Method of manufacturing molded body and molded body manufacturing apparatus

Abstract

A method of manufacturing a molded body, the method including producing a first molded body by pressurizing a material containing fibers by a pressurizing mechanism to transfer a pattern, and bonding the fibers, and producing a second molded body by performing processing at a position corresponding to the pattern formed when the first mold body is produced.

Description

[0001] The present application is based on, and claims priority from JP Application Serial Number 2024-218805, filed Dec. 13, 2024, the disclosure of which is hereby incorporated by reference herein in its entirety.BACKGROUND1. Technical Field

[0002] The present disclosure relates to a method of manufacturing a molded body and a molded body manufacturing apparatus.2. Related Art

[0003] For example, JP-A-2024-113315 discloses a device for manufacturing a sheet from fibers.

[0004] However, the manufacture of a product using a sheet manufactured by the method described in JP-A-2024-113315 has not been sufficiently studied.SUMMARY

[0005] According to an aspect of the present disclosure, there is provided a method of manufacturing a molded body, the method including producing a first molded body by pressurizing a material containing fibers by a pressurizing mechanism to transfer a pattern, and bonding the fibers, and producing a second molded body by performing processing at a position corresponding to the pattern formed when the first mold body is produced.

[0006] According to another aspect of the present disclosure, there is provided a molded body manufacturing apparatus including a pressurizing mechanism that pressurizes a material containing fibers, and produces a first molded body having a pattern, in which the fibers are bonded, and a molding portion that produces a second molded body by performing processing at a position corresponding to the pattern formed by the pressurizing mechanism.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 is a configuration diagram illustrating an outline of a molded body manufacturing apparatus according to a first embodiment of the present disclosure.

[0008] FIG. 2 is a flowchart of a method of manufacturing a molded body according to the first embodiment of the present disclosure.

[0009] FIG. 3 is a cross-sectional view illustrating a primary accumulated sheet, a secondary accumulated sheet, and a state where the secondary accumulated sheets are stacked.

[0010] FIG. 4 is a cross-sectional view illustrating a first molded body, a state where a third molded body is disposed on the first molded body, and a second molded body.

[0011] FIG. 5 is a perspective view of the second molded body.

[0012] FIG. 6 is a cross-sectional view illustrating a pressurizing portion included in a molded body manufacturing apparatus according to a second embodiment of the present disclosure.

[0013] FIG. 7 is a cross-sectional view of a third molded body manufactured by a molded body manufacturing apparatus according to a third embodiment of the present disclosure.

[0014] FIG. 8 is a flowchart of a method of manufacturing a molded body according to the third embodiment of the present disclosure.

[0015] FIG. 9 is a cross-sectional view of a third molded body manufactured by a molded body manufacturing apparatus according to a fourth embodiment of the present disclosure.

[0016] FIG. 10 is a flowchart of a method of manufacturing a molded body according to the fourth embodiment of the present disclosure.DESCRIPTION OF EMBODIMENTS

[0017] Hereinafter, a method of manufacturing a molded body and a molded body manufacturing apparatus according to the present disclosure will be described in detail based on preferred embodiments illustrated in the accompanying drawings.First Embodiment

[0018] FIG. 1 is a configuration diagram illustrating an outline of a molded body manufacturing apparatus according to a first embodiment of the present disclosure. FIG. 2 is a flowchart of a method of manufacturing a molded body according to the first embodiment of the present disclosure. FIG. 3 is a cross-sectional view illustrating a primary accumulated sheet, a secondary accumulated sheet, and a state where the secondary accumulated sheets are stacked. FIG. 4 is a cross-sectional view illustrating a first molded body, a state where a third molded body is disposed on the first molded body, and a second molded body. FIG. 5 is a perspective view of the second molded body.

[0019] Hereinafter, in FIGS. 1, 3, 4, and 5, an upper side may be referred to as “upper” or “upward”, and a lower side may be referred to as “lower” or “downward”. In addition, FIG. 1 is a schematic configuration diagram, and the positional relationship, orientation, size, and the like of each part of a molded body manufacturing apparatus 100 are not limited to those illustrated. In addition, in FIG. 1, a direction in which a material or a molded body is transported is also referred to as a transport direction. In addition, a tip end side of an arrow in FIG. 1 indicating the transport direction is also referred to as a “downstream”, and a base end side of the arrow is also referred to as an “upstream”.Molded Body Manufacturing Apparatus 100

[0020] The molded body manufacturing apparatus 100 illustrated in FIG. 1 is an apparatus that executes a method of manufacturing a molded body of the present disclosure, and is an apparatus that manufactures a second molded body S5 as a molded body by molding a material M1 containing fibers. The molded body manufacturing apparatus 100 includes an accumulation portion 1, a fixing portion 2, a cutting portion 3, a first molding portion 4, a cooling portion 5, a second molding portion 6 (molding portion), and a control device 7. In addition, as illustrated in FIG. 2, the method of manufacturing a molded body includes an accumulating step, a fixing step, a cutting step, a first molding step, a cooling step, and a second molding step. In the present embodiment, the case where a tote bag is manufactured by using the second molded body S5 will be described, and the present disclosure is not limited thereto. The final product manufactured by the second molded body S5 may be various products, such as a mask, gloves, socks, a book cover, a business card case, or slippers. In addition, the second molded body S5 may be a final product. Hereinafter, each part of the molded body manufacturing apparatus 100 and each step of the method of manufacturing a molded body will be described in detail.Material M1

[0021] First, a material M1 will be described. The material M1 includes a fiber F and the binder P that bonds the fibers F to each other.

[0022] The fiber F is not particularly limited, and examples thereof include various natural fibers, various chemical fibers, and the like.

[0023] The average fiber length of the fiber F is not particularly limited, but is preferably, for example, 0.1 mm or more and 10 mm or less, and more preferably 1 mm or more and 5 mm or less. As a result, the strength of the second molded body S5 can be more reliably enhanced, and the formation of a recessed portion 201, folding processing, and cutting processing, which will be described later, can be easily performed.

[0024] From the same viewpoint, the average width (average diameter) of the fiber F is not particularly limited, but is preferably, for example, 0.5 μm or more and 200 μm or less, and more preferably 1.0 μm or more and 100 μm or less.

[0025] From the same viewpoint, the content of the fiber F in the material M1 is not particularly limited, but is preferably, for example, 20% by weight or more and 99% by weight or less, and more preferably 50% by weight or more and 90% by weight or less.

[0026] Examples of the binder P include thermoplastic resins, such as various polyolefins, acrylic resins, polyvinyl chloride, polyesters, and polyamides, various thermoplastic elastomers, and natural material-derived components, such as starch, dextrin, glycogen, amylose, hyaluronic acid, kudzu, konjac, potato starch, etherified starch, esterified starch, natural gum paste, fiber-induced paste, seaweed, and animal protein, and one or more selected from these can be used in combination.

[0027] The binder P is in the form of particles or fibers.

