Evaluation method for evaluating elongation of decorative sheet and method for manufacturing decorative molded article

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

Evaluation method for evaluating elongation of decorative sheet and manufacturing method of decorated molded product

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

[0002] Conventionally, decorative molded products, in which a decorative sheet is laminated on the surface of a resin molded product, have been used as interior and exterior parts for automobiles, interior and exterior materials for building materials, and housings for home appliances. In the manufacturing process of such decorative molded products, the decorative sheet is molded into a shape that corresponds to the surface shape of the decorative 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, some regions of the decorative sheet may elongate significantly. For example, some regions of the decorative sheet may elongate by 50% to 200%. If some regions of the decorative sheet bearing a pattern elongate by such a large elongation rate, the pattern on the decorative sheet may be significantly distorted, and a design different from the intended design may be imparted to the decorated molded product.

[0004] It is possible to prepare a plurality of molds with different surface shapes and evaluate the elongation of the decorative sheet molded using each mold, but this method increases the time and cost required to complete the decorated molded product.

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

[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 mold or a decorated molded product.

[0007] An 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 a 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 a 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 provisionally determining a mold to be used in 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, based on the molded product data or the mold data, primary molding conditions for stretching the decorative sheet before molding so as to conform to the decorative molded product; and a primary elongation data generating step of 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 to generate primary elongation data. and a secondary elongation data generation process for calculating the elongation of each part of the decorative sheet after the secondary molding relative to the decorative sheet before molding, based on the primary elongation data and the molding mold data, by secondary molding in which the decorative sheet after the primary molding is molded using the provisionally determined molding mold, to generate secondary elongation data.

[0009] [2] The evaluation method according to [1], further comprising 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 the 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 portion of the decorative sheet represented by the secondary elongation data in 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 as a line distortion corresponding to the magnitude of the elongation.

[0012] [5] The evaluation method according to any one of [1] to [4], further comprising a 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 the primary molding, based on the primary elongation data.

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

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

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

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

[0017]

[10] A method for evaluating the elongation of a decorative sheet after molding relative to a 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 provisionally determining a plurality of molds to be used in molding the decorative sheet based on the molded product data; a step of generating mold data representing the three-dimensional shape of each provisionally determined mold; a step of provisionally determining, based on the molded product data or the mold data, primary molding conditions for stretching the decorative sheet before molding so as to conform to the decorative molded product; and a primary elongation data generating step of 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 to generate primary elongation data. and a secondary elongation data generation process for calculating, based on the primary elongation data and each molding die data, the elongation of each part of the decorative sheet after the secondary molding relative to the decorative sheet before molding, which is caused by secondary molding in which the decorative sheet after the primary molding is molded using the provisionally determined molding die, to generate a plurality of secondary elongation data.

[0018]

[11] A method for evaluating the elongation of a decorative sheet after molding relative to a 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 a 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 provisionally determining a mold to be used in 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 a plurality of primary molding conditions for stretching the decorative sheet before molding so as to conform to the decorative molded product based on the molded product data or the mold data; and a primary elongation data generating step of calculating the elongation of each part of the decorative sheet after primary molding relative to the decorative sheet before molding based on each of the provisionally determined primary molding conditions to generate a plurality of primary elongation data. and a secondary elongation data generation process for calculating the elongation of each part of the decorative sheet after the secondary molding relative to the decorative sheet before molding, based on each primary elongation data and the molding die data, by secondary molding in which the decorative sheet after the primary molding is molded using the provisionally determined molding die, to generate a plurality of secondary elongation data.

[0019]

[12] A method for evaluating the elongation of a decorative sheet after molding relative to a 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 provisionally determining a plurality of molds to be used in molding the decorative sheet based on the molded product data; a step of generating mold data representing the three-dimensional shape of each provisionally determined mold; a step of provisionally determining a plurality of primary molding conditions for stretching the decorative sheet before molding so as to conform to the decorative molded product based on the molded product data or the mold data; and a primary elongation data generating step of calculating the elongation of each part of the decorative sheet after primary molding relative to the decorative sheet before molding based on each of the provisionally determined primary molding conditions to generate a plurality of primary elongation data. and a secondary elongation data generation process for calculating elongation of each part of the decorative sheet after the secondary molding relative to the decorative sheet before molding, based on each primary elongation data and each molding mold data, by secondary molding in which the decorative sheet after the primary molding is molded using the provisionally determined molding mold, to generate a plurality of secondary elongation data.

[0020]

[13] The evaluation method according to any one of

[10] to

[12] , further comprising: a post-secondary-forming image data generating step of generating a plurality of post-secondary-forming image data representing the decorative sheet after the secondary forming based on each secondary elongation data and the pre-forming image data.

[0021]

[14] The evaluation method according to any one of

[10] to

[13] , further comprising a step of selecting one secondary elongation data from the plurality of secondary elongation data, wherein in the step of selecting the secondary elongation data, any of the average, deviation, maximum value, and ratio of the maximum value and minimum value of elongation of a plurality of portions of each decorative sheet after the secondary molding relative to the decorative sheet before molding is calculated based on each secondary elongation data, and one secondary elongation data is selected based on the average, deviation, maximum value, and ratio of the maximum value and minimum value of elongation.

[0022]

[15] A method for producing a decorated molded product including a molded decorative sheet, comprising: 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 subjected to primary molding under provisionally determined primary molding conditions and secondary molding using provisionally determined molding mold according to the evaluation method described in any of [1] to

[14] ; and a step of determining the decorative sheet and / or the primary molding conditions and / or the molding mold based on the evaluation results of the elongation.

[0023]

[16] A method for evaluating the elongation of a molded decorative sheet relative to a pre-molded decorative sheet when producing a decorative molded product including the molded decorative sheet, the method comprising: a step of generating or acquiring molded product data representing a three-dimensional shape of the decorative molded product; a step of generating or acquiring pre-molded image data representing the decorative sheet before molding; a step of provisionally determining a mold to be used in 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 a bent shape of the pre-molded decorative sheet based on the molded product data or the mold data; and an elongation data generation step of calculating the elongation of each part of the molded decorative sheet relative to the pre-molded decorative sheet, which is caused by molding the bent decorative sheet with the provisionally determined mold, based on the provisionally determined bent shape and the mold data, to generate elongation data.

[0024]

[17] The evaluation method according to

[16] , further comprising a 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 the elongation of 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 portion of the decorative sheet represented by the elongation data in 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 portion of the decorative sheet represented by the elongation data as a distortion of a line corresponding to the magnitude of the elongation.

[0027]

[20] The evaluation method according to any one of

[16] to

[19] , further comprising a post-molding image data generation step of generating post-molding image data representing the decorative sheet after molding based on the elongation data and the pre-molding image data.

[0028]

[21] The decorative sheet has a pattern, and the post-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 represented by the elongation data. The evaluation method according to

[20] .

[0029]

[22] The evaluation method according to

[20] or

[21] , wherein the decorative sheet has a color, and 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 represented by the elongation data.

[0030]

[23] The evaluation method according to any one of

[16] to

[22] , wherein the molding is vacuum molding using the molding die.

[0031]

[24] A method for evaluating the elongation of a decorative sheet after molding relative to a decorative sheet before molding when producing a decorative molded product including the molded decorative sheet, the evaluation method 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 provisionally determining a plurality of molding dies to be used in molding the decorative sheet based on the molded product data; a step of generating molding die data representing the three-dimensional shape of each provisionally determined molding die; a step of provisionally determining a bent shape of the decorative sheet before molding so as to fit the decorative molded product, based on the molded product data or the molding die data; and an elongation data generation step of calculating the elongation of each part of the decorative sheet after molding relative to the decorative sheet before molding, which is caused by molding the bent decorative sheet with the provisionally determined molding die, based on the provisionally determined bent shape and each molding die data, to generate a plurality of elongation data.

[0032]

[25] A method for evaluating the elongation of a decorative sheet after molding relative to a decorative sheet before molding when producing a decorative molded product including the molded decorative sheet, the method 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 provisionally determining a molding die to be used in molding the decorative sheet based on the molded product data; a step of generating molding die data representing the three-dimensional shape of the provisionally determined molding die; a step of provisionally determining a plurality of bent shapes obtained by bending the decorative sheet before molding so as to fit the decorative molded product, based on the molded product data or the molding die data; and an elongation data generating step of calculating the elongation of each part of the decorative sheet after molding relative to the decorative sheet before molding, which is caused by molding the bent decorative sheet with the provisionally determined molding die, based on the provisionally determined bent shapes and the molding die data, to generate a plurality of elongation data.

[0033]

[26] A method for evaluating the elongation of a decorative sheet after molding relative to a decorative sheet before molding when producing a decorative molded product including the molded decorative sheet, the evaluation method 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 provisionally determining a plurality of molding dies to be used in molding the decorative sheet based on the molded product data; a step of generating molding die data representing the three-dimensional shape of each provisionally determined molding die; a step of provisionally determining a plurality of bent shapes obtained by bending the decorative sheet before molding so as to fit the decorative molded product, based on the molded product data or the molding die data; and an elongation data generating step of calculating the elongation of each part of the decorative sheet after molding relative to the decorative sheet before molding, which is caused by molding the bent decorative sheet with the provisionally determined molding die, based on each provisionally determined bent shape and each molding die data, to generate a plurality of elongation data.

[0034]

[27] The evaluation method according to any one of

[24] to

[26] , further comprising: a post-molding image data generating step of generating a plurality of post-molding image data representing the decorative sheet after molding based on each elongation data and the pre-molding image data.

