and as shown in Figure 23, the decorative sheet 3 stretches and adheres closely to the main forming section 14 and the sub-forming section 15. Subsequently, the temperature of the decorative sheet 3 is lowered to solidify it. As a result, the decorative sheet 3 is molded into a shape corresponding to the surface shape of the vacuum forming die 13.

[0148] Next, the decorative sheet 3 is removed from the vacuum forming mold 13. Then, as shown in Figure 24, the unnecessary parts are removed from the decorative sheet 3 that has been removed from the vacuum forming mold 13. Through this process, the decorative sheet 3 is vacuum formed.

[0149] To produce the decorated molded product 1 shown in Figure 19 using the molded decorative sheet 3, the decorative sheet 3 is placed in the mold corresponding to the decorated molded product 1 shown in Figure 19, and the molded part 2 is produced in the same manner as shown in Figures 10 to 13.

[0150] In this method for manufacturing the decorated molded product 1, the decorative sheet 3 is bent so as to roughly conform to the decorated molded product 1, and then formed to match the shape of the decorated molded product 1 by vacuum forming. Therefore, compared to the case where a flat decorative sheet 3 is formed in a vacuum forming die 13, the distance between each part of the decorative sheet 3 and each part of the vacuum forming die 13 at the start of vacuum forming can be reduced. As a result, the difference in elongation of each part of the decorative sheet 3 can be reduced, and the risk of a part of the decorative sheet 3 being excessively stretched is suppressed. Consequently, the risk of the decorative sheet 3 tearing during vacuum forming, a significant change in the color of a part of the decorative sheet 3, or significant distortion of the pattern on the decorative sheet 3 is suppressed.

[0151] However, even with this method of molding the decorative sheet 3, the color of a part of the decorative sheet 3 may change significantly, or the pattern of the decorative sheet 3 may become significantly distorted. If the color of the decorative sheet 3 changes or the pattern becomes distorted due to significant stretching of the decorative sheet 3, it is conceivable that the color change and pattern distortion can be suppressed by modifying the surface shape of the decorative molded product 1 and the shape of the molding die (vacuum forming mold) 13. This makes it possible to bring the design applied to the decorative molded product 1 closer to the intended design. However, repeatedly remaking the molding die 13 until a satisfactory decorative molded product 1 is produced leads to an increase in the time and cost required to complete the decorative molded product 1.

[0152] Taking this into consideration, the manufacturing method of the decorated molded product 1 in the second embodiment allows for the evaluation of the elongation of the decorative sheet 3 when producing the decorated molded product 1 without producing a mold 13 or the decorated molded product 1, by using the evaluation device 50 shown in Figure 25. The evaluation device 50 shown in Figure 25 includes a storage unit 51, a mold data generation unit 52, a clamp data generation unit 53, and an elongation data generation unit 54. In the example shown in Figure 25, the evaluation device 50 further includes a post-molding image data generation unit 55 and a display unit 56.

[0153] The memory unit 51 stores molded product data representing the three-dimensional shape of the decorated molded product 1. The molded product data is, for example, three-dimensional CAD data. The molded product data is generated based on, for example, CAD data for designing the decorated molded product, or a model or image data representing the external shape of the decorated molded product. The molded product data may be generated by the person who evaluates the elongation of the decorative sheet 3, or it may be obtained from someone other than the person who performs the evaluation (for example, a customer who requests the manufacture of the decorated molded product 1).

[0154] Furthermore, the memory unit 51 stores image data representing the decorative sheet 3 before molding (hereinafter also referred to as "pre-molding image data"). The decorative sheet 3 represented by the pre-molding image data has a color and a pattern. The pre-molding image data is generated, for example, based on a sample of the decorative sheet 3. The pre-molding image data may be two-dimensional image data including the design of the decorative sheet 3, or it may be three-dimensional image data including the design and surface structure of the decorative sheet 3. The pre-molding image data may be generated by the person evaluating the elongation of the decorative sheet 3, or it may be obtained from a person other than the person performing the evaluation (for example, a supplier of the decorative sheet 3).

[0155] The mold data generation unit 52 generates mold data representing the three-dimensional shape of the mold that has been provisionally determined as the vacuum forming mold 13 used for molding the decorative sheet 3, based on the molded product data stored in the storage unit 51. For example, if the molded product data represents a three-dimensional shape as shown in Figure 19, mold data representing the shape of the mold 13 shown in Figure 22 is generated based on the molded product data. The mold data includes data relating to the area corresponding to the main molding section 14 and data relating to the area corresponding to the sub-molding section 15. As described above, the main molding section 14 is the part of the vacuum forming mold 13 that corresponds to the decorative molded product 1. By including data relating to areas other than the area corresponding to the decorative molded product 1 in the mold data, the elongation of each part of the decorative sheet 3 when molded with the mold 13 represented by the mold data can be evaluated with greater accuracy. The mold data is, for example, three-dimensional CAD data.

[0156] The clamp data generation unit 53 provisionally determines the clamp 40 based on the mold data generated by the mold data generation unit 52, and generates clamp data representing the three-dimensional shape of the provisionally determined clamp 40. For example, if the mold data represents the three-dimensional shape of the mold 13 shown in Figure 22, clamp data representing the shape of the clamp 40 shown in Figure 20 is generated based on that mold data. The clamp data is, for example, three-dimensional CAD data.