[0028] When the binder P is in the form of particles, the average particle size (volume basis) is not particularly limited, but is preferably, for example, 0.5 μm or more and 200 μm or less, and more preferably 1.0 μm or more and 100 μm or less. As a result, the strength of the second molded body S5 can be more reliably enhanced, and the formation of a recessed portion 201, folding processing, and cutting processing, which will be described later, can be easily performed.

[0029] From the same viewpoint, when the binder P is in the form of fibers, the average fiber length of the binder P is not particularly limited, but is preferably, for example, 0.1 mm or more and 10 mm or less, and more preferably 1 mm or more and 10 mm or less.

[0030] From the same viewpoint, when the binder P is in the form of fibers, the average width (average diameter) of the binder P is not particularly limited, but is preferably, for example, 0.5 μm or more and 200 μm or less, and more preferably 1.0 μm or more and 100 μm or less. As a result, the strength of the second molded body S5 can be more effectively enhanced.

[0031] From the same viewpoint, the content of the binder P in the material M1 is not particularly limited, but is preferably, for example, 1% by weight or more and 80% by weight or less, and more preferably 10% by weight or more and 50% by weight or less. As a result, the strength of the second molded body S5 can be more effectively enhanced.

[0032] In addition, the material M1 may contain other components other than the binder P. Examples of the other components include a colorant for coloring the fibers, an aggregation inhibitor for preventing the aggregation of the fibers, a flame retardant for making the fibers and the like unlikely to burn, and one or more of these can be used in combination.

[0033] When the material M1 contains other components, the content of the other components in the material M1 is not particularly limited, but is preferably, for example, 0.1% by weight or more and 10% by weight or less, and more preferably 0.5% by weight or more and 5% by weight or less. As a result, the effects of blending other components can be obtained, the amount of fiber F and binder P can be sufficiently secured, the strength of the second molded body S5 can be more effectively enhanced. In addition, when the fibers F themselves are dissolved or softened and the fibers F are bonded to each other, the binder P may not be added in addition to the fibers F.Accumulation Portion 1, Accumulating Step

[0034] As illustrated in FIG. 1, the accumulation portion 1 is a portion that performs the accumulating step, and disperses the material M1 in the air to produce an accumulated material M2 of the material M1. As illustrated in FIG. 1, the accumulation portion 1 includes a dispersion portion 11, a mesh belt 12, a suction portion 13, and a sheet supply portion 14.

[0035] The dispersion portion 11 loosens and releases the fibers F entangled with each other in the material M1. The dispersion portion 11 includes a drum 111 that introduces and releases the material M1, and a housing 112 that houses the drum 111.

[0036] The drum 111 is formed of a cylindrical net body, and is a sieve that is rotated around a central axis thereof. When the drum 111 is rotated, the fibers F and the like having a size smaller than the mesh opening of the net in the material M1 can pass through the drum 111. At that time, the material M1 is loosened and released together with the air. That is, the drum 111 functions as a release portion that releases the material M1 containing the fibers F.

[0037] The drum 111 is coupled to a drive source (not illustrated) and is rotated by a rotational force output from the drive source. The drive source is electrically coupled to the control device 7, and the operation thereof is controlled.

[0038] In addition, the material M1 released by the drum 111 falls while being dispersed in the air, and heads toward the mesh belt 12 located below the drum 111.

[0039] A material supply portion (not illustrated) is coupled to the drum 111. Examples of the material supply portion include a supply portion configured to have a raw material supply portion, a crushing portion, a defibrating portion, a mixing portion, and the like, in a sheet manufacturing apparatus described in JP-A-2024-113315, and a supply portion configured to supply the material M1 in a cartridge type.

[0040] The mesh belt 12 is a mesh member, and in the illustrated configuration, the mesh belt 12 is configured as an endless belt. A sheet S is supplied to the mesh belt 12 from a sheet supply portion 14 described later, and the material M1 dispersed and released by the dispersion portion 11 is accumulated on the sheet S to produce an accumulated material M2. The mesh belt 12 is hung around four tension rollers 121. When the tension roller 121 is rotated and driven, the accumulated material M2 on the mesh belt 12 is transported downstream.

[0041] In the illustrated configuration, the mesh belt 12, which is an endless belt, is used as an example of the mesh member, and the present disclosure is not limited thereto. For example, a flat plate-shaped mesh member may be used.

[0042] The suction portion 13 is a suction mechanism that suctions air from below the mesh belt 12. As a result, the material M1 can be sucked onto the mesh belt 12. Therefore, the accumulation of the material M1 on the sheet S is promoted. In addition, it is possible to produce the accumulated material M2 having a uniform thickness.

[0043] A pipe 131 is coupled to the suction portion 13. In addition, the blower 132 is installed in the middle of the pipe 131. By operating the blower 132, a suction force can be generated in the suction portion 13. The blower 132 is electrically coupled to the control device 7, and the operation thereof is controlled.

[0044] The sheet supply portion 14 has a supply roller 141 and has a function of feeding out the sheet S by rotating the supply roller 141. The sheet S fed by the supply roller 141 is supplied onto the mesh belt 12. The accumulated material M2 is formed at the sheet S. The sheet S and the accumulated material M2 accumulated on the sheet S are collectively referred to as a “primary accumulated sheet S1” below.

[0045] The supply roller 141 is coupled to a drive source (not illustrated) and is rotated by a rotational force output from the drive source. The drive source is electrically coupled to the control device 7, and the operation thereof is controlled.

[0046] The sheet S has air permeability and is made of a woven fabric, a non-woven fabric, or the like. Examples of the fibers constituting the sheet S include the fiber F described above. By supplying such a sheet S, the strength of the second molded body S5 can be more effectively enhanced.

[0047] As illustrated in FIG. 3, the average thickness TS of the sheet S is not particularly limited, but is preferably 0.01 mm or more and 20 mm or less, and more preferably 0.1 mm or more and 2 mm or less. As a result, the strength of the second molded body S5 can be more reliably enhanced, and the formation of a recessed portion 201, folding processing, and cutting processing, which will be described later, can be easily performed.

[0048] From the same viewpoint, the density ρM1 of the material M1 of the accumulated material M2 is not particularly limited, but is preferably 0.01 g / cm3 or more and 2.0 g / cm3 or less, and more preferably 0.1 g / cm3 or more and 1.0 g / cm3 or less.

[0049] From the same viewpoint, as illustrated in FIG. 3, the average thickness TM2 of the accumulated material M2 is not particularly limited, but is preferably 1 mm or more and 100 mm or less, and more preferably 1.5 mm or more and 50 mm or less.