[0035]

[28] The evaluation method according to any one of

[24] to

[27] , further comprising a step of selecting one piece of elongation data from the plurality of pieces of elongation data, wherein in the step of selecting the elongation data, any of the average, deviation, maximum value, and ratio of the maximum and minimum values ​​of elongation of a plurality of portions of the decorative sheet after molding relative to the decorative sheet before molding is calculated based on each piece of elongation data, and one piece of elongation data is selected based on the average, deviation, maximum value, and ratio of the maximum and minimum values ​​of elongation.

[0036]

[29] A method for producing a decorated molded product including a molded decorative sheet, comprising: a step of evaluating the elongation of each part of the decorative sheet after molding relative to the decorative sheet before molding, when the decorative sheet is bent into the provisionally determined bent shape and molded using the provisionally determined molding die according to the evaluation method described in any of

[16] to

[28] ; and a step of determining the decorative sheet and / or the molding die based on the evaluation results of the elongation.

[0037] According to the embodiments of the present disclosure, the elongation of a decorative sheet when producing a decorated molded article can be evaluated without producing a mold or a decorated molded article.

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

[0039] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. Note that in the drawings accompanying this specification, the scale and aspect ratios have been appropriately changed and exaggerated from those of the actual objects for the sake of ease of illustration and understanding.

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

[0041] The decorated molded product 1 is used, for example, as an interior or exterior part of a mobile body, an interior or exterior material for a building material, or a housing for a home appliance. A mobile body is a movable object. A mobile body may be manned or unmanned. Examples of mobile bodies include automobiles, railroad cars, dollies, ships, airplanes, helicopters, drones, and robots. As shown in FIG. 2 , the decorated molded product 1 includes a molded portion 2 and a decorative sheet 3.

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

[0043] The decorative sheet 3 covers at least a portion of the surface of the molded portion 2. In the illustrated example, the decorative sheet 3 is produced 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 can form the base sheet 4 include acrylic resins such as polymethyl methacrylate, polyethylene terephthalate, vinyl chloride, ABS (acrylonitrile butadiene styrene copolymer), polycarbonate, polyethylene naphthalate, polystyrene, cyclic polyolefins, polypropylene, etc. Sheets of the exemplified materials may be used in a single layer or in multiple layers; for example, acrylic resin and ABS may be laminated. The base sheet 4 may be transparent or opaque. The base sheet 4 may be colored or uncolored.

[0044] The design layer 5 may be a layer on which a design such as a color, pattern, figure, design, picture, photograph, character, mark, pictogram, letter, or number is formed. The design layer 5 may be a layer having an internal uneven structure that gives a sense of depth and three-dimensionality. The design layer 5 may express the texture of materials such as wood, cloth, leather, stone, or metal. The design layer 5 may be formed by printing or transfer.

[0045] The surface protective layer 6 forms the outermost surface of the decorated molded article 1. The surface protective layer 6 may have scratch resistance or the like. The surface protective layer 6 is made of, for example, a resin material. Examples of resin materials that can be used to form the surface protective 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 above example. For example, the decorative sheet 3 may include functional layers such as an ultraviolet absorbing layer, an anti-reflection layer, a light diffusing layer, an adhesive layer, a backer layer, and a light-shielding pattern.

[0047] Next, a method for manufacturing the decorated molded article 1 in the first embodiment will be described with reference to Fig. 3 to Fig. 13. Fig. 3 is a perspective view of a clamp 10 used in manufacturing the decorated molded article 1. Figs. 4 to 13 are diagrams for explaining an example of a method for manufacturing the decorated molded article 1 shown in Fig. 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 means injection molding in which a bonded object such as a decorative sheet is placed in a cavity. In-mold decoration includes insert molding and in-mold molding. Insert molding makes it possible to produce a product in which the injected resin and the bonded object are integrated. In this insert molding, the bonded object may be deformed.

[0049] First, as shown in Figures 4 to 9, the decorative sheet 3 is preformed. The preforming causes plastic deformation of the decorative sheet 3. After preforming, the decorative sheet 3 has a shape similar to that of the intended decorated formed product 1. In the examples shown in Figures 4 to 9, vacuum forming or pressure forming is performed as the preforming.

[0050] In the vacuum forming of the illustrated decorative sheet 3, first, as shown in Fig. 3, the edge of the decorative sheet 3 is held by a clamp 10. In the example shown in Fig. 3, the clamp 10 is formed in a ring shape. This clamp 10 holds 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 a ring shape.

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

[0052] Next, as shown in Fig. 5, a blow molding device 12 blows gas onto one side of the softened decorative sheet 3 to perform blow molding. This causes the planar decorative sheet 3 to stretch and curve. 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 decorated molded product 1 (more specifically, to the shape of the decorative sheet 3 in the decorated molded product 1). Hereinafter, the molding of the decorative sheet 3 by the blow molding device 12 will also be referred to as "primary molding."

[0053] Next, as shown in Figure 6, a vacuum forming die 13 is brought into contact with the stretched decorative sheet 3. The vacuum forming die 13 has a main forming portion 14 and a sub-forming portion 15. The main forming portion 14 has a surface shape that corresponds to the shape of the decorated molded product 1 (more specifically, corresponds to the shape of the decorative sheet 3 in the decorated molded product 1). The sub-forming portion 15 is located around the main forming portion 14. An opening 16 is formed in the surface of the sub-forming portion 15. The opening 16 is connected to a gas flow path 17 formed in the vacuum forming die 13. A suction pump (not shown) is connected to the flow path 17. The decorative sheet 3 is placed so as to cover the main forming portion 14 and the sub-forming portion 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 is stretched and adheres to the surfaces of the main molding portion 14 and the sub-molding portion 15. Thereafter, the temperature of the decorative sheet 3 is lowered, and the decorative sheet 3 is solidified. This causes the decorative sheet 3 to be molded into a shape corresponding to the surface shape of the vacuum forming die 13. Hereinafter, the molding of the decorative sheet 3 using the vacuum forming die 13 will also be referred to as "secondary molding." Note that the primary molding and secondary molding may be performed in the same device.

[0055] Next, the decorative sheet 3 is removed from the vacuum forming mold 13. Thereafter, as shown in Fig. 9, unnecessary portions are removed from the decorative sheet 3 removed from the vacuum forming mold 13. In this manner, the decorative sheet 3 is preformed.

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

[0057] As shown in Fig. 11 , the decorative sheet 3 is placed in a cavity 22 in an injection molding die 21. In the example shown, the decorative sheet 3 is placed in the cavity 22 so that the surface protective layer 6 contacts the second die 21B and the base sheet 4 is exposed in the cavity 22. Next, as shown in Fig. 12 , molten injection resin 2a is injected into the cavity 22 through a gate 23. The injected resin 2a is cooled in the cavity 22 and solidifies by welding to the decorative sheet 3. A molded part 2 bonded to the surface protective layer 6 of the decorative sheet 3 is obtained from the solidified injected resin 2a.

[0058] 13, the first die 21A and the second die 21B are separated from each other, and the decorated molded article 1 including the decorative sheet 3 and the molded portion 2 is removed from the cavity 22. In this manner, the decorated molded article 1 is obtained.

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

[0060] According to 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 fit the shape of the decorated molded product 1, and then vacuum forming (secondary molding) to form it along the shape of the decorated molded product 1. Therefore, compared to when a planar decorative sheet 3 is molded using a vacuum forming mold 13, the distance between each part of the decorative sheet 3 and each part of the vacuum forming mold 13 at the start of vacuum forming can be made smaller. As a result, the difference in elongation between each part of the decorative sheet 3 can be made smaller, and the risk of a part of the decorative sheet 3 being excessively stretched is suppressed. Therefore, the risk of the decorative sheet 3 tearing, a noticeable color change in part of the decorative sheet 3, or a noticeable distortion of the pattern on the decorative sheet 3 during vacuum forming is suppressed.

[0061] However, even with this method of forming the decorative sheet 3, the color of the portion of the decorative sheet 3 may change significantly, or the pattern on 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 elongation of the decorative sheet 3, it is possible to suppress the color change or pattern distortion by modifying the surface shape of the decorated molded product 1 or the shape of the molding die (vacuum molding die) 13. This allows the design imparted to the decorated molded product 1 to approach the intended design. However, repeatedly remaking the molding die 13 until a satisfactory decorated molded product is produced increases the time and cost required to complete the decorated molded product 1.

[0062] Taking this into consideration, the manufacturing method of the decorated molded product 1 of this embodiment uses an evaluation device 30 shown in Fig. 14, which makes it possible to evaluate the elongation of the decorative sheet 3 when producing the decorated molded product 1, without actually producing a molding die 13 or producing the decorated molded product 1. The evaluation device 30 shown in Fig. 14 includes a storage unit 31, a primary molding condition determination unit 32, a primary elongation data generation unit 33, a molding die data generation unit 34, and a secondary elongation data generation unit 35. In the example shown in Fig. 14, the evaluation device 30 further includes a post-secondary molding image data generation unit 36 ​​and a display unit 37.

[0063] The storage 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, for example, based on 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 may be obtained from a party other than the person who evaluates the elongation (for example, a customer who requests the production of the decorated molded product 1).

[0064] The storage unit 31 also 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 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 who evaluates the elongation of the decorative sheet 3, or may be obtained from a party other than the person who performs 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 will have a shape that roughly matches the shape of the decorated molded product 1. The primary molding condition determination unit 32 provisionally determines the conditions for primary molding based on molded product data in the storage unit 31. Of course, the primary molding condition determination unit 32 may provisionally determine the conditions for primary molding based on mold data generated by a mold data generation unit 34, which will be described later. When the primary molding is blow molding, the primary molding conditions provisionally determined by the primary molding condition determination unit 32 include, for example, the length of time for which gas is blown onto the decorative sheet 3 from the blow molding device 12, the flow rate and flow velocity of the gas blown onto the decorative sheet 3 from the blow molding device 12, the temperature of the decorative sheet 3 during primary molding, and the planar shape of the clamp 10.