[0157] The elongation data generation unit 54 calculates the elongation of each part of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding. The elongation data generation unit 54 stores the calculated data representing the elongation of each part of the decorative sheet 3 after molding as elongation data. The elongation data generation unit 54 calculates the elongation of each part of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when the decorative sheet 3, which is held and bent by the clamp 40, is molded with a provisionally determined mold 13. The elongation data generation unit 54 generates elongation data based on the clamp data generated by the clamp data generation unit 53 and the mold data generated by the mold data generation unit 52.

[0158] In the illustrated example, the stretch data generation unit 54 generates stretch display image data that visually represents the correspondence between the stretch of each part of the decorative sheet 3 before molding and the stretch of each part of the decorative sheet 3 after molding, based on the stretch data. The stretch display image data may represent the stretch of each part of the decorative sheet 3 represented by the stretch data using colors corresponding to the magnitude of the stretch. In this case, the stretch display image data may include a chart showing the correspondence between the magnitude of the stretch and the color. Alternatively, the stretch display image data may represent the stretch of each part of the decorative sheet 3 represented by the stretch data using line distortion (for example, distortion of lines forming a grid) corresponding to the magnitude of the stretch.

[0159] The post-molding image data generation unit 55 generates post-molding image data representing the decorative sheet 3 after secondary molding, based on the stretch data generated by the stretch data generation unit 54 and the pre-molding image data stored in the storage unit 51. The post-molding image data may include data relating to the region molded by the main molding unit 14 and data relating to the region molded by the sub-molding unit 15 of the provisionally determined molding die 13, or it may include only data relating to the region molded by the main molding unit 14.

[0160] The post-molding image data may be generated, for example, by deforming the pattern of the pre-molding decorative sheet 3 represented by the pre-molding image data according to the stretch of each part of the decorative sheet 3 represented by the stretch data (for example, by enlarging the pattern of the areas of the decorative sheet 3 that have greater stretch than the pattern of the decorative sheet 3 represented by the pre-molding image data). Alternatively, the post-molding image data may be generated, for example, by changing the color of the pre-molding decorative sheet 3 represented by the pre-molding image data according to the stretch of each part of the decorative sheet 3 represented by the stretch data (for example, by changing the color of the areas of the decorative sheet 3 that have greater stretch to a lighter color than the color of the decorative sheet 3 represented by the pre-molding image data).

[0161] Furthermore, if the decorative sheet 3 represented by the pre-molding image data has an embossed surface and a matte texture, or if the decorative sheet 3 is made of a material that reduces the gloss of its surface (for example, a material with a matte texture), the post-secondary molding image data may be generated so that the areas of the decorative sheet 3 with greater elongation appear to have a higher gloss than the areas with less elongation.

[0162] Furthermore, as described above, if the decorative sheet 3 represented by the pre-molding image data is made of a light-transmitting material, the post-secondary molding image data may be generated such that the areas of the decorative sheet 3 with greater elongation appear brighter than the areas with less elongation.

[0163] Furthermore, as described above, if the decorative sheet 3 represented by the pre-molding image data has multiple light-transmitting holes formed at a uniform density in a plan view of the decorative sheet 3, the post-secondary molding image data may be generated such that the areas of the decorative sheet 3 with greater elongation appear brighter than the areas with less elongation, or the areas of the decorative sheet 3 with greater elongation appear darker than the areas with less elongation.

[0164] The display unit 56 receives input from the elongation data generation unit 54 and displays elongation display image data. The display unit 56 also receives input from the post-molding image data generation unit 55 and displays post-secondary molding image data. The display unit 56 may also receive input from the clamp data generation unit 53 and display clamp data.

[0165] The display unit 56 shows elongation display image data, making it easy to evaluate the elongation of each part of the decorative sheet 3 after molding. Furthermore, based on the elongation display image data displayed on the display unit 56, it is possible to determine whether the provisionally determined mold is suitable as the mold (vacuum forming die) 13 for the decorative sheet 3. If necessary, the design of the provisionally determined mold can be modified considering the elongation display image data displayed on the display unit 56.

[0166] Furthermore, the display unit 56 shows the clamp data, allowing for a determination of whether the shape of the clamp 40 is appropriate. If necessary, the provisional conditions of the clamp 40 can be modified by considering the clamp data. Note that the appropriateness of the clamp 40 shape may also be determined based on the elongation display image data shown on the display unit 56. If necessary, the provisional conditions of the clamp 40 can also be modified by considering the elongation display image data.

[0167] Furthermore, the display unit 56 shows the post-molding image data, making it easy to understand the changes in the color and pattern of the decorative sheet 3 after molding. If necessary, the design of the provisionally determined mold 13 and clamp 40, the color and pattern of the decorative sheet 3, and the positional relationship between the decorative sheet 3 and the mold can be changed, taking the post-molding image data into consideration.

[0168] The display unit 56 may display the post-molding image data in translation, rotation, enlargement, and / or reduction mode according to the request of the person performing the overall evaluation (for example, by operating an input means such as a keyboard or mouse (not shown)). This allows the decorative sheet 3 to be observed in the same way as when actually holding and observing the decorated molded product 1.

[0169] Next, with reference to Figure 26A, a method for evaluating the elongation of the decorative sheet 3 using the evaluation device 50 shown in Figure 25 and a method for manufacturing the decorative molded product 1 will be described.

[0170] First, molded product data and pre-molding image data are generated or acquired and stored in the storage unit 51 (step S51). Next, the mold 13 is tentatively determined based on the molded product data in the storage unit 51 (step S52). Next, the mold data generation unit 52 generates mold data representing the three-dimensional shape of the tentatively determined mold 13 (step S53). Next, the clamp data generation unit 53 tentatively determines the clamp 40 based on the mold data generated in the mold data generation unit 52 (step S54), and generates clamp data representing the three-dimensional shape of the tentatively determined clamp 40 (step S55).