[0050] From the same viewpoint, the average thickness TS1 of the primary accumulated sheet S1 is not particularly limited, but is preferably 1.1 mm or more and 120 mm or less, and more preferably 1.3 mm or more and 60 mm or less.Fixing Portion 2, Fixing Step

[0051] As illustrated in FIG. 1, the fixing portion 2 performs a fixing step, and fixes the accumulated material M2 of the primary accumulated sheet S1 and transports the accumulated material M2 downstream. The fixing performed by the fixing portion 2 refers to a process of compressing the primary accumulated sheet S1, reducing the thickness of the accumulated material M2, and enhancing the density. By performing such fixing (temporary fixing), it is possible to prevent the fibers F from scattering and to improve the handling property.

[0052] The fixing portion 2 includes a pair of heating and pressurizing rollers 21 provided downstream of the accumulation portion 1. Each heating and pressurizing roller 21 is disposed above and below via a transport path of the primary accumulated sheet S1. When the primary accumulated sheet S1 passes between the pair of heating and pressurizing rollers 21, the accumulated material M2 is heated and pressurized. As a result, a secondary accumulated sheet S2 is produced. The secondary accumulated sheet S2 is transported downstream by the rotation of the pair of heating and pressurizing rollers 21.

[0053] The pair of heating and pressurizing rollers 21 is coupled to a drive source and a heat source (not illustrated), and is rotated by a rotational force output from the drive source. The heating and pressurizing roller 21 is heated with heat generated by the heat source. Each of the drive source and the heat source is electrically coupled to the control device 7, and the operation thereof is controlled.

[0054] When the fixing portion 2 performs pressurization and heating, the binder P in the accumulated material M2 can be melted or softened to be impregnated between the fibers F. Therefore, the fibers F can be bonded to each other to restrict the unintentional movement of the fibers F in the secondary accumulated sheet S2 and to easily maintain the shape. Therefore, the handling property in the subsequent steps can be improved.

[0055] As illustrated in FIG. 3, the average thickness TS2 of the secondary accumulated sheet S2 is not particularly limited, but is preferably 0.8 mm or more and 100 mm or less, and more preferably 1.2 mm or more and 50 mm or less. As a result, the handling property in the subsequent steps can be more effectively improved.

[0056] The ratio TS2 / TS1 of the average thickness TS2 of the secondary accumulated sheet S2 to the average thickness TS1 of the primary accumulated sheet S1 is not particularly limited, but is preferably 0.1 or more and 0.9 or less, and more preferably 0.2 or more and 0.8 or less. By applying pressure to this extent by the fixing portion 2, the handling property in the subsequent steps can be more effectively improved.

[0057] The density ρS2 of the material M1 in the secondary accumulated sheet S2 is not particularly limited, but is preferably 0.02 g / cm3 or more and 3.0 g / cm3 or less, and more preferably 0.15 g / cm3 or more and 1.5 g / cm3 or less. By applying pressure to this extent by the fixing portion 2, the handling property in the subsequent steps can be more effectively improved.

[0058] A ratio ρM1 / ρS2 of the density ρM1 of the material M1 of the accumulated material M2 to the density ρS2 of the material M1 in the secondary accumulated sheet S2 is not particularly limited, but is preferably 0.1 or more and 0.9 or less, and more preferably 0.2 or more and 0.8 or less. By applying pressure to this extent by the fixing portion 2, the handling property in the subsequent steps can be more effectively improved.

[0059] The heating temperature T2 by the fixing portion 2 is not particularly limited, and is preferably, for example, 30° C. or higher and 200° C. or lower, and more preferably 35° C. or higher and 150° C. or lower. As a result, the binder P in the accumulated material M2 can be more effectively melted or softened.

[0060] The fixing portion 2 may perform only pressurization. That is, in the fixing step, only pressurization may be performed. In addition, the fixing portion 2 may be omitted. That is, in the method of manufacturing a molded body of the present disclosure, the fixing step may be omitted.Cutting Portion, Cutting Step

[0061] As illustrated in FIG. 1, the cutting portion 3 performs a cutting step and cuts the secondary accumulated sheet S2 to a desired size. The cutting portion 3 has a pair of cutting blades 31 provided downstream of the fixing portion 2. Each of the cutting blades 31 is disposed above and below via a transport path of the secondary accumulated sheet S2. Each of the cutting blades 31 is disposed such that the cutting edges face each other, and is configured such that the cutting edges can approach and separate from each other. When the cutting edges of each of the cutting blades 31 approach until the cutting edges are brought into contact with each other, the secondary accumulated sheet S2 passing therebetween is cut. In addition, the length of the secondary accumulated sheet S2 can be adjusted by adjusting the timing of the approach and separation of each of the cutting blades 31.

[0062] The cutting blade 31 is coupled to a drive source (not illustrated) and approaches and separates by a force output from the drive source. The drive source is electrically coupled to the control device 7, and the operation thereof is controlled.

[0063] In addition, a pair of transport rollers 32 is provided downstream of the cutting blade 31. The pair of transport rollers 32 is disposed above and below via the transport path of the secondary accumulated sheet S2. When the transport roller 32 is rotated in a state where the cut secondary accumulated sheet S2 is interposed, the secondary accumulated sheet S2 can be transported downstream, that is, to the first molding portion 4.

[0064] The transport roller 32 is coupled to a drive source (not illustrated) and is rotated by a rotational force output from the drive source. The drive source is electrically coupled to the control device 7, and the operation thereof is controlled.

[0065] The cutting portion 3 is not limited to the above configuration, and may have a configuration in which a cutting roller having a blade formed at an outer peripheral portion of the roller is provided instead of the cutting blade 31.

[0066] In addition, although not illustrated, the cutting portion 3 may have a cutting blade for cutting both edge portions of the secondary accumulated sheet S2 in the width direction.

[0067] In addition, the cutting portion 3 may be omitted. In this case, it is preferable that the secondary accumulated sheet S2 is folded and stacked in the thickness direction before the molding is performed in the first molding portion 4 described later.First Molding Portion 4, First Molding Step

[0068] As illustrated in FIG. 1, the first molding portion 4 is a portion that performs a first molding step of heating and pressurizing the secondary accumulated sheet S2 by the pressurizing portion 41 to produce a first molded body S3 having a pattern 200.

[0069] The pressurizing portion 41 includes a block-shaped pressurizing member 411 and a pressurizing member 412 as a pressurizing mechanism. The pressurizing member 411 and the pressurizing member 412 are metal molds, are not limited thereto, and may be made of ceramics or the like. A plurality of secondary accumulated sheets S2 are stacked and disposed on the pressurizing member 411. The pressurizing member 412 is coupled to a drive source (not illustrated) and can approach and separate from the pressurizing member 411. When the pressurizing member 412 approaches the pressurizing member 411, the secondary accumulated sheet S2 on the pressurizing member 411 is interposed between the pressurizing member 411 and the pressurizing member 412, and the secondary accumulated sheet S2 is heated and pressurized to produce the first molded body S3. When the pressurization is released, the secondary accumulated sheet S2 can be disposed on the pressurizing member 411, or the first molded body S3 can be taken out from the pressurizing member 411.