[0066] The primary elongation data generating 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 tentatively determined by the primary molding condition determining unit 32. The primary elongation data generating unit 33 stores 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 generating unit 33 generates primary elongation display image data based on the primary elongation data, visually representing 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. The primary elongation display image data may represent the elongation of each part of the decorative sheet 3 represented by the primary elongation data with a color 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. Furthermore, the primary elongation display image data may represent the elongation of each part of the decorative sheet 3 represented by the primary elongation data with a line distortion corresponding to the magnitude of the elongation.

[0068] Based on the molded product data stored in the storage unit 31, the mold data generation unit 34 generates mold data representing the three-dimensional shape of a mold provisionally determined as the vacuum forming mold 13 used for secondary molding of the decorative sheet 3. For example, if the molded product data represents a three-dimensional shape as shown in FIG. 1, mold data representing the shape of the mold 13 shown in FIG. 6 is generated based on the molded product data. The mold data includes data relating to the region corresponding to the main molding portion 14 and data relating to the region corresponding to the sub-molding portion 15. As described above, the main molding portion 14 is the portion of the vacuum forming mold 13 that corresponds to the decorated molded product 1. By including data relating to regions other than the region corresponding to the decorated molded product in the mold data, it is possible to more accurately evaluate the elongation of each portion of the decorative sheet 3 when molded using the mold represented by the mold data. The mold data is, for example, three-dimensional CAD data.

[0069] The secondary elongation data generating 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 generating unit 35 stores data representing the calculated elongation of each part of the decorative sheet 3 after secondary molding as secondary elongation data. The secondary elongation data generating 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 using a provisionally determined molding die 13. The secondary elongation data generating unit 35 generates secondary elongation data based on the primary elongation data generated by the primary elongation data generating unit 33 and the molding die data generated by the molding die data generating unit 34.

[0070] In the illustrated example, the secondary elongation data generating unit 35 generates secondary elongation display image data based on the secondary elongation data, visually representing the correspondence between the elongation of each portion of the decorative sheet 3 before molding and the elongation of each portion of the decorative sheet 3 after secondary molding. The secondary elongation display image data may represent the elongation of each portion of the decorative sheet 3 represented by the secondary elongation data with a color 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. Furthermore, the secondary elongation display image data may represent the elongation of each portion of the decorative sheet 3 represented by the secondary elongation data with a line distortion (e.g., a distortion of lines forming a grid) corresponding to the magnitude of the elongation.

[0071] The post-secondary-forming image data generating unit 36 ​​generates post-secondary-forming image data that represents the decorative sheet 3 after secondary forming, based on the secondary elongation data generated by the secondary elongation data generating unit 35 and the pre-forming image data stored in the storage unit 31. The post-secondary-forming image data may include data on the region formed in the main forming section 14 of the provisionally determined forming mold 13 and data on the region formed in the sub-forming section 15, or may include only data on the region formed in the main forming section 14.

[0072] The post-secondary molding image data may be generated, for example, by deforming the pattern of the decorative sheet 3 before molding represented by the pre-molding image data in accordance with the elongation of each part of the decorative sheet 3 represented by the secondary elongation data (for example, by enlarging the pattern of the decorative sheet 3 in the area with greater elongation than the pattern of the decorative sheet 3 represented by the pre-molding image data). Furthermore, the post-secondary molding image data may be generated, for example, by changing the color of the decorative sheet 3 before molding represented by the pre-molding image data in accordance with the elongation of each part of the decorative sheet 3 represented by the secondary elongation data (for example, by changing the color of the decorative sheet 3 in the area with greater elongation 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 with 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 areas of the decorative sheet 3 with greater elongation appear to have a higher gloss than areas with less elongation.

[0074] Furthermore, the phenomenon of the decorative sheet 3 stretching can also be considered as the phenomenon of the film thickness of the decorative sheet 3 becoming thinner. For example, 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 so that areas of the decorative sheet 3 that have a large stretch appear brighter than areas that have a small stretch.

[0075] Furthermore, when the decorative sheet 3 represented by the pre-molding image data has a plurality of transparent holes that promote light transmission and are formed at a uniform density in a plan view of the decorative sheet 3, it is considered that the opening area of ​​the transparent holes in areas of high elongation in the decorative sheet 3 is larger than the opening area of ​​the transparent holes in areas of low elongation. In this case, the post-secondary molding image data may be generated so that the areas of the decorative sheet 3 with high elongation appear brighter than the areas with low elongation.

[0076] Alternatively, if the decorative sheet 3 represented by the pre-molding image data has a plurality of transparent holes that promote light transmission and are formed at a uniform density in a plan view of the decorative sheet 3, it is conceivable that the density of transparent holes in areas of high elongation in the decorative sheet 3 will be lower than the density of transparent holes in areas of low elongation. In this case, the post-secondary molding image data may be generated so that the areas of the decorative sheet 3 with high elongation appear darker than the areas with low elongation.

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

[0078] By displaying the secondary elongation display image data on the display unit 37, it is easy to evaluate the elongation of each part of the decorative sheet 3 that is further subjected to secondary molding after the primary molding. Furthermore, based on the secondary elongation display image data displayed on the display unit 37, it is possible to determine whether or not the provisionally determined forming mold is appropriate as the forming mold (vacuum forming mold) 13 for secondary molding. Furthermore, if necessary, the design of the provisionally determined forming mold 13 can be changed in consideration of the secondary elongation display image data displayed on the display unit 37.

[0079] Furthermore, by displaying the primary elongation display image data on the display unit 37, it is possible to determine whether the primary molding conditions are appropriate. Furthermore, if necessary, the provisionally determined primary molding conditions can be changed in consideration of the primary elongation display image data. Note that whether the primary molding conditions are appropriate may also be determined based on the secondary elongation display image data displayed on the display unit 37. Furthermore, if necessary, the provisionally determined primary molding conditions may be changed in consideration of the secondary elongation display image data.

[0080] Furthermore, by displaying the image data after secondary molding on the display unit 37, it is easy to grasp the changes in the color and pattern of the decorative sheet 3 after secondary molding. Furthermore, if necessary, the design of the provisionally determined molding die 13, the provisionally determined conditions for primary molding, the color and pattern of the decorative sheet 3, and the positional relationship between the decorative sheet 3 and the molding die 13 can be changed in consideration of the image data after secondary molding.

[0081] Here, even when decorative sheets are molded using the same molding die, the color change of the molded decorative sheet relative to the pre-molded decorative sheet may be easily noticeable in some cases, depending on the color of the decorative sheet. For example, if the color of the pre-molded decorative sheet is dark, and a portion of the decorative sheet significantly elongates due to molding, observers tend to easily notice the color change of that portion of the molded decorative sheet relative to the pre-molded decorative sheet. On the other hand, if the color of the pre-molded decorative sheet is light, even if a portion of the decorative sheet significantly elongates due to molding, observers tend not to notice the color change of that portion of the molded decorative sheet relative to the pre-molded decorative sheet. Therefore, if the color change of the molded decorative sheet relative to the pre-molded decorative sheet is noticeable based on the post-secondary molding image data, it is recommended to consider changing to a lighter colored decorative sheet 3.

[0082] Furthermore, even when decorative sheets are molded using the same molding die, the deformation of the pattern of the decorative sheet after molding may be easily perceived or difficult to perceive, depending on the pattern of the decorative sheet. For example, if the decorative sheet before molding has a pattern consisting of a regular two-dimensional arrangement pattern, such as a mesh pattern, and if a portion of the decorative sheet significantly elongates due to molding, an observer tends to easily notice the deformation of the pattern of the decorative sheet after molding compared to the decorative sheet before molding. On the other hand, if the decorative sheet before molding has a pattern whose regularity is difficult to grasp at a glance, such as a wood grain pattern, an observer tends to have difficulty noticing the deformation of the pattern of the decorative sheet after molding compared to the decorative sheet before molding, even if a portion of the decorative sheet significantly elongates due to molding. Therefore, if the deformation of the pattern of the decorative sheet after molding compared to the decorative sheet before molding is perceptible in the post-secondary molding image data, it is considered to change to a decorative sheet 3 with a pattern whose regularity is difficult to perceive.

[0083] Furthermore, even when decorative sheets are formed using the same mold, the degree of deformation of the decorative sheet's pattern after molding relative to the decorative sheet before molding may differ depending on the positional relationship between the decorative sheet's pattern and the mold when molding the decorative sheet. For example, consider a case where the decorative sheet's pattern is a striped pattern composed of multiple lines. In this case, if the lines constituting the striped pattern extend over a region of the decorative sheet that is significantly stretched, the observer tends to easily notice the deformation of the decorative sheet's pattern after molding relative to the decorative sheet before molding. On the other hand, if the lines constituting the striped pattern do not extend over a region of the decorative sheet that is significantly stretched, the observer tends to have a hard time noticing the deformation of the decorative sheet's pattern after molding relative to the decorative sheet before molding. Therefore, if the post-secondary molding image data reveals a deformation of the decorative sheet's pattern after molding relative to the decorative sheet before molding, changing the positional relationship between the decorative sheet 3 and the mold is considered.

[0084] The display unit 37 may be capable of displaying the post-secondary molding image data in a translated, rotated, enlarged, and / or reduced manner in response to a request from the person making the overall evaluation (for example, by operating an input means (not shown) such as a keyboard or a mouse). This allows the decorative sheet 3 to be observed in the same way as if the person were actually holding and observing the decorated molded product 1.