[0171] Next, the elongation data generation unit 54 generates elongation data and elongation display image data based on the clamp data generated by the clamp data generation unit 53 and the mold data generated by the mold data generation unit 52, and displays the secondary elongation display image data on the display unit 56 (step S56). Next, the elongation of the molded decorative sheet 3 relative to the unmolded decorative sheet 3 is evaluated based on the elongation display image data displayed on the display unit 56 (step S57). In step S57, if the elongation of the molded decorative sheet 3 relative to the unmolded decorative sheet 3 is below a threshold (YES), the molded image data generation unit 55 generates molded image data representing the molded decorative sheet 3 based on the elongation data and the unmolded image data, and displays it on the display unit 56 (step S58).

[0172] Next, based on the post-molding image data displayed on the display unit 56, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding section 14 of the vacuum forming die 13) is performed (step S59). The overall evaluation includes an evaluation of the color change and pattern deformation of the decorative sheet 3 in each part of the decorative sheet 3. The overall evaluation may be performed by someone other than the person who evaluated the elongation of the decorative sheet 3 in step S57 (for example, the customer who requested the production of the decorative molded product 1). If the decorative sheet 3 represented by the secondary post-molding image data is approved ("Yes" in step S59), it is decided to produce the decorative molded product 1 by adopting the molding die 13 provisionally determined in step S52 and the clamp 40 provisionally determined in step S54 (step S60). Then, the determined molding die 13 is produced. After that, the decorative sheet 3 represented by the pre-molding image data is held and bent with the determined clamp 40, and the bent decorative sheet 3 is molded using the produced molding die 13 to produce the decorative molded product 1.

[0173] If, in step S57, the elongation of any part of the molded decorative sheet 3 is greater than the threshold ("No" in step S57), or if, in step S59, the molded image data is not approved ("No" in step S59), the process returns to step S52 to perform a provisional determination of the mold 13 again. Specifically, the shape of the mold 13 that was provisionally determined in step S52 is changed or modified. Then, based on the changed or modified mold 13, the process from step S52 onward is repeated.

[0174] Furthermore, various modifications can be made to the embodiment described above.

[0175] <Variation 2-1> For example, in the example shown in Figure 26A, the elongation of the decorative sheet 3 is evaluated in step S57 based on elongation display image data, but this is not limited to this. The elongation of the decorative sheet 3 may also be evaluated based on elongation data.

[0176] <Modification 2-2> Furthermore, the evaluation of the elongation of the decorative sheet 3 in step S57 of Figure 26A may be performed by considering the average, deviation, maximum, or ratio of the maximum and minimum elongations of each part of the decorative sheet 3. For example, in step S57, if the deviation of the elongation of the decorative sheet 3 after molding compared to the decorative sheet 3 before molding is below a threshold, the process may proceed to step S58 to generate post-molding image data. Alternatively, in step S57, if the deviation of the elongation of the decorative sheet 3 after molding compared to the decorative sheet 3 before molding is greater than a threshold, the process may return to step S52 to perform a preliminary determination of the molding die 13 again.

[0177] <Modified example 2-3> Furthermore, as shown in Figure 26B, if the elongation of the decorative sheet 3 is greater than the threshold in step S57 ("No" in step S57), the process may return to step S54 and perform the provisional determination of the clamp 40 again. Specifically, the shape of the clamp 40 that was provisionally determined in step S54 may be changed or modified. Alternatively, if the result in step S57 is "No", the pre-molding image data in step S51 may be changed or modified. For example, the color of the decorative sheet 3 represented by the pre-molding image data may be changed to a lighter color, or the pattern may be changed to a pattern that is difficult to grasp the regularity of at a glance.

[0178] <Modification 2-4> Furthermore, as shown in Figure 26C, if the post-molding image data is not approved in step S59 ("No" in step S59), the process may return to step S54 and perform the provisional determination of the clamp 40 again. Alternatively, if "No" is obtained in step S59, the pre-molding image data in step S51 may be changed or modified.

[0179] <Modification 2-5> The examples shown in Figures 26A to 26C describe a case where one elongation data is generated for one pre-molding image data in step S56, but the method is not limited to this.

[0180] <Variation 2-5-1> In the manufacturing method shown in Figure 27A, first, molded product data and pre-molding image data are generated or acquired and stored in the storage unit 51 (step S61).

[0181] Next, multiple molds 13 are tentatively determined based on the molded product data (step S62). For example, molds 13E and 13F, which have different surface shapes, are tentatively determined.

[0182] Next, the mold data generation unit 52 generates mold data representing the three-dimensional shape of each provisionally determined mold 13 (step S63). In step S63, multiple mold data sets are generated. For example, mold data 13ED representing the three-dimensional shape of mold 13E and mold data 13FD representing the three-dimensional shape of mold 13F are generated.

[0183] Next, the clamp data generation unit 53 provisionally determines the three-dimensional shape of the clamp 40 based on each provisionally determined mold 13 (step S64). In step S64, one clamp 40 common to the multiple provisionally determined molds 13 is provisionally determined. For example, clamp 40G is provisionally determined for molds 13E and 13F.

[0184] Next, the mold data generation unit 52 generates clamp data representing the three-dimensional shape of the provisionally determined clamp 40 (step S65). For example, clamp data 40GD representing the three-dimensional shape of clamp 40G is generated.