[0070] The pressurizing member 411 and the pressurizing member 412 are not limited to the block shapes, and may include, for example, a roller.

[0071] The surface of the pressurizing member 411 on the side where the secondary accumulated sheet S2 is disposed is flat. The surface of the pressurizing member 412 on which the secondary accumulated sheet S2 is disposed is formed with unevenness. The shape of the unevenness corresponds to a pattern to be formed at the surface of the first molded body S3. The surface on which the unevenness is formed may be the surface of the pressurizing member 411 and the surface of the pressurizing member 412 may be flat, or may be the surfaces of both the pressurizing member 411 and the pressurizing member 412.

[0072] In addition, the pressurizing member 411 is coupled to a heat source (not illustrated), and can heat with the heat generation of the heat source. The drive source and the heat source are electrically coupled to the control device 7, and the pressurization timing, the heating timing, the degree of pressurization, and the degree of heating are controlled. The pressurizing member 412 may also be coupled to the heat source, or only the pressurizing member 412 may be coupled to the heat source. When the heat source is coupled only to the pressurizing member 411 in which a protrusion 413 is not provided, the heat source does not need to be coupled to the pressurizing member 412 in which the protrusion 413 is provided, and thus the pressurizing member 412 can be easily manufactured. In addition, when a plurality of pressurizing members 412 having different shapes of the protrusions 413 are prepared and one of the plurality of pressurizing members 412 is selectively used, the replacement work can be easily performed.

[0073] When the first molding portion 4 performs pressurization and heating, the binder P in the secondary accumulated sheet S2 can be melted or softened to be impregnated between the fibers F. Therefore, the fibers F can be bonded to each other to enhance the strength of the first molded body S3, and the adjacent stacked secondary accumulated sheets S2 can be satisfactorily joined to each other.

[0074] At the same time as the fibers F are bonded to each other, the unevenness of the surface of the pressurizing member 412 is transferred, and a desired pattern can be formed at the surface of the first molded body S3.

[0075] In the first molding portion 4, the plurality of secondary accumulated sheets S2 are pressurized in a state of being stacked, and the first molded body S3 as illustrated in FIG. 4 is produced. The number of sheets of the secondary accumulated sheets S2 stacked on the pressurizing member 411 is not particularly limited, but is preferably 2 sheets or more and 20 sheets or less, and more preferably 3 sheets or more and 10 sheets or less. As a result, the strength of the first molded body S3 can be more effectively enhanced, and the adjacent stacked secondary accumulated sheets S2 can be satisfactorily joined to each other. The present disclosure is not limited to this configuration, and in the first molding portion 4, a configuration in which one sheet of the secondary accumulated sheet S2 is pressurized may be adopted.

[0076] The pressurization in the first molding portion 4 is performed such that the pressure is higher than the pressure in the fixing portion 2, that is, the degree of compression of the fibers F is higher than the degree of compression of the fibers F in the fixing portion 2.

[0077] As illustrated in FIG. 4, the average thickness TS3 of one secondary accumulated sheet S2 of the first molded body S3 is not particularly limited, but is preferably 0.7 mm or more and 90 mm or less, and more preferably 1.1 mm or more and 40 mm or less. By applying pressure to this extent by the first molding portion 4, the strength of the first molded body S3 can be more effectively enhanced, a relatively deep recessed portion 201 can be easily formed, and the function as the pattern 200 can be more reliably enhanced.

[0078] The density ρS3 of the material M1 in one secondary accumulated sheet S2 of the first molded body S3 is not particularly limited, but is preferably 0.03 g / cm3 or more and 4.0 g / cm3 or less, and more preferably 0.2 g / cm3 or more and 2.5 g / cm3 or less. By applying pressure to this extent by the first molding portion 4, the strength of the first molded body S3 can be more effectively enhanced.

[0079] The ratio ρS2 / ρS3 of the density ρS2 of the material M1 in the secondary accumulated sheet S2 to the density ρS3 of the material M1 in one secondary accumulated sheet S2 of the first molded body S3 is not particularly limited, but is preferably 0.2 or more and 0.8 or less, and more preferably 0.3 or more and 0.7 or less. By applying pressure to this extent by the first molding portion 4, the strength of the first molded body S3 can be more effectively enhanced, and the formation of the recessed portion 201, folding processing, cutting processing, and the like can be easily performed.

[0080] The ratio ρM1 / ρS3 of the density ρM1 of the material M1 of the accumulated material M2 to the density ρS3 of the material M1 in the one secondary accumulated sheet S2 of the first molded body S3 is not particularly limited, but is preferably 0.05 or more and 0.7 or less, and more preferably 0.1 or more and 0.5 or less. By applying pressure to this extent by the first molding portion 4, the strength of the first molded body S3 can be more effectively enhanced, and the formation of the recessed portion 201, folding processing, cutting processing, and the like can be easily performed.

[0081] The heating temperature T4 in the first molding portion 4 is not particularly limited, and is preferably, for example, 40° C. or higher and 220° C. or lower, and more preferably 150° C. or higher and 190° C. or lower. As a result, the binder P can be more effectively melted or softened, and the bonding between the fibers F can be made stronger. Therefore, the strength of the first molded body S3 can be more effectively enhanced, and the formation of the recessed portion 201, the folding processing, the cutting processing, and the like can be easily performed.

[0082] In addition, the ratio T2 / T4 of the heating temperature T2 in the fixing portion 2 to the heating temperature T4 in the first molding portion 4 is not particularly limited, and is preferably 0.1 or more and 1.0 or less, and more preferably 0.4 or more and 0.7 or less. As a result, the binder P can be more effectively melted or softened, and the bonding between the fibers F can be made stronger. Therefore, the strength of the first molded body S3 can be more effectively enhanced, and the formation of the recessed portion 201, the folding processing, and the cutting processing can be easily performed.

[0083] The first molding portion 4 may perform only pressurization. That is, in the first molding step, only pressurization may be performed.

[0084] As illustrated in FIG. 1, the protrusion 413 protruding downward is provided on the lower surface (pressurizing surface) of the pressurizing member 412. In a plan view of the lower surface of the pressurizing member 412, the protrusion 413 has a predetermined shape. When the first molding portion 4 performs pressurization, the protrusion 413 is buried in the secondary accumulated sheet S2. As a result, the recessed portion 201 (groove) that is a pattern 200 corresponding to the shape of the protrusion 413 is formed at the upper surface of the first molded body S3. That is, the recessed portion 201 is formed by transferring the shape of the protrusion 413. By forming the pattern 200 in such a method, the pattern 200 can be easily and accurately formed.

[0085] The pattern 200 has a pattern, such as a figure, a picture, or a character, and is represented by a line, a point, or a combination thereof. The pattern 200 has a function of visually or tactually indicating an assembly position (stacking position) that indicates the position where the third molded body S4 is stacked with the first molded body S3 in a second molding step described later.