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

[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). Next, the mold data generating unit 34 generates mold data representing the three-dimensional shape of the tentatively determined mold 13 (step S5).

[0088] Next, in the secondary elongation data generation unit 35, secondary elongation data and secondary elongation display image data are generated 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 the secondary elongation display image data is displayed 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). If the elongation of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding is equal to or less than the threshold value (YES) in step S7, the after-secondary molding image data generating unit 36 ​​generates after-secondary molding image data representing the decorative sheet 3 after secondary molding based on the secondary elongation data and the before-molding image data, and displays it on the display unit 37 (step S8).

[0090] Next, an overall evaluation of the decorative sheet 3 (particularly the region corresponding to the main molding portion 14 of the vacuum forming mold 13) is performed based on the post-secondary-forming image data displayed on the display unit 37 (step S9). The overall evaluation includes evaluation of color change and pattern deformation in each portion 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 (e.g., the customer who requested the production of the decorated molded product 1). If the decorative sheet 3 represented by the post-secondary-forming image data is approved ("Yes" in step S9), it is decided to produce the decorated molded product 1 using the primary molding conditions provisionally determined in step S2 and the molding mold 13 provisionally determined in step S4 (step S10). The determined molding mold 13 is then produced. The decorative sheet 3 represented by the pre-molding image data is then primarily molded under the determined primary molding conditions, and the primarily molded decorative sheet 3 is then secondary molded using the mold 13 produced to produce the decorated molded product 1.

[0091] If the elongation of any part of the decorative sheet 3 after secondary molding is greater than the threshold value in step S7 ("No" in step S7), and if the image data after secondary molding is not approved in step S9 ("No" in step S9), the process returns to step S4 to provisionally determine the molding die 13 again. Specifically, the shape of the molding die 13 provisionally determined in step S4 is changed or modified. Thereafter, the processes from step S5 onwards are repeated based on the changed or modified molding die 13.

[0092] It should be noted that various modifications can be made to the embodiment described above.

[0093] 15A, in step S7, the elongation of the decorative sheet 3 is evaluated based on the secondary elongation display image data, but this is not limiting. 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 taking into consideration any of the average, deviation, maximum value, and ratio of the maximum value to the minimum value of the elongation of each part of the decorative sheet 3. For example, if in step S7 the deviation of the elongation of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding is equal to or less than a threshold value, the process may proceed to step S8 to generate post-secondary molding image data. Furthermore, if in step S7 the deviation of the elongation of the decorative sheet 3 after secondary molding relative to the decorative sheet 3 before molding is greater than the threshold value, the process may return to step S4 and provisionally determine the molding mold again.

[0095] <Modification 1-3> Furthermore, as shown in FIG. 15B , if the elongation of the decorative sheet 3 is greater than the threshold value in step S7 described above ("No" in step S7), the process may return to step S2 and provisionally determine the conditions for primary molding again. Specifically, the conditions for primary molding provisionally determined in step S2 may be changed or modified. Alternatively, if the result in step S7 is "No," the pre-molding image data in 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 whose regularity is difficult to grasp at a glance.

[0096] <Modification 1-4> Furthermore, as shown in Fig. 15C, if the post-secondary molding image data is not approved in step S9 described above ("No" in step S9), the process may return to step S2 and provisionally determine the primary molding conditions again. Specifically, the primary molding conditions provisionally determined in step S2 may be changed or modified. Alternatively, if the result in step S9 is "No," the pre-molding image data in step S1 may be changed or modified.

[0097] 15C, if the elongation of the decorative sheet 3 is greater than the threshold value in step S7 ("No" in step S7), the process returns to step S2 and the conditions for primary molding are tentatively determined again. As yet another variation, if the elongation of the decorative sheet 3 is greater than the threshold value in step S7 ("No" in step S7), the process returns to step S4 and the molding die is tentatively determined again, and if the image data after secondary molding is not approved in step S9 ("No" in step S9), the process returns to step S2 and the conditions for primary molding are tentatively determined again.

[0098] <Modification 1-5> In the example shown in FIGS. 15A to 15C, a case has been described in which one piece of secondary elongation data is generated for one piece of pre-forming image data in step S8, but the present invention is not limited to this.

[0099] 16A, first, molded product data and pre-molded 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 conditions for primary molding 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 condition for primary molding. For example, condition A may be set such that the time length for blowing gas from the blow molding device 12 onto the decorative sheet 3 is A1 seconds, and the flow rate of gas blown onto the decorative sheet 3 from the blow molding device 12 is A2m. ３ / s.

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

[0101] Next, a plurality of molding dies 13 are provisionally determined based on the molded product data (step S14). For example, molding dies 13C and 13D having different surface shapes are provisionally determined.

[0102] Next, 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 are generated. For example, mold data 13CD representing the three-dimensional shape of mold 13C and mold data 13DD representing the three-dimensional shape of mold 13D are generated.

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

[0104] Next, based on the plurality of secondary elongation data or plurality of 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 taking into consideration the average, deviation, maximum value, or ratio of the maximum value and minimum value of the elongation of each part of the decorative sheet 3.

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

[0106] Next, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding portion 14 of the vacuum forming mold 13) is performed based on the post-secondary-forming image data displayed on the display unit 37 (step S19). If the decorative sheet 3 represented by the post-secondary-forming image data is approved ("Yes" in step S19), it is decided to produce the decorated molded product 1 using the primary molding conditions and molding mold 13 corresponding to the secondary elongation data or secondary elongation display image data selected in step S17 (step S20). The decided molding mold 13 is then produced. The decorative sheet 3 represented by the pre-molding image data is then primarily molded under the decided primary molding conditions, and the primarily molded decorative sheet 3 is then secondarily molded using the mold 13 thus prepared, to produce the decorated molded product 1.

[0107] If the post-secondary molding image data is not approved in step S19 ("No" in step S19), the process returns to step S14 and again provisionally selects a molding die 13. For example, a molding die having a different shape from molding dies 13C and 13D is provisionally selected as the molding die 13 for secondary molding. Then, the process from step S15 onwards is repeated based on the newly provisionally selected molding die 13.

[0108] If the post-secondary molding image data is not approved in step S19 ("No" in step S19), the process may return to step S12 and provisionally determine the conditions for one molding again, as shown in Fig. 16B. For example, condition B, which is different from condition A, may be provisionally determined as the conditions for one molding. For example, condition B may be set to B1 seconds for the duration of blowing gas from the blow molding device 12 onto the decorative sheet 3, and the flow rate of gas blown from the blow molding device 12 onto the decorative sheet 3 may be set to B2 m ３ / s. Thereafter, the processes from step S13 onward are repeated based on the newly provisionally determined conditions for the primary molding. If the decorative sheet 3 is primarily molded under different conditions, the shape of the decorative sheet 3 after the primary molding will be different, and the elongation of each part of the decorative sheet 3 after the secondary molding will also be different.

[0109] <Modification 1-5-2> In the manufacturing method shown in FIG. 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 a plurality of primary molding conditions (step S22) based on the molded product data in the storage unit 31. For example, the primary molding condition determination unit 32 provisionally determines condition A and condition B, which are different from each other.

[0111] Next, the primary elongation data generating unit 33 generates primary elongation data based on the provisionally determined conditions for primary molding (step S23). The primary elongation data generating unit 33 generates a plurality of primary elongation data. For example, the primary elongation data generating unit 33 generates primary elongation data AD representing the elongation of each portion of the decorative sheet 3 primarily molded under condition A and primary elongation data BD representing the elongation of each portion of the decorative sheet 3 primarily molded under condition B.

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

[0113] Next, in secondary elongation data generation unit 35, multiple secondary elongation data and multiple secondary elongation display image data are generated based on the primary elongation data generated in primary elongation data generation unit 33 and the forming mold data generated in forming mold data generation unit 34, and the multiple secondary elongation data or multiple secondary elongation display image data are displayed on display unit 37 (step S26). For example, based on the primary elongation data AD generated in step S23 and the forming mold data generated in step S25, secondary elongation data or secondary elongation display image data is generated and displayed on display unit 37. Also, based on the primary elongation data BD generated in step S23 and the forming mold data generated in step S25, secondary elongation data or secondary elongation display image data is generated and displayed on display unit 37.

[0114] Next, based on the plurality of secondary elongation data or plurality of 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 taking into consideration any of the average, deviation, maximum value, and ratio of the maximum value and minimum value of the elongation of each part of the decorative sheet 3.

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

[0116] Next, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding portion 14 of the vacuum forming mold 13) is performed based on the post-secondary-forming image data displayed on the display unit 37 (step S29). If the decorative sheet 3 represented by the post-secondary-forming image data is approved ("Yes" in step S29), it is decided to produce the decorated molded product 1 using the primary molding conditions and molding mold 13 corresponding to the secondary elongation data or secondary elongation display image data selected in step S27 (step S30). The decided molding mold 13 is then produced. The decorative sheet 3 represented by the pre-molding image data is then primarily molded under the decided primary molding conditions, and the primarily molded decorative sheet 3 is then secondarily molded using the mold 13 thus prepared, to produce the decorated molded product 1.

[0117] If the post-secondary molding image data is not approved in step S29 ("No" in step S29), the process returns to step S24 to again provisionally determine the molding die 13. For example, molding die 13D is provisionally determined as the molding die 13 for secondary molding. Then, the processes from step S25 onwards are repeated based on the newly provisionally determined molding die 13D.