[0185] Next, the elongation data generation unit 54 generates multiple elongation data and multiple elongation display image data based on the clamp data generated by the clamp data generation unit 53 and the mold data generated by the mold data generation unit 52, and displays the multiple elongation data or multiple elongation display image data on the display unit 56 (step S66). For example, elongation data and elongation display image data are generated based on the clamp data 40GD and the mold data 13ED. Also, elongation data and elongation display image data are generated based on the clamp data 40GD and the mold data 13FD.

[0186] Next, based on the multiple stretch data or stretch display image data displayed on the display unit 56, the elongation of each decorative sheet 3 after molding is evaluated relative to the decorative sheet 3 before molding, and one stretch data or one stretch display image data is selected (step S67). In step S67, one stretch data or one stretch display image data is selected by considering the average, deviation, maximum, or ratio of the maximum and minimum elongations of each part of the decorative sheet 3.

[0187] Next, the post-molding image data generation unit 55 generates post-molding image data based on the selected elongation data or elongation display image data and the pre-molding image data, and displays it on the display unit 56 (step S68).

[0188] Next, based on the post-molding image data displayed on the display unit 56, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding section 14 of the vacuum forming die 13) is performed (step S69). If the decorative sheet 3 represented by the post-molding image data is approved ("Yes" in step S69), it is decided to use the clamp 40 and mold 13 corresponding to the elongation data or elongation display image data selected in step S67 to produce the decorative molded product 1 (step S70). Then, the determined mold 13 is manufactured. After that, the decorative sheet 3 represented by the pre-molding image data is held in a bent state using the determined clamp 40, and the bent decorative sheet 3 is molded using the manufactured mold 13 to produce the decorative molded product 1.

[0189] If the post-molding image data is not approved in step S69 ("No" in step S69), the process returns to step S62 to perform a provisional determination of the mold 13 again. For example, a mold with a different shape from molds 13E and 13F is provisionally determined as the mold 13 for molding. Then, the process from step S63 onwards is repeated based on the newly provisionally determined mold 13.

[0190] If the post-molding image data is not approved in step S69 ("No" in step S69), the process may return to step S64 and tentatively determine the shape of the clamp 40 again, as shown in Figure 27B. For example, if clamp 40G has been tentatively determined for molds 13E and 13F, a clamp 40H with a different shape from clamp 40G may be tentatively determined as the clamp for molds 13E and 13F. In this case, the bending shape of the decorative sheet 3 when held by clamp 40H will be different from the bending shape of the decorative sheet 3 when held by clamp 40G. After that, the process from step S65 onwards is repeated based on the newly tentatively determined clamp 40. When the decorative sheet 3 is held by a clamp of a different shape and bent into a different shape, the elongation of each part of the decorative sheet 3 after molding will also be different.

[0191] <Modification 2-5-2> In the manufacturing method shown in Figure 28A, first, molded product data and pre-molding image data are generated or acquired and stored in the storage unit 51 (step S71).

[0192] Next, a single mold 13 is tentatively determined based on the molded product data (step S72). For example, mold 13E is tentatively determined as the mold 13 for vacuum forming.

[0193] Next, the mold data generation unit 52 generates mold data representing the three-dimensional shape of the provisionally determined mold 13 (step S73). For example, it generates mold data 13ED representing the three-dimensional shape of mold 13E.

[0194] Next, the clamp data generation unit 53 provisionally determines multiple three-dimensional shapes for the clamp 40 based on the provisionally determined mold 13 (step S74). For example, two clamps 40G and 40H, each with a different shape, are provisionally determined as clamps 40 for the mold 13E. The bending shape of the decorative sheet 3 when held by clamp 40G is different from the bending shape of the decorative sheet 3 when held by clamp 40H.

[0195] Next, the mold data generation unit 52 generates clamp data representing the three-dimensional shape of each provisionally determined clamp 40 (step S75). For example, it generates clamp data 40GD representing the shape of clamp 40G and clamp data 40HD representing the shape of clamp 40H.

[0196] Next, the elongation data generation unit 54 generates multiple elongation data and multiple elongation display image data based on the clamp data generated by the clamp data generation unit 53 and the mold data generated by the mold data generation unit 52, and displays the multiple elongation data or multiple elongation display image data on the display unit 56 (step S76). For example, elongation data and elongation display image data are generated based on the clamp data 40GD and the mold data 13ED. Also, elongation data and elongation display image data are generated based on the clamp data 40HD and the mold data 13ED.

[0197] Next, based on the multiple stretch data or stretch display image data displayed on the display unit 56, the elongation of each decorative sheet 3 after molding is evaluated relative to the decorative sheet 3 before molding, and one stretch data or one stretch display image data is selected (step S77). In step S77, one stretch data or one stretch display image data is selected by considering the average, deviation, maximum, or ratio of the maximum and minimum elongations of each part of the decorative sheet 3.

[0198] Next, the post-molding image data generation unit 55 generates post-molding image data based on the selected elongation data or elongation display image data and the pre-molding image data, and displays it on the display unit 56 (step S78).

[0199] Next, based on the post-molding image data displayed on the display unit 56, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding section 14 of the vacuum forming die 13) is performed (step S79). If the decorative sheet 3 represented by the post-molding image data is approved ("Yes" in step S79), it is decided to use the clamp 40 and mold 13 corresponding to the elongation data or elongation display image data selected in step S77 to produce the decorative molded product 1 (step S80). Then, the determined mold 13 is manufactured. After that, the decorative sheet 3 represented by the pre-molding image data is held in a bent state using the determined clamp 40, and the bent decorative sheet 3 is molded using the manufactured mold 13 to produce the decorative molded product 1.

[0200] If the post-molding image data is not approved in step S79 ("No" in step S79), the process returns to step S72 to perform a provisional determination of the mold 13 again. For example, a mold 13F with a different surface shape from mold 13E is provisionally determined as the mold 13 for molding. Then, the process from step S73 onwards is repeated based on the newly provisionally determined mold 13.

[0201] If the post-molding image data is not approved in step S79 ("No" in step S79), the process may return to step S74 and perform a provisional determination of the clamp 40 shape again, as shown in Figure 28B. For example, if clamps 40G and 40H have been provisionally determined for the mold 13E, a clamp 40 with a different shape from clamps 40G and 40H may be newly provisionally determined as the clamp for the mold 13E. After that, the process from step S75 onwards is repeated based on the newly provisionally determined clamp 40.

[0202] <Modified example 2-5-3> In the manufacturing method shown in Figure 29A, first, molded product data and pre-molding image data are generated or acquired and stored in the storage unit 51 (step S81).

[0203] Next, multiple molds 13 are tentatively determined based on the molded product data (step S82). For example, molds 13E and 13F, which have different surface shapes, are tentatively determined.

[0204] Next, the mold data generation unit 52 generates mold data representing the three-dimensional shape of each provisionally determined mold 13 (step S83). In step S83, multiple mold data sets are generated. For example, mold data set 13ED representing the three-dimensional shape of mold 13E and mold data set 13FD representing the three-dimensional shape of mold 13F are generated.

[0205] Next, the clamp data generation unit 53 provisionally determines multiple clamps 40 based on the provisionally determined mold 13 (step S84). For example, clamps 40G and 40H, which have different shapes from each other, are provisionally determined as clamps 40 for molds 13E and 13F. The bending shape of the decorative sheet 3 when held by clamp 40G and the bending shape of the decorative sheet 3 when held by clamp 40H are different from each other.

[0206] Next, the mold data generation unit 52 generates clamp data representing the three-dimensional shape of each provisionally determined clamp 40 (step S85). For example, it generates clamp data 40GD representing the shape of clamp 40G and clamp data 40HD representing the shape of clamp 40H.

[0207] Next, the elongation data generation unit 54 generates multiple elongation data and multiple elongation display image data based on the clamp data generated by the clamp data generation unit 53 and the mold data generated by the mold data generation unit 52, and displays the multiple elongation data or multiple elongation display image data on the display unit 56 (step S86). For example, elongation data and elongation display image data are generated based on the clamp data 40GD and the mold data 13ED. Also, elongation data and elongation display image data are generated based on the clamp data 40GD and the mold data 13FD. Also, elongation data and elongation display image data are generated based on the clamp data 40HD and the mold data 13ED. Also, elongation data and elongation display image data are generated based on the clamp data 40HD and the mold data 13FD.

[0208] Next, based on the multiple stretch data or stretch display image data displayed on the display unit 56, the elongation of each decorative sheet 3 after molding is evaluated relative to the decorative sheet 3 before molding, and one stretch data or one stretch display image data is selected (step S87). In step S87, one stretch data or one stretch display image data is selected by considering the average, deviation, maximum, or ratio of the maximum and minimum elongations of each part of the decorative sheet 3.

[0209] Next, the post-molding image data generation unit 55 generates post-molding image data based on the selected elongation data or elongation display image data and the pre-molding image data, and displays it on the display unit 56 (step S88).

[0210] Next, based on the post-molding image data displayed on the display unit 56, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding section 14 of the vacuum forming die 13) is performed (step S89). If the decorative sheet 3 represented by the post-molding image data is approved ("Yes" in step S89), it is decided to use the clamp 40 and mold 13 corresponding to the elongation data or elongation display image data selected in step S87 to produce the decorative molded product 1 (step S90). Then, the determined mold 13 is manufactured. After that, the decorative sheet 3 represented by the pre-molding image data is held in a bent state using the determined clamp 40, and the bent decorative sheet 3 is molded using the manufactured mold 13 to produce the decorative molded product 1.

[0211] If the post-molding image data is not approved in step S89 ("No" in step S89), the process returns to step S82 to perform a provisional determination of the mold 13 again. For example, a mold 13 with a different surface shape from molds 13E and 13F is provisionally determined as the mold 13 for molding. Then, the process from step S83 onwards is repeated based on the newly provisionally determined mold 13.

[0212] If the post-molding image data is not approved in step S89 ("No" in step S89), the process may return to step S84 and perform a provisional determination of the clamp 40 again, as shown in Figure 29B. For example, a clamp 40 with a different shape from clamps 40G and 40H may be provisionally determined as clamp 40. After that, the process from step S85 onwards is repeated based on the newly provisionally determined clamp 40.

[0213] The evaluation method according to the second embodiment described above is a method for evaluating the elongation of the molded decorative sheet 3 relative to the molded decorative sheet 3 when manufacturing a decorative molded product 1 including the molded decorative sheet 3. This method comprises the following steps. • A process for generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. • A step of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. ·A step of tentatively determining a mold 13 used for molding the decorative sheet 3 based on the molded product data. ·A step of generating mold data representing the three-dimensional shape of the tentatively determined mold 13. ·A step of tentatively determining a bent shape in which the decorative sheet 3 before molding is bent along the decorated molded product 1 based on the molded product data or the mold data (a step of tentatively determining the clamp 40). ·A stretch data generation step of generating stretch data. Here, the stretch data is calculated based on the tentatively determined bent shape and the mold data of the tentatively determined mold 13, and is data indicating the stretch of each part of the decorative sheet 3 after molding with respect to the decorative sheet 3 before molding by molding the bent decorative sheet 3 with the tentatively determined mold 13.

[0214] The evaluation method according to the modification example of the second embodiment described above is a method for evaluating the stretch of the decorative sheet 3 after molding with respect to the decorative sheet 3 before molding when producing the decorated molded product 1 including the molded decorative sheet 3. This method includes the following steps. ·A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. ·A step of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. ·A step of tentatively determining a plurality of molds 13 used for molding the decorative sheet 3 based on the molded product data. ·A step of generating mold data representing the three-dimensional shape of each tentatively determined mold 13. ·A step of tentatively determining a bent shape in which the decorative sheet 3 before molding is bent along the decorated molded product 1 based on the molded product data or the mold data (a step of tentatively determining the clamp 40). ·A stretch data generation step of generating a plurality of stretch data. Here, each stretch data is calculated based on the tentatively determined bent shape and the mold data of each tentatively determined mold 13, and is data indicating the stretch of each part of the decorative sheet 3 after molding with respect to the decorative sheet 3 before molding by molding the bent decorative sheet 3 with the tentatively determined mold 13.

[0215] The evaluation method according to another modification of the second embodiment described above is a method for evaluating the elongation of the decorated sheet 3 after molding with respect to the decorated sheet 3 before molding when producing the decorated molded product 1 including the molded decorated sheet 3. This method includes the following steps. · A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. · A step of generating or acquiring pre-molding image data representing the decorated sheet 3 before molding. · A step of tentatively determining the molding die 13 used for molding the decorated sheet 3 based on the molded product data. · A step of generating molding die data representing the three-dimensional shape of the tentatively determined molding die 13. · A step of tentatively determining a plurality of bending shapes which are the shapes in which the decorated sheet 3 before molding is bent along the decorated molded product 1 (a step of tentatively determining a plurality of clamps 40) based on the molded product data or the molding die data. · An elongation data generation step of generating a plurality of elongation data. Here, each elongation data is data indicating the elongation of each part of the decorated sheet 3 after molding with respect to the decorated sheet 3 before molding by molding the bent decorated sheet 3 with the tentatively determined molding die 13, which is calculated based on each tentatively determined bending shape and the molding die data of the tentatively determined molding die 13.

[0216] The evaluation method according to another modification of the second embodiment described above is a method for evaluating the elongation of the decorated sheet 3 after molding with respect to the decorated sheet 3 before molding when producing the decorated molded product 1 including the molded decorated sheet 3. This method includes the following steps. · A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product 1. · A step of generating or acquiring pre-molding image data representing the decorated sheet 3 before molding. · A step of tentatively determining a plurality of molding dies used for molding the decorated sheet 3 based on the molded product data. · A step of generating molding die data representing the three-dimensional shape of each tentatively determined molding die 13. - A step of provisionally determining multiple bent shapes, which are the shapes of the decorative sheet 3 before molding bent to conform to the decorative molded product 1, based on the molded product data or mold data (a step of provisionally determining multiple clamps 40). • A stretch data generation process that generates multiple stretch data sets. Here, each stretch data set is calculated based on the provisionally determined bending shapes and the provisionally determined mold data for each mold 13, and represents the stretch of each part of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding, resulting from molding the bent decorative sheet 3 with the provisionally determined mold 13.

[0217] These evaluation methods allow for efficient design of the clamp 40 and vacuum forming die 13, as well as determination of the color and pattern of the decorative sheet 3. In other words, these evaluation methods allow for evaluation of the elongation of each part of the decorative sheet 3 when producing the decorative molded product 1, without actually manufacturing the clamp 40 and vacuum forming die 13, or molding the decorative sheet 3. Therefore, the effort required for prototyping the decorative molded product 1 is significantly reduced, and the time and cost required to complete the decorative molded product are significantly reduced.

[0218] The evaluation method according to the second embodiment and its modified form described above further comprises the following steps. - A process for generating stretch display image data that visually represents the correspondence between the stretch of each part of the decorative sheet 3 before molding and the stretch of each part of the decorative sheet 3 after molding, based on stretch data and pre-molding image data.

[0219] In this case, the correspondence between the elongation of each part of the decorative sheet 3 before molding and each part of the decorative sheet 3 after molding can be easily understood.

[0220] The evaluation method according to the second embodiment and its modified form described above further comprises the following steps. A post-molding image data generation process that generates post-molding image data representing the post-molding decorative sheet 3 based on elongation data and pre-molding image data.

[0221] In this case, it is easy to evaluate the entire decorated sheet 3 after molding. In particular, it is easy to grasp the color and pattern of the decorated sheet 3 after molding.

[0222] The evaluation method according to the second embodiment and its modification described above further includes the following steps.

[0223] Although several modifications to the above-described embodiments have been described above, it is of course possible to appropriately combine and apply a plurality of modifications.

Explanation of Signs

[0224] 1 Decorated molded product 2 Molding part 3 Decorated sheet 4 Base material sheet <e000947>5 Design layer 6 Surface protection layer 10 Clamp 11 Heater 12 Blow molding device 13 Vacuum molding die​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​

Claims

1. A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product that includes a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining the mold used for molding the decorative sheet based on the molded product data, A step of generating mold data representing the three-dimensional shape of the provisionally determined mold, A step of provisionally determining the conditions for primary molding to stretch the decorative sheet before molding so that it conforms to the decorative molded product, based on the molded product data or the mold data, A primary elongation data generation step that generates primary elongation data by calculating the elongation of each part of the decorative sheet after primary molding relative to the decorative sheet before molding, based on the provisionally determined primary molding conditions, A secondary elongation data generation step involves generating secondary elongation data by calculating the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding, based on the primary elongation data and the molding die data, in which the decorative sheet after primary molding is molded using the provisionally determined molding die. A step of evaluating the elongation of the decorative sheet after secondary molding relative to the decorative sheet before molding, based on the secondary elongation data, An evaluation method comprising the following features.

2. A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product including a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining the mold used for molding the decorative sheet based on the molded product data, A step of generating mold data representing the three-dimensional shape of the provisionally determined mold, A step of provisionally determining the conditions for primary molding to stretch the decorative sheet before molding so that it conforms to the decorative molded product, based on the molded product data or the mold data, A primary elongation data generation step that generates primary elongation data by calculating the elongation of each part of the decorative sheet after primary molding relative to the decorative sheet before molding, based on the provisionally determined primary molding conditions, A secondary elongation data generation step involves generating secondary elongation data by calculating the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding, based on the primary elongation data and the molding die data, in which the decorative sheet after primary molding is molded using the provisionally determined molding die. A step of generating secondary elongation display image data that visually represents the correspondence between the elongation of each part of the decorative sheet before molding and the elongation of each part of the decorative sheet after secondary molding, based on the secondary elongation data, A step of evaluating the elongation of the decorative sheet after secondary molding relative to the decorative sheet before molding, based on the secondary elongation display image data, An evaluation method comprising the following features.

3. The evaluation method according to claim 2, wherein the secondary elongation display image data represents the elongation of each part of the decorative sheet represented by the secondary elongation data, with a color corresponding to the magnitude of the elongation.

4. The evaluation method according to claim 2, wherein the secondary elongation display image data represents the elongation of each part of the decorative sheet represented by the secondary elongation data, expressed as line distortion corresponding to the magnitude of the elongation.

5. The evaluation method according to claim 1 or 2, further comprising the step of generating primary elongation display image data that visually represents the correspondence between the elongation of each part of the decorative sheet before molding and the elongation of each part of the decorative sheet after primary molding, based on the primary elongation data.

6. The evaluation method according to claim 1 or 2, further comprising a step of generating post-secondary molded image data that represents the decorative sheet after secondary molding, based on the secondary elongation data and the pre-molding image data.

7. The decorative sheet has a pattern, The evaluation method according to claim 6, wherein the post-secondary molding image data is generated by deforming the pattern of the decorative sheet before molding in accordance with the elongation of each part of the decorative sheet as represented by the secondary elongation data.

8. The aforementioned decorative sheet has color, The evaluation method according to claim 6, wherein the post-secondary molding image data is generated by changing the color of each part of the decorative sheet before molding according to the elongation of each part of the decorative sheet as represented by the secondary elongation data.

9. The aforementioned primary molding is blow molding. The evaluation method according to claim 1 or 2, wherein the secondary molding is vacuum molding using the molding die.

10. A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product that includes a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining multiple molds to be used for molding the decorative sheet based on the molded product data, A process to generate mold data representing the three-dimensional shape of each provisionally determined mold, A step of provisionally determining the conditions for primary molding to stretch the decorative sheet before molding so that it conforms to the decorative molded product, based on the molded product data or the mold data, A primary elongation data generation step that generates primary elongation data by calculating the elongation of each part of the decorative sheet after primary molding relative to the decorative sheet before molding, based on the provisionally determined primary molding conditions, A secondary elongation data generation step involves generating a plurality of secondary elongation data by performing secondary molding, in which the decorative sheet after primary molding is molded using the provisionally determined mold, and the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding is calculated based on the primary elongation data and each mold data, and a secondary elongation data is generated. A step of evaluating the elongation of each decorative sheet after secondary molding relative to the decorative sheet before molding, based on a plurality of secondary elongation data, An evaluation method comprising the following features.

11. A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product including a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining multiple molds to be used for molding the decorative sheet based on the molded product data, A process to generate mold data representing the three-dimensional shape of each provisionally determined mold, A step of provisionally determining the conditions for primary molding to stretch the decorative sheet before molding so that it conforms to the decorative molded product, based on the molded product data or the mold data, A primary elongation data generation step that generates primary elongation data by calculating the elongation of each part of the decorative sheet after primary molding relative to the decorative sheet before molding, based on the provisionally determined primary molding conditions, A secondary elongation data generation step involves generating a plurality of secondary elongation data by performing secondary molding, in which the decorative sheet after primary molding is molded using the provisionally determined mold, and the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding is calculated based on the primary elongation data and each mold data, and a secondary elongation data is generated. A step of generating multiple secondary elongation display image data that visually represent the correspondence between the elongation of each part of the decorative sheet before molding and the elongation of each part of the decorative sheet after secondary molding, based on multiple secondary elongation data, A step of evaluating the elongation of each decorative sheet after secondary molding relative to the decorative sheet before molding, based on a plurality of secondary elongation display image data, An evaluation method comprising the following features.

12. A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product that includes a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining the mold used for molding the decorative sheet based on the molded product data, A step of generating mold data representing the three-dimensional shape of the provisionally determined mold, A step of provisionally determining multiple conditions for primary molding to stretch the decorative sheet before molding so that it conforms to the decorative molded product, based on the molded product data or the mold data, A primary elongation data generation step that calculates the elongation of each part of the decorative sheet after primary molding relative to the decorative sheet before molding, based on the provisionally determined primary molding conditions, and generates a plurality of primary elongation data; A secondary elongation data generation step involves generating a plurality of secondary elongation data by calculating the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding, based on the primary elongation data and the molding die data, in which the decorative sheet after primary molding is molded using the provisionally determined molding die. A step of evaluating the elongation of each decorative sheet after secondary molding relative to the decorative sheet before molding, based on multiple secondary elongation data, An evaluation method comprising the following features.

13. A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product including a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining the mold used for molding the decorative sheet based on the molded product data, A step of generating mold data representing the three-dimensional shape of the provisionally determined mold, A step of provisionally determining multiple conditions for primary molding to stretch the decorative sheet before molding so that it conforms to the decorative molded product, based on the molded product data or the mold data, A primary elongation data generation step that calculates the elongation of each part of the decorative sheet after primary molding relative to the decorative sheet before molding, based on the provisionally determined primary molding conditions, and generates a plurality of primary elongation data; A secondary elongation data generation step involves generating a plurality of secondary elongation data by calculating the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding, based on the primary elongation data and the molding die data, in which the decorative sheet after primary molding is molded using the provisionally determined molding die. A step of generating multiple secondary elongation display image data that visually represent the correspondence between the elongation of each part of the decorative sheet before molding and the elongation of each part of the decorative sheet after secondary molding, based on multiple secondary elongation data, A step of evaluating the elongation of each decorative sheet after secondary molding relative to the decorative sheet before molding, based on a plurality of secondary elongation display image data, An evaluation method comprising the following features.

14. A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding, when manufacturing a decorative molded product that includes a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining multiple molds to be used for molding the decorative sheet based on the molded product data, A process to generate mold data representing the three-dimensional shape of each provisionally determined mold, A step of provisionally determining multiple conditions for primary molding to stretch the decorative sheet before molding so that it conforms to the decorative molded product, based on the molded product data or the mold data, A primary elongation data generation step that calculates the elongation of each part of the decorative sheet after primary molding relative to the decorative sheet before molding, based on the provisionally determined primary molding conditions, and generates a plurality of primary elongation data; A secondary elongation data generation step involves generating a plurality of secondary elongation data by calculating the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding, based on each primary elongation data and each mold data, in which the decorative sheet after primary molding is molded using the provisionally determined mold. A step of evaluating the elongation of each decorative sheet after secondary molding relative to the decorative sheet before molding, based on a plurality of secondary elongation data, An evaluation method comprising the following features.

15. A method for evaluating the elongation of a decorative sheet after molding relative to a decorative sheet before molding, when manufacturing a decorative molded product including a molded decorative sheet, A step of generating or acquiring molded product data representing the three-dimensional shape of the decorated molded product, A step of generating or acquiring pre-molding image data representing the decorative sheet before molding, A step of provisionally determining multiple molds to be used for molding the decorative sheet based on the molded product data, A process to generate mold data representing the three-dimensional shape of each provisionally determined mold, A step of provisionally determining multiple conditions for primary molding to stretch the decorative sheet before molding so that it conforms to the decorative molded product, based on the molded product data or the mold data, A primary elongation data generation step that calculates the elongation of each part of the decorative sheet after primary molding relative to the decorative sheet before molding, based on the provisionally determined primary molding conditions, and generates a plurality of primary elongation data; A secondary elongation data generation step involves generating a plurality of secondary elongation data by calculating the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding, based on each primary elongation data and each mold data, in which the decorative sheet after primary molding is molded using the provisionally determined mold. A step of generating multiple secondary elongation display image data that visually represent the correspondence between the elongation of each part of the decorative sheet before molding and the elongation of each part of the decorative sheet after secondary molding, based on multiple secondary elongation data, A step of evaluating the elongation of each decorative sheet after secondary molding relative to the decorative sheet before molding, based on a plurality of secondary elongation display image data, An evaluation method comprising the following features.

16. A post-molding image data generation step generates multiple post-molding image data representing the decorative sheet after post-molding, based on each post-molding elongation data and the pre-molding image data, The evaluation method according to any one of claims 10 to 15, comprising:

17. The process further includes selecting one secondary elongation data from a plurality of secondary elongation data, The evaluation method according to any one of claims 10 to 15, wherein in the step of selecting the secondary elongation data, the average, deviation, maximum, or ratio of the maximum and minimum values ​​of the elongation of multiple parts of the decorative sheet after secondary molding relative to the decorative sheet before molding is calculated based on each secondary elongation data, and a single secondary elongation data is selected based on the average, deviation, maximum, or ratio of the maximum and minimum values ​​of the elongation.

18. A method for manufacturing a decorative molded article including a molded decorative sheet, A step of evaluating the elongation of each part of the decorative sheet after secondary molding relative to the decorative sheet before molding, when the decorative sheet is primary molded under the provisionally determined primary molding conditions and secondary molded with the provisionally determined molding die, according to the evaluation method described in any one of claims 1, 2, 10 to 15; A step of determining the conditions for the decorative sheet and / or the primary molding and / or the molding die based on the results of the elongation evaluation, A step of manufacturing the decorated molded product using the determined decorative sheet and / or the conditions for primary molding and / or the mold, A manufacturing method that includes the following features.

Images