[0086] As illustrated in FIG. 4, the recessed portion 201 is an example of an aspect of the pattern 200, and is an assembly pattern that serves as an assembly position mark in the second molding step. By forming such a recessed portion 201 simultaneously with the heating and pressurizing in the first molding portion 4, the first molded body S3 can be efficiently manufactured because one step can be omitted as compared with a case where the step of heating and pressurizing (the step of molding) and the step of attaching the mark (for example, the printing step) are separately performed. As a result, the productivity of the second molded body S5 can be improved.

[0087] In particular, since the pattern 200 is formed by the recessed portion 201, in the second molding step, the third molded body S4 is stacked with the first molded body S3, that is, the positional displacement when assembling is effectively prevented, and the alignment of these molded bodies can be accurately performed. In addition, after the assembly and before the joining by the second molding portion 6, the positional displacement of the third molded body S4 is restricted by the inner surface of the recessed portion 201, and the assembly accuracy of the second molded body S5 can be improved.

[0088] The portion where the recessed portion 201 is formed is a portion where the thickness of the first molded body S3 is the minimum thickness Tmin, and the portion where the recessed portion 201 is not formed is a portion where the thickness of the first molded body S3 is the maximum thickness Tmax. The ratio Tmax / Tmin of the maximum thickness Tmax to the minimum thickness Tmin is preferably 1.2 or more and 2 or less, and more preferably 1.25 or more and 1.9 or less. As a result, the depth of the recessed portion 201 can be sufficiently secured, and the function as a mark can be more effectively exhibited, and it is possible to prevent excessive unevenness in the strength, that is, the density of the material M1, and to maintain the high quality of the first molded body S3.

[0089] The pattern 200 is not limited to the recessed portion 201, and may have a configuration, such as a slit penetrating the first molded body S3 in the thickness direction, or may have a configuration in which independent recesses are arranged in a predetermined pattern to form a pattern 200 as a whole.

[0090] The protrusion 413 is appropriately designed according to the pattern of the pattern 200 to be formed. In the present embodiment, the protrusion 413 includes two long projections. In addition, the protrusion 413 has a rectangular cross-sectional shape. As a result, the recessed portion 201 is formed as a groove, and the long third molded body S4 can be inserted into the recessed portion 201 in the second molding step.

[0091] However, the present disclosure is not limited to this configuration, and the number of protrusions 413 may be one, or three or more.

[0092] In addition, the cross-sectional shape of the protrusion 413 and the cross-sectional shape of the recessed portion 201 are not limited to a rectangle, and may have other shapes, such as a wedge shape and a semicircular shape.

[0093] The time for which the first molding portion 4 heats and pressurizes is not particularly limited, and is preferably, for example, 1 second or more and 60 seconds or less, and more preferably 2 seconds or more and 40 seconds or less. As a result, the formation of the pattern 200 and the melting or softening of the binder P can be more reliably performed.Cooling Portion 5, Cooling Step

[0094] The cooling portion 5 is a portion that performs a cooling step of cooling the first molded body S3. The cooling performed by the cooling portion 5 refers to lowering the temperature of the first molded body S3 immediately after the first molding step is completed. The temperature after cooling may be any temperature lower than the melting point of the binder P, and is preferably, for example, room temperature, but is not limited thereto. In the present embodiment, a configuration is adopted in which a cooling block or a cooling roller is brought into contact with both surfaces of the first molded body S3. However, the present disclosure is not limited to this configuration, and the cooling portion 5 may be configured to blow the cold air onto the first molded body S3, or may be configured to dispose the first molded body S3 in the chamber and dissipate heat of the first molded body S3.

[0095] By performing such a cooling step, the binder P of the first molded body S3 can be solidified to firmly bond the fibers F to each other. Therefore, the second molding step described later can be performed in a state where the strength of the first molded body S3 is more effectively enhanced. In addition, the handling property in the second molding step can be improved.

[0096] When heating is not performed in the first molding step, the cooling step may be omitted.

[0097] In addition, when heating is performed in the fixing step, a cooling step may be performed between the fixing step and the first molding step. In this case, the cooling step performed between the fixing step and the first molding step is the first cooling step, and the cooling step performed between the first molding step and the second molding step is the second cooling step. The cooling temperature may be the same or different in the first cooling step and the second cooling step.Second Molding Portion 6, Second Molding Step

[0098] The second molding portion 6 is a molding portion that performs the second molding step of performing processing at a position corresponding to the pattern 200 formed in the first molding step, and performs an aligning step and a joining step. That is, the second molding step includes the aligning step and the joining step.

[0099] The aligning step is a step of detecting the pattern 200 of the first molded body S3 and stacking the third molded body S4 with at least a part (in the present embodiment, the entire part) of the pattern 200 formed in the first molding step in accordance with the position of the detected pattern 200.

[0100] The joining step is a step in which, after the aligning step, the second molding step is performed in which the first molded body S3 and the third molded body S4 are joined to produce the second molded body S5.

[0101] The second molding portion 6 has a sensor (not illustrated), a robot hand (not illustrated), and a sewing machine 61. The second molding portion 6 specifies the position of the pattern 200 with the sensor, and stacks the third molded body S4 on the specified pattern 200 at the position of the pattern 200 using the robot hand. Thereafter, the second molding portion 6 uses the sewing machine 61 to join the first molded body S3 and the third molded body S4 by sewing. The sewing method by the sewing machine 61 is not particularly limited, and examples thereof include straight stitch, zigzag stitch, overlock stitch, and hem stitch.

[0102] The second molding portion 6 may be configured to perform joining other than sewing, for example, joining by pressurization, joining by heating, or joining using an adhesive.

[0103] The width of the third molded body S4 is the same as the width of the recessed portion 201. As a result, it is possible to effectively prevent the positional displacement during assembly. That is, the alignment can be accurately performed. Furthermore, the positional displacement of the third molded body S4 is effectively restricted after the assembly and before the joining by the second molding portion 6, and the assembly accuracy of the second molded body S5 can be more reliably improved.

[0104] As described above, in the second molding step, the first molded body S3 and the third molded body S4 are joined to each other in a state where at least a part (in the configuration of the drawing, the entire part) of the third molded body S4 is inserted into the recessed portion 201. As a result, the first molded body S3 and the third molded body S4 can be joined in a state where the third molded body S4 is accurately aligned with the first molded body S3. Therefore, the quality of the second molded body S5 can be further improved.

[0105] The present disclosure is not limited to the above configuration, and the width of the third molded body S4 may be wider or narrower than the width of the recessed portion 201.

[0106] The material of the third molded body S4 is not particularly limited. The third molded body S4 may be made of a material containing fibers, or may be made of a material not containing fibers, for example, by injection molding of a resin material. When the third molded body S4 is made of a material containing fibers, the third molded body S4 may be a molded body made by the above-described steps from the accumulating step to the cooling step, in which a material containing fibers is accumulated and the fibers are bonded to each other, or may be a molded body made by another method. As the fibers or the binder P of the third molded body S4, the materials exemplified as constituent materials of the material M1 can be used.