[0118] If the post-secondary molding image data is not approved in step S29 ("No" in step S29), the process may return to step S22 and provisionally determine the conditions for the first molding again, as shown in Fig. 17B. For example, provisionally determine conditions for the first molding that are different from conditions A and B. Thereafter, the process from step S23 onward is repeated based on the newly provisionally determined conditions for the first molding.

[0119] <Modification 1-5-3> In the manufacturing method shown in FIG. 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 a plurality of primary molding conditions (step S32) based on the molded product data in the storage unit 31. For example, the primary molding condition determination unit 32 provisionally determines condition A and condition B, which are different from each other.

[0121] Next, the primary elongation data generating unit 33 generates primary elongation data based on the provisionally determined primary molding conditions (step S33). The primary elongation data generating unit 33 generates a plurality of primary elongation data. For example, the primary elongation data generating unit 33 generates primary elongation data AD representing the elongation of each portion of the decorative sheet 3 primarily molded under condition A and primary elongation data BD representing the elongation of each portion of the decorative sheet 3 primarily molded under condition B.

[0122] Next, a plurality of molding dies 13 are provisionally determined based on the molded product data (step S34). For example, molding dies 13C and 13D having different surface shapes are provisionally determined.

[0123] Next, 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 are generated. For example, mold data 13CD representing the three-dimensional shape of mold 13C and mold data 13DD representing the three-dimensional shape of mold 13D are generated.

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

[0125] Next, based on the plurality of secondary elongation data or plurality of 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 taking into consideration any of the average, deviation, maximum value, and ratio of the maximum value and minimum value of the elongation of each part of the decorative sheet 3.

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

[0127] Next, an overall evaluation of the decorative sheet 3 (particularly the region corresponding to the main molding portion 14 of the vacuum forming mold 13) is performed based on the post-secondary-forming image data displayed on the display unit 37 (step S39). If the decorative sheet 3 represented by the post-secondary-forming image data is approved ("Yes" in step S39), it is decided to produce the decorated molded product 1 using the primary molding conditions and molding mold 13 corresponding to the secondary elongation data or secondary elongation display image data selected in step S37 (step S40). The decided molding mold 13 is then produced. The decorative sheet 3 represented by the pre-molding image data is then primarily molded under the decided primary molding conditions, and the primarily molded decorative sheet 3 is then secondarily molded using the mold 13 thus prepared, to produce the decorated molded product 1.

[0128] If the post-secondary molding image data is not approved in step S39 ("No" in step S39), the process returns to step S34 and again provisionally selects a molding die 13. For example, a molding die with a surface shape different from molding dies 13C and 13B is provisionally selected as the molding die 13 for secondary molding. Then, the process from step S35 onwards is repeated based on the newly provisionally selected molding die 13.

[0129] If the post-secondary molding image data is not approved in step S39 ("No" in step S39), the process may return to step S32 and provisionally determine the conditions for the first molding again, as shown in Fig. 18B. For example, provisionally determine conditions for the first molding that are different from conditions A and B. Thereafter, the process from step S33 onward is repeated based on the newly provisionally determined conditions for the first molding.

[0130] The evaluation method according to the first embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorative molded article 1 including the molded decorative sheet 3. This method includes the following steps: - A step of generating or acquiring molded article data representing the three-dimensional shape of the decorative molded article 1. - A step of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. - A step of provisionally determining the molding die 13 to be used for secondary molding of the decorative sheet 3 based on the molded article data. - A step of generating molding die data representing the three-dimensional shape of the provisionally determined molding die 13. - A step of provisionally determining the conditions for primary molding based on the molded article data or the molding die data. Here, the primary molding is performed to stretch the decorative sheet 3 before molding so that it fits the decorative molded article 1. - A primary elongation data generation step of generating primary elongation data. Here, the primary elongation data is data calculated based on the provisionally determined conditions for primary molding and indicating the elongation of each part of the decorative sheet 3 after primary molding relative to the decorative sheet 3 before molding. A secondary elongation data generating step of generating secondary elongation data. Here, the secondary elongation data is data calculated based on the primary elongation data and the forming mold data, and indicates 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 indicates 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 the provisionally determined forming mold 13.

[0131] The evaluation method according to the modified example of the first embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorative molded article 1 including the molded decorative sheet 3. This method includes the following steps: - A step of generating or acquiring molded article data representing the three-dimensional shape of the decorative molded article 1. - A step of generating or acquiring pre-molding image data representing the decorative sheet 3 before molding. - A step of provisionally determining multiple molding dies 13 to be used for secondary molding of the decorative sheet 3 based on the molded article data. - A step of generating molding die data representing the three-dimensional shape of each provisionally determined molding die 13. - A step of provisionally determining primary molding conditions based on the molded article data or the molding die data. Here, the primary molding is performed to stretch the decorative sheet 3 before molding so that it fits the decorative molded article 1. - A primary elongation data generation step of generating primary elongation data. Here, the primary elongation data is data calculated based on the provisionally determined primary molding conditions and indicating the elongation of each part of the decorative sheet 3 after primary molding relative to the decorative sheet 3 before molding. A secondary elongation data generating step of generating a plurality of secondary elongation data. Here, the secondary elongation data is data calculated based on the primary elongation data and each molding die data, and indicates 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 indicates 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 provisionally determined molding die 13.

[0132] The evaluation method according to another modification of the first embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorative 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 decorative 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 molding die 13 to be used for secondary molding of the decorative sheet 3 based on the molded product data. - A step of generating molding die data representing the three-dimensional shape of the provisionally determined molding die 13. - A step of provisionally determining multiple conditions for primary molding based on the molded product data or the molding die data. Here, the primary molding is performed to stretch the decorative sheet 3 before molding so that it fits the decorative molded product 1. - A primary elongation data generation step of generating multiple primary elongation data. Here, each primary elongation data is data that indicates 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 provisionally determined condition of primary molding. A secondary elongation data generating step of generating a plurality of secondary elongation data. Here, each secondary elongation data is calculated based on each primary elongation data and forming mold data, and is data indicating 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 indicates 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 forming mold 13 under each provisionally determined condition.

[0133] The evaluation method according to another modification of the first embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorative 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 decorative 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 multiple molding dies 13 to be used for secondary molding of the decorative sheet 3 based on the molded product data. - A step of generating molding die data representing the three-dimensional shape of each provisionally determined molding die 13. - A step of provisionally determining multiple conditions for primary molding based on the molded product data or the molding die data. Here, the primary molding is performed to stretch the decorative sheet 3 before molding so that it fits the decorative molded product 1. - A primary elongation data generation step of generating multiple primary elongation data. Here, each primary elongation data is data that indicates 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 provisionally determined condition of primary molding. A secondary elongation data generating step of generating a plurality of secondary elongation data. Here, each secondary elongation data is calculated based on each primary elongation data and each molding die data, and is data indicating 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 indicates 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 provisionally determined molding die 13 under each provisionally determined condition.

[0134] These evaluation methods allow for efficient design of the mold 13, determination of the conditions for primary molding, 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 decorated molded product 1, without actually producing the mold 13 or performing primary molding or secondary molding of the decorative sheet 3. Therefore, the effort required for prototyping the decorated molded product 1 is significantly reduced, and the time and cost required to complete the decorated molded product 1 are also significantly reduced.

[0135] The evaluation method according to the first embodiment and its modified examples described above further includes the following steps: A step of 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 the elongation of each part of the decorative sheet 3 after secondary molding, based on the secondary elongation data.

[0136] In this case, it is possible to easily grasp 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 secondary molding.

[0137] The evaluation method according to the first embodiment and its modified examples described above further includes the following steps: A step of 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 the primary elongation data.

[0138] In this case, 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 can be easily grasped, making it easy to determine whether the conditions for primary molding are appropriate.

[0139] The evaluation method according to the first embodiment and its modified examples described above further includes the following steps: A post-secondary-forming image data generation step of generating post-secondary-forming image data representing the decorative sheet 3 after secondary forming based on the secondary elongation data and the pre-forming image data.

[0140] In this case, it is easy to perform an overall evaluation of the decorative sheet 3 after secondary molding, and 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. Fig. 19 is a perspective view of a decorated molded product 1 according to the second embodiment. Fig. 20 is a perspective view of a clamp 40 used in manufacturing the decorated molded product 1 shown in Fig. 19. Figs. 21 to 24 are views for explaining an example of a method for forming the decorative sheet 3 of the decorated molded product 1 shown in Fig. 19. In the description of the second embodiment, parts similar to those of the first embodiment shown in Figs. 1 to 18 are designated by the same reference numerals, and detailed description thereof will be omitted.

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

[0143] The clamp 40 shown in Fig. 20 can hold the decorative sheet 3 in a bent state. More specifically, the clamp 40 can hold the decorative sheet 3 so that the bent shape roughly follows the shape of the decorated molded product 1 shown in Fig. 19 (more specifically, the shape of the decorative sheet 3 in the decorated molded product 1). In other words, the bent shape of the decorative sheet 3 during molding is determined by the clamp 40. In the example shown in Fig. 19, the clamp 40 is formed in an annular shape and holds four sides of the decorative sheet 3, but this 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 preforming the decorative sheet 3 according to the second embodiment will be described. First, as shown in Fig. 20, the edge of the decorative sheet 3 is held with a clamp 40. This allows the decorative sheet 3 to be held in a bent state so that it can roughly fit the decorated molded product 1 shown in Fig. 19 (more specifically, the shape of the decorative sheet 3 in the decorated molded product 1).

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

[0146] 22, the decorative sheet 3 is placed facing the vacuum forming die 13. The decorative sheet 3 is placed so as to cover the main molding portion 14 and the sub-molding portion 15 of the vacuum forming die 13.

[0147] Next, the gas inside 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 Figure 23, the decorative sheet 3 stretches and comes into close contact with the main molding portion 14 and the sub-molding portion 15. Thereafter, the temperature of the decorative sheet 3 is lowered, and the decorative sheet 3 is solidified. This causes the decorative sheet 3 to be 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. Thereafter, as shown in Fig. 24, unnecessary portions are removed from the decorative sheet 3 removed from the vacuum forming mold 13. In this way, 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 a mold corresponding to the decorated molded product 1 shown in Figure 19, and the molded part 2 is produced in a manner similar to that shown in Figures 10 to 13.

[0150] According to this manufacturing method for the decorated molded product 1, the decorative sheet 3 is bent so that it can roughly fit the shape of the decorated molded product 1, and then vacuum-formed to conform to the shape of the decorated molded product 1. Therefore, compared to forming a planar decorative sheet 3 using a vacuum-forming mold 13, the distance between each part of the decorative sheet 3 and each part of the vacuum-forming mold 13 at the start of vacuum forming can be made smaller. As a result, the difference in elongation between each part of the decorative sheet 3 can be made smaller, and the risk of excessive stretching of a part of the decorative sheet 3 is reduced. Therefore, the risk of the decorative sheet 3 tearing, a noticeable color change in a part of the decorative sheet 3, or a noticeable distortion of the pattern on the decorative sheet 3 during vacuum forming is reduced.

[0151] However, even with this method of forming the decorative sheet 3, the color of the portion of the decorative sheet 3 may change significantly, or the pattern on 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 elongation of the decorative sheet 3, it is possible to suppress the color change or pattern distortion by modifying the surface shape of the decorated molded article 1 or the shape of the molding die (vacuum molding die) 13. This allows the design imparted to the decorated molded article 1 to approach the intended design. However, repeatedly remaking the molding die 13 until a satisfactory decorated molded article 1 is produced increases the time and cost required to complete the decorated molded article 1.

[0152] Taking this into consideration, the manufacturing method of the decorated molded product 1 of the second embodiment uses an evaluation device 50 shown in Fig. 25, which makes it possible to evaluate the elongation of the decorative sheet 3 when producing the decorated molded product 1 without producing a molding die 13 or producing the decorated molded product 1. The evaluation device 50 shown in Fig. 25 includes a storage unit 51, a molding die data generation unit 52, a clamp data generation unit 53, and an elongation data generation unit 54. In the example shown in Fig. 25, the evaluation device 50 further includes a post-molding image data generation unit 55 and a display unit 56.

[0153] The storage 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, for example, based on 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 may be obtained from a party other than the person who evaluates the elongation (for example, a customer who requests the production of the decorated molded product 1).

[0154] The storage unit 51 also 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 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 who evaluates the elongation of the decorative sheet 3, or may be obtained from a party other than the person who performs 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 a mold provisionally determined as the vacuum forming mold 13 to be used in forming 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 FIG. 19, mold data representing the shape of the mold 13 shown in FIG. 22 is generated based on the molded product data. The mold data includes data relating to the region corresponding to the main molding portion 14 and data relating to the region corresponding to the sub-molding portion 15. As described above, the main molding portion 14 is the portion of the vacuum forming mold 13 that corresponds to the decorated molded product 1. By including data relating to regions other than the region corresponding to the decorated molded product 1 in the mold data, it is possible to more accurately evaluate the elongation of each portion of the decorative sheet 3 when molded using the mold 13 represented by the mold data. The mold data is, for example, three-dimensional CAD data.

[0156] The clamp data generation unit 53 provisionally determines the clamps 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 clamps 40. For example, if the mold data represents the three-dimensional shape of the mold 13 shown in Fig. 22, then the clamp data representing the shape of the clamps 40 shown in Fig. 20 is generated based on the 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 data representing the calculated 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 held and bent by the clamps 40 is molded using the provisionally determined molding die 13. The elongation data generation unit 54 generates the elongation data based on the clamp data generated by the clamp data generation unit 53 and the molding die data generated by the molding die data generation unit 52.

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

[0159] The post-molding image data generating unit 55 generates post-molding image data representing the decorative sheet 3 after secondary molding, based on the elongation data generated by the elongation data generating unit 54 and the pre-molding image data stored in the storage unit 51. The post-molding image data may include data on the region molded in the main molding section 14 of the provisionally determined molding die 13 and data on the region molded in the sub-molding section 15, or may include only data on the region molded in the main molding section 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 in accordance with the elongation of each part of the decorative sheet 3 represented by the elongation data (for example, by enlarging the pattern of the decorative sheet 3 in the area with greater elongation than the pattern of the decorative sheet 3 represented by the pre-molding image data). The post-molding image data may also be generated, for example, by changing the color of the pre-molding decorative sheet 3 represented by the pre-molding image data in accordance with the elongation of each part of the decorative sheet 3 represented by the elongation data (for example, by changing the color of the pre-molding decorative sheet 3 in the area with greater elongation 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 with 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 areas of the decorative sheet 3 with greater elongation appear to have a higher gloss than 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 material that transmits light, the post-secondary molding image data may be generated so that areas of the decorative sheet 3 with greater elongation appear brighter than areas with less elongation.

[0163] Furthermore, as described above, if the decorative sheet 3 represented by the pre-molding image data has multiple transparent holes that promote light transmission and are formed at a uniform density when viewed in a plane on the decorative sheet 3, the post-secondary molding image data may be generated so that areas of the decorative sheet 3 with greater elongation appear brighter than areas with less elongation, or so that areas of the decorative sheet 3 with greater elongation appear darker than areas with less elongation.

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

[0165] Displaying the elongation display image data on the display unit 56 makes it easy to evaluate the elongation of each part of the formed decorative sheet 3. Furthermore, based on the elongation display image data displayed on the display unit 56, it can be determined whether or not the provisionally determined forming mold is appropriate as the forming mold (vacuum forming mold) 13 for the decorative sheet 3. Furthermore, if necessary, the design of the provisionally determined forming mold can be changed in consideration of the elongation display image data displayed on the display unit 56.

[0166] Furthermore, by displaying the clamp data on the display unit 56, it is possible to determine whether the shape of the clamp 40 is appropriate. Furthermore, if necessary, the conditions of the provisionally determined clamp 40 can be changed in consideration of the clamp data. Note that whether the shape of the clamp 40 is appropriate may be determined based on the elongation display image data displayed on the display unit 56. Furthermore, if necessary, the conditions of the provisionally determined clamp 40 can be changed in consideration of the elongation display image data.

[0167] Furthermore, by displaying the post-molding image data on the display unit 56, it is easy to grasp changes in the color and pattern of the decorative sheet 3 after molding. Furthermore, if necessary, the post-molding image data can be taken into consideration to change the provisionally determined design of the molding die 13 and clamps 40, change the color and pattern of the decorative sheet 3, or change the positional relationship between the decorative sheet 3 and the molding die.

[0168] The display unit 56 may be capable of displaying the post-molding image data in a translated, rotated, enlarged, and / or reduced manner in response to a request from the person making the overall evaluation (for example, by operating an input means (not shown) such as a keyboard or a mouse). This allows the decorative sheet 3 to be observed in the same way as if the person were actually holding the decorated molded product 1 in his or her hands.

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

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

[0171] Next, the elongation data generating unit 54 generates elongation data and elongation display image data based on the clamp data generated by the clamp data generating unit 53 and the molding die data generated by the molding die data generating unit 52, and displays the secondary elongation display image data on the display unit 56 (step S56). Next, based on the elongation display image data displayed on the display unit 56, the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding is evaluated (step S57). If, in step S57, the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding is equal to or less than a threshold value (YES), the post-molding image data generating unit 55 generates post-molding image data representing the decorative sheet 3 after molding based on the elongation data and pre-molding image data, and displays the data on the display unit 56 (step S58).

[0172] Next, an overall evaluation of the decorative sheet 3 (particularly the region corresponding to the main molding portion 14 of the vacuum forming mold 13) is performed based on the post-molding image data displayed on the display unit 56 (step S59). The overall evaluation includes evaluation of color change and pattern deformation in each portion 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 (e.g., the customer who requested the production of the decorated molded product 1). If the decorative sheet 3 represented by the post-molding image data is approved ("Yes" in step S59), it is decided to use the molding die 13 provisionally determined in step S52 and the clamps 40 provisionally determined in step S54 to produce the decorated molded product 1 (step S60). The determined molding die 13 is then produced. The decorative sheet 3 represented by the pre-molding image data is then bent while held by the determined clamps 40, and the bent decorative sheet 3 is molded using the produced molding die 13 to produce the decorated molded product 1.

[0173] If the elongation of any part of the molded decorative sheet 3 is greater than the threshold value in step S57 ("No" in step S57), and if the molded image data is not approved in step S59 ("No" in step S59), the process returns to step S52 to provisionally determine the molding die 13 again. Specifically, the shape of the molding die 13 provisionally determined in step S52 is changed or modified. Thereafter, the processes from step S52 onwards are repeated based on the changed or modified molding die 13.

[0174] It should be noted that various modifications can be made to the embodiment described above.

[0175] 26A, in step S57, the elongation of the decorative sheet 3 is evaluated based on the elongation display image data, but this is not limiting. The elongation of the decorative sheet 3 may also be evaluated based on elongation data.

[0176] 26A , the evaluation of the elongation of the decorative sheet 3 may be performed by taking into consideration any of the average, deviation, maximum value, and ratio of the maximum value to the minimum value of the elongation of each portion of the decorative sheet 3. For example, if the deviation of the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding is equal to or less than a threshold value in step S57, the process may proceed to step S58 to generate post-molding image data. If the deviation of the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding is greater than the threshold value in step S57, the process may return to step S52 and provisionally determine the molding die 13 again.