[0107] The first molded body S3 and the third molded body S4 may be integrated with each other. Although not illustrated, the second molded body S5 as a bag is obtained by stacking and partially joining the first molded bodies S3 that are integrally folded back. In this case, a part of the first molded body S3 can be regarded as the third molded body S4. The third molded body S4 in the form of a string that serves as a handle is stacked with the bag and partially joined to obtain the second molded body S5 as a tote bag.Control Device 7

[0108] Each part included in the molded body manufacturing apparatus 100 is electrically coupled to the control device 7. The operation of each of these parts is controlled by the control device 7.

[0109] As illustrated in FIG. 1, the control device 7 includes a control portion 71, a storage portion 72, and a communication portion 73.

[0110] The control portion 71 has at least one processor and executes various programs stored in the storage portion 72. As the processor, for example, a central processing unit (CPU) can be used. In addition, the control portion 71 has various functions, such as a function of controlling the driving of each part of the apparatus related to the manufacturing of the molded body.

[0111] The storage portion 72 stores, for example, a program for executing the method of manufacturing a molded body of the present disclosure. The program for executing the method of manufacturing a molded body of the present disclosure may be stored in a storage device other than the storage portion 72, for example, a storage device of a server, an external storage device that can be attached to and detached from the control device 7, or the like.

[0112] The communication portion 73 includes, for example, an I / O interface, and communicates with each part of the molded body manufacturing apparatus 100. In addition, the communication portion 73 has a function of communicating with a computer or a server (not illustrated) via a network, for example.

[0113] The control device 7 may be built into the molded body manufacturing apparatus 100 or may be provided in an external device, such as an external computer. In addition, for example, the control portion 71 and the storage portion 72 may be built into one unit, the control portion 71 may be built into the molded body manufacturing apparatus 100 and the storage portion 72 may be provided in an external device, such as an external computer, or the storage portion 72 may be built into the molded body manufacturing apparatus 100 and the control portion 71 may be provided in an external device, such as an external computer.

[0114] As described above, the method of manufacturing a molded body of the present disclosure includes the first molding step of pressurizing the material M1 containing the fibers F by the pressurizing portion 41 as a pressurizing mechanism to transfer the pattern 200 and bonding the fibers F to produce the first molded body S3, and the second molding step of performing processing at a position corresponding to the pattern 200 formed in the first molding step to produce the second molded body S5. As a result, in the first molding step, the pressurization of the first molded body S3 and the formation of the pattern 200 (in the present embodiment, the recessed portion 201) can be collectively performed. Therefore, the first molded body S3 can be efficiently manufactured. As a result, the productivity of the second molded body S5 can be improved.

[0115] In addition, the molded body manufacturing apparatus 100 includes the pressurizing portion 41 as a pressurizing mechanism that pressurizes the material M1 containing the fibers F to produce the first molded body S3 having the pattern 200 and in which the fibers F are bonded to each other, and the second molding portion 6 as a molding portion that performs processing at a position corresponding to the pattern 200 formed by the pressurizing portion 41 to produce the second molded body S5. As a result, the first molding portion 4 can collectively perform the pressurization of the first molded body S3 and the formation of the pattern 200 (in the present embodiment, the recessed portion 201). Therefore, the first molded body S3 can be efficiently manufactured. As a result, the productivity of the second molded body S5 can be improved.

[0116] As an example of the “position according to the pattern 200 formed in the first molding step”, in the present embodiment, a case where the second molding step is performed in a state where the entire pattern 200 and the third molded body S4 overlap with each other in a plan view is described, and the present disclosure is not limited thereto. The second molding step may be performed in a state where at least a part of the pattern 200 and the third molded body S4 overlap with each other, and the third molded body S4 may be disposed along the pattern 200 without stacking with each other.

[0117] In addition, in the present embodiment, the aligning step and the joining step are described as examples of the “processing” in the second molding step, and the present disclosure is not limited thereto. The processing may be a folding step, a cutting step, or the like, or a step in which these steps are combined.

[0118] In addition, in the present embodiment, in the first molding step, a case where the secondary accumulated sheet S2 is pressurized is described, and the present disclosure is not limited thereto. The material M1 may have any aspect as long as the material M1 contains the fiber F.

[0119] In addition, the pressurizing portion 41 which is a pressurizing mechanism has the pressurizing member 412 having the protrusion 413 on the surface, and in the first molding step, when the secondary accumulated sheet S2, which is the accumulated material, is pressurized, the shape of the protrusion 413 is transferred to the first molded body S3 to form the pattern 200. As a result, the pattern 200 can be easily and accurately formed.

[0120] In addition, in the second molding step, the first molded body S3 and the third molded body S4 are joined to produce the second molded body S5 in a state where the third molded body S4 is stacked with at least a part of the pattern 200 of the first molded body S3. As a result, the second molded body S5 can be more accurately aligned with the pattern 200. In addition, the third molded body S4 can hide at least a part of the pattern 200, and the design property can be further improved.

[0121] In addition, the first molded body S3 has the recessed portion 201 formed by transferring the shape of the protrusion 413, and in the second molding step, the first molded body S3 and the third molded body S4 are joined in a state where at least a part of the third molded body S4 is inserted into the recessed portion 201. As a result, the first molded body S3 and the third molded body S4 can be joined in a state where the third molded body S4 is accurately aligned with the first molded body S3. Therefore, the quality of the second molded body S5 can be further improved.

[0122] The ratio Tmax / Tmin of the maximum thickness Tmax of the first molded body to the minimum thickness Tmin of the first molded body is preferably 1.2 or more and 2 or less. As a result, the depth of the recessed portion 201 can be sufficiently secured, and the function as an index can be more effectively exhibited, and it is possible to prevent excessive unevenness in the strength, that is, the density of the material M1, and to maintain the high quality of the first molded body S3.

[0123] The pressurizing portion 41 as the pressurizing mechanism has a pair of pressurizing members 411 and 412, and heats and pressurizes the secondary accumulated sheet S2, which is an accumulated material, between the pair of pressurizing members 411 and 412. The one pressurizing member 412 has the protrusion 413 on the surface and does not heat, and the other pressurizing member 411 does not have the protrusion corresponding to the pattern and heats. As a result, it is not necessary to couple the heat source to the pressurizing member 412 having the protrusion 413, and thus the pressurizing member 411 can be easily manufactured. In addition, when a plurality of pressurizing members 412 having different shapes of the protrusions 413 are prepared and one of the plurality of pressurizing members 412 is selectively used, the replacement work can be easily performed.

[0124] In the first molding step, the first molded body S3 is produced by pressurizing the plurality of accumulated materials M2 in a state where the plurality of accumulated materials M2 are stacked. As a result, it is possible to produce the first molded body S3 having a sufficient strength even when one accumulated material M2 is relatively thin.

[0125] In the method of manufacturing a molded body of the present disclosure, a cooling step of cooling the first molded body S3 is provided after the first molding step and before the second molding step. As a result, the second molding step can be performed in a state where the strength of the first molded body S3 is sufficiently enhanced, and the handling property in the second molding step can be improved.Second Embodiment

[0126] FIG. 6 is a cross-sectional view illustrating a pressurizing portion included in a molded body manufacturing apparatus according to a second embodiment of the present disclosure.

[0127] Hereinafter, a method of manufacturing a molded body and a molded body manufacturing apparatus according to the second embodiment of the present disclosure will be described with reference to FIG. 6. Hereinafter, the description will be mainly made focusing on the differences from the first embodiment, and the description of the same matters will be omitted.

[0128] As illustrated in FIG. 6, the pressurizing member 412 does not have the protrusion 413 described in the first embodiment, and the surface is flat. In addition, unlike the first embodiment, a rod heater 414 as a heat source is built into. Two rod heaters 414 are provided and are built into the pressurizing member 412 in directions parallel to each other. However, the shape of the heater may have a shape corresponding to the pattern to be transferred, and the shape is not limited to the rod heater. In addition, the heater may be exposed on the surface of the pressurizing member 412, or may be built into without being exposed.

[0129] In the pressurizing member 412, the region corresponding to the rod heater 414 has a higher temperature than the periphery. As a result, when the secondary accumulated sheet S2 is pressurized, the secondary accumulated sheet S2 can be partially heated. By partially heating, the secondary accumulated sheet S2 is partially discolored, and a discolored portion 202 as the pattern 200 is formed in the first molded body S3. This can be said to be to transfer the pattern formed by the rod heater 414 included in the pressurizing member 412 by heat or to make a burn mark. The pressurizing member 411 also includes a heater, and the pattern may be transferred to the front and back sides by the heaters of both the pressurizing member 411 and the pressurizing member 412.

[0130] The discolored portion 202 is an assembly pattern that serves as a mark indicating a position when the third molded body S4 is stacked with the first molded body S3 in the second molding step. By forming the discolored portion 202 simultaneously with the heating and pressurizing in the first molding portion 4, the first molded body S3 can be efficiently manufactured because one step can be omitted as compared with a case where the step of heating and pressurizing (the step of molding) and the step of attaching the mark (for example, the printing step) are separately performed. As a result, the productivity of the second molded body S5 can be improved.

[0131] With such a configuration, in addition to the above effects, the pattern 200 can be formed with a simpler configuration. Furthermore, by appropriately switching between heating and not heating the rod heater 414, it is possible to select whether or not to form the discolored portion 202, which is highly convenient.

[0132] The pressurizing portion 41 as the pressurizing mechanism performs pressurization and heating, and in the first molding step, the pattern 200 is transferred to the first molded body S3 by partially discoloring the secondary accumulated sheet S2 as the accumulated material with heat. As a result, the first molded body S3 can be efficiently manufactured with a simpler configuration, and the productivity of the second molded body S5 can be improved. Furthermore, it is highly convenient. In particular, since the discolored pattern 200 is easily visible, the work of stacking the third molded body S4 on the first molded body S3 can be more smoothly performed. The discoloration may be caused by the carbonization of the accumulated material due to heating, or may be the discoloration of a colorant, such as a leuco dye contained in the accumulated material, or may be discoloration due to other principles.Third Embodiment

[0133] FIG. 7 is a cross-sectional view of a third molded body manufactured by a molded body manufacturing apparatus according to a third embodiment of the present disclosure. FIG. 8 is a flowchart of a method of manufacturing a molded body according to the third embodiment of the present disclosure.

[0134] Hereinafter, a method of manufacturing a molded body and a molded body manufacturing apparatus according to the third embodiment of the present disclosure will be described with reference to FIGS. 7 and 8. Hereinafter, the description will be mainly made focusing on the differences from the first embodiment, and the description of the same matters will be omitted.

[0135] As illustrated in FIG. 7, in the present embodiment, a folding pattern 203 is formed as the pattern 200 in the first molded body S3. The folding pattern 203 is a mark indicating a folding position where the second molded body S5 is folded. The folding pattern 203 includes a recessed portion (groove) formed at a position different from the recessed portion 201. In the illustrated configuration, the folding pattern 203 is formed between the recessed portions 201. Although not illustrated, the folding pattern 203 is formed by performing the first molding step by providing a protrusion for forming the folding pattern 203 between the protrusions 413 of the pressurizing member 412 illustrated in FIG. 1.

[0136] The folding pattern 203 and the recessed portion 201 have different cross-sectional shapes. As a result, the folding pattern 203 and the recessed portion 201 can be easily visually distinguished. Therefore, each of the joining step and the folding step can be accurately performed. The present disclosure is not limited to the above configuration, and the folding pattern 203 and the recessed portion 201 may have the same shape.

[0137] In addition, as illustrated in FIG. 8, the method of manufacturing a molded body of the present embodiment includes the folding step of folding the second molded body S5 with the folding pattern 203 as the second molding step. As a result, the second molded body S5 can be folded and processed into a desired shape.

[0138] With such a configuration, in the first molding step, the folding pattern 203 can be simultaneously processed in addition to the recessed portion 201. Therefore, the first molded body S3 can be efficiently manufactured as in the first embodiment, and the folding processing can be quickly and accurately performed. As a result, the second molded body S5 having a wide variety can be quickly and accurately obtained, and the productivity thereof can be improved. The folding step may be performed before the joining step, or may be performed after the joining step. A folding pattern may be formed with unevenness as in the first embodiment, or a folding pattern may be formed with discoloration as in the second embodiment.

[0139] As described above, the pattern 200 includes the folding pattern 203 indicating the folding position where the second molded body S5 is folded, and the second molding step includes the folding step of folding the second molded body S5 with the folding pattern 203. As a result, the folding processing can be quickly and accurately performed, the second molded body S5 having a wide variety can be quickly and accurately obtained, and the productivity thereof can be improved.Fourth Embodiment

[0140] FIG. 9 is a cross-sectional view of a third molded body manufactured by a molded body manufacturing apparatus according to a fourth embodiment of the present disclosure. FIG. 10 is a flowchart of a method of manufacturing a molded body according to the fourth embodiment of the present disclosure.

[0141] Hereinafter, a method of manufacturing a molded body and a molded body manufacturing apparatus according to the fourth embodiment of the present disclosure will be described with reference to FIGS. 9 and 10. Hereinafter, the description will be mainly made focusing on the differences from the first embodiment, and the description of the same matters will be omitted.

[0142] As illustrated in FIG. 9, in the present embodiment, a cutting pattern 204 is formed as the pattern 200 in the first molded body S3. The cutting pattern 204 is a mark indicating a cutting position at which the second molded body S5 is cut. The cutting pattern 204 includes a recessed portion (groove) formed at a position different from the recessed portion 201. In the illustrated configuration, the cutting pattern 204 is formed at both edge portions of the second molded body S5. Although not illustrated, the cutting pattern 204 is formed by performing the first molding step by providing a protrusion for forming the cutting pattern 204 on the outside of each of the protrusions 413 of the pressurizing member 412 illustrated in FIG. 1.

[0143] The cutting pattern 204 and the recessed portion 201 have different cross-sectional shapes. As a result, the cutting pattern 204 and the recessed portion 201 can be easily visually distinguished. Therefore, each of the joining step and the cutting step can be accurately performed. The present disclosure is not limited to the above configuration, and the cutting pattern 204 and the recessed portion 201 may have the same shape.

[0144] In addition, as illustrated in FIG. 10, the method of manufacturing a molded body of the present embodiment includes the cutting step of cutting the second molded body S5 along the cutting pattern 204 as the second molding step. As a result, the second molded body S5 can be cut and processed into a desired shape.

[0145] With such a configuration, in the first molding step, the cutting pattern 204 can be simultaneously processed in addition to the recessed portion 201. Therefore, the first molded body S3 can be efficiently manufactured as in the first embodiment, and the cutting processing can be quickly and accurately performed. As a result, the second molded body S5 having a wide variety can be quickly and accurately obtained, and the productivity thereof can be improved. The cutting step may be performed before the joining step, or may be performed after the joining step. A cutting pattern may be formed with unevenness as in the first embodiment, or a cutting pattern may be formed with discoloration as in the second embodiment.

[0146] As described above, the pattern 200 includes the cutting pattern 204 indicating the cutting position at which the second molded body S5 is cut, and the second molding step includes the cutting step of cutting the second molded body S5 at the cutting position. As a result, the cutting processing can be quickly and accurately performed, the second molded body S5 having a wide variety can be quickly and accurately obtained, and the productivity thereof can be improved.

[0147] Hereinbefore, the method of manufacturing a molded body and the molded body manufacturing apparatus of the present disclosure are described with reference to the embodiments illustrated in the drawings, and the present disclosure is not limited to these embodiments. Each part and each step constituting the method of manufacturing a molded body and the molded body manufacturing apparatus of the present disclosure can be replaced with any structure and step that can exhibit the same function. In addition, any component or step may be added to the method of manufacturing a molded body and the molded body manufacturing apparatus of the present disclosure. In addition, the method of manufacturing a molded body and the molded body manufacturing apparatus of the present disclosure may be combined with the features of each of the embodiments. In the second molding step, all the steps may be automatically performed by a machine, or at least a part of the steps may be performed by a human.

[0148] For example, the first embodiment and the second embodiment may be combined, the first embodiment, the second embodiment, and the third embodiment may be combined, the first embodiment, the second embodiment, the third embodiment, and the fourth embodiment may be combined, the first embodiment and the third embodiment may be combined, the first embodiment and the fourth embodiment may be combined, the second embodiment and the third embodiment may be combined, the second embodiment, the third embodiment, and the fourth embodiment may be combined, and the third embodiment and the fourth embodiment may be combined.

[0149] When the first embodiment and the second embodiment are combined, the following effects can be obtained. For example, when the rod heater 414 in the second embodiment is disposed in the protrusion 413 in the first embodiment, a discolored portion can be formed at the inner surface of the recessed portion 201. As a result, the pattern 200 can be easily recognized both visually and tactually. In addition, when the width of the rod heater 414 is narrower than the width of the recessed portion 201, a part of the bottom surface of the recessed portion 201 can be selectively discolored. In this case, even when the width of the third molded body S4 is narrower than the width of the recessed portion 201, the discolored portion can be easily hidden by the third molded body S4. Therefore, the design property can be further improved.

[0150] In addition, the pattern is not limited to the assembly pattern, the folding pattern, and the cutting pattern described above, and may be a pattern for other purposes.

[0151] In addition, the term “simultaneous” may be in the same step. The transfer of the pattern and the bonding of the fibers may not be completely matched in time. For example, these start times may be staggered, and these end times may be staggered. Even when the recessed portion is formed by the start of pressurization, the discoloration is caused by heating during the subsequent pressurization, and the fibers are bonded and the recessed portion is solidified by cooling after the end of heating, it can be said to be “simultaneous” by performing this in the same step, and it can be said that the pattern is transferred by pressurization and the fibers are bonded to each other.

Claims

1. A method of manufacturing a molded body, the method comprising:producing a first molded body by pressurizing a material containing fibers by a pressurizing mechanism to transfer a pattern and bond the fibers; andproducing a second molded body by performing processing at a position corresponding to the pattern formed when the first molded body is produced.

2. The method of manufacturing a molded body according to claim 1, whereinthe pressurizing mechanism has a pressurizing member having a protrusion on a surface, andwhen an accumulated material is pressurized, the pattern is formed by transferring a shape of the protrusion to the first molded body.

3. The method of manufacturing a molded body according to claim 2, whereinthe first molded body and a third molded body are joined to produce the second molded body, in a state where the third molded body is stacked with at least a part of the pattern of the first molded body.

4. The method of manufacturing a molded body according to claim 3, whereinthe first molded body has a recessed portion formed by transferring the shape of the protrusion, andthe first molded body and the third molded body are joined in a state where at least a part of the third molded body is inserted into the recessed portion.

5. The method of manufacturing a molded body according to claim 4, whereina ratio Tmax / Tmin of a maximum thickness Tmax of the first molded body to a minimum thickness Tmin of the first molded body is 1.2 or more and 2 or less.

6. The method of manufacturing a molded body according to claim 2, whereinthe pressurizing mechanism has a pair of pressurizing members, and heats and pressurizes the accumulated material between the pair of pressurizing members,one pressurizing member has a protrusion on a surface, andanother pressurizing member performs heating.

7. The method of manufacturing a molded body according to claim 1, whereinthe pressurizing mechanism performs pressurization and heating, andthe pattern is transferred by partially discoloring the accumulated material with heat.

8. The method of manufacturing a molded body according to claim 1, whereinthe first molded body is produced by pressurizing a plurality of the accumulated materials in a state where the plurality of the accumulated materials are stacked.

9. The method of manufacturing a molded body according to claim 1, the method further comprising:a cooling step of cooling the first molded body after the first molded body is produced, and before the second molded body is produced.

10. The method of manufacturing a molded body according to claim 1, whereinthe pattern includes a folding pattern indicating a folding position at which the second molded body is folded, andthe second molded body is folded with the folding pattern.

11. The method of manufacturing a molded body according to claim 1, whereinthe pattern includes a cutting pattern indicating a cutting position at which the second molded body is cut, andthe second molded body is cut at the cutting position.

12. A molded body manufacturing apparatus comprising:a pressurizing mechanism that pressurizes a material containing fibers, and produces a first molded body having a pattern, in which the fibers are bonded; anda molding portion that produces a second molded body by performing processing at a position corresponding to the pattern formed by the pressurizing mechanism.

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