[0177] <Modification 2-3> Furthermore, as shown in FIG. 26B , if the elongation of the decorative sheet 3 is greater than the threshold value in step S57 ("No" in step S57), the process may return to step S54 and provisionally determine the clamps 40 again. Specifically, the shape of the clamps 40 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 whose regularity is difficult to grasp at a glance.

[0178] 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 provisionally determine the clamps 40 again. Alternatively, if the result in step S59 is "No," the pre-molding image data in step S51 may be changed or corrected.

[0179] <Modification 2-5> In the example shown in FIGS. 26A to 26C, a case has been described in which one piece of elongation data is generated for one piece of pre-shaping image data in step S56, but the present invention is not limited to this.

[0180] <Modification 2-5-1> In the manufacturing method shown in FIG. 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, a plurality of molding dies 13 are provisionally determined based on the molded product data (step S62). For example, molding dies 13E and 13F having different surface shapes are provisionally determined.

[0182] Next, 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 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 forming dies 13 (step S64). In step S64, one clamp 40 is provisionally determined to be common to the provisionally determined multiple forming dies 13. For example, clamp 40G is provisionally determined for forming dies 13E and 13F.

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

[0185] Next, in the elongation data generation unit 54, a plurality of elongation data and a plurality of elongation display image data are generated based on the clamp data generated by the clamp data generation unit 53 and the respective forming mold data generated by the forming mold data generation unit 52, and the plurality of elongation data or the plurality of elongation display image data are displayed on the display unit 56 (step S66). For example, the elongation data and the elongation display image data are generated based on the clamp data 40GD and the forming mold data 13ED. Also, the elongation data and the elongation display image data are generated based on the clamp data 40GD and the forming mold data 13FD.

[0186] Next, based on the plurality of elongation data or plurality of elongation display image data displayed on the display unit 56, the elongation of each decorative sheet 3 after molding relative to the decorative sheet 3 before molding is evaluated, and one piece of elongation data or one piece of elongation display image data is selected (step S67). In step S67, one piece of elongation data or one piece of elongation display image data is selected taking into consideration the average, deviation, maximum value, or ratio of the maximum value and minimum value of the elongation of each part of the decorative sheet 3.

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

[0188] Next, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding portion 14 of the vacuum forming mold 13) is performed based on the post-molding image data displayed on the display unit 56 (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 clamps 40 and molding die 13 corresponding to the elongation data or elongation display image data selected in step S67 to produce the decorated molded product 1 (step S70). The determined molding die 13 is then produced. The decorative sheet 3 represented by the pre-molding image data is then held in a bent state using the determined clamps 40, and the bent decorative sheet 3 is molded using the prepared molding die 13, producing the decorated 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 and a new molding die 13 is provisionally selected. For example, a molding die 13 having a different shape from molding dies 13E and 13F is provisionally selected as the molding die 13 for molding. Then, the process from step S63 onward is repeated based on the newly provisionally selected molding die 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 provisionally determine the shape of the clamps 40 again, as shown in FIG. 27B . For example, if clamps 40G have been provisionally determined for the molding dies 13E and 13F, clamps 40H having a different shape from clamps 40G may be provisionally determined as new clamps for the molding dies 13E and 13F. In this case, the bending shape of the decorative sheet 3 when held by clamps 40H will be different from the bending shape of the decorative sheet 3 when held by clamps 40G. Thereafter, the processes from step S65 onward are repeated based on the newly provisionally determined clamps 40. If the decorative sheet 3 is held by clamps of different shapes and bent into different shapes, the elongation of each portion of the decorative sheet 3 after molding will also be different.

[0191] <Modification 2-5-2> In the manufacturing method shown in FIG. 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 provisionally determined based on the molded product data (step S72). For example, mold 13E is provisionally determined as the vacuum forming mold 13.

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

[0194] Next, the clamp data generating unit 53 provisionally determines a plurality of three-dimensional shapes of the clamps 40 based on the provisionally determined forming die 13 (step S74). For example, clamps 40G and 40H, which have different shapes, are provisionally determined as the clamps 40 for the forming die 13E. The curved shape of the decorative sheet 3 when held by the clamp 40G is different from the curved shape of the decorative sheet 3 when held by the clamp 40H.

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

[0196] Next, in the elongation data generation unit 54, multiple elongation data and multiple elongation display image data are generated 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 the multiple elongation data or multiple elongation display image data are displayed on the display unit 56 (step S76). For example, the elongation data and elongation display image data are generated based on the clamp data 40GD and the mold data 13ED. Also, the 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 plurality of elongation data or plurality of elongation display image data displayed on the display unit 56, the elongation of each decorative sheet 3 after molding relative to the decorative sheet 3 before molding is evaluated, and one piece of elongation data or one piece of elongation display image data is selected (step S77). In step S77, one piece of elongation data or one piece of elongation display image data is selected taking into consideration the average, deviation, maximum value, or ratio of the maximum value and minimum value of the elongation of each part of the decorative sheet 3.

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

[0199] Next, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding portion 14 of the vacuum forming mold 13) is performed based on the post-molding image data displayed on the display unit 56 (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 clamps 40 and molding die 13 corresponding to the elongation data or elongation display image data selected in step S77 to produce the decorated molded product 1 (step S80). The determined molding die 13 is then produced. The decorative sheet 3 represented by the pre-molding image data is then held in a bent state using the determined clamps 40, and the bent decorative sheet 3 is molded using the prepared molding die 13, producing the decorated 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 and a new tentative mold 13 is selected. For example, mold 13F, which has a different surface shape from mold 13E, is tentatively selected as the mold 13 for molding. Then, the process from step S73 onward is repeated based on the newly tentatively selected 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 provisionally determine the shape of clamp 40 again, as shown in Figure 28B. For example, if clamps 40G and 40H have been provisionally determined for molding die 13E, clamps 40 having a different shape from clamps 40G and 40H may be provisionally determined as new clamps for molding die 13E. Thereafter, the processes from step S75 onwards are repeated based on the newly provisionally determined clamps 40.

[0202] <Modification 2-5-3> In the manufacturing method shown in FIG. 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, a plurality of molding dies 13 are provisionally determined based on the molded product data (step S82). For example, molding dies 13E and 13F having different surface shapes are provisionally determined.

[0204] Next, 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 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.

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

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

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

[0208] Next, based on the plurality of elongation data or plurality of elongation display image data displayed on the display unit 56, the elongation of each decorative sheet 3 after molding relative to the decorative sheet 3 before molding is evaluated, and one piece of elongation data or one piece of elongation display image data is selected (step S87). In step S87, one piece of elongation data or one piece of elongation display image data is selected taking into consideration the average, deviation, maximum value, or ratio of the maximum value and the minimum value of the elongation of each part of the decorative sheet 3.

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

[0210] Next, an overall evaluation of the decorative sheet 3 (particularly the area corresponding to the main molding portion 14 of the vacuum forming mold 13) is performed based on the post-molding image data displayed on the display unit 56 (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 clamps 40 and molding die 13 corresponding to the elongation data or elongation display image data selected in step S87 to produce the decorated molded product 1 (step S90). The determined molding die 13 is then produced. The decorative sheet 3 represented by the pre-molding image data is then held in a bent state using the determined clamps 40, and the bent decorative sheet 3 is molded using the prepared molding die 13, producing the decorated 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 and a new tentative mold 13 is selected. For example, a mold 13 having a surface shape different from that of molds 13E and 13F is tentatively selected as the mold 13 for molding. Then, the process from step S83 onward is repeated based on the newly tentatively selected mold 13.

[0212] If the post-molding image data is not approved in step S89 ("No" in step S89), as shown in FIG. 29B, the process may return to step S84 and provisionally determine the clamps 40 again. For example, the clamps 40 may have a shape different from the clamps 40G and 40H. Thereafter, the process from step S85 onward is repeated based on the newly provisionally determined clamps 40.

[0213] The evaluation method according to the second embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorated molded product 1 including the molded decorative sheet 3. This method comprises 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 provisionally determining the molding die 13 to be used for molding the decorative sheet 3 based on the molded product data. A step of generating molding die data representing the three-dimensional shape of the provisionally determined molding die 13. A step of provisionally determining a bent shape, which is a shape obtained by bending the decorative sheet 3 before molding so that it fits the decorated molded product 1, based on the molded product data or the molding die data (a step of provisionally determining the clamps 40). An elongation data generation step of generating elongation data. Here, the elongation data is data calculated based on the provisionally determined bending shape and the molding die data of the provisionally determined molding die 13, and indicates the elongation of each part of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding, when the bent decorative sheet 3 is molded using the provisionally determined molding die 13.

[0214] The evaluation method according to the modified example of the second embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorated molded product 1 including the molded decorative sheet 3. This method comprises 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 provisionally determining multiple molding dies 13 to be used in molding the decorative sheet 3 based on the molded product data. A step of generating molding die data representing the three-dimensional shape of each provisionally determined molding die 13. A step of provisionally determining a bent shape, which is a shape obtained by bending the decorative sheet 3 before molding so as to fit the decorated molded product 1, based on the molded product data or the molding die data (a step of provisionally determining the clamps 40). An elongation data generation step of generating multiple elongation data. Here, each elongation data is calculated based on the provisionally determined bending shape and the provisionally determined molding die data of each molding die 13, and is data that indicates the elongation of each part of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding, when the bent decorative sheet 3 is molded using the provisionally determined molding die 13.

[0215] The evaluation method according to another modification of the second embodiment described above is a method for evaluating the elongation of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorated molded product 1 including the molded decorative sheet 3. This method comprises 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 provisionally determining the molding die 13 to be used for molding the decorative sheet 3 based on the molded product data. A step of generating molding die data representing the three-dimensional shape of the provisionally determined molding die 13. A step of provisionally determining multiple bent shapes, which are shapes obtained by bending the decorative sheet 3 before molding so as to fit the decorated molded product 1, based on the molded product data or the molding die data (a step of provisionally determining multiple clamps 40). An elongation data generation step of generating multiple elongation data. Here, each elongation data is calculated based on each provisionally determined bending shape and the molding die data of the provisionally determined molding die 13, and is data indicating the elongation of each part of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding, when the bent decorative sheet 3 is molded using the provisionally 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 decorative sheet 3 after molding relative to the decorative sheet 3 before molding when producing a decorated molded product 1 including the molded decorative sheet 3. This method comprises 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 provisionally determining multiple molding dies to be used in molding the decorative sheet 3 based on the molded product data. A step of generating molding die data representing the three-dimensional shape of each provisionally determined molding die 13. A step of provisionally determining multiple bent shapes, which are shapes obtained by bending the decorative sheet 3 before molding so as to fit the decorated molded product 1, based on the molded product data or the molding die data (a step of provisionally determining multiple clamps 40). An elongation data generation step of generating multiple elongation data. Here, each elongation data is calculated based on the provisionally determined bending shape and the molding die data of each provisionally determined molding die 13, and is data that indicates the elongation of each part of the decorative sheet 3 after molding relative to the decorative sheet 3 before molding, when the bent decorative sheet 3 is molded using the provisionally determined molding die 13.

[0217] These evaluation methods allow for efficient design of the clamp 40 and the vacuum forming die 13, and for determining 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 decorated molded product 1, without actually producing the clamp 40 and the vacuum forming die 13, or forming the decorative sheet 3. This significantly reduces the effort required to prototype the decorated molded product 1, and significantly reduces the time and cost required to complete the decorated molded product.

[0218] The evaluation method according to the second embodiment and its modified example described above further includes the following steps: A step of generating 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 molding, based on the elongation data and the pre-molding image data.

[0219] In this case, 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 molding can be easily grasped.

[0220] The evaluation method according to the second embodiment and its modified example described above further includes the following steps: A post-molding image data generation step of generating post-molding image data representing the decorative sheet 3 after molding based on the elongation data and the pre-molding image data.

[0221] In this case, it is easy to perform an overall evaluation of the molded decorative sheet 3. In particular, it is easy to grasp the color and pattern of the molded decorative sheet 3.

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

[0223] Although several modifications of the above-described embodiment have been described, it is of course possible to combine a plurality of modifications as appropriate.

[0224] REFERENCE SIGNS LIST 1 Decorated molded product 2 Molding section 3 Decorative sheet 4 Base sheet 5 Design layer 6 Surface protective layer 10 Clamp 11 Heater 12 Blow molding device 13 Vacuum molding mold 14 Main molding section 15 Sub-molding section 20 Injection molding device 21 Injection molding mold 30 Evaluation device 31 Memory section 32 Primary molding condition determination section 33 Primary elongation data generation section 34 Mold data generation section 35 Secondary elongation data generation section 36 Post-secondary molding image data generation section 37 Display section 40 Clamp 50 Evaluation device 51 Memory section 52 Mold data generation section 53 Clamp data generation section 54 Elongation data generation section 55 Post-molding image data generation section 56 Display section

Claims

1. A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding when producing a decorative molded product including the molded decorative sheet, comprising: generating or acquiring molded product data representing a three-dimensional shape of the decorated molded product; generating or acquiring pre-molding image data representing the decorative sheet before molding; a step of provisionally determining a molding die to be used for molding the decorative sheet based on the molded product data; generating forming mold data representing the provisionally determined three-dimensional shape of the forming mold; a step of provisionally determining conditions for primary molding for stretching the pre-molded decorative sheet so as to conform to the decorated molded product based on the molded product data or the mold data; a primary elongation data generating step of calculating elongation of each portion of the decorative sheet after the primary molding relative to the decorative sheet before molding based on the provisionally determined conditions of the primary molding, and generating primary elongation data; a secondary elongation data generating step of calculating elongation of each part of the decorative sheet after the secondary molding relative to the decorative sheet before molding, based on the primary elongation data and the molding die data, by secondary molding in which the decorative sheet after the primary molding is molded using the provisionally determined molding die, to generate secondary elongation data; An evaluation method comprising:

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

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

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

6. The evaluation method according to claim 1, further comprising a post-secondary-forming image data generating step of generating post-secondary-forming image data representing the decorative sheet after the secondary forming based on the secondary elongation data and the pre-forming image data.

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

8. The decorative sheet has a color, The evaluation method according to claim 6, wherein the post-secondary forming image data is generated by changing the color of each portion of the decorative sheet before forming in accordance with the elongation of each portion of the decorative sheet represented by the secondary elongation data.

9. the primary molding is blow molding, The evaluation method according to claim 1 , wherein the secondary forming is vacuum forming using the forming mold.

10. A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding when producing a decorative molded product including the molded decorative sheet, comprising: generating or acquiring molded product data representing a three-dimensional shape of the decorated molded product; generating or acquiring pre-molding image data representing the decorative sheet before molding; a step of provisionally determining a plurality of molding dies to be used for molding the decorative sheet based on the molded product data; generating forming mold data representing the three-dimensional shape of each provisionally determined forming mold; a step of provisionally determining conditions for primary molding for stretching the pre-molded decorative sheet so as to conform to the decorated molded product based on the molded product data or the mold data; a primary elongation data generating step of calculating elongation of each portion of the decorative sheet after the primary molding relative to the decorative sheet before molding based on the provisionally determined conditions of the primary molding, and generating primary elongation data; a secondary elongation data generating step of calculating elongation of each part of the decorative sheet after the secondary molding relative to the decorative sheet before molding, based on the primary elongation data and each molding die data, by secondary molding in which the decorative sheet after the primary molding is molded using the provisionally determined molding die, to generate a plurality of secondary elongation data; An evaluation method comprising:

11. A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding when producing a decorative molded product including the molded decorative sheet, comprising: generating or acquiring molded product data representing a three-dimensional shape of the decorated molded product; generating or acquiring pre-molding image data representing the decorative sheet before molding; a step of provisionally determining a molding die to be used for molding the decorative sheet based on the molded product data; generating forming mold data representing the provisionally determined three-dimensional shape of the forming mold; a step of provisionally determining a plurality of primary molding conditions for stretching the pre-molded decorative sheet so as to conform to the decorated molded product based on the molded product data or the mold data; a primary elongation data generating step of calculating elongation of each portion of the decorative sheet after the primary molding relative to the decorative sheet before molding based on each provisionally determined condition of the primary molding, and generating a plurality of primary elongation data; a secondary elongation data generating step of calculating elongation of each part of the decorative sheet after the secondary molding relative to the decorative sheet before molding, based on each primary elongation data and the molding die data, by secondary molding in which the decorative sheet after the primary molding is molded using the provisionally determined molding die, to generate a plurality of secondary elongation data; An evaluation method comprising:

12. A method for evaluating the elongation of a decorative sheet after molding relative to the decorative sheet before molding when producing a decorative molded product including the molded decorative sheet, comprising: generating or acquiring molded product data representing a three-dimensional shape of the decorated molded product; generating or acquiring pre-molding image data representing the decorative sheet before molding; a step of provisionally determining a plurality of molding dies to be used for molding the decorative sheet based on the molded product data; generating forming mold data representing the three-dimensional shape of each provisionally determined forming mold; a step of provisionally determining a plurality of primary molding conditions for stretching the pre-molded decorative sheet so as to conform to the decorated molded product based on the molded product data or the mold data; a primary elongation data generating step of calculating elongation of each portion of the decorative sheet after the primary molding relative to the decorative sheet before molding based on each provisionally determined condition of the primary molding, and generating a plurality of primary elongation data; a secondary elongation data generating step of calculating elongation of each part of the decorative sheet after the secondary molding relative to the decorative sheet before molding, based on each primary elongation data and each molding die data, by secondary molding in which the decorative sheet after the primary molding is molded using the provisionally determined molding die, to generate a plurality of secondary elongation data; An evaluation method comprising:

13. a post-secondary-forming image data generating step of generating a plurality of post-secondary-forming image data representing the decorative sheet after the secondary forming based on each secondary elongation data and the pre-forming image data; The evaluation method according to claim 10 , comprising:

14. Further comprising a step of selecting one secondary elongation data from the plurality of secondary elongation data, 13. The evaluation method according to claim 10, wherein in the step of selecting the secondary elongation data, any of the average, deviation, maximum value, and ratio of the maximum value and minimum value of elongation of a plurality of portions of each decorative sheet after the secondary molding relative to the decorative sheet before molding is calculated based on each secondary elongation data, and one secondary elongation data is selected based on the average, deviation, maximum value, and ratio of the maximum value and minimum value of elongation.

15. A method for producing a decorated molded product including a molded decorative sheet, comprising: a step of evaluating elongation of each portion of the decorative sheet after the secondary molding relative to the decorative sheet before molding, when the decorative sheet is subjected to primary molding under provisionally determined conditions for the primary molding and then subjected to secondary molding using the provisionally determined mold, according to the evaluation method of any one of claims 1 and 10 to 12; determining the decorative sheet and / or the primary molding conditions and / or the molding die based on the evaluation result of the elongation; A manufacturing method comprising: