Film molding device and method for manufacturing decorative component

Abstract

Provided is a film molding device (300) including a first mold (310) and a second mold (320). The film molding device (300) molds an edge part (15e) sandwiched between the first mold (310) and the second mold (320) by heating the edge part (15e) of a film (15) partially sticked to an adherend (AB).

Description

Film molding apparatus and method for manufacturing decorative members

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

[0002] As described in JP2019-531951A, a film application device is known for attaching a film to an adherend. The film application device moves the film in a first direction relative to the adherend. The adherend and the film attached to the adherend constitute a decorative member. It is required to attach the film to an adherend having a three-dimensional shape. However, a film attached to such an adherend will sag. The sagging of the film deteriorates the aesthetic appearance of the decorative member.

[0003] This disclosure aims to suppress the deterioration of the design of decorative components.

[0004] A first film forming apparatus according to one embodiment of the present disclosure comprises a first mold and a second mold, and forms the edge of a film partially attached to an adherend by heating the edge of the film sandwiched between the first mold and the second mold.

[0005] A second film forming apparatus according to one embodiment of the present disclosure comprises a first mold and a second mold, wherein at least one of the first mold and the second mold heats the edge of the film, thereby forming the edge sandwiched between the first mold and the second mold.

[0006] According to this disclosure, deterioration of the design of the decorative member can be suppressed.

[0007] Figure 1 is a diagram of one embodiment and is an exploded perspective view of the decorative moving body. Figure 2 is a cross-sectional view of the decorative member included in the decorative moving body of Figure 1. Figure 3 is a diagram of an example of a film application device for attaching the film included in the decorative moving body of Figure 1 to an adherend. Figure 4 is a diagram of an example of a film application device for attaching the film included in the decorative moving body of Figure 1 to an adherend. Figure 5 is a view of the holding device of Figures 3 and 4 from the second side in the first direction. Figure 6 is a diagram for explaining the operation of the fixing member in the holding device of Figure 5. Figure 7 is a diagram for explaining the operation of the fixing member in the holding device of Figure 5. Figure 8 is a perspective view of the suction device, holding device and film. Figure 9 is a cross-sectional view of Figure 8 along the line IX-IX. Figure 10 is a view of the adherend of Figures 3 and 4 when viewed from the first side in the first direction. Figure 11 is a view of the adherend, film and holding device of Figures 3 and 4 when viewed from the first side in the first direction. Figure 12 is a view of the internal space of the holding device under pressure, observed from the second side in the third direction. Figure 13 is a view of the internal space of the holding device under pressure, observed from the second side in the second direction. Figure 14 is a view of the holding device of Figure 12 moved toward the adherend by a moving device, observed from the second side in the third direction. Figure 15 is a view of the film partially attached to the adherend and separated from the holding device, observed from the first side in the first direction. Figure 16 is a perspective view of the film forming apparatus and the edge of the film. Figure 17 is a perspective view of the first type of film forming apparatus of Figure 16. Figure 18 is a perspective view of the second type of film forming apparatus of Figure 16. Figure 19 is a view of the film forming apparatus of Figure 16 from the Y direction. Figure 20 is a view of the film forming apparatus of Figure 16 from the Z direction. Figure 21 is a perspective view of the film formed by the film forming apparatus. Figure 22 is a diagram illustrating an example of the cooling process. Figure 23 is a side view of the adherend shown in Figure 21. Figure 24 is a top view of the adherend shown in Figure 21. Figure 25 is a cross-sectional view of a modified example of the decorative member in Figure 2. Figure 26 corresponds to Figure 12 and is a diagram illustrating a modified example of a film application device. Figure 27 corresponds to Figure 13 and is a diagram illustrating the film application device in Figure 26.Figure 28 is a diagram illustrating the operation of the film application device shown in Figure 26. Figure 29 is a diagram illustrating the operation of the film application device shown in Figure 26. Figure 30 is a side view of another modified example of the film application device. Figure 31 is a cross-sectional view of an example of a film assembly. Figure 32 is a diagram illustrating the operation of the film application device shown in Figure 30. Figure 33 is a diagram illustrating the operation of the film application device shown in Figure 30. Figure 34 is a diagram illustrating an example of a sealing device, and is a perspective view of a sheet included in the sealing device. Figure 35 is a flowchart of an example of a film application method. Figure 36 is a flowchart of an example of a first application process. Figure 37 is a flowchart of a modified example of the film application method. Figure 38 is a flowchart of a modified example of the first application process.

[0008] One embodiment of the present disclosure relates to the following [1] to

[68] .

[0009] [1] A film application device for applying a film to an object by moving the film in a first direction, comprising a holding device for holding the film, wherein the film is applied to the object in a state where it protrudes toward the object in the first direction.

[0010] [2] The film application device of [1], wherein the holding device closes the first space in a direction perpendicular to the first direction and closes the first space from one of the first side and the second side in the first direction, and the film closes the first space from the other of the first side and the second side in the first direction.

[0011] [3] The film application device of [1], wherein the holding device holds both side edges of the film in a second direction nonparallel to the first direction, and both side edges of the film in a third direction nonparallel to both the first and second directions.

[0012] [4] A film application device according to [1] or [3], wherein the film is joined to the holding device from the second surface at both side edges in the second direction and both side edges in the third direction.

[0013] [5] The holding device includes a circumferential frame opening to a first side and a second side in the first direction, and a cover that closes the opening from one of the first side and the second side in the first direction, and the film is attached to the opening of the frame from the other of the first side and the second side, any of the film attachment devices of [1] to [4].

[0014] [6] A film application device according to any of [1] to [5], wherein the film has a first surface and a second surface, and is attached to the adherend from the second surface, the holding device closes a first space that the first surface of the film faces in a direction perpendicular to the first direction, and closes the first space from either the first side or the second side in the first direction, and the film closes the first space from the other of the first side or the second side in the first direction.

[0015] [7] The holding device includes a circumferential frame opening to the first and second sides in the first direction, and a fixing member connected to the frame, wherein the fixing member fixes the film by pressing the film against the frame, and is a film application device according to any of [1] to [6].

[0016] [8] A film application device according to any of [1] to [7], further comprising a moving device for moving the holding device.

[0017] [9] The moving device is the film application device of [8] which moves the holding device that holds the film in the first direction relative to the object to be applied.

[0018]

[10] The film application apparatus according to [8] or [9], wherein the moving device includes a stage that supports the holding device, a drive device connected to the stage, and legs that support the stage.

[0019]

[11] The film application device of

[10] , wherein the stage is movable in the first direction relative to the legs by the operation of the drive device.

[0020]

[12] A film application device according to any of [8] to

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

[0021]

[13] The film pasting device according to

[12] , further comprising an imaging device that acquires an image related to the adherend, wherein the control device controls the operation of the moving device based on the image.

[0022]

[14] The film pasting device according to any one of [1] to

[11] , further comprising a pressurizing device that pressurizes a first space facing the first surface in a state where the holding device holds the film.

[0023]

[15] The film pasting device according to

[14] , wherein the pressurizing device projects the film toward the adherend in the first direction.

[0024]

[16] The film pasting device according to

[14] or

[15] , wherein the pressurizing device increases the pressure of the first space when the film is partially in contact with the adherend compared to before the contact.

[0025]

[17] The film pasting device according to any one of

[14] to

[16] , further comprising a control device that controls the operation of the pressurizing device.

[0026]

[18] The film pasting device according to

[17] , further comprising an imaging device that acquires at least one of an image related to the film and an image related to the holding device, wherein the control device controls the operation of the pressurizing device based on the at least one image.

[0027]

[19] The film pasting device according to any one of

[14] to

[18] , wherein the pressurizing device increases the pressure of the first space when the film is partially in contact with the adherend compared to before the contact.

[0028]

[20] The film pasting device according to any one of [1] to

[19] , further comprising a fluid supply device that supplies a fluid onto the first surface.

[0029]

[21] For the film according to

[20] , the temperature of the fluid is higher than the softening temperature of the film.

[0030]

[22] The film pasting device according to

[20] or

[21] , wherein the film includes a base material layer, and the temperature of the fluid is higher than the softening temperature of the base material layer.

[0031]

[23] The holding device holds a film assembly having a front surface and a back surface. The film assembly includes, in order from the front surface to the back surface, a protective material and the film bonded to the protective material from the first surface side. The fluid supply device supplies the fluid between the protective material and the film, and is the film sticking device according to any one of

[20] to

[22] .

[0032]

[24] The protective material is provided with through holes penetrating the protective material. The fluid supply device supplies the fluid to a position overlapping the through holes of the film, and is the film sticking device according to

[23] .

[0033]

[25] The peeling force of the film from the protective material on the first surface of the film is smaller than the peeling force on the second surface of the film, and is the film sticking device according to

[23] or

[24] .

[0034]

[26] The film sticking device according to any one of

[20] to

[25] further includes a removing device for removing the fluid on the film. [[ID=

[10] ] [[ID=

[11] ]

[0035]

[27] The film sticking device according to any one of [1] to

[26] further includes a sealing device for sealing the second space facing the second surface, and a decompression device for decompressing the second space sealed by the sealing device.

[0036]

[28] The sealing device includes a sheet, and is the film sticking device according to

[27] .

[0037]

[29] The film is a decorative film, and is the film sticking device according to any one of [1] to

[28] .

[0038]

[30] The film sticking device according to any one of [1] to

[29] further includes a cutting device for cutting the film in contact with the adherent.

[0039]

[31] The film application device of any of [1] to

[30] , wherein the holding device includes a circumferential frame opening to a first side and a second side in the first direction, and a cover that closes the opening from one of the first side and the second side in the first direction, the film further comprises a cutting device that closes the opening of the frame from the other of the first side and the second side and cuts the film by emitting light, the cover is disposed between the cutting device and the film and is transparent.

[0040]

[32] The holding device includes a circumferential frame opening to a first side and a second side in the first direction, and a cover that closes the opening from one of the first side and the second side in the first direction, the film closing the opening of the frame from the other of the first side and the second side, and further comprising an imaging device that acquires an image of the film, the cover being disposed between the imaging device and the film and transparent, any of the film application devices of [1] to

[31] .

[0041]

[33] A film application device according to any one of [1] to

[32] , further comprising an imaging device that acquires an image of at least one of the images relating to the film and the image relating to the holding device.

[0042]

[34] The holding device includes a circumferential frame opening to a first side and a second side in the first direction, and a cover that closes the opening from one of the first side and the second side in the first direction, the film closing the opening of the frame from the other of the first side and the second side, and further comprising an imaging device that acquires an image of the film, the cover being disposed between the imaging device and the film and transparent, any of the film application devices of [1] to

[33] .

[0043]

[35] A film application device according to any one of [1] to

[34] , further comprising: an imaging device that acquires an image of the film and an image of the object to be applied; a cutting device that cuts the film; and a control device that controls the operation of the cutting device based on the image of the at least one of the images.

[0044]

[36] The film application device according to

[35] , wherein the control device stores the number of times the film is applied by the film application device.

[0045]

[37] A film application device further comprising a suction device for sucking the film from the first or second surface, wherein the holding device holds the film in the state sucked by the suction device, any of [1] to

[36] .

[0046]

[38] A film application device according to any one of [1] to

[37] , further comprising a pressing device for pressing the film onto the object to be applied from the first side.

[0047]

[39] The film application device according to

[38] , the pressing device further comprising: a pressing member that applies a pressing force to the film in a compressed state; and a compression device that supplies a compressive force to compress the pressing member.

[0048]

[40] The film application device of

[38] or

[39] , wherein the pressing member includes a pressing surface that protrudes toward the object to be adhered in the first direction.

[0049]

[41] A film application apparatus according to any one of [1] to

[40] , wherein the film includes a base layer, and the base layer includes thermoplastic polyurethane.

[0050]

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

[41] , wherein the peeling force of the film applied from the second surface is 3 N / 25 mm or more.

[0051]

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

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

[0052]

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

[43] .

[0053]

[45] A method for manufacturing a decorative member comprising an adherend and a film attached to the adherend, the method comprising the step of attaching the film to the adherend using a film attachment device according to any of [1] to

[44] .

[0054]

[46] A method for manufacturing a decorative member comprising an adherend and a film attached to the adherend, the method comprising: attaching the film to the adherend using a film attachment device according to any of

[38] to

[40] ; and pressing the film to the adherend using a pressing device.

[0055]

[47] A method for manufacturing a decorative member comprising an adherend and a film attached to the adherend, the method comprising the step of attaching the film to the adherend using a film attachment device of any of

[20] to

[26] , wherein the step comprises the step of supplying the fluid to the first surface of the film using a fluid supply device.

[0056]

[48] ​​A film forming apparatus comprising a first type and a second type, wherein the edge of a film partially attached to an object is heated to form the edge sandwiched between the first type and the second type.

[0057]

[49] The film forming apparatus of

[48] wherein at least one of the first type and the second type heats the edge portion.

[0058]

[50] A film forming apparatus comprising a first mold and a second mold, wherein at least one of the first mold and the second mold heats the edge of the film, thereby forming the edge sandwiched between the first mold and the second mold.

[0059]

[51] A film molding apparatus according to

[49] or

[50] in which at least one of the molds generates heat.

[0060]

[52] A film molding apparatus according to any one of

[48] to

[51] , wherein the film includes a bonding layer for bonding the film to the adherend, and the material of at least one of the molds is a fluororesin, a silicone resin, or an olefin resin in the portion that contacts the bonding layer.

[0061]

[53] A film forming apparatus according to any one of

[49] to

[52] , wherein the material of at least one of the molds is aluminum.

[0062]

[54] A film molding apparatus according to any of

[48] to

[53] , wherein the portion in contact with the edge is made of a coating containing a release agent.

[0063]

[55] A film forming apparatus according to any of

[48] to

[54] , wherein the film includes a corner portion in which a plurality of edges are connected to one another, and the corner portion is formed between the first mold and the second mold.

[0064]

[56] A film forming apparatus according to any of

[48] to

[55] , wherein one of the first and second molds is provided with a recess for accommodating the other of the first and second molds, and the edge is bent in the recess.

[0065]

[57] A film forming apparatus of any of

[48] to

[56] , wherein the first and second types are pivotably connected to each other.

[0066]

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

[48] to

[57] .

[0067]

[59] A film forming apparatus of any of

[48] to

[58] wherein the first mold includes a recess for accommodating the second mold, the recess includes a first bottom surface and a first side surface extending from the first bottom surface in a direction nonparallel to the first bottom surface, the first side surface includes a first portion and a second portion extending in directions nonparallel to each other, the second mold includes a second bottom surface and a second side surface extending from the second bottom surface in a direction nonparallel to the second bottom surface, the second side surface includes a first portion and a second portion extending in directions nonparallel to each other, and the edge is heated while sandwiched between the first bottom surface and the second bottom surface, between the first portion of the first side surface and the first portion of the second side surface, and between the second portion of the first side surface and the second portion of the second side surface.

[0068]

[60] A film forming apparatus of any of

[48] to

[59] , wherein the first type includes a first body and a first handle connected to the first body, and the second type includes a second body and a second handle connected to the second body, and the edge is sandwiched between the first body and the second body.

[0069]

[61] The film molding apparatus of

[60] , wherein the first mold includes a recess in the first body for housing the second body, the second mold heats the edge portion when the second body housed in the recess generates heat, and the second body is provided with holes through which a cooling fluid flows to cool the heated second body.

[0070]

[62] The film forming apparatus of

[61] , wherein the hole is opened in a portion that does not come into contact with the film.

[0071]

[63] The film forming apparatus of

[61] or

[62] , wherein the holes are opened at multiple positions on the second main body.

[0072]

[64] A method for manufacturing a decorative member, comprising: a first application step of partially attaching a film to an adherend; a molding step of forming the edge of the film using any of the film molding apparatuses of

[48] to

[63] ; and a second application step of attaching the edge to the adherend.

[0073]

[65] The method for manufacturing the decorative member according to

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

[0074]

[66] A method for manufacturing a decorative member according to

[64] or

[65] , wherein the film comprises a base layer, and the base layer comprises thermoplastic polyurethane.

[0075]

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

[64] to

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

[0076] A method for manufacturing a decorative member, comprising: a first application step of partially applying a film to a substrate using a film application device of any of [1] to

[44] ; a molding step of forming the edge of the film using a film molding device of any of

[48] to

[63] ; and a second application step of applying the edge to the substrate.

[0077] An implementation of this disclosure will be described by reference to the drawings. For ease of illustration and understanding, dimensional ratios in the drawings may be modified from those of the actual object. Shapes, terms used to specify geometric conditions such as "parallel" and "orthogonal," lengths, and angle values ​​should not be interpreted strictly, but rather within a range that allows for the expectation of similar functionality. Components shown in one drawing may be omitted in another.

[0078] Directions common to multiple drawings are indicated by arrows with a common reference numeral in each drawing. In each illustrated direction, the tip of the arrow is the first side, and the opposite side, i.e., the base of the arrow, is the second side. The first side in a direction perpendicular to the drawing is indicated by a symbol of a circle with a dot inside. The second side in a direction perpendicular to the drawing is indicated by a symbol of a circle with an X inside.

[0079] Multiple candidates for the lower limit of a certain parameter and multiple candidates for the upper limit of that parameter may be listed. The candidate numerical range of the parameter will be a combination of one of the multiple candidates for the lower limit and one of the multiple candidates for the upper limit. For example, B1, B2, and B3 may be listed as multiple candidates for the lower limit of parameter A. B1, B2, and B3 are all different numerical values. C1, C2, and C3 may be listed as multiple candidates for the upper limit of parameter A. C1, C2, and C3 are all different numerical values. In this example, the candidate numerical ranges of parameter A will be B1 or greater and C1 or less, B1 or greater and C2 or less, B1 or greater and C3 or less, B2 or greater and C1 or less, B2 or greater and C2 or less, B2 or greater and C3 or less, B3 or greater and C1 or less, B3 or greater and C2 or less, B3 or greater and C3 or less.

[0080] Figures 1 to 24 are diagrams illustrating one embodiment. Figure 1 is a perspective view of the movable body 100. The movable body 100 includes a decorative member 25. The decorative member 25 displays a design. The decorative member 25 includes an adherend AB and a film 15 attached to the adherend AB. In the decorative member 25, the film 15 may display a design. The film 15 that displays the design may be described as a decorative film 20, as will be described later. In the decorative member 25, the adherend AB may display a design. The movable body 100 may include a plurality of decorative members 25.

[0081] The mobile body 100 is a movable device or equipment. Examples of the mobile body 100 include automobiles, motorcycles, bicycles, tricycles, trains, aircraft, ships, snowmobiles, industrial robots, drones, etc. Below, one embodiment will be described using an example in which the decorative film 20 is applied to an automobile 1, particularly a passenger car. Examples of automobiles 1 other than passenger cars include trucks, buses, taxis, ambulances, fire trucks, police vehicles, construction vehicles, etc.

[0082] In the example shown in Figure 1, the automobile 1 includes a plurality of exterior members 10. The exterior members 10 are members that form the outer surface of the automobile 1. The exterior members 10 form a part of the outer surface of the moving body 100. The automobile 1 includes a roof 11, pillars 12, and a trunk lid 13 as exterior members 10. The exterior members 10 may also be adherends AB. In the illustrated example, adherends AB are the roof 11. That is, the film 15 is attached to the roof 11. The decorative film 20 may be attached to exterior members 10 other than the roof 11.

[0083] The exterior member 10 may be made of a metal such as aluminum or stainless steel. The exterior member 10 may also contain a synthetic resin such as fiber-reinforced plastic (FRP). The exterior member 10 may be manufactured by processing sheet material. The exterior member 10 may be formed by various processing methods such as press working. The exterior member 10 may have a three-dimensional shape. "Having a three-dimensional shape" means having a curved surface that is bent around two or more axes that extend non-parallel to each other.

[0084] The exterior member 10 may be coated with paint. The exterior member 10 may display a design by being coated with paint. The exterior member 10 may be colored with paint. The exterior member 10 may be coated with a coating agent. The exterior member 10 may be given a glossy appearance by being coated with a coating agent.

[0085] In the example shown in Figure 1, the roof 11 extends in the longitudinal and lateral directions of the automobile 1. The roof 11 has a front edge and a rear edge, which are edges in the longitudinal direction, and side edges, which are edges in the lateral direction. The front edge and rear edge extend in the lateral direction. The side edges extend in the longitudinal direction.

[0086] The roof 11 in Figure 1 has a three-dimensional shape. In other words, the roof 11 has a curved surface 11R that is bent around two or more axes that extend non-parallel to each other. As described above, the roof 11 is the adherend AB of the film 15. The curved surface 11R may also be described as the adherend surface of the adherend AB. Furthermore, the illustrated roof 11 protrudes upward, that is, upward in the vertical direction.

[0087] The term "front-rear direction" used for the automobile 1, exterior component 10, and film 15 attached to the exterior component 10 is based on the normal direction of travel of the automobile 1 on the driving surface. The term "up-down direction" used for the automobile 1 and exterior component 10 means the direction perpendicular to the driving surface. The term "left-right direction" used for the automobile 1 and exterior component 10 means the direction perpendicular to both the front-rear direction and the up-down direction. The term "front" or "forward" used for the automobile 1 and exterior component 10 means the direction toward the direction of travel in the front-rear direction. The term "rear" or "backward" used for the automobile 1 and exterior component 10 means the direction opposite to the direction of travel in the front-rear direction.

[0088] The film 15 in Figure 2 has a first surface 15a and a second surface 15b opposite to the first surface 15a. The film 15 in Figure 2 is attached to the substrate AB from the second surface 15b. The illustrated film 15 can be observed from the first surface 15a.

[0089] In the film 15, a separator (not shown) may be superimposed on at least one of the first surface 15a and the second surface 15b. The film 15 improves scratch resistance on the surface on which the separator is superimposed. Furthermore, when at least one of the first surface 15a and the second surface 15b is composed of the bonding layer 32 described later, the film 15 can be prevented from unintentionally bonding on the surface on which the separator is superimposed. The separator may be peeled off when the film 15 is attached to the adherend AB.

[0090] As shown in Figure 1, in the decorative member 25, the film 15 may be a decorative film 20. The decorative film 20 displays a design on the surface to which the decorative film 20 is applied. When the film 15 is a decorative film 20, the film 15 displays the design in the decorative member 25. In the illustrated decorative member 25, the display of the design by the film 15 eliminates the need to display the design by the adherend AB. In particular, in the illustrated movable body 100, the display of the design by the film 15 eliminates the need to paint the adherend AB, i.e., the exterior member 10. The painting method for the exterior member 10 includes a paint film baking step. The paint film baking step can also be eliminated by the film 15 displaying the design. Therefore, when manufacturing the illustrated decorative member 25, greenhouse gas emissions in the paint film baking step can be suppressed.

[0091] From the viewpoint of stably displaying the design, a lower limit may be set for the thickness of the film 15. The thickness of the film 15 may be 50 μm or more, or 100 μm or more. The thickness of the film 15 may be 50 μm or more and 500 μm or less, or 100 μm or more and 500 μm or less. Furthermore, from the viewpoint of stably maintaining the state in which it is attached to the adherend AB, an upper limit may be set for the thickness of the film 15. The thickness of the film 15 may be 500 μm or less. Note that the thickness of the film 15 is the dimension of the film 15 in the direction in which the first surface 15a and the second surface 15b face each other.

[0092] The thickness of the film 15 and the thickness of its constituent elements are determined by observing a cross-sectional image of the film 15 using a scanning transmission electron microscope (STEM). The thickness of the film 15 and the thickness of its constituent elements are determined as the arithmetic mean of five measurements taken at five different locations.

[0093] The film 15 in Figure 1 includes an edge 15e extending in the front-to-back direction or the left-to-right direction. The illustrated edge 15e includes a first edge 15ea extending in the front-to-back direction and a second edge 15eb extending in the left-to-right direction. The edge 15e includes two first edges 15ea that are separated from each other in the left-to-right direction. The edge 15e includes two second edges 15eb that are separated from each other in the front-to-back direction. The film 15 in Figure 1 is curved along the adherend AB at the edge 15e. The edge 15e of the film 15 includes a portion that is curved along the adherend AB.

[0094] The film 15 in Figure 1 includes corners 15r where the ends of the edge 15e are connected to each other. The film 15 in Figure 1 includes four corners 15r. The film 15 is curved along the adherend AB at the corners 15r. The corners 15r of the decorative film 20 include portions that are curved along the adherend AB.

[0095] The decorative film 20 in Figure 1 includes an edge portion 20e extending in the front-to-back direction or the left-to-right direction. The edge portion 20e of the decorative film 20 constitutes the edge portion 15e of the film 15. The illustrated edge portion 20e includes a first edge portion 20ea extending in the front-to-back direction and a second edge portion 20eb extending in the left-to-right direction. The first edge portion 20ea of ​​the decorative film 20 constitutes the first edge portion 15ea of ​​the film 15. The second edge portion 20eb of the decorative film 20 constitutes the second edge portion 15eb of the film 15.

[0096] The decorative film 20 in Figure 1 includes corners 20r where the ends of the edges 20e are connected to each other. The corners 20r of the decorative film 20 constitute the corners 15r of the film 15. The decorative film 20 in Figure 1 includes four corners 20r.

[0097] In the film 15, an upper limit may be set for the 3% strain tensile stress at room temperature. Specifically, the 3% strain tensile stress of the film 15 may be 40 N / 10 mm or less, 30 N / 10 mm or less, or 20 N / 10 mm or less in an environment of 25°C. By setting such an upper limit, the film 15 can be stably attached to the adherend AB even at room temperature, according to its shape. Furthermore, when the illustrated film 15 is attached to the adherend AB using the film attachment device 40 described later, it can be easily moved in the first direction D1 even at room temperature by applying pressure in the first space S1.

[0098] In film 15, a lower limit may be set for the 3% strain tensile stress at room temperature from the viewpoint of ensuring strength at room temperature. Specifically, the 3% strain tensile stress of film 15 may be 1 N / 10 mm or more, or 3 N / 10 mm or more, in an environment of 25°C.

[0099] Therefore, the 3% strain tensile stress of the film 15 may be 1 N / 10 mm or more and 40 N / 10 mm or less, 1 N / 10 mm or more and 30 N / 10 mm or less, 1 N / 10 mm or more and 20 N / 10 mm or less, 3 N / 10 mm or more and 40 N / 10 mm or less, 3 N / 10 mm or more and 30 N / 10 mm or less, or 3 N / 10 mm or more and 20 N / 10 mm or less in an environment of 25°C.

[0100] The "3% strain tensile stress" in a film is determined using a tensile testing machine conforming to JIS B 7721:2009 by the following method. First, a film sample is prepared that has a length of 120 mm in one direction and a length of 10 mm in a direction perpendicular to that direction. Next, both ends of the sample in the longitudinal direction are clamped in chucks with a distance of 100 mm between the chucks. Then, the sample clamped in the chucks is pulled at a tensile speed of 200 mm / min, and the stress is measured when the strain of the sample reaches 3%. When measuring the 3% strain tensile stress in an environment of 25°C, the sample is pulled in an environment of 25±2°C.

[0101] Five measurement values ​​are obtained by measuring the tensile stress in five samples under the above conditions. The 3% strain tensile stress of film 15 is determined as the average of the three measurement values, excluding the largest and smallest values ​​from the five measurement values. The 3% strain tensile stress of film 15 is measured under conditions other than those described above, in accordance with JIS K 7161:1994.

[0102] <<Decorative Film 20>> The decorative film 20 may display designs such as colors and geometric patterns. The decorative film 20 may display textures such as metallic and leather-like finishes. The decorative film 20 may have a matte finish. The decorative film 20 in Figure 1 conforms to the shape of the adherend AB.

[0103] The decorative film 20 in Figure 2 includes a first surface 20a and a second surface 20b opposite to the first surface 20a. The first surface 20a of the decorative film 20 constitutes the first surface 15a of the film 15. The second surface 20b of the decorative film 20 constitutes the second surface 15b of the film 15. The film 15 includes a surface layer 34, a design layer 33, a base layer 31, and a bonding layer 32, extending from the first surface 20a to the second surface 20b. The first surface 15a of the film 15 is composed of the surface layer 34. The second surface 15b of the film 15 is composed of the bonding layer 32.

[0104] In the film 15, the above-described separator may be superimposed on at least one of the first surface 15a and the second surface 15b. The separator may be peeled off when the film 15 is attached to the adherend AB.

[0105] <Base Layer 31> The base layer 31 in Figure 2 supports the layers of the film 15 other than the base layer 31. The base layer 31 may be a film. The base layer 31 may contain a synthetic resin. In particular, the base layer 31 may contain a thermoplastic resin. The base layer 31 may contain one or more of the following as thermoplastic resins: (meth)acrylic resin, polyvinyl chloride (PVC), acrylonitrile-butadiene-styrene copolymer synthetic resin (ABS resin), polyolefin resin, polyester resin, urethane resin, fluororesin, polycarbonate, and cellulose resin. Note that the urethane resin includes thermoplastic polyurethane (TPU). From the viewpoint of improving conformability to the shape of the adherend AB and the durability of the film 15, the thermoplastic resin contained in the base layer 31 is preferably a urethane resin, particularly thermoplastic polyurethane (TPU), from the above examples. Furthermore, the thermoplastic resin contained in the base layer 31 is preferably thermoplastic polyurethane (TPU) from the viewpoint of being easily deformed by the high-temperature fluid 81 supplied from the fluid supply device 80 described later.

[0106] Polyolefin resins may contain polyethylene and polypropylene. Polyolefin resins may also contain thermoplastic polyolefin (TPO). Polyester resins may contain one or more polyethylene naphthalate (PEN), polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). Fluorine resins may contain one or more polyvinylidene fluoride (PVDF), perfluoroalkoxyalkane (PFA), ethylene-tetrafluoroethylene copolymer (ETFE), perfluoroethylene propene copolymer (FEP), and polytetrafluoroethylene (PTFE).

[0107] From the viewpoint of stably supporting layers other than the base layer 31, a lower limit may be set for the thickness of the base layer 31. The thickness of the base layer 31 may be 20 μm or more, 45 μm or more, 70 μm or more, 120 μm or more, or 170 μm or more. From the viewpoint of reducing the thickness of the film 15, the thickness of the base layer 31 may be 550 μm or less, 450 μm or less, or 350 μm or less.

[0108] The base layer 31 may be the layer with the greatest thickness in the film 15. The thickness of the base layer 31 may be 40% to 95% of the thickness of the film 15. The thickness of the base layer 31 may be 40% to 60% of the thickness of the film 15.

[0109] The base layer 31 may be transparent. When the film 15 and its components are "transparent," it means that the total light transmittance of those components is 70% or more. The total light transmittance of the transparent components may be 80% or more, or 90% or more.

[0110] As mentioned above, total light transmittance is a numerical value expressed in percentages. A D65 light source is used to measure total light transmittance. The D65 light source is a light source that mimics the spectrum of D65. D65 is a standard illuminant defined by the International Commission on Illumination (CIE). Before measuring total light transmittance, the D65 light source is lit for 15 minutes to stabilize its output. The angle of incidence to the sample when measuring total light transmittance is set to 0°. The test environment when measuring total light transmittance is set to a temperature of 23°C ± 2°C and a relative humidity of 50% ± 5%. The sample is placed in the test environment for 16 hours before the start of the test. Other measurement conditions when measuring total light transmittance follow JIS K7361-1:1997.

[0111] The total light transmittance used to determine that the film 15 and its components are transparent is the average of five measurements taken at five different locations under the conditions described above.

[0112] <Bonding layer 32> The bonding layer 32 in Figure 2 is located between the base material layer 31 and the adherend AB. The bonding layer 32 improves the adhesion of the film 15 to the adherend AB. The bonding layer 32 may contain an adhesive or tack material. The adhesive contained in the bonding layer 32 may include one or more of acrylic adhesives, rubber adhesives, urethane adhesives, and silicone adhesives. The tack material contained in the bonding layer 32 may include one or more of acrylic adhesives, rubber adhesives, urethane adhesives, and silicone adhesives. The bonding layer 32 may be omitted from the film 15. The bonding layer 32 may contain an acrylic tack material mainly composed of an acrylic acid ester monomer. The acrylic acid ester monomer may be butyl acrylate or 2-ethylhexyl acrylate.

[0113] A lower limit may be set for the peeling force on the second surface 15b of the film 15. The peeling force on the second surface 15b of the film 15 may be 3N / 25mm or more, 5N / 25mm or more, or 7N / 25mm or more. By setting such a lower limit for the peeling force on the second surface 15b of the film 15, the peeling of the film 15 from the adherend AB can be suppressed. Furthermore, when joining the film 15 to the holding device 50 described later, by setting such a lower limit for the peeling force on the second surface 15b of the film 15, the peeling of the film 15 from the holding device 50 can also be suppressed. In particular, if the peeling force on the second surface 15b of the film 15 is 7N / 25mm or more, even if the film 15 moves relative to the holding device 50 due to the pressurization of the first space S1 described later, the peeling of the film 15 from the holding device 50 can also be suppressed.

[0114] An upper limit may be set for the peeling force on the second surface 15b of the film 15. The peeling force on the second surface 15b of the film 15 may be 45 N / 25 mm or less, 35 N / 25 mm or less, or 25 N / 25 mm or less. By setting such an upper limit for the peeling force on the second surface 15b of the film 15, any excess film 15 generated when it is attached to the adherend AB can be easily peeled off from the frame 51.

[0115] Therefore, the peeling force on the second surface 15b of the film 15 may be 3N / 25mm or more and 45N / 25mm or less, 3N / 25mm or more and 35N / 25mm or less, or 3N / 25mm or more and 25N / 25mm or less. The peeling force on the second surface 15b of the film 15 may be 5N / 25mm or more and 45N / 25mm or less, 5N / 25mm or more and 35N / 25mm or less, or 5N / 25mm or more and 25N / 25mm or less. The peeling force on the second surface 15b of the film 15 may be 7N / 25mm or more and 45N / 25mm or less, 7N / 25mm or more and 35N / 25mm or less, or 7N / 25mm or more and 25N / 25mm or less.

[0116] The peeling force on the second surface 15b of the film 15 refers to the magnitude of the force required to peel off the film 15 that has been attached to another component on the second surface 15b. The peeling force on the second surface 15b of the film 15 is measured by the following method. First, a sample of film having a length of 100 mm in one direction and a length of 25 mm in a direction perpendicular to that direction is attached to a painted steel plate having a length of 70 mm from the second surface. The sample is attached to a portion of the painted steel plate other than the portion that will be held by the chuck described later. The portion of the sample attached to the painted steel plate has a length of 40 mm in the longitudinal direction. The portion of the sample attached to the painted steel plate includes one end of the sample in the longitudinal direction. The painted steel plate has paint (KINO1210TW Clear, manufactured by Kansai Paint Co., Ltd.) applied to the surface that comes into contact with the sample. When attaching the sample to the painted steel plate, the sample is pressed down by moving a roller (SA-1003-B, manufactured by Tester Industries Co., Ltd.) back and forth once with a load of 2 kilograms-force (kgf).

[0117] Next, 30 minutes after the sample is attached to the painted steel plate, a 180-degree peel strength test is performed as follows: The edge of the painted steel plate is clamped in one chuck. The portion of the sample not attached to the painted steel plate is folded back 180 degrees relative to the portion attached to the painted steel plate. A cellophane tape with a width of 24 mm (manufactured by Nichiban Co., Ltd.: CT405AP-24) is attached to the folded portion of the sample, and this cellophane tape is clamped in the other chuck. The sample in this state is pulled at a tensile speed of 200 mm / min under conditions of 25°C, and the average stress is measured from 10 mm to 30 mm in length as the sample peels off from the painted steel plate. By measuring this average stress for five samples, five measurement values ​​are obtained. The peel force on the second surface 15b of the film 15 is determined as the average value of the three measurement values ​​obtained by excluding the largest and smallest measurement values ​​from the five measurement values ​​described above. The peeling force on the second surface 15b of the film 15 is measured in accordance with JIS Z 0237:2009 under conditions other than those described above.

[0118] <Design Layer 33> The design layer 33 in Figure 2 is located between the base layer 31 and the surface layer 34. The design layer 33 displays the design shown by the decorative film 20. The design displayed by the design layer 33 may include one or more graphic elements such as figures, patterns, designs, colors, pictures, photographs, characters, marks, pictograms, letters, and numbers. The design layer 33 may include a binder resin portion and a colorant held by the binder resin portion. The binder resin portion may include a thermoplastic resin. The colorant may be a dye, a pigment, or a combination of a dye and a pigment. The design layer 33 may be formed by printing. The design layer 33 may be formed by transfer.

[0119] <Surface layer 34> The surface layer 34 in Figure 2 constitutes the outer surface of the film 15, i.e., the first surface 15a. The surface layer 34 may perform functions required for the outer surface of the film 15. For example, the surface layer 34 may be a hard coat layer with scratch resistance. The surface layer 34 may be an anti-fouling layer that provides anti-fouling functionality. The surface layer 34 may be omitted from the film 15.

[0120] The surface layer 34 may contain a cured resin product. The cured resin product is a cured product of a thermosetting resin composition or a cured product of an ionizing radiation-curable resin composition. The thermosetting resin composition contains a thermosetting resin. A thermosetting resin is usually a resin that crosslinks upon heating. The thermosetting resin composition hardens by crosslinking of the thermosetting resin. The thermosetting resin composition may further contain a curing agent. The curing agent may function as a catalyst to promote the hardening of the thermosetting resin, or it may react with the thermosetting resin. The thermosetting resin may crosslink upon reaction with the curing agent. The curing agent may be included in the cured product of the thermosetting resin composition. In a thermosetting resin composition, the thermosetting resin may be referred to as the main component.

[0121] The thermosetting resin contained in the thermosetting resin composition may include one or more of the following: phenolic resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, unsaturated polyester resin, polyurethane resin, epoxy resin, amino alkyd resin, melamine-urea cocondensation resin, and silicon resin. The curing agent contained in the thermosetting resin composition may be an isocyanate compound. The isocyanate compound is a compound containing an isocyanate group. The isocyanate compound may also be a polyisocyanate containing multiple isocyanate groups.

[0122] An ionizing radiation-curable resin composition contains an ionizing radiation-curable resin. An ionizing radiation-curable resin is a resin that crosslinks upon irradiation with ionizing radiation. Ionizing radiation means electromagnetic waves or charged particle beams that have energy quanta capable of polymerizing or crosslinking molecules. Electromagnetic waves may be ultraviolet (UV), X-rays, or gamma rays. Charged particle beams may be electron beams (EB), alpha rays, or ion beams. Among ionizing radiation-curable resins, those that crosslink upon irradiation with ultraviolet radiation may be referred to as ultraviolet-curable resins. Among ionizing radiation-curable resins, those that crosslink upon irradiation with electron beams may be referred to as electron-beam-curable resins.

[0123] In an ionizing radiation-curable resin composition, the ionizing radiation-curable resin may contain functional groups having ethylenically double bonds, such as (meth)acryloyl groups, vinyl groups, and allyl groups. The ionizing radiation-curable resin may also contain one or more epoxy groups and oxetanyl groups. The ionizing radiation-curable resin may also contain ethylenically unsaturated bonding groups. The ionizing radiation-curable resin may also contain siloxane bonds.

[0124] <<Film Application Device 40>> The film 15 having the above layer configuration is applied to the substrate AB by the film application device 40 shown in Figures 3 and 4. The illustrated film application device 40 applies the decorative film 20 to the substrate AB. The details of the film application device 40 for applying the decorative film 20 to the substrate AB will be described below, mainly with reference to Figures 3 and 4. However, the film 15 applied to the substrate AB using the film application device 40 is not limited to the decorative film 20.

[0125] In Figures 3 and 4, the automobile 1, including the adherend AB (roof 11), is positioned so that the film 15 can be attached to the adherend AB by the film application device 40. The film application device 40 attaches the film 15 to the adherend AB from the second surface 15b by moving the film 15 in a first direction D1 relative to the adherend AB. The illustrated film application device 40 is used to attach the film 15 to the roof 11 of the automobile 1.

[0126] The first direction D1 shown in Figures 3 and 4, etc., is parallel to the vertical direction of the automobile 1. The first side S11 of the first direction D1 is upward, i.e., the upper side in the vertical direction. The second side S12 of the first direction D1 is downward, i.e., the lower side in the vertical direction. The first direction D1 may not be parallel to the vertical direction, as shown in the figures. The first direction D1 may be parallel to the left-right direction of the automobile 1, or parallel to the front-rear direction of the automobile 1. The first direction D1 may be inclined with respect to both the vertical direction and the front-rear direction. An inclined first direction D1 may be located between the vertical direction and the front-rear direction.

[0127] The film application device 40 includes a holding device 50 and at least one of a moving device 42 and a pressurizing device 60. The holding device 50 holds the film 15. The moving device 42 moves the holding device 50, which is holding the film 15, in a first direction D1. That is, the moving device 42 moves the film 15 together with the holding device 50. The pressurizing device 60 pressurizes the first space S1 that the first surface 15a of the film 15 faces, while the holding device 50 is holding the film 15. The first space S1 is also the space that the first surface 20a of the decorative film 20 faces. The pressurizing device 60 makes the pressure in the first space S1 greater than the pressure in the second space S2 that the second surface 15b of the film 15 faces. The second space S2 is also the space that the second surface 20b of the decorative film 20 faces.

[0128] The film 15 may be partially moved in the first direction D1 while being held by the holding device 50 due to the pressure in the first space S1. The film application device 40 may include the holding device 50, the moving device 42, and the pressurizing device 60, as shown in Figures 3 and 4. Contrary to the figures, the film application device 40 may not include the moving device 42 or the pressurizing device 60.

[0129] In the film application device 40, the film 15 moves in a first direction D1 by the operation of at least one of the moving device 42 and the pressing device 60. The illustrated film 15 moves toward the second side S12 in the first direction D1 with respect to the adherend AB and the automobile 1 including the adherend AB. The film 15 moving in the first direction D1 is attached to the adherend AB from the second surface 20b.

[0130] The film application device 40 may include components other than those described above. As shown in Figures 3 and 4, the film application device 40 may include one or more of the following: a first support member 41, a cutting device 43, an imaging device 44, a control device 70, a display device 90, and an input device 91. One or more of these components may be omitted in the film application device 40. Furthermore, as shown in Figures 3 and 4, the film application device 40 may further include a second support member 430 that supports the cutting device 43.

[0131] In Figure 5, the film 15 held by the holding device 50 is spread out in a second direction D2 and a third direction D3. The second direction D2 is a direction nonparallel to the first direction D1. In particular, the illustrated second direction D2 is perpendicular to the first direction D1. The third direction D3 is a direction nonparallel to both the first direction D1 and the second direction D2. In particular, the illustrated third direction D3 is perpendicular to both the first direction D1 and the second direction D2.

[0132] In the film application apparatus 40 shown in Figures 3 and 4, the second direction D2 is parallel to the front-rear direction of the automobile 1. The third direction D3 is parallel to the left-right direction of the automobile 1. The first side S21 of the second direction D2 is the rear, i.e., the rear side in the front-rear direction. The second side S22 of the second direction D2 is the front, i.e., the front side in the front-rear direction.

[0133] The film 15 in Figure 5 has a first edge 151, a second edge 152, a third edge 153, and a fourth edge 154. The first edge 151 and the second edge 152 are the side edges of the film 15 in the second direction D2. The third edge 153 and the fourth edge 154 are the side edges of the film 15 in the third direction D3. Each of the first edge 151 and the second edge 152 extends in the third direction D3. Each of the third edge 153 and the fourth edge 154 extends in the second direction D2. The first edge 151 and the second edge 152 are separated from each other in the second direction D2. The third edge 153 and the fourth edge 154 are separated from each other in the third direction D3. The first edge 151 and the second edge 152 are connected to the third edge 153 or the fourth edge 154 at both ends in the third direction D3. The third edge 153 and the fourth edge 154 are connected to the first edge 151 or the second edge 152 at both ends in the second direction D2.

[0134] The holding device 50 in Figures 3 and 4 is positioned between the adherend AB and the cutting device 43 in the first direction D1. The holding device 50 may be movable away from between the adherend AB and the cutting device 43. When the film 15 is being attached to the adherend AB, the holding device 50 may be positioned between the adherend AB and the cutting device 43 with the film 15 attached. When the attachment of the film 15 to the adherend AB is complete, the holding device 50 may move away from between the adherend AB and the cutting device 43.

[0135] The holding device 50 may be fixed between the adherend AB and the cutting device 43. The film 15 may be placed between the adherend AB and the holding device 50. The holding device 50 may hold the film 15 placed between the holding device 50 and the adherend AB.

[0136] The holding device 50 in Figure 5 holds the first edge 151, second edge 152, third edge 153, and fourth edge 154 of the film 15. With these side edges held by the holding device 50, the film 15 is moved in the first direction D1 by one or more of the moving device 42, pressurizing device 60, and fluid supply device 80.

[0137] The film 15 in Figures 3 and 4 protrudes toward the adherend AB in a first direction D1. The film 15 is attached to the adherend AB while protruding toward the adherend AB in a first direction D1. The adherend AB in Figures 3 and 4 protrudes toward the film 15 in a first direction D1. The film 15 may protrude toward the first direction D1 by its own weight. The film 15 may also protrude toward the first direction D1 by pressurizing the first space S1 by a pressurizing device 60, which will be described later.

[0138] As shown in Figure 4, the film 15 held by the holding device 50 may be closest to the adherend AB on the center line ML2 in the second direction D2 of the holding device 50. As shown in Figure 3, the film 15 held by the holding device 50 may be closest to the adherend AB on the center line ML3 in the third direction D3 of the holding device 50.

[0139] The film 15 may be joined to the holding device 50 from the second surface 15b at the first edge 151, second edge 152, third edge 153, and fourth edge 154. By joining the film 15 to the holding device 50 at these side edges, movement of the film 15 in the second direction D2 and third direction D3 relative to the holding device 50 may be restricted. As shown in Figure 2, the second surface 15b of the film 15 is composed of a bonding layer 32. The film 15 may also be joined to the holding device 50 from the bonding layer 32.

[0140] The material of the holding device 50 may be selected such that the amount of deformation caused by the pressurized air in the first space S1 is less than that of the film 15. The material of the holding device 50 may be selected from materials having a greater tensile modulus than that of the film 15. The holding device 50 may include any of the following materials: metal, glass, cured resin, or thermoplastic resin. Details of the deformation caused by the pressurized air in the first space S1 will be described later.

[0141] <First Support Member 41> The first support member 41 in Figures 3 and 4 supports the holding device 50, the moving device 42, and the cutting device 43. As a result, in Figures 3 and 4, the holding device 50, the moving device 42, and the cutting device 43 are positioned on the first side S11 in the first direction D1 relative to the object AB.

[0142] The first support member 41 in Figures 3 and 4 supports the moving device 42 from the second side in the first direction D1. While supported by the first support member 41, the movement of the moving device 42 in a direction perpendicular to the first direction D1 may be restricted.

[0143] As shown in Figures 3 and 4, the first support member 41 may include a plurality of legs 412 and a connecting portion 413 that connects the plurality of legs 412. The plurality of legs 412 and the connecting portion 413 may be made of metal such as aluminum or stainless steel.

[0144] The multiple legs 412 shown in Figures 3 and 4 extend in a first direction D1. Each of the multiple legs 412 is located outward in a third direction D3 from the automobile 1. The legs 412 are further to the left and right from the centerline of the automobile 1 in the left-right direction than the automobile 1.

[0145] The connecting portion 413 shown in Figure 4 extends in the second direction D2. The connecting portion 413 connects two leg portions 412 that are aligned in the second direction D2.

[0146] <Moving device 42> The moving device 42 may include a stage 421, a drive device 422 connected to the stage 421, and legs 423 that support the stage 421, as shown in Figures 3 and 4. The drive device 422 drives the stage 421. The moving device 42 may include a plurality of drive devices 422, as shown in Figures 3 and 4.

[0147] The stage 421 shown in Figures 3 and 4 is a plate that extends in a second direction D2 and a third direction D3. The stage 421 is connected to legs 423 at its corners, i.e., at its ends in both the second direction D2 and the third direction D3. The illustrated stage 421 is connected to four legs 423. The illustrated legs 423 extend in a first direction D1. At the end on the second side S12 in the first direction D1, it is connected to a first support member 41.

[0148] The stage 421 in Figures 3 and 4 is movable in a first direction D1 relative to the legs 423. The stage 421 is movable in a first direction D1 relative to the legs 423 by the operation of the drive unit 422. The drive unit 422 may also have a function to restrict the movement of the stage 421 in the first direction D1 relative to the legs 423.

[0149] The stage 421 in Figures 3 and 4 includes a portion positioned between the adherend AB and the holding device 50 in the first direction D1. When the holding device 50 holds the film 15, the stage 421 includes a portion positioned between the adherend AB and the film 15 in the first direction D1. The illustrated moving device 42 supports the holding device 50 and the cutting device 43 on the stage 421 from the second side S12 in the first direction D1. The stage 421 and the legs 423 may be made of metal such as aluminum or stainless steel.

[0150] The stage 421 in Figures 3 and 4 includes an opening 421A. The opening 421A is located between the film 15 and the adherend AB in a first direction D1. In Figures 3 and 4, the dimension of the opening 421A in the direction perpendicular to the first direction D1 is larger than the dimension of the adherend AB in the direction perpendicular to the vertical direction. Specifically, in Figure 3, the dimension of the opening 421A in a third direction D3 is larger than the left-right dimension of the adherend AB. In Figure 4, the dimension of the opening 421A in a second direction D2 is larger than the front-back dimension of the adherend AB.

[0151] The drive unit 422 in Figure 4 may be electric. The electric drive unit 422 may include a motor. The drive unit 422 may be able to move the stage 421 relative to the legs 423 by hydraulics. The drive unit 422 may be able to move the stage 421 relative to the legs 423 by compressed air.

[0152] <Holding device 50> The holding device 50 in Figures 5 and 12 to 14 includes a frame 51 and a cover 52. As shown in Figure 5, the holding device 50 may further include a fixing member 53 connected to the frame 51. The fixing member 53 fixes the film 15. The fixing member 53 fixes the film 15 by pressing the film 15 against the frame 51. The fixing member 53 restricts the movement of the film 15 relative to the frame 51.

[0153] The frame 51 in Figure 5 has openings on the first side S11 and the second side S12 in the first direction D1. The frame 51 in Figures 12 to 14 is provided with openings 51h that open on the first side S11 and the second side S12 in the first direction D1. In Figures 12 to 14, the opening 51h is a space that is closed off from the first direction D1 by the cover 52 and the film 15. The opening 51ha of the frame 51 is the contour of the opening 51h when observed from the first side S11 in the first direction D1. The opening 51hb of the frame 51 is the contour of the opening 51h when observed from the second side S12 in the first direction D1.

[0154] The cover 52 shown in Figures 12 to 14 closes the opening 51ha of the frame 51 from the first side S11 in the first direction D1. When the cover 52 "closes" the opening 51ha or opening 51hb of the frame 51 from the first side S11 or second side S12 in the first direction D1, it means that when observed from the first side S11 or second side S12 in the first direction D1, the opening 51ha or opening 51hb of the frame 51 is covered by the cover 52.

[0155] The film 15 shown in Figures 5 and 12 to 14 covers the opening 51hb of the frame 51 from the second side 12 in the first direction D1. When the film 15 "covers" the opening 51ha or opening 51hb of the frame 51 from the first side S11 or second side S12 in the first direction D1, it means that when observed from the first side S11 or second side S12 in the first direction D1, the opening 51ha or opening 51hb of the frame 51 is covered by the film 15.

[0156] The frame 51 in Figure 5 extends circumferentially. The frame 51 includes a portion extending in a second direction D2 and a portion extending in a third direction D3. The portion of the frame 51 extending in the second direction D2 is connected at both ends to the portion of the frame 51 extending in the third direction D3. The portion of the frame 51 extending in the third direction D3 is connected at both ends to the portion of the frame 51 extending in the second direction D2. The frame 51 may be made of a metal such as aluminum.

[0157] The frame 51 in Figures 6 and 7 includes a first surface 51a and a second surface 51b that are separated from each other in a first direction D1. Figure 5 is a view of the frame 51 from the second surface 51b side. The first surface 51a is located on the first side S11 of the first direction D1 than the second surface 51b. Each of the first surface 51a and the second surface 51b extends in a direction perpendicular to the first direction D1. The first surface 51a and the second surface 51b extend circumferentially.

[0158] The frame 51 may include protrusions 51s for connecting to the fixing member 53, as shown in Figures 6 and 7. The protrusions 51s project outward in a direction perpendicular to the first direction D1. Outward in a direction perpendicular to the first direction D1 means a direction away from the centerline of that direction. As an example, the protrusions 51s shown in Figures 6 and 7 project outward in the third direction D3.

[0159] In the frame 51 shown in Figures 12 to 14, a cover 52 is superimposed from the first side S11 in the first direction D1, and a film 15 is superimposed from the second side S12 in the first direction D1. The illustrated frame 51 is positioned between the cover 52 and the film 15 in the first direction D1. The frame 51 may be in contact with the cover 52 on its first surface 51a. The frame 51 may be in contact with the film 15 on its second surface 51b.

[0160] The cover 52 in Figures 12 to 14 is a plate-shaped member that extends in a second direction D2 and a third direction D3. The cover 52 in Figures 12 to 14 has a first surface 52a and a second surface 52b. The first surface 52a and the second surface 52b are separated from each other in the first direction D1. The illustrated cover 52 is superimposed on the frame 51 from the second surface 52b side. The thickness direction of the cover 52 is parallel to the first direction D1.

[0161] As shown in Figures 12 and 14, the cover 52 may be provided with a through hole 52h that connects to the opening 51h of the frame 51. The illustrated through hole 52h opens to the first surface 52a and the second surface 52b. The hose 61 of the pressurizing device 60 is connected to the illustrated through hole 52h. In this way, the pump 62 of the pressurizing device 60 and the opening 51h are connected to each other via the hose 61 and the through hole. Note that the pump 62 is omitted in Figures 8, 12 and 14. Further details of the hose 61 and pump 62 will be described later.

[0162] The cover 52 may contain one or more of metal, glass, cured resin, or thermoplastic resin. The cover 52 may also be transparent for reasons described later.

[0163] When a component of the film application device 40 is "transparent," it means that the total light transmittance of that component is 70% or more. The total light transmittance of a transparent component may be 80% or more, or 90% or more. The total light transmittance of the component of the film application device 40 is determined by the same method as the total light transmittance of the component of the film 15.

[0164] The film 15 shown in Figures 12 to 14 is superimposed on the frame 51 from the first surface 15a side. As a result, the first space S1 is located between the cover 52 and the film 15 in the first direction D1. In particular, the illustrated first space S1 is formed by the opening 51h of the frame 51. The second space S2 is located between the film 15 and the adherend AB in the first direction D1. In Figures 12 to 14, the first space S1 is closed by the cover 52 from the first side S11 in the first direction D1. The first space S1 is closed by the film 15 from the second side S12 in the first direction D1. The first space S1 is closed by the frame 51 in a direction perpendicular to the first direction D1.

[0165] The holding device 50 in Figure 5 includes a plurality of fixing members 53. Each of the plurality of fixing members 53 is connected to a frame 51. The fixing members 53 are connected to protrusions 51s of the frame 51, as shown in Figures 6 and 7. The fixing members 53 may be pivotably connected to the frame 51, as shown in Figures 6 and 7. The fixing member 53 in Figure 7 pivots counterclockwise about axis AS relative to the fixing member 53 in Figure 6. The illustrated axis AS extends parallel to the second direction D2. The fixing member 53 in Figure 6 may be described as being in the open state. The fixing member 53 in Figure 7 may be described as being in the closed state.

[0166] As shown in Figure 5, the fixing member 53 may press the first edge 151 and the second edge 152 of the film 15 against the frame 51 along the entire length in the third direction D3. The fixing member 53 may also press the third edge 153 and the fourth edge 154 of the decorative film 20 against the frame 51 along the entire length in the second direction D2. As a result, the holding device 50 may hold the side edges of the film 15 around its entire circumference. By holding the film 15 in this manner, the holding device 50 can effectively suppress the leakage of air from the pressurized first space S1 between the film 15 and the frame 51.

[0167] As shown in Figures 6 and 7, the fixing member 53 may include a plate portion 531 and a connecting portion 532 connected to the plate portion 531. The illustrated fixing member 53 is pivotably connected to the protruding portion 51s of the frame 51 at the connecting portion 532. The fixing member 53 may also be pivotably attached to the frame 51 via a pin.

[0168] The fixing member 53 may be in contact with the film 15 at its plate portion 531, as shown in Figure 7. The film 15 may include a portion located between the frame 51 and the fixing member 53 when its movement relative to the frame 51 is restricted, as shown in Figure 7. The illustrated decorative film 20 is located between the frame 51 and the fixing member 53 at its third edge 153. Similar to Figure 7, when the film 15 is held by the holding device 50, it may be located between the frame 51 and the fixing member 53 at its first edge 151, second edge 152, and fourth edge 154. The illustrated third edge 153 is located between the frame 51 and the plate portion 531 of the fixing member 53 in the first direction D1.

[0169] When the fixing member 53 restricts the movement of the film 15 relative to the frame 51, it may also restrict the swinging of the fixing member 53 relative to the frame 51 by a bolt 55, as shown in Figure 7. By restricting the swinging of the fixing member 53 relative to the frame 51, the illustrated fixing member 53 can stably restrict the movement of the film 15 on the frame 51. As a result, the holding device 50, including the fixing member 53 and the bolt 55, can stably hold the film 15. The fixing member 53, like the frame 51, may be made of a metal such as aluminum. The bolt 55 may be made of a metal such as aluminum or stainless steel.

[0170] Furthermore, the film 15 may be joined to the fixing member 53 from the second surface 15b at the first edge 151, second edge 152, third edge 153, and fourth edge 154. The film 15 shown in Figure 7 may be joined to the plate portion 531 of the fixing member 53 from the second surface 15b at the third edge 153. The film 15 may also be joined to the fixing member 53 from the second surface 15b as a result of the second surface 15b being formed by the bonding layer 32.

[0171] As shown in Figures 6 and 7, the frame 51 may be provided with a threaded hole 51t that engages with the bolt 55. Similarly, the fixing member 53 may be provided with a through hole 53t through which the shaft of the bolt 55 can pass.

[0172] As shown in Figure 6, the fixing member 53 may hold the bolt 55. The illustrated fixing member 53 holds the bolt 55 in the through hole 53t. The illustrated through hole 53t includes a first portion 53ta and a second portion 53tb adjacent to the first portion 53ta. As shown in Figures 6 and 7, the outer diameter of the second portion 53tb is larger than the outer diameter of the first portion 53ta. The illustrated first portion 53ta is provided with a screw hole. The fixing member 53 holds the bolt 55 in the first portion 53ta of the through hole 53t.

[0173] The bolt 55 in Figures 6 and 7 includes a bolt head 551, a threaded portion 552, and an intermediate portion 553. The intermediate portion 553 is located between the bolt head 551 and the threaded portion 552 in the axial direction of the bolt 55. The outer diameter of the intermediate portion 553 is smaller than the outer diameter of the first portion 53ta of the through hole 53t. This allows the intermediate portion 553 to pass through the first portion 53ta of the through hole 53t. The outer diameter of the intermediate portion 553 may also be smaller than the outer diameter of the bolt head 551 and the outer diameter of the threaded portion 552.

[0174] In Figures 6 and 7, the bolt 55 engages with the first portion 53ta of the through hole 53t or the threaded hole 51t at its threaded portion 552. When the bolt 55 engages with the first portion 53ta of the through hole 53t at its threaded portion 552, it is fixed to the fixing member 53. In other words, the fixing member 53 holds the bolt 55 by engaging with the threaded portion 552 at the first portion 53ta of the through hole 53t. When the bolt 55 engages with the threaded hole 51t provided in the frame 51, it is fixed to the frame 51.

[0175] As shown in Figures 6 and 7, the holding device 50 may include a cushioning material 530 connected to the fixing member 53. The illustrated cushioning material 530 is attached to the end of the fixing member 53. The illustrated cushioning material 530 extends in a second direction D2 along its longitudinal direction. In Figure 7, the cushioning material 530 is in contact with the film 15. The film 15 is in contact with the cushioning material 530 at its first edge 151, second edge 152, third edge 153, and fourth edge 154. In Figure 7, contact between the fixing member 53 and the film 15 is avoided. By including the cushioning material 530, the holding device 50 can avoid damage to the film 15 due to contact with the fixing member 53.

[0176] The cushioning material 530 may be deformed by compression between the fixing member 53 and the film 15. The cushioning material 530 may be in contact with the film 15 in a compressed state. This action of the cushioning material 530 improves the airtightness between the fixing member 53 and the film 15. This prevents the air in the first space S1, which is pressurized by the pressurizing device 60, from leaking out between the film 15 and the fixing member 53. The cushioning material 530 may be made of rubber.

[0177] The through hole 53t may accommodate the head of the bolt 55, as shown in Figure 7. The through hole 53t may be enlarged in the portion that accommodates the head of the bolt 55, as shown in Figures 6 and 7. By accommodating the bolt 55 in the through hole 53t, it is possible to prevent the head of the bolt 55 from protruding from the fixing member 53.

[0178] <Pressurizing device 60> The pressurizing device 60 pressurizes the first space S1 described above. The pressurizing device 60 may include a hose 61 and a pump 62 connected to the hose 61, as shown in Figure 4. The first space S1 may be pressurized by compressed air supplied from the pump 62 flowing in through the hose 61. The pressure in the second space S2 may be the same as atmospheric pressure. The pressure in the first space S1 pressurized by the pressurizing device 60 is greater than the pressure in the second space S2. Therefore, the pressurizing device 60 makes the pressure in the first space S1 greater than that in the second space S2 when the holding device 50 is holding the film 15. As will be described later, the pressurizing device 60 moves the film 15 in the first direction D1 relative to the holding device 50 by making the pressure in the first space S1 greater than that in the second space S2.

[0179] Figures 8 to 14 show the operation of the film 15 due to the pressurization of the first space S1. In Figure 8, the first space S1 is not pressurized. In Figures 12 to 14, the first space S1 is pressurized by the pressurizing device 60 to have a greater pressure than the second space S2. In Figure 14, the film 15 is in contact with the adherend AB (roof 11) with the first space S1 pressurized. In Figures 12 and 13, the film 15 is not in contact with the adherend AB (roof 11) at the second surface 20b.

[0180] <Cutting device 43> The cutting device 43 cuts the film 15. The cutting device 43 may cut the film 15 that is in contact with the adherend AB. The cutting device 43 may cut the film 15 that is in partial contact with the adherend AB.

[0181] The cutting device 43 may cut the film 15 by emitting light. The cutting device 43 shown in Figures 3, 4, and 14 cuts the film 15 by emitting light. The light emitted from the cutting device 43 travels toward the film 15 in the second side S12 of the first direction D1. The light emitted from the cutting device 43 may be adjusted to focus on the film 15. By adjusting the position of the light focus, it is possible to prevent components other than the film 15, including the holding device 50 and the adherend AB, from being cut.

[0182] The cutting device 43 that emits light may also be a laser light source. The cutting device 43 shown in Figures 3 and 4 is a laser light source. The film 15 is cut by the light emitted from the laser light source and that reaches the film 15. The light emitted from the laser light source may have energy sufficient to cut the film 15. The laser light source may be an Nd:YAG laser emitting light with a wavelength of 1064 nm, or a fiber laser, or CO ２ A laser would also work.

[0183] At least a portion of the light emitted from the cutting device 43 may pass through the cover 52 before reaching the film 15. The cover 52 may be positioned between the cutting device 43 and the film 15 in the first direction D1, as shown in Figures 3, 4, and 14. From the viewpoint of suppressing the absorption of light before it reaches the film 15, the cover 52 may be transparent. By making the cover 52 transparent, the absorption of light emitted from the cutting device 43 by the cover 52 can be suppressed. As a result, the cutting device 43 can efficiently cut the film 15 even when the cover 52 is positioned between the cutting device 43 and the film 15.

[0184] The film application device 40 may include a second support member 430 that supports the cutting device 43, as shown in Figures 3 and 4. The illustrated second support member 430 is supported by the stage 421 of the moving device 42. The second support member 430 is supported by the stage 421 from the second side S12 in the first direction D1.

[0185] The second support member 430 may include a stage 431 and a plurality of legs 432 connected to the stage 431, as shown in Figures 3 and 4. The illustrated stage 431 extends in a second direction D2 and a third direction D3. The illustrated cutting device 43 is supported on the stage 431 by the second support member 430. The stage 431 is connected to the legs 432 at its corners, i.e., at its ends in both the second direction D2 and the third direction D3. The illustrated stage 431 is connected to four legs 432. The legs 432 extend in a first direction D1.

[0186] The cutting device 43 shown in Figures 3 and 4 is movably supported on the second support member 430. The cutting device 43 is movable relative to the second support member 430 in a direction perpendicular to the first direction D1. The cutting device 43 may also move relative to the second support member 430 in the second direction D2 or in the third direction D3. The cutting device 43 may also be movable relative to the second support member 430 in the first direction D1.

[0187] <Imaging device 44> The imaging device 44 in Figures 3 and 4 is positioned on the first side S11 in the first direction D1 relative to the adherend AB and the film 15. The film 15 is positioned between the adherend AB and the imaging device 44 in the first direction D1. The film application device 40 may include a plurality of imaging devices 44.

[0188] The imaging device 44 acquires one or more images of the object to be adhered AB, the film 15, and the holding device 50. The object to be adhered AB, the film 15, and the holding device 50 can be subjects of the imaging device 44. The imaging device 44 may include an illumination device to illuminate the subjects. The images acquired by the imaging device 44 may be still images or moving images. When images of the film 15, the object to be adhered AB, and the holding device 50 are shown together, the image of the film 15 may be described as the first image, the image of the object to be adhered AB as the second image, and the image of the holding device 50 as the third image.

[0189] As shown in Figures 3 and 4, the cover 52 of the holding device 50 may be positioned between the film 15 and the imaging device 44 in the first direction D1. The imaging device 44 may image the film 15 through the cover 52. The cover 52 positioned between the imaging device 44 and the film 15 may be transparent. By making the cover 52 transparent, the imaging device 44 can acquire a clear image of the film 15 even through the cover 52.

[0190] The imaging device 44 in Figures 3 and 4 is electrically connected to the control device 70. The image acquired by the imaging device 44 may be transmitted to the control device 70 via the electrical connection between the imaging device 44 and the control device 70.

[0191] <Control device 70> The control device 70 in Figures 3 and 4 is electrically connected to the imaging device 44. The control device 70 is electrically connected to one or more of the moving device 42, the cutting device 43, and the pressurizing device 60. The control device 70 may also be electrically connected to the moving device 42, particularly to the drive device 422.

[0192] The control device 70 may control the operation of one or more of the moving device 42, cutting device 43, and pressurizing device 60. The control device 70 may control the operation of the moving device 42, particularly the drive device 422. The control device 70 may generate a signal for one or more of the moving device 42, cutting device 43, and pressurizing device 60 to start operation. The control device 70 may generate a signal for one or more of the moving device 42, cutting device 43, and pressurizing device 60 to stop operation. The signals generated by the control device 70 may be transmitted to one or more of the moving device 42, cutting device 43, and pressurizing device 60 via the electrical connections described above.

[0193] The control device 70 may receive electrical signals from the imaging device 44. It may receive electrical signals relating to images acquired by the imaging device 44. The control device 70 may control one or more operations of the moving device 42, cutting device 43, and pressurizing device 60 based on images acquired by the imaging device 44. The control device 70 may control the operation of the moving device 42, particularly the operation of the drive device 422, based on one or more of the first, second, and third images acquired by the imaging device 44. The control device 70 may control the operation of the cutting device 43 based on at least one of the first and second images acquired by the imaging device 44. The control device 70 may control the operation of the pressurizing device 60 based on one or more of the first, second, and third images acquired by the imaging device 44.

[0194] The control device 70 may be a computer. The computer may include a control circuit. The control circuit may include a processor such as a CPU (Central Processing Unit) and an MPU (Micro Processing Unit). The control circuit may include a main memory such as RAM (Random Access Memory). The control circuit may also include an auxiliary storage device such as ROM (Read Only Memory) and a hard disk.

[0195] The control device 70 may output various determination results when attaching the film 15 to the substrate AB. The control device 70 may output determination results based on the image acquired by the imaging device 44. The control device 70 may control one or more operations of the moving device 42, cutting device 43, and pressurizing device 60 based on the determination results. Details of the determination results will be described later.

[0196] The control device 70 may calculate the number of films 15 attached. The number of films 15 attached is the number of films 15 attached to the substrate AB. The control device 70 may calculate the number of films 15 attached based on the image acquired by the imaging device 44. The control device 70 may calculate the number of films 15 attached based on the determination result.

[0197] <Display device 90> The display device 90 in Figure 4 is electrically connected to the control device 70. The display device 90 may display an image based on an electrical signal transmitted from the control device 70. The display device 90 may display the determination result by the control device 70. The display device 90 may display an image acquired by the imaging device 44. The display device 90 may display the number of films 15 attached. The display device 90 may be a display as shown in Figure 4.

[0198] <Input device 91> The input device 91 in Figure 4 is electrically connected to the control device 70. The control device 70 may control the operation of one or more of the moving device 42, cutting device 43, and pressurizing device 60 based on the operation of the input device 91.

[0199] As shown in Figure 4, the display device 90 and the input device 91 may be the same. The film application device 40 may include a touch panel as the display device 90 and the input device 91.

[0200] The operation of the film application device 40 will be explained with reference to Figures 3 to 21. Specifically, an example of a method for applying the film 15 to the adherend AB using the film application device 40, and an example of a method for manufacturing the decorative member 25 will be explained.

[0201] When the adherend AB is an exterior component 10 of an automobile 1, the film 15 may be applied to the adherend AB indoors, such as in a factory, car dealership, or store. The factory may be a manufacturing plant that produces the automobile 1, or a repair shop that services the automobile 1. The store may be a retail store that sells automobile-related goods.

[0202] An example of a method for attaching the film 15 described below includes a first attachment step STP1, a molding step STP2, and a second attachment step STP4, as shown in Figure 35. In the first attachment step STP1, the film 15 is partially attached to the adherend AB by the film attachment device 40. The first attachment step STP1 includes a placement step STP22 and a moving step STP23 in that order, as shown in Figure 36. The placement step STP22 is the step of placing the film 15, held by the holding device 50, onto the adherend AB. The moving step STP23 is the step of moving the film 15 in a first direction D1. The molding step STP2 is the step of molding the film 15 that has been partially attached to the adherend AB. The second attachment step STP4 is the step of attaching the molded portion of the film 15. Furthermore, when the first application step STP1 includes the second moving step STP28 described later, the moving step STP23 may be referred to as "first moving step STP23".

[0203] In Figures 3 to 21, the moving step STP23 is performed by the operation of at least one of the moving device 42 and the pressurizing device 60. Placing the film 15 held by the holding device 50 on the adherend AB means placing the film 15 held by the holding device 50 on the first side S11 or the second side S12 in the first direction D1 relative to the adherend AB. In the moving step STP23, the film 15 is partially attached to the adherend AB. Therefore, in the placement step STP22, the film 15 is positioned so that it can be at least partially attached to the adherend AB in the moving step STP23.

[0204] <<First Application Process STP1>> The first application process STP1 may include processes other than the placement process STP22 and the moving process STP23, as shown in Figure 36. The first application process STP1 may include at least one of the holding process STP21 and the cutting process STP26. The holding process STP21 is the process of holding the film 15 with the holding device 50. The cutting process STP26 is the process of cutting the film 15 with the cutting device 43. The first application process STP1 may include the holding process STP21, the placement process STP22, the moving process STP23, and the cutting process STP26 in this order, as shown in Figure 36. The following describes each process of the first application process STP1.

[0205] <Holding Process STP21> In holding process STP21, the holding device 50 holds the film 15. In holding process STP21, the film 15 placed on the holding device 50 is held by the holding device 50.

[0206] The film 15 placed on the holding device 50 may be a portion of a long film 15 supplied by roll-to-roll. Alternatively, a single sheet of film 15 may be placed on the holding device 50.

[0207] When a separator is placed on at least one of the first surface 15a and the second surface 15b of the film 15, the separator may be peeled off during the holding process STP21. The separator may be partially peeled off from at least one of the surfaces in the portion where the film 15 and the holding device 50 overlap. The separator may be peeled off from at least one of the surfaces in the portion where the film 15 and the holding device 50 overlap, and in the portion of the film 15 that is attached to the adherend AB.

[0208] In the holding process STP21, the film 15 may be placed on the holding device 50 by a suction device 56, as shown in Figures 8 and 9. The film application device 40 may include a suction device 56. The suction device 56 sucks the film 15 from the first surface 15a or the second surface 15b. The illustrated suction device 56 sucks the film 15 from the first surface 15a. In Figure 9, the suction device 56 restricts the movement of the film 15 relative to the holding device 50 by sucking the film 15 from the first surface 15a.

[0209] The holding device 50 may hold the film 15 in a state where its movement relative to the holding device 50 is restricted by the suction device 56. In the holding process STP21, the holding device 50 described with reference to Figures 5 to 7 may be used, as shown in Figures 8 and 9. Note that in Figure 8, the fixing member 53 is omitted from the viewpoint of making it easier to understand the positional relationship between the suction device 56, the holding device 50, and the film 15.

[0210] The suction device 56 in Figures 8 and 9 includes a first surface 56a that supports the holding device 50 and a second surface 56b that supports the film 15. The first surface 56a extends circumferentially. The second surface 56b is surrounded by the circumferential first surface 56a in a plan view, i.e., observed from the direction normal to the second surface 56b.

[0211] The suction device 56 in Figures 8 and 9 is provided with a hole 56h that opens on the second surface 56b. The suction device 56 may be provided with multiple holes 56h, as shown in Figures 8 and 9. Each of the multiple holes 56h is connected to a pump (not shown) that sucks air from the opening of the hole 56h shown in the figures. The pump may suck air between the film 15 and the suction device 56 when the film 15 is placed on the second surface 56b of the suction device 56. The film 15 may be sucked toward the holding device 50 by the pump.

[0212] The film 15 may be held in the holding device 50 while being sucked toward the holding device 50, as shown in Figure 9. In Figure 9, the film 15 is being sucked from the first surface 20a by the suction device 56. In Figure 9, air is being sucked between the suction device 56 and the film 15 through a hole 56h provided in the suction device 56.

[0213] The film 15 may be restricted from moving relative to the holding device 50 by the suction device 56 when the aforementioned fixing member 53 of the holding device 50 is in the open state. The fixing member 53 may swing from the open state to the closed state when the film 15 is restricted from moving relative to the holding device 50. After swinging to the closed state, the fixing member 53 may be restricted from further swinging by the bolt 55. The holding device 50 in Figures 8 and 9 may hold the film 15 by the swinging of a plurality of fixing members 53 and the connection of the bolt 55. The holding process STP21 may be completed when the connection of the bolt 55 is completed. The suction device 56 may release the restriction on the movement of the film 15 when the holding process STP21 is completed. Specifically, in the suction device 56, the pump connected to the aforementioned hole 56h may stop suction when the holding device 50 has completed holding the film 15.

[0214] <Placement Process STP22> In placement process STP22, the film 15 is placed on the adherend AB while being held by the holding device 50. In placement process STP22, the film 15 is placed in a position where it can be attached to the adherend AB. The position where it can be attached to the adherend AB may be within the projection of the adherend AB in the first direction D1. In the film application apparatus 40 of Figures 3 and 4, the holding device 50 is fixed on the stage 421 of the moving device 42 while holding the film 15 in place during placement process STP22. The holding device 50 may also be manually fixed on the stage 421 of the moving device 42.

[0215] Prior to the arrangement step STP22, the adherend AB may be positioned in a location where the film 15 can be attached by the film attachment device 40. In Figures 3, 4, 10, and 11, the adherend AB is positioned within the projection of the opening 421A of the stage 421 into the first direction D1. In these figures, the position where the film 15 can be attached by the film attachment device 40 is within the projection of the opening 421A of the stage 421 into the first direction D1.

[0216] In Figures 3, 4, 10, and 11, the adherend AB may be positioned so that the film 15 can be attached as the automobile 1 moves in the front-rear direction. As described above, the adherend AB shown is the roof 11. The shown roof 11 is positioned within the projection of the opening 421A of the stage 421 into the first direction D1. The automobile 1 may move in the front-rear direction by self-propulsion. The automobile 1 may also move in the front-rear direction by the movement of the mounting surface of the automobile 1. The mounting surface of the automobile 1 may move, in particular, in the automobile 1 manufacturing plant.

[0217] The imaging device 44 in Figures 3 and 4 may acquire an image of the object to be attached AB when the object to be attached AB is placed in the above-described position. The control device 70 may output a first determination result based on the image of the object to be attached AB. The first determination result means that the object to be attached AB is placed in a position to which the film 15 can be attached (normal determination), or that the object to be attached AB is not placed in a position to which the film 15 can be attached (abnormal determination). The abnormal determination in the first determination result may mean that the projection of the opening 421A of the stage 421 into the first direction D1 is shifted in a direction perpendicular to the first direction D1. The first determination result may be displayed on the display device 90.

[0218] The control device 70 may output a second determination result based on the first determination result. The second determination result means that the placement process STP22 can be performed (possible determination) or that the placement process STP22 cannot be performed (impossible determination). The second determination result may be displayed on the display device 90. The placement process STP22 may be performed based on the second determination result.

[0219] The imaging device 44 in Figures 3 and 4 may acquire an image of the film 15 during the placement step STP 22. The imaging device 44 may also acquire an image of the holding device 50 during the placement step STP 22. The control device 70 may output a third determination result based on at least one of the images of the film 15 and the holding device 50. The third determination result means that the film 15 is placed in a position where it can be attached to the substrate AB (normal determination), or that the film 15 is not placed in a position where it can be attached to the substrate AB (abnormal determination). The third determination result may be displayed on the display device 90. The placement step STP 22 may be completed when a normal determination is output as the third determination result.

[0220] <Moving Process STP23> In moving process STP23, the film 15 moves in the first direction D1 toward the adherend AB. Figures 12 to 14 show the moving process STP23. In the film application apparatus 40 of Figures 3 and 4, the film 15 moves to the second side S12 of the first direction D1 toward the adherend AB. In moving process STP23, the film 15 moves in the first direction D1 while protruding toward the adherend AB. The film 15 may move while being held by the holding device 50 at its first edge 151, second edge 152, third edge 153 and fourth edge 154.

[0221] The moving process STP23 is performed by the operation of at least one of the moving device 42 and the pressurizing device 60. The moving process STP23 may also be performed by a combination of the operation of the moving device 42 and the operation of the pressurizing device 60, as shown in Figures 12 to 14.

[0222] In the moving process STP23, the film 15 is attached to the adherend AB by moving from a state where it is protruding toward the adherend AB in the first direction D1 to the adherend AB in the first direction D1. The illustrated film 15 contacts the adherend AB from the second surface 15b. A contact area is created on the film 15 by contact with the adherend AB at the second surface 15b. When the second surface 15b of the film 15 is composed of a bonding layer 32, the film 15 may be bonded to the adherend AB at the contact area. The contact area expands as the amount of movement of the film 15 in the first direction D1 increases.

[0223] The moving process STP23 may include the pre-application moving process STP24 and the post-application moving process STP25 in this order. The pre-application moving process STP24 is a process of moving the film 15, which does not include the portion attached to the adherend AB, toward the adherend AB in a first direction D1. The post-application moving process STP25 is a process of moving the film 15, which includes the portion attached to the adherend AB, toward the adherend AB in a first direction D1. Figures 12 and 13 show the pre-application moving process STP24. Figure 14 shows the post-application moving process STP25. Each of the pre-application moving process STP24 and the post-application moving process STP25 is performed by the operation of at least one of the moving device 42 and the pressurizing device 60.

[0224] First, the moving process STP23, which is performed by the operation of the moving device 42, will be explained. The moving device 42 moves the holding device 50, which holds the film 15, in the first direction D1 relative to the adherend AB. The film 15 moves together with the holding device 50, with the first edge 151, second edge 152, third edge 153, and fourth edge 154 being held by the holding device 50. Note that the operation of the moving device 42 in the pre-application moving process STP24 may be the same as the operation of the moving device 42 in the post-application moving process STP25.

[0225] In the moving device 42 shown in Figures 3 and 4, the drive device 422 moves the stage 421 along the legs 423 in a first direction D1. This movement of the stage 421 causes the holding device 50, which is fixed on the stage 421, to move in the first direction D1. The holding device 50 moves in the first direction D1 while holding the film 15.

[0226] The operation of the moving device 42 in the moving process STP23 may be controlled by the control device 70. In particular, the movement of the stage 421 by the drive device 422 in the moving device 42 may be controlled by the control device 70. The control device 70 may transmit an electrical signal (movement start signal) to the moving device 42 via an electrical connection to the moving device 42 to initiate operation. The control device 70 may transmit an electrical signal (movement stop signal) to the moving device 42 via an electrical connection to the moving device 42 to stop operation.

[0227] The control device 70 may generate a movement start signal based on the third determination result described above. The control device 70 may generate a movement start signal when the third determination result is a normal determination. The control device 70 does not have to generate a movement start signal when the third determination result is an abnormal determination. The control device 70 may generate a movement start signal based on the third determination result and the input operation from the input device 91.

[0228] The control device 70 may calculate the amount of movement of the holding device 50 in the first direction D1 by the moving device 42. The control device 70 may also calculate the amount of movement of the holding device 50 based on the measurement results of a displacement sensor (not shown) capable of measuring the amount of movement of the holding device 50.

[0229] The control device 70 may generate a movement stop signal based on the amount of movement of the holding device 50. The control device 70 may store a threshold value related to the amount of movement of the holding device 50. The control device 70 may generate a movement stop signal based on a comparison between the threshold value and the amount of movement.

[0230] Next, the transfer process STP23, which is carried out by the operation of the pressurizing device 60, will be described. Figures 12 to 14 show the movement of the film 15 in the transfer process STP23. In Figures 12 to 14, the transfer process STP23 is carried out by at least the pressurizing device 60. In the pressurizing device 60, the pump 62 supplies air to the first space S1. The air passes through the hose 61 and the through hole 52h and then reaches the first space S1, that is, the opening 51h of the frame 51 in Figures 12 to 14. As a result of the supply of air from the pump 62 to the first space S1, the pressure in the first space S1 becomes greater than the pressure in the second space S2.

[0231] When the pressure in the first space S1 becomes greater than the pressure in the second space S2, the components that close the first space S1 are pushed outward by the air inside the first space S1. In other words, the components that close the first space S1 are pushed toward the space outside the first space S1, which includes the second space S2. In Figures 12 to 14, the components that close the first space S1 are the retaining device 50 and the film 15. More specifically, the components that close the first space S1 are the frame 51, the cover 52 and the film 15.

[0232] As described above, the material of the holding device 50 may be selected such that the amount of deformation caused by the pressurized air in the first space S1 is less than that of the film 15. By selecting the material of the holding device 50 in this way, the amount of deformation of the film 15 may be greater than the amount of deformation of the holding device 50, as shown in Figures 12 to 14. In Figures 12 to 14, the film 15 is projected in a first direction D1 toward the adherend AB by the pressurized air in the first space S1. That is, in the moving process STP23, the pressurizing device 60 causes the film 15 to project in a first direction D1 toward the adherend AB. In Figures 12 and 13, the portion of the film 15 projecting in the first direction D1 toward the adherend AB is convexly curved. In Figures 12 and 13, the convexly curved portion of the film 15 projects in the first direction D1 in the opposite direction to the adherend AB (roof 11).

[0233] In Figures 12 to 14, the film 15 expands toward the adherend AB in the first direction D1, thereby moving toward the adherend AB in the first direction D1 relative to the holding device 50, at least partially. In Figures 12 and 13, the amount of movement of the film 15 toward the first direction D1 is greatest at the point where the intersection of the center line ML2 of the second direction D2 and the center line ML3 of the third direction D3 coincides with the first direction D1. In Figure 14, the portion of the film 15 that expands toward the adherend AB in the first direction D1 is in contact with the adherend AB from the second surface 15b.

[0234] As shown in Figures 12 to 14, the adherend AB has a three-dimensional shape and protrudes toward the film 15 in the first direction D1. Specifically, the curved surface 11R of the illustrated roof 11 protrudes toward the first side S11 in the first direction D1. Because the adherend AB has this shape, the film 15 is attached to the adherend AB starting from the portion that protrudes the most in the first direction D1. The film 15 is prevented from being attached to the adherend AB starting from the portion that protrudes the least in the first direction D1. Therefore, the shape of the illustrated adherend AB can prevent it from being unintentionally attached to the adherend AB during the moving process STP23.

[0235] The control device 70 may control the pressurizing device 60 so that the pressure in the first space S1 during the post-application movement process STP25 is different from the pressure in the first space S1 during the pre-application movement process STP24. The pressurizing device 60 may also increase the pressure in the first space S1 during the post-application movement process STP25 compared to the pressure in the pre-application movement process STP24. In other words, the pressurizing device 60 may increase the pressure in the first space S1 in the state shown in Figure 14 compared to the state shown in Figures 12 and 13.

[0236] The operation of the pressurizing device 60 in the transfer process STP23 may be controlled by the control device 70. The control device 70 may transmit an electrical signal (pressurizing start signal) to the pressurizing device 60 via an electrical connection to the pressurizing device 60 to initiate operation. The control device 70 may transmit a signal (pressurizing maintenance signal) to the pressurizing device 60 via an electrical connection to the pressurizing device 60 to maintain the pressure in the first space S1 in a pressurized state. The control device 70 may transmit an electrical signal (pressurizing stop signal) to the pressurizing device 60 via an electrical connection to the pressurizing device 60 to stop operation. Upon receiving the pressurizing stop signal, the pressurizing device 60 may become the same as the pressure in the second space S2.

[0237] The control device 70 may generate a pressurization start signal based on the third determination result described above. The control device 70 may generate a pressurization start signal when the third determination result is a normal determination. The control device 70 does not have to generate a pressurization start signal when the third determination result is an abnormal determination. The control device 70 may generate a pressurization start signal based on the third determination result and the input operation from the input device 91.

[0238] The control device 70 may receive an electrical signal relating to the pressure in the first space S1 from a pressure sensor (not shown) installed in the first space S1. The control device 70 may calculate the pressure in the first space S1 based on the measurement results of the pressure sensor. The control device 70 may generate a pressurization maintenance signal based on the pressure in the first space S1. The control device 70 may generate a pressurization stop signal based on the pressure in the first space S1. The control device 70 may store a threshold value relating to the pressure in the first space S1. The control device 70 may generate a pressurization maintenance signal and a pressurization stop signal based on a comparison between the pressure in the first space S1 and the threshold value.

[0239] The control device 70 may transmit a pressure maintenance signal to the pump 62 based on a comparison of the measured pressure in the first space S1 with a threshold. The control device 70 may also control the pressurizing device 60 to stop the pressure increase in the first space S1 when the pressure in the first space S1 reaches a threshold.

[0240] As described above, the movement process STP23 is performed by the pressurizing device 60. During the movement process STP23, the control device 70 may calculate the size of the contact area based on the image of the film 15 acquired by the imaging device 44. As shown in Figure 15, the color of the film 15 may change due to contact with the adherend AB. For example, in observation from the imaging device 44, the brightness of the contact area of ​​the film 15 may change as the amount of reflected light from the contact area decreases compared to the amount of reflected light from areas other than the contact area. The control device 70 may calculate the size of the contact area based on the change in the color of the film 15 in the image acquired by the imaging device 44. Based on the calculated size of the contact area, the control device 70 may generate a movement stop signal, a pressurizing maintenance signal, or a pressurizing stop signal.

[0241] The film can be attached to the substrate by moving it in a first direction, even in a conventional film application apparatus as illustrated in JP2019-531951A. The decorative member is formed by the substrate and the film attached to the substrate. When a conventional film application apparatus attaches the film to the substrate, it pulls the film in at least one of a second direction and a third direction. The second direction is a direction nonparallel to the first direction. The third direction is a direction nonparallel to both the first and second directions. As a result, the decorative film is pulled so that it spreads out in a plane perpendicular to the first direction.

[0242] The inventors of this case have found that pulling a film in a second or third direction can promote the formation of wrinkles in the film. When a film is pulled in a second or third direction, variations in tension can occur. These variations in tension can increase, in particular, with increasing film size. It was presumed that in conventional film application devices, wrinkles are formed due to variations in tension on the film. In particular, it was presumed that when a film application device is applied to an automobile, more specifically when a large exterior component such as a roof is used as the adherend, the formation of wrinkles becomes more pronounced.

[0243] When a wrinkled film is applied to an object, air pockets may form between the object and the film. Furthermore, the film may bond to itself at the wrinkled areas. As a result, the design of the decorative component formed by the object and the film may be significantly degraded at the wrinkled areas of the film.

[0244] The inventors of this invention have found a method of attaching a film to an adherend in which the film protrudes toward the adherend in a first direction toward the adherend. In the film application device 40 shown in Figures 3 and 4, the film 15 (decorative film 20) protrudes toward the adherend AB in a first direction D1 by its own weight or by the pressure of the first space S1 described above. The film 15 (decorative film 20) is attached in a state where it protrudes toward the adherend AB in a first direction D1 by the operation of at least one of the moving device 42 and the pressurizing device 60 described above. By protruding toward the adherend AB in a first direction D1, the film 15 (decorative film 20) suppresses the increase in tension in the direction perpendicular to the first direction D1. As a result, the occurrence of wrinkles due to tension variations can be suppressed compared to a decorative film that is pulled in a second or third direction. Therefore, the film application device 40 can suppress the deterioration of the design of the decorative member 25.

[0245] Furthermore, when the pressurizing device 60 causes the film 15 (decorative film 20) to protrude in the first direction D1 toward the adherend AB, the pressure in the first space S1 becomes greater than the pressure in the second space S2. The film 15 (decorative film 20) is prevented from deforming toward the opposite side of the adherend AB, i.e., toward the first side S11 in the first direction D1, by the pressure difference between the first space S1 and the second space S2. As a result, the film 15 (decorative film 20) can be prevented from deforming due to disturbances such as airflow in the installation environment of the film application device 40 and vibrations of the film application device 40. As a result of preventing deformation due to disturbances, the occurrence of wrinkles in the film 15 (decorative film 20) can be effectively suppressed. Therefore, the film application device 40, which includes a pressurizing device 60 that pressurizes the first space S1, can more effectively suppress the deterioration of the design of the decorative member 25, including the film 15.

[0246] As described above, the pressurizing device 60 may further pressurize the first space S1 in the post-application movement step STP25 compared to the pre-application movement step STP24. In other words, the pressurizing device 60 may increase the pressure in the first space S1 when the film 15 partially contacts the adherend AB from the second surface 15b. When the film 15 is in partial contact with the adherend AB, it is at least partially supported by the adherend AB from a direction opposite to the direction of movement in the first direction D1 (the second side S12 in Figures 3 and 4). When the film 15 is supported by the adherend AB, even if the first space S1 is further pressurized, the increase in the amount of movement in the first direction D1 is suppressed. As a result, the film application device 40 can press the film 15 (decorative film 20) toward the adherend AB in the post-application movement step STP25. In addition, when the second surface 15b of the film 15 is composed of a bonding layer 32, the film application device 40 can stably bond the film 15 to the adherend AB in the post-application moving step STP 25.

[0247] <Cutting Process STP26> In cutting process STP26, the film 15 is cut by the cutting device 43. As described above, the cutting device 43 may cut the film 15 by emitting light. The film 15 cut by the cutting device 43 is separated from the holding device 50. Figure 15 shows the film 15 separated from the holding device 50. In the illustrated film application device 40, the portion of the film 15 separated from the holding device 50 is applied to the adherend AB.

[0248] In the cutting process STP26, the film 15 may have a positioning portion 15f formed thereon for positioning the film forming apparatus 300 described later. The illustrated decorative film 20 has a positioning portion 20f formed thereon in the cutting process STP26 for positioning the film forming apparatus 300 described later. The positioning portion 20f of the decorative film 20 constitutes the positioning portion 15f of the film 15. The positioning portion 15f may also be a through hole penetrating the film 15, as shown in Figure 15.

[0249] The control device 70 may count up the number of times the film 15 has been applied by the film application device 40 upon completion of the cutting process STP 26.

[0250] As described above, in the first application step STP1, the film 15 is applied to the adherend AB using the film application device 40. In the first application step STP1, the film 15 is partially applied to the adherend AB. In the first application step STP1, parts of the film 15 other than the edge portion 15e may also be applied to the adherend AB.

[0251] The control device 70 may store the number of times the film 15 has been applied by the film application device 40. Based on the stored number of times the film 15 has been applied, the timing for maintenance and replacement of the components of the film application device 40 may be determined. By determining the timing for maintenance and replacement in this way, it is possible to avoid a long-term shutdown of the application work due to a failure of any component of the film application device 40. Therefore, by the control device 70 storing the above-mentioned number of applications, the efficiency of the film application work of the film 15 by the film application device 40 can be improved.

[0252] <<Molding Process STP2>> The decorative film 20 is then molded in molding process STP2 using the film molding apparatus 300 shown in Figures 16 to 20. The film molding apparatus 300 is not limited to the decorative film 20, but can also mold the film 15. The film 15 is molded at the edge portion 15e by molding process STP2. The film 15 may also be molded at the corner portion 15r by molding process STP2, as shown in Figures 16 and 21. Below, the configuration of the film molding apparatus 300 will be explained with reference to Figures 16 to 20. Next, molding process STP2 will be explained with reference to Figures 16 to 21. Note that the adherend AB is omitted in Figures 16 to 20.

[0253] The film forming apparatus 300 in Figure 16 includes a first mold 310, a second mold 320, and wiring 330 electrically connected to the second mold 320. In Figure 16, the edge 15e of the film 15 is sandwiched between the first mold 310 and the second mold 320.

[0254] In Figure 16, the film 15 is turned inside out at the corner 15r. In the turned-out region, the film 15 is sandwiched between the first mold 310 and the second mold 320. In Figure 16, the first surface 15a of the film 15 faces the first mold 310. The second surface 15b of the film 15 faces the second mold 320.

[0255] The film forming apparatus 300 heats the film 15 using at least one of the first mold 310 and the second mold 320. In the illustrated film forming apparatus 300, of the first mold 310 and the second mold 320, the second mold 320 heats the film 15. More specifically, the illustrated second mold 320 generates heat in the second body 325, which will be described later. The second mold 320 may generate heat in the second body 325 due to the current from the wiring 330.

[0256] The film 15 is formed at its edges 15e by heating. As described above, the film 15 may also be formed by the film forming apparatus 300 at the corners 15r where multiple edges 15e connect to each other. In the film forming apparatus 300 shown in Figure 16, the second mold 320 heats the film 15.

[0257] The film forming apparatus 300 may include a fixing device 350 for fixing the film 15 to the film forming apparatus 300, as shown in Figure 16. The illustrated fixing device 350 fixes the film 15 to the first mold 310. The fixing device 350 may also be a screw, as shown in Figure 16. The illustrated screw passes through the positioning portion 15f provided on the film 15 at its shaft. The film 15 may be positioned relative to the film forming apparatus 300 by the fixing device 350 passing through the positioning portion 15f. Note that the fixing device 350 is not shown in Figure 20.

[0258] Figure 17 shows the first type 310. The second type 320 is omitted in Figure 17. In Figure 17, the film 15 is indicated by a dashed line. The illustrated first type 310 includes a first body 315 and a first handle 316 connected to the first body 315. The first handle 316 is the handle of the first type 310. The first type 310 may include a plurality of first handles 316. The first type 310 in Figure 17 includes two first handles 316. As shown in Figure 17, in the first type 310, the first body 315 and the first handle 316 may be integrated. The first type 310 may be made of a metal such as aluminum.

[0259] In the first type 310 of Figure 16, each of the two first patterns 316 extends from the first body 315 in the X direction DX. The first body 315 extends in the X direction DX and the Y direction DY when viewed from the Z direction DZ. The X direction DX, the Y direction DY, and the Z direction DZ are directions used with respect to the film forming apparatus 300 and the film 15 formed by the film forming apparatus 300. The Y direction DY and the Z direction DZ are directions perpendicular to the X direction DX. The Y direction DY and the Z direction DZ are directions perpendicular to each other.

[0260] The first mold 310 in Figure 17 includes a recess 340 in the first body 315 that accommodates the second mold 320. The recess 340 is open in the Z direction DZ and the X direction DX. The film 15 is molded while sandwiched between the first mold 310 and the second mold 320 which is housed in the recess 340 of the first mold 310. The film 15 is molded to have a shape complementary to the recess 340, as will be described later. The shape of the recess 340 may be determined based on the shape of the adherend AB.

[0261] The recess 340 in Figure 17 is composed of a first bottom surface 311 and a first side surface 312 extending from the first bottom surface 311 in the Z direction DZ. The angle θ between the first bottom surface 311 and the first side surface 312 is... １２ This may be set based on the shape of the adherend AB. The illustrated angle θ １２ This may be set based on the shape of the exterior member 10. Note that the angle θ in the recess 340 shown in the figure １２ It is 90°.

[0262] The angle θ between the first bottom surface 311 and the first side surface 312 １２ is measured from a cross-section of the first type 310 by a plane extending in a direction orthogonal to the first bottom surface 311 and in a direction orthogonal to the first side surface 312. The angle θ １２ in the illustrated recess 340 is measured from a cross-section of the first main body 315 by a plane extending in the first bending direction DF1 and the Z direction DZ, or by a plane extending in the second bending direction DF2 and the Z direction DZ.

[0263] Also, the first side surface 312 of FIG. 17 includes a first portion 312A extending in the Z direction DZ and the first bending direction DF1, and a second portion 312B extending in the Z direction DZ and the second bending direction DF2. Each of the first bending direction DF1 and the second bending direction DF2 is a direction orthogonal to the Z direction DZ, as shown in FIG. 20. As a result, the illustrated recess 340 is constituted by the first bottom surface 311, the first portion 312A of the first side surface 312, and the second portion 312B of the first side surface 312.

[0264] The angle θ between the first portion 312A and the second portion 312B on the first side surface 312 ＡＢ may be set based on the shape of the adherent AB. The illustrated angle θ ＡＢ may be set based on the shape of the exterior member 10.

[0265] The angle θ between the first portion 312A and the second portion 312B on the first side surface 312 ＡＢ is measured from a cross-section by a plane extending in a direction orthogonal to the first portion 312A and in a direction orthogonal to the second portion 312B. In the illustrated first side surface 312, both the first portion 312A and the second portion 312B extend from the first bottom surface 311 in the Z direction DZ. Therefore, the angle θ ＡＢ is measured from a cross-section of the first main body 315 by a plane orthogonal to the Z direction DZ.

[0266] The first mold 310 may be provided with a hole 314 that opens in the Z direction DZ. The first mold 310 in Figure 17 is provided with two holes 314. The holes 314 in Figure 17 are provided in the first body 315. The holes 314 open to the first side in the Z direction DZ. Screw holes may be provided in the holes 314. By engaging screws in the screw holes, the fixing device 350 may restrict the movement of the film 15 relative to the first mold 310.

[0267] In the first type 310 shown in Figures 17 and 20, the two first handles 316 are separated from each other in the Y direction DY. The first type 310 may be provided with a first hole 317 that penetrates each of the two first handles 316, as shown in Figures 17 and 20. The first hole 317 extends in the Y direction DY. A pin P, described later, for connecting the first type 310 and the second type 320 may be inserted into the first hole 317.

[0268] The first type 310 in Figures 17 and 20 includes a connecting portion 318 that connects two first handles 316. The connecting portion 318 extends in the Y direction DY. In the illustrated first type 310, the first hole 317 is located between the first body 315 and the connecting portion 318 in the X direction DX.

[0269] Figure 18 shows the second type 320. The second type 320 in Figure 18 is reversed from the state in Figure 16. In Figure 18, the first type 310 and film 15 are omitted. The second type 320 shown in Figure 16 and Figures 18 to 20 includes a second body 325 and a second handle 326 connected to the second body 325. The second handle 326 is the handle of the second type 320. The second handle 326 extends from the second body 325 in the X direction DX. When observed from the Z direction DZ, the second body 325 spreads in the X direction DX and the Y direction DY. In the second type 320, the second body 325 and the second handle 326 may be separate parts. The second handle 326 may be made of metal such as aluminum. Contrary to the illustration, the second body 325 and the second handle 326 may be a single unit.

[0270] The second body 325 in Figure 18 includes a second bottom surface 321 and a second side surface 322 extending from the second bottom surface 321 in the Z direction DZ. In the second mold 320, the second bottom surface 321 and a portion of the second side surface 322 are portions that contact the film 15. In the second mold 320 in Figure 18, the second bottom surface 321 and the first portion 322A and the second portion 322B of the second side surface 322 are portions of the second side surface 322 that contact the second surface 15b of the film 15. The first portion 322A of the second side surface 322 is a portion that extends in the Z direction DZ and the first bending direction DF1. The second portion 322B of the second side surface 322 is a portion that extends in the Z direction DZ and the second bending direction DF2.

[0271] The second side surface 322 may include portions that do not contact the film 15. As an example of portions that do not contact the film 15, the second side surface 322 in Figure 18 includes a third portion 322C and a fourth portion 322D. In the second side surface 322, the third portion 322C is connected to the first portion 322A. In the second side surface 322, the fourth portion 322D is connected to the first portion 322B. The third portion 322C and the fourth portion 322D face each other in the Y direction DY. Each of the third portion 322C and the fourth portion 322D extends in the X direction DX and the Z direction DZ. The second side surface 322 in Figure 18 also includes a fifth portion 322E as another example of portions that do not contact the film 15. The fifth portion 322E extends in the Y direction DY and the Z direction DZ.

[0272] As shown in Figure 18, a hole 300H may be provided inside the second body 325. Cooling fluid FL flows through the hole 300H of the second body 325. Cooling fluid FL is a fluid for cooling the second body 325 after the film 15 has been heated, and the film 15 that is in contact with the second body 325.

[0273] The hole 300H in Figure 18 contains a first hole 300HA and a second hole 300HB that intersect each other within the second body 325. The first hole 300HA extends in the Y direction DY within the second body 325. The second hole 300HB extends in the X direction DX within the second body 325.

[0274] The hole 300H is open at at least one location in the second body 325. As shown in Figure 18, the hole 300H may be open at multiple locations in the second body 325. In the hole 300H, one opening may constitute an inlet IL for the cooling fluid FL. In the hole 300H, another opening different from one may constitute an outlet OL for the cooling fluid FL. In the hole 300H, multiple openings may constitute an inlet IL for the cooling fluid FL, or multiple openings may constitute an outlet OL for the cooling fluid FL.

[0275] In the second body 325, the hole 300H may open in a portion that does not come into contact with the film 15. As an example of a portion that does not come into contact with the film 15, the first hole 300HA in Figure 18 opens into the third portion 322C and the fourth portion 322D of the second body 325 at both ends in the Y direction DY. One end of the opening of the first hole 300HA opens into the third portion 322C of the second side surface 322. The other end of the opening of the first hole 300HA opens into the fourth portion 322D of the second side surface 322. Also, as another example of a portion that does not come into contact with the film 15, the second hole 300HB in Figure 18 opens into the fifth portion 322E of the second side surface 322.

[0276] The second body 325 may be made of synthetic resin such as fluororesin, silicone resin, or olefin resin, for example. In particular, it is preferable that the material of the second body 325 be one of fluororesin, silicone resin, or olefin resin. By selecting the material of the second body 325 in this way, the film 15 can be easily peeled off the second body 325. Therefore, the molded film 15 can be easily removed from the second mold 320.

[0277] The material of the second body 325 may also be a metal such as aluminum, as an alternative example. In particular, the material of the second body 325 is preferably aluminum. This improves the thermal conductivity of the second body 325 of the second mold 320. The film 15 (decorative film 20) sandwiched between the first mold 310 and the second mold 320 can be heated quickly, and the film 15 (decorative film 20) can be efficiently formed.

[0278] In the second type 320, the entire second body 325 may be made of the above-mentioned material. In the second type 320, the second bottom surface 321 and the second side surface 322, i.e., the parts that come into contact with the film 15 (decorative film 20), may be made of a coating. The coating that makes up the second bottom surface 321 and the second side surface 322 may contain a release agent. The release agent may contain any of a silicone compound, a fluorine-based compound, or a long-chain alkyl compound. Polydimethylsiloxane (PDMS) is an example of a silicone compound. Polytetrafluoroethylene (PTFE) and fluororesin are examples of fluorine-based compounds. "Toshikal® S Coating" manufactured by Toshiko Co., Ltd. is an example of a release agent.

[0279] In the second type 320, the angle φ between the second bottom surface 321 and the second side surface 322 １２ This may be set based on the shape of the adherend AB. The angle φ shown in the diagram. １２ This may be set based on the shape of the exterior member 10. Note that the angle φ shown in the figure is also shown. １２ The angle is 90°. Similarly, on the second side surface 322, the angle φ between the first portion 322A and the second portion 322B is 90°. ＡＢ This may be set based on the shape of the adherend AB. The angle φ shown in the diagram. ＡＢ This may be set based on the shape of the exterior component 10.

[0280] As shown in Figures 18 and 19, the second body 325 may include a connecting surface 323 located between the second bottom surface 321 and the second side surface 322. The connecting surface 323 may be rounded, as shown in Figures 18 and 19. The radius (R) of the rounded connecting surface 323 may be set based on the thickness of the film 15 and the 3% strain tensile stress of the film 15 at room temperature. The radius (R) of the rounded connecting surface 323 may also be set based on the shape of the adherend AB.

[0281] As described above, wiring 330 may be connected to the second type 320. The wiring 330 may extend from the second side surface 322 of the second body 325, as shown in Figure 18. In Figure 18, the wiring 330 extends from the fifth portion 322E of the second side surface 322.

[0282] The second type 320 in Figure 18 is provided with a second hole 327 that penetrates the second handle 326 in the Y direction DY. The second hole 327 extends in the Y direction DY. A pin P, described later, for connecting the first type 310 and the second type 320 may be inserted into the second hole 327.

[0283] The second type 320 in Figure 18 is provided with a housing portion 328 that at least partially accommodates the connecting portion 318 of the first type 310. The housing portion 328 is located on the second handle 326. The second handle 326 opens to the second side in the Y direction DY and the Z direction DZ in the portion where the housing portion 328 is provided.

[0284] The first type 310 and the second type 320 shown in Figures 16 and 19 are connected to each other by a pin P extending in the Y direction DY. The illustrated pin P passes through a first hole 317 provided in the first type 310 and a second hole 327 provided in the second type 320.

[0285] The first mold 310 and the second mold 320 may be pivotably connected to each other by the pin P described above, as shown in Figure 19. As a result, the film forming apparatus 300 in Figure 16 can switch between a closed state and an open state while the movement of the first mold 310 and the second mold 320 relative to each other is restricted. The closed state is when the second mold 320 is at least partially housed in the first mold 310. The open state is when the second mold 320 is not housed in the first mold 310. In Figures 19 and 20, the first mold 310 and the second mold 320 are pivotable relative to each other about axis AX. Axis AX extends in the Y direction DY. The user of the film forming apparatus 300 may pivot the first mold 310 and the second mold 320 relative to each other while gripping the first handle 316 of the first mold 310 and the second handle 326 of the second mold 320.

[0286] The film forming apparatus 300 in Figure 16 is in a closed state. The film forming apparatus 300 in Figure 19 is in an open state. The film forming apparatus 300 heats the film 15 in the closed state. The film forming apparatus 300 forms the film 15 in the closed state. The oscillation of the first mold 310 and the second mold 320 relative to each other may be restricted by the connection portion 318 of the first mold 310.

[0287] In the closed-mold film forming apparatus 300, the first bottom surface 311 of the first mold 310 and the second bottom surface 321 of the second mold 320 face each other in the Z direction DZ. In the closed-mold film forming apparatus 300, the first side surface 312 of the first mold 310 and the second side surface 322 of the second mold 320 face each other in a direction perpendicular to the Z direction DZ. In particular, in the film forming apparatus 300 shown in Figure 20, the first portion 312A of the first side surface 312 and the first portion 322A of the second side surface 322 face each other in the second bending direction DF2. Also, the second portion 312B of the first side surface 312 and the second portion 322B of the second side surface 322 face each other in the first bending direction DF1.

[0288] An example of a molding process STP2 using the film molding apparatus 300 having the above configuration will be described. In molding process STP2, first, the film molding apparatus 300 is opened. By opening the film molding apparatus 300, the film 15 can be placed between the first mold 310 and the second mold 320.

[0289] In molding step STP2, the film 15 is then placed between the first mold 310 and the second mold 320. The film 15 may be turned inside out in the part to be molded, as shown in Figure 16. The film 15 may not be turned inside out in the part to be molded, as shown in the figure. The film 15 is placed on the first body 315 of the first mold 310. The film 15 is placed on the second side of the first body 315 in the Z direction DZ, as shown in Figure 17. By placing the film 15 on the first body 315, the first surface 15a of the film 15 faces the first body 315 of the first mold 310. The second surface 15b of the film 15 faces the second body 325 of the second mold 320.

[0290] The film 15 may be positioned relative to the first mold 310 by the positioning part 15f. The film 15 may be arranged such that the positioning part 15f and the hole 314 provided in the first body 315 overlap in the Z direction DZ. The fixing device 350 fixes the film 15, which is positioned relative to the first mold 310, to the first mold 310.

[0291] In molding step STP2, the film molding apparatus 300 is then closed. The film molding apparatus 300 is closed by swinging the second mold 320 relative to the first mold 310 in the swing direction DR. By closing the film molding apparatus 300, the film 15 is sandwiched between the first mold 310 and the second mold 320 at its edge 20e, as shown in Figures 16 and 20. In particular, the illustrated film 15 is sandwiched between the first mold 310 and the second mold 320 at its corner 15r.

[0292] The film 15 sandwiched between the first type 310 and the second type 320 has a first portion 15X, a second portion 15Y, and a third portion 15Z, as shown in Figure 20. The first portion 15X is the portion sandwiched between the first portion 312A of the first side surface 312 and the first portion 322A of the second side surface 322. The second portion 15Y is the portion sandwiched between the second portion 312B of the first side surface 312 and the second portion 322B of the second side surface 322. The third portion 15Z is the portion sandwiched between the first bottom surface 311 and the second bottom surface 321. The first portion 15X, the second portion 15Y, and the third portion 15Z are all located at the corners 15r of the film 15.

[0293] The decorative film 20 sandwiched between the first type 310 and the second type 320 has a first portion 20X, a second portion 20Y, and a third portion 20Z, as shown in Figure 20. The first portion 20X of the decorative film 20 constitutes the first portion 15X of the film 15. The second portion 20Y of the decorative film 20 constitutes the second portion 15Y of the film 15. The third portion 20Z of the decorative film 20 constitutes the third portion 15Z of the film 15. The first portion 20X, the second portion 20Y, and the third portion 20Z are all located at the corners 20r of the decorative film 20.

[0294] In the film 15 sandwiched between the first type 310 and the second type 320, the first portion 15X is connected to the second portion 15Y at the first end in the first bending direction DF1. The second portion 15Y is connected to the first portion 15X at the second end in the second bending direction DF2. The third portion 15Z is connected to the first portion 15X at the second end in the second bending direction DF2. The third portion 15Z is connected to the second portion 15Y at the first end in the first bending direction DF1. The first portion 15X is bent along the first bending direction DF1 with respect to the third portion 15Z. The second portion 15Y is bent along the second bending direction DF2 with respect to the third portion 15Z.

[0295] In molding step STP2, the film 15 is then heated. In the film molding apparatus 300 shown in Figure 16, as described above, the second mold 320 heats the film 15. The film 15 is molded by heating. The film 15 is molded so that the first portion 15X is bent relative to the third portion 15Z, and the second portion 15Y is bent relative to the third portion 15Z.

[0296] Contrary to the above description, the film 15 may also be formed in the molding process STP2 by being sandwiched between the first mold 310 and the preheated second mold 320. In this example as well, the film 15 can be formed such that the first portion 15X is bent relative to the third portion 15Z, and the second portion 15Y is bent relative to the third portion 15Z.

[0297] In molding step STP2, after the film 15 is formed, the film molding apparatus 300 is opened again. The film 15 is released from being sandwiched between the first mold 310 and the second mold 320. As shown in Figure 21, the formed film 15 is maintained with the first portion 20X bent relative to the third portion 20Z and the second portion 20Y bent relative to the third portion 20Z. The illustrated film 15 is formed to have a shape complementary to the shape of the recess 340 provided in the first mold 310.

[0298] The molded film 15 may be cooled. The method for attaching the film 15 may include a cooling step STP3 between the molding step STP2 and the second attachment step STP4. In the cooling step STP3, the film 15 may be cooled by a blower such as a fan. In the cooling step STP3, the film 15 may be cooled by a spot air supply device such as a cold spray. In the cooling step STP3, the mold that heated the film 15 in the molding step STP2 may be cooled. In the above example, the second mold 320 may be cooled in the cooling step STP3. The film 15 may be cooled via the second mold 320.

[0299] An example of the cooling process STP3 will be explained with reference to Figure 22. Figure 22 shows the first hole 300HA and the second hole 300HB provided in the second body 325. In the cooling process STP3, the cooling fluid FL is introduced into the hole 300H provided in the second body 325 from at least one of the multiple openings. In Figure 22, the opening located in the fifth portion 322E of the second side surface 322 constitutes the inlet IL for the cooling fluid FL. In Figure 22, the opening located in the third portion 322C and the trench located in the fourth portion 322D of the second side surface 322 constitute the outlet OL for the cooling fluid FL. In Figure 22, the cooling fluid FL that has entered from the inlet IL flows through the first hole 300HA. A portion of the cooling fluid FL flows from the first hole 300HA into the second hole 300HB at the intersection of the first hole 300HA and the second hole 300HB. The cooling fluid FL flowing through the second hole 300HB flows out from either the outlet OL located in the third section 322C or the outlet OL located in the fourth section 322D.

[0300] The second type 320 in Figure 22 includes a second body 325. The second body 325 is provided with holes 325 opening at multiple locations on the second body. In the holes 325, one of the multiple openings can be used as an inlet IL for the cooling fluid FL, while another of the multiple openings can be used as an outlet OL for the cooling fluid FL. According to the specific example in Figure 22, by flowing the cooling fluid FL as described above, the second body 325 of the second type 320 and the film 15 in contact with the second body 325 can be efficiently cooled.

[0301] Furthermore, in the second body 325 of Figure 22, the hole 325 is open in a portion that does not come into contact with the film 15. According to the specific example in Figure 22, the cooling fluid FL can be continuously flowed from the inlet IL to the outlet OL while the second body 325 is in contact with the film 15. Therefore, the second body 325 of the second type 320 can be efficiently cooled while the film 15 remains sandwiched between the first type 310 and the second type 320.

[0302] Unlike the above examples, in the cooling step STP3, the second mold 320 may be cooled by a fluid flowing from wiring (not shown) connected to the second mold 320. It is preferable that the cooling step STP3 be performed in a closed film molding apparatus 300 from the viewpoint of suppressing unintended deformation of the molded film 15.

[0303] As described above, the film 15 is formed using the film forming apparatus 300 in the forming process STP2. The film forming apparatus 300 is removed from the formed film 15. The portion of the formed film 15 including the positioning portion 15f may be removed.

[0304] Films applied to substrates with a three-dimensional shape are prone to wrinkles and sagging as they cannot conform to the shape of the substrate. As described above, if at least one of these wrinkles or sagging is observed from the outside, the design of the decorative member deteriorates.

[0305] Conventionally, films are applied to three-dimensional substrates while stretched in a planar manner. In other words, a film stretched in a planar manner is pulled in the direction of its expansion. However, when a film is stretched in a planar manner, a large area of ​​excess material may be left unattached to the substrate. Films stretched in a planar manner are prone to wrinkles and sagging in the excess areas. Therefore, the design of decorative members may deteriorate even when the film is applied to the substrate while stretched in a planar manner.

[0306] In the molding process STP2 described above, the film molding apparatus 300 heats the film 15 (decorative film 20) in the portion sandwiched between the first mold 310 and the second mold 320. In the illustrated film molding apparatus 300, the second mold 320 is heating the film 15 (decorative film 20). The film 15 (decorative film 20) deforms by heating in the portion sandwiched between the first mold 310 and the second mold 320, instead of being stretched planarly. When the film molding apparatus 300 attaches to an adherend AB having a three-dimensional shape, it can suppress the occurrence of a wide area of ​​excess material in the film 15 (decorative film 20). By reducing the excess material in the film 15 (decorative film 20), the occurrence of wrinkles and sagging at the edges 15e (edges 20e) is suppressed. Therefore, the film molding apparatus 300 can suppress deterioration of the design of the decorative member 25.

[0307] <<Second Adhesion Step STP4>> The film 15 is then attached to the adherend AB in the second adhesion step STP4. In the second adhesion step STP4, the portion molded in the molding step STP2 is attached to the adherend AB. In the second adhesion step STP4, the edge portion 15e of the film 15 may be attached to the adherend AB. In the second adhesion step STP4, the corner portion 15r of the film 15 may be attached to the adherend AB.

[0308] The adherend AB in Figure 21 includes a first adherend AB1 and a second adherend AB2 that is bent relative to the first adherend AB1. When the adherend AB is an exterior member 10 of an automobile 1, the second adherend AB2 may extend forward, backward, or downward relative to the first adherend AB1.

[0309] Angle ψ between the first adhered portion AB1 and the second adhered portion AB2 １２ This is the angle θ between the first bottom surface 311 and the first side surface 312 in the first type 310. １２ It may be 0.9 times or more and 1.1 times or less. Angle ψ between the first adherend AB1 and the second adherend AB2 １２ The angle φ between the second bottom surface 321 and the second side surface 322 in the second type 320. １２It may be 0.9 times or more and 1.1 times or less. Note that the angle ψ between the first adherend AB1 and the second adherend AB2 １２ As shown in Figure 23, the angle θ is measured from the cross-section of the adherend AB by planes extending in directions perpendicular to the first adherend AB1 and perpendicular to the second adherend AB2. １２ and angle φ １２ An angle ψ for at least one of the values ​​of １２ By setting the multiplier of the value to the numerical range described above, the film forming apparatus 300 can bring the shape of the formed film 15 closer to the shape of the adherend AB. This makes it possible to more effectively reduce the excess portion of the film 15.

[0310] As shown in Figure 21, the second adherend AB2 may include a first portion AB21 and a second portion AB22 that is curved relative to the first portion AB21. In the second adherend AB2, the angle ψ between the first portion AB21 and the second portion AB22 ２２ The angle θ between the first portion 312A and the second portion 312B on the first side surface 312 of the first type 310. ＡＢ It may be 0.9 times or more and 1.1 times or less. Angle ψ between the first part AB21 and the second part AB22 ２２ The angle φ between the first portion 322A and the second portion 322B on the second side surface 322 of the second type 320. ＡＢ It may be 0.9 times or more and 1.1 times or less. The angle φ between the first part AB21 and the second part AB22 is also acceptable. ２２ As shown in Figure 24, the angle θ is measured from the cross-section of the adherend AB by planes extending in directions perpendicular to the first adherend AB1 and perpendicular to the second adherend AB2. ＡＢ and angle φ ＡＢ An angle ψ for at least one of the values ​​of ２２ By setting the multiplier of the value to the numerical range described above, the film forming apparatus 300 can bring the shape of the formed film 15 closer to the shape of the adherend AB. This makes it possible to more effectively reduce the excess portion of the film 15.

[0311] The corner portion 15r of the film 15 is turned inside out from the state shown in Figure 21. Of the corner portion 15r formed in molding process STP2, the third portion 15Z is attached to the first adherend AB1. The first portion 15X is attached to the first portion AB21 of the second adherend AB2. The second portion 15Y is attached to the second portion AB22 of the second adherend AB2.

[0312] As described above, the film 15 (decorative film 20) is attached to the adherend AB. The completion of the second attachment step STP4 completes the method of attaching the film 15 (decorative film 20) as described above. By attaching the decorative film 20 to the adherend AB, a decorative member 25 including the film 15 (decorative film 20) and the adherend AB is manufactured.

[0313] In the embodiment described above, the film application device 40 applies the film 15 to the adherend AB by moving the film 15 in a first direction D1. The film application device 40 includes a holding device 50 for holding the film 15 and a moving device 42 for moving the holding device 50. The film 15 is applied to the adherend AB with the film 15 protruding toward the adherend AB in the first direction D1.

[0314] In the embodiment described above, the film application device 40 applies the film 15, which has a first surface 15a and a second surface 15b, to the adherend AB by moving the film 15 in a first direction D1, starting from the second surface 15b. The film application device 40 includes a holding device 50 for holding the film 15 and a pressurizing device 60 for pressurizing the first space S1 that the first surface 15a faces. The pressurizing device 60 causes the film 15 to protrude in the first direction D1 toward the adherend AB.

[0315] According to these embodiments, when the film 15 is attached to the adherend AB, it is prevented from being pulled in a direction perpendicular to the first direction D1. This prevents wrinkles from forming in the film 15 when it is attached to the adherend AB. Therefore, the film application device 40 can prevent deterioration of the design of the decorative member 25, which is composed of the adherend AB and the film 15.

[0316] Furthermore, the film application apparatus 40, including the pressurizing device 60, can increase the amount of protrusion of the film 15 toward the adherend AB compared to the protrusion due to its own weight by pressurizing the first space S1. In addition, the air in the first space S1 pressurized by the pressurizing device 60 presses the film 15 toward the adherend AB in the first direction D1. By pressing the film 15 toward the adherend AB with the air in the first space S1, peeling of the film 15 attached to the adherend AB and re-application of the peeled film 15 can be suppressed. By suppressing the re-application of the film 15, the mixing of air bubbles between the film 15 and the adherend AB due to re-application can be suppressed. Therefore, deterioration of the design of the decorative member 25 can be effectively suppressed.

[0317] In the film application apparatus 40 described above, the holding device 50 closes the first space S1 in a direction perpendicular to the first direction D1. The holding device 50 closes the first space S1 from one of the first side S11 and the second side S12 in the first direction D1. The film 15 closes the first space S1 from the other of the first side S11 and the second side S12 in the first direction D1. According to this specific example, the film 15 can be efficiently projected toward the adherend AB by pressurizing the first space S1 using the pressurizing device 60.

[0318] In the film application apparatus 40 described above, the holding device 50 holds both side edges of the film 15 in the second direction D2, namely the first edge 151 and the second edge 152. The holding device 50 also holds both side edges of the film 15 in the third direction D3, namely the third edge 153 and the fourth edge 154. According to this specific example, as shown in Figures 12 and 13, the central portion of the film 15 in the second direction D2 and the central portion of the third direction D3 can be stably projected toward 90 while held by the holding device 50.

[0319] In the film application apparatus 40 described above, the film 15 may be joined to the holding device 50 from the second surface 15b at the first edge 151, second edge 152, third edge 153, and fourth edge 154. According to this specific example, by joining the film 15 to the holding device 50 at these side edges, the film 15 is restricted from moving in the second direction D2 and the third direction D3 relative to the holding device 50. Therefore, the holding device 50 can stably hold the film 15 even when it moves, for example, in the arrangement process described above.

[0320] In the film application apparatus 40 described above, the holding device 50 includes a frame 51 that opens in a first direction D1 and a cover 52 that closes the opening 51ha from the first direction D1. The film 15 closes the opening 51hb of the frame 51. According to this specific example, the first space S1 can be closed by a combination of a holding device 50 and a film 15 with a simple configuration.

[0321] The film application apparatus 40 described above includes an imaging device 44 that acquires at least one image of the film 15 (first image) and an image of the holding device 50 (second image). According to this specific example, the operation of at least one of the moving device 42 and the pressurizing device 60 can be controlled by remotely checking the state of at least one of the film 15 and the holding device 50. Therefore, according to this specific example, the first application process STP1 described above can be performed efficiently.

[0322] The film application apparatus 40 may include a cutting device 43 for cutting the film 15, an imaging device 44 for acquiring at least one of the first image and the second image, and a control device 70 for controlling the operation of the cutting device 43. The control device 70 may control the operation of the cutting device 43 based on at least one of the first image and the second image. According to this specific example, by controlling the cutting device 43 with the control device 70, the cutting device 43 can cut the film 15 with high precision and automatically. According to this specific example, the above-described cutting process STP 26 can be performed efficiently.

[0323] The film application apparatus 40 described above includes a suction device 56 that sucks the film 15 from the first surface 15a or the second surface 15b. The holding device 50 holds the film 15 in the state in which it has been sucked by the suction device 56. According to this specific example, the holding device 50 can stably hold the film 15 in a state in which its movement is restricted by the suction device 56. According to this specific example, it is possible to suppress the occurrence of wrinkles in the film 15 in the holding step STP21 described above.

[0324] The adherend AB described above has a three-dimensional shape and protrudes toward the film 15 in the first direction D1. According to this specific example, as the film 15 moves toward the adherend AB in the first direction D1, the expansion of the area adhered to the adherend AB can be mitigated. According to this specific example, it is possible to effectively suppress the adhesion of the wrinkled film 15 to the adherend AB. From the above viewpoint, in the first adhesion step, preferably, the portion of the film 15 that protrudes the most toward the adherend AB is first adhered to the portion of the adherend AB that protrudes the most toward the film 15.

[0325] In the embodiment described above, the film forming apparatus 300 includes a first mold 310 and a second mold 320. The film 15 is sandwiched between the first mold 310 and the second mold 320 at its edge 15e. The film forming apparatus 300 forms the edge 15e of the film 15 by heating the edge 15e of the film 15 which is partially attached to the adherend AB.

[0326] Furthermore, in the embodiment described above, the film forming apparatus 300 includes a first mold 310 and a second mold 320. The film 15 is sandwiched between the first mold 310 and the second mold 320 at its edge 15e. In the film forming apparatus 300, at least one of the first mold 310 and the second mold 320 heats the edge 15e. As a result, the film forming apparatus 300 forms the edge 15e of the film 15.

[0327] According to these embodiments, heating the film 15 reduces the excess portion generated at the edges 15e during the molding of the film 15. This suppresses the occurrence of wrinkles and sagging at the edges 15e. Therefore, the film molding apparatus 300 can suppress deterioration of the design of the decorative member 25.

[0328] In the film forming apparatus 300 described above, the first mold 310 includes a recess 340 for accommodating the second mold 320. In the first mold 310, the recess 340 includes a first bottom surface 311 and a first side surface 312 extending from the first bottom surface 311 in a direction nonparallel to the first bottom surface 311. The first side surface 312 includes a first portion 312A and a second portion 312B extending in directions nonparallel to each other. The second mold 320 includes a second bottom surface 321 and a second side surface 322 extending from the second bottom surface 321 in a direction nonparallel to each other. The second side surface 322 includes a first portion 322A and a second portion 322B extending in directions nonparallel to each other. The edge portion 15e of the film 15 is heated while sandwiched between the first bottom surface 311 and the second bottom surface 321, between the first portion 312A of the first side surface 312 and the first portion 322A of the second side surface 322, and between the second portion 312B of the first side surface 312 and the second portion 322B of the second side surface 322. According to this specific example, by sandwiching the film 15 between the first mold 310 and the second mold 320, the edge portion 15e of the film 15 can be formed to have a three-dimensional corner portion 15r.

[0329] In the film forming apparatus 300 described above, the first mold 310 includes the recess 340 described above in the first body 315. In the film forming apparatus 300, when the second body 325 is housed in the recess 340, at least one of the first body 315 and the second body 325 (the second body 325 in the above example) generates heat. The second body 325 is provided with holes 300H through which a cooling fluid FL flows to cool the heated second body 325. According to this specific example, the edge 15e of the film 15 is cooled by the cooling fluid FL via the second body 325 while sandwiched between the first body 315 and the second body 325. By cooling the edge 15e while sandwiched between the first body 315 and the second body 325, the shape of the edge 15e can be stabilized to the shape sandwiched between the first body 315 and the second body 325, i.e., the shape after forming. Therefore, according to this specific example, the edge film 15 portion 15e can be stably formed. In the film forming apparatus 300, the first body 315 may also generate heat, not just the second body 325. In the film forming apparatus 300 in which the first body 315 generates heat, a hole 300H for the cooling fluid FL to flow through may be provided in the first body 315.

[0330] In the film forming apparatus 300 described above, the first mold 310 includes a first body 315 and a first handle 316 connected to the first body 315. The second mold 320 includes a second body 325 and a second handle 326 connected to the second body 325. In the film forming apparatus 300, at least one of the molds, the first mold 310 and the second mold 320, generates heat and heats the edge 15e of the film 15, thereby forming the edge 15e sandwiched between the first body 315 and the second body 325. According to this specific example, the operator of the film forming apparatus 300 can easily form the edge 15e by holding the first handle 316 and the second handle 326 and sandwiching the edge 15e of the film 15 between the first body 315 and the second body 325.

[0331] Although one embodiment has been described by referring to specific examples, the above-mentioned examples do not limit this embodiment. The above-described embodiment can be implemented in various other examples, and various omissions, substitutions, modifications, and additions can be made without departing from its essence.

[0332] In the arrangement step STP22 described above, the adherend AB was positioned so that the film 15 could be attached by moving the automobile 1 in the front-rear direction. The direction of movement of the automobile 1 is not limited to the front-rear direction. The direction of movement of the automobile 1 may also be the left-right direction.

[0333] In the moving process STP23 described above, the control device 70 calculated the size of the contact area based on the image of the film 15 acquired by the imaging device 44. Based on the calculated size of the contact area, the control device 70 generated one of the following signals: a movement stop signal, a pressure maintenance signal, or a pressure stop signal. Alternatively, the control device 70 may generate one of the above signals based on the reaction force from the adherend AB to the holding device 50 instead of the size of the contact area. The reaction force from the adherend AB to the holding device 50 increases with increasing contact area. The film application device 40 may include a sensor capable of measuring the reaction force from the adherend AB to the holding device 50. For example, the film application device 40 may include a load cell capable of measuring the reaction force from the adherend AB to the holding device 50.

[0334] The film 15 described above included a surface layer 34, a design layer 33, a base layer 31, and a bonding layer 32 in this order, from the first surface 15a to the second surface 15b. The design layer 33 was located between the surface layer 34 and the base layer 31. The design layer 33 was located on the first surface 15a side of the base layer 31. The layer configuration of the film 15 is not limited to the example described above. In another example, the film 15 may include a surface layer 34, a base layer 31, a design layer 33, and a bonding layer 32 in this order, from the first surface 15a to the second surface 15b. In this example, the design layer 33 is located between the base layer 31 and the bonding layer 32. The base layer 31 is located on the first surface 15a side of the design layer 33.

[0335] In the decorative member 25 described above, the film 15 was a decorative film 20. In the decorative member 25 described above, the film 15 displayed the design. However, it is not limited to this, and in the decorative member 25, the adherend AB may display the design as shown in Figure 25. As shown in Figure 25, the film 15 does not have to include the design layer 33 described above. The film 15 may have a function to protect the adherend AB. From the viewpoint of clearly displaying the design displayed by the adherend AB, the film 15 may be transparent. The film 15 shown in Figure 25 may be attached to the adherend AB by the film application device 40 shown in Figures 3 and 4, etc.

[0336] The film application device 40 may further include a pressing device 200 that presses the film 15 onto the adherend AB from the first surface 15a side, as shown in Figures 26 to 29. The method of applying the film 15 may further include a pressing step STP5 between the first application step STP1 and the molding step STP2, as shown in Figure 37, in which the film 15 is pressed onto the adherend AB. In the pressing step STP5, the pressing device 200 presses the film 15, which has been at least partially applied by the first application step STP1 described above, toward the adherend AB. Note that the moving device 42, the cutting device 43, and the pump 62 of the pressurizing device 60 are not shown in Figures 26 to 29.

[0337] The pressing device 200 can suppress the peeling of the film 15 that was attached to the adherend AB in the first attachment step STP1 by pressing the film 15 onto the adherend AB from the first surface 15a side. The pressing device 200 can suppress the entry of air between the film 15 and the adherend AB, which can occur when the film 15 that has peeled off from the adherend AB is reattached to the adherend AB. Therefore, the film attachment apparatus 40 including the pressing device 200, and the film attachment method including the pressing step STP5, can stably bond the film 15 and the adherend AB.

[0338] The pressing device 200 shown in Figures 26 to 29 includes a pressing member 210 and a compression device 220. The compression device 220 supplies a compression force FC to compress the pressing member 210 between the compression device 220 and the film 15. The pressing member 210 supplies a pressing force FP to the film 15 in a compressed state.

[0339] The pressing member 210 in Figures 26 to 29 includes a surface material 211 that forms a protruding surface 215, and a gas 212 sealed between the surface material 211 and the compression device 220. In the film application device 40, the gas 212 is located in the third space S3.

[0340] The surface material 211 in Figures 26 to 29 is in sheet form. The material of the surface material 211 is preferably a material that is elastically deformable under compressive force FC. The surface material 211 may contain natural rubber or synthetic rubber. The synthetic rubber contained in the surface material 211 may be any of BR (butadiene rubber), SBR (rubber copolymer of styrene and butadiene), ABR (acrylate butadiene rubber), IIR (butyl rubber), NBR (nitrile rubber), or silicone rubber. The surface material 211 may also contain synthetic resin as a material. The synthetic resin contained in the surface material 211 may be one or more of polyurethane (PU), polyvinyl chloride (PVC), ethylene vinyl acetate (EVA), polypropylene (PP), or polyethylene (PE).

[0341] The gas 212 sealed between the skin material 211 and the compression device 220 may be one or more of air, nitrogen, or helium. The pressure of the gas 212 may be greater than atmospheric pressure. By sealing the gas 212 at high pressure, the pressure in the third space S3 may be greater than that in the second space S2 when the compression device 220 is not compressing the pressing member 210.

[0342] The pressing member 210 in Figures 26 to 28 includes a pressing surface 215 that protrudes in a first direction D1 toward the film 15 and the adherend AB. The pressing surface 215 protrudes toward the second side S12 in the first direction D1. In Figures 26 to 29, the pressing surface 215 is oriented in the same direction as the film 15 and protrudes in the opposite direction from the adherend AB (roof 11). As will be described later, the pressing member 210 contacts the film 15 from the protruding surface 215. The protruding surface 215 in Figure 29 is deformed by contact with the film 15.

[0343] The compression device 220 in Figures 26 to 29 includes a support plate 221 that supports the pressing member 210, and a second drive device 222 that moves the support plate 221 and the pressing member 210 relative to the film 15. Compared with Figures 26 to 28, the second drive device 222 in Figure 29 moves the pressing member 210 and the support plate 221 toward the film 15. The material of the support plate 221 can be any material that can stably support the pressing member 210. For example, the support plate 221 may include wood, synthetic resin, or metal. The second drive device 222 may have the same configuration as the drive device 422 described above. In the film application device 40 including the drive device 422 and the second drive device 222, the drive device 422 may also be referred to as the first drive device 422.

[0344] As shown in Figures 26 to 29, the holding device 50 may hold the pressing device 200. The pressing device 200 may be at least partially positioned in the second space S2 as a result of being held by the holding device 50. The holding device 50 in Figures 26 to 29 further includes a second frame 57 that overlaps the frame 51. The second frame 57, like the frame 51, is provided with a second opening 56h that opens to a first side S11 and a second side S12 in the first direction D1. The cover 52 and the pressing device 200 are attached to the second frame 57. In Figures 26 to 29, the opening 51h and the second opening 56h form a space that is closed from the first direction D1 by the cover 52 and the film 15. In the holding device 50 including the frame 51 and the second frame 57, the frame 51 may also be referred to as the first frame 51. Unlike in Figures 26 to 29, the frame 51 may hold the pressing device 200. In other words, in the holding device 50 that holds the film 15 and the pressing device 200, the frame 51 and the second frame 57 may be integrated.

[0345] The pressing device 200 may be electrically connected to the control device 70. In particular, in the film application apparatus 40 shown in Figures 26 to 29, the second drive unit 222 of the compression device 220 may be electrically connected to the control device 70. The control device 70 may control the operation of the pressing device 200, and in particular the operation of the second drive unit 222, via an electrical connection with the pressing device 200.

[0346] An example of the operation of the pressing device 200 shown in Figures 26 to 29 will be explained. Figures 26 to 28 show the movement process STP23. Figures 28 and 29 show the pressing process STP5. The details of the movement process STP23 shown in Figures 26 to 28 are as described above, except that the pressing device 200 moves toward the object AB in the first direction D1 together with the holding device 50.

[0347] In Figure 28, as a result of the moving process STP23, the film 15 is partially attached to the adherend AB. The film 15 is attached to the adherend AB in the portion that protrudes toward the adherend AB in the first direction D1. The pressing process STP5 is started after the film 15 is at least partially attached to the adherend AB.

[0348] The pressing member 210 in Figure 28 has moved in a first direction D1 toward the adherend AB and the film 15 from the state shown in Figures 26 and 27. The pressing member 210 is moved by the operation of the second drive unit 222 of the compression device 220. The pressing member 210 is moving relative to the film 15 and adherend AB in the second side S12 of the first direction D1. The pressing member 210 in Figure 28 is in contact with the film 15 at its pressing surface 215. The pressing surface 215 is in contact with the film 15 at the portion that protrudes most in the first direction D1 toward the adherend AB.

[0349] The pressing member 210 moves further in the first direction D1 from the state shown in Figure 28, and is compressed by the compression device 220 as shown in Figure 29. In the pressing member 210 in Figure 29, at least the gas 212 is compressed. In the pressing member 210 in Figure 29, the volume of the third space S3 is reduced by the compressive force FC. The pressure in the third space S3, in other words, the internal pressure of the pressing member 210, increases further from the state shown in Figure 28 due to the compressive force FC. The pressing member 210 applies a pressing force FP to the film 15 due to the increase in internal pressure. The film 15 is pressed against the adherend AB at the portion in contact with the pressing member 210 by the pressing force FP.

[0350] By moving the pressing device 200 further in the first direction D1 from the state shown in Figure 29, the area in which the film 15 is pressed expands. Through these operations, the pressing device 200 can stably bond the film 15 and the adherend AB.

[0351] The operation of the pressing device 200 in the pressing process STP5 may be controlled by the control device 70. The control device 70 may transmit an electrical signal (movement start signal) to the second drive device 222 via an electrical connection to the second drive device 222 for the pressing device 200 to start moving. The control device 70 may also transmit an electrical signal (movement stop signal) to the moving device 42 via an electrical connection to the second drive device 222 for the pressing device 200 to stop moving.

[0352] The pressing device 200 shown in Figures 26 to 29 includes a pressing member 210 that applies a pressing force FP to the film 15 in a compressed state, and a compression device 220 that compresses the pressing member 210. The pressing member 210 can stably apply the pressing force FP to the film 15 due to the repulsive force caused by compression. As a result, the pressing device 200 can more stably bond the film 15 and the adherend AB.

[0353] Furthermore, the pressing member 210 shown in Figures 26 to 28 includes a pressing surface 215 facing the adherend AB in a first direction D1. The illustrated pressing surface 215, like the film 15, contacts the film 15 from the portion that protrudes most in the first direction D1 toward the adherend AB. As a result, the pressing device 200 can press the film 15, which has been attached to the adherend AB by the mechanism described above, against the adherend AB in a manner that suppresses the occurrence of wrinkles. Therefore, the film application device 40 can stably bond the film 15 to the adherend AB while suppressing the occurrence of wrinkles.

[0354] As shown in Figure 30, the film application device 40 may further include a fluid supply device 80 that supplies fluid 81 onto the first surface 15a of the film 15. The fluid 81 supplied onto the first surface 15a may cause the film 15 to protrude in the first direction D1 toward the adherend AB due to the weight of the fluid 81 itself. In the case of the film 15 held by the holding device 50, the protrusion in the first direction D1 may be promoted by the combination of the weight of the film 15 and the weight of the fluid 81 supplied onto the first surface 15a.

[0355] The fluid supply device 80 in Figure 30 may supply fluid 81 to a position on the film 15 that protrudes in a first direction D1 toward the adherend AB due to its own weight. For example, the fluid supply device 80 may supply fluid 81 to the central portion of the film 15 held by the holding device 50 in a second direction D2. The fluid supply device 80 may supply fluid 81 to the central portion of the film 15 held by the holding device 50 in a third direction D3.

[0356] The fluid 81 supplied from the fluid supply device 80 may be at a relatively high temperature. For example, the temperature of the fluid 81 may be higher than the softening temperature of the base layer 31 of the film 15. In this specific example, the fluid 81 can soften the base layer 31 and stably soften the film 15. In another example, the temperature of the fluid 81 may be higher than the softening temperature of the entire film 15. In this specific example as well, the fluid 81 can stably soften the film 15. The stable softening of the film 15 can further promote the protrusion of the film 15 in the first direction D1 toward the adherend AB.

[0357] The temperature of the fluid 81 may, for example, be between 50°C and 100°C, between 70°C and 100°C, between 80°C and 100°C, between 90°C and 100°C, or between 95°C and 100°C.

[0358] The softening temperature of the base layer 31 is the temperature at which the tensile storage modulus E' (Pa) decreases by 50% or more compared to that at room temperature, and a peak occurs in the loss tangent tanδ. When comparing the tensile storage modulus, "room temperature" is defined as 25°C. The softening temperature of the base layer 31 is 25°C or higher.

[0359] The tensile storage modulus E' (Pa) and loss tangent tanδ of the base layer 31 are measured using a dynamic viscoelasticity measuring device by the following method. First, the base layer 31 is peeled off from the film 15. The base layer 31 is identified as the layer with the greatest thickness in the cross-sectional image of the film 15. Next, a test specimen with a length of 30 mm and a width of 5 mm is prepared from the peeled base layer 31 sample. The prepared test specimen is stored in an atmosphere of 23°C ± 5°C for at least one hour. Next, the test specimen is mounted on the dynamic viscoelasticity measuring device so that the distance between the chucks is 10 mm. Next, the temperature of the area surrounding the test specimen is set to 0°C, and the temperature of the test specimen is lowered to 0°C. Next, while applying a sinusoidal tensile force cycle with a frequency of 1 Hz to the test specimen, the temperature of the area surrounding the test specimen is raised from 0°C to 150°C at a heating rate of 5°C / min. During the heating, the tensile force cycle and the displacement cycle of the test specimen are measured. From these measurement results, the tensile storage modulus E' and loss tangent tanδ are calculated under temperature conditions from 0°C to 150°C. The tensile storage modulus E' and loss tangent tanδ are measured under conditions other than those specified above, in accordance with JIS K 7244-4:1999. For the measurement of the tensile storage modulus E'(Pa) and loss tangent tanδ, a dynamic viscoelasticity measuring device capable of measuring under the conditions specified in JIS K 7244-4:1999 and above is used.

[0360] A graph (first graph) is created showing the change in tensile storage modulus E' (Pa) due to temperature changes, based on the measured tensile storage modulus E' (Pa). The horizontal axis of the first graph represents the temperature of the region surrounding the test specimen. The vertical axis of the first graph represents the measured tensile storage modulus E' (Pa). In addition, a graph (second graph) is created showing the change in loss tangent tanδ due to temperature changes, based on the measured loss tangent tanδ. The horizontal axis of the second graph represents the temperature of the region surrounding the test specimen. The vertical axis of the second graph represents the loss tangent tanδ. From the first and second graphs, the softening temperature of the base layer 31 is identified as the temperature at which the tensile storage modulus E' (Pa) decreases by 50% or more compared to room temperature, and when a peak occurs in the loss tangent tanδ.

[0361] The softening temperature of the film 15 is determined by the method described above, except that the film 15 is used instead of the base layer 31 as a sample for measuring the tensile storage modulus E' (Pa) and loss tangent.

[0362] The fluid 81 supplied from the fluid supply device 80 may be a liquid. For example, the fluid 81 may be water. The water used for the fluid 81 may be seawater, freshwater, tap water, experimental water, or pure water. As mentioned above, since the fluid 81 is relatively hot, the fluid 81 may also be hot water. When the fluid 81 is a liquid, the temperature of the fluid 81 may be lower than the boiling point of the fluid 81. By adjusting the temperature of the fluid 81 in this way, the state of the fluid 81 can be stably maintained as a liquid. The liquid fluid 81 is not limited to water. The liquid fluid 81 may be an oil such as vegetable oil or mineral oil, or an alcohol such as ethanol. The fluid 81 supplied from the fluid supply device 80 may also be a gas such as air or nitrogen.

[0363] The film application device 40 may further include a removal device 82 for removing fluid 81 on the film 15, as shown in Figure 30. The removal device 82 may include a hose 83 connected to the fluid 81 on the film 15 and a pump 84 connected to the hose 83, as shown in Figure 30. The removal device 82 may remove the fluid 81 on the film 15 by sucking it through the hose 83 using the pump 84.

[0364] In the film application device 40, the holding device 50 may hold the film assembly 16. As shown in Figure 31, the film assembly 16 includes a film 15 and a protective material 17 that protects the first surface 15a of the film 15. The protective material 17 protects the first surface 15a of the film 15 until the film 15 is applied to the adherend AB. However, the protective material 17 does not constitute the decorative member 25. The protective material 17 may be peeled off the film 15, for example, after the film 15 has been applied to the adherend AB.

[0365] The film assembly 16 in Figure 31 has a front surface 16a and a back surface 16b. The film assembly 16 in Figure 31 includes a protective material 17 and a film 15, in the order from the front surface 16a to the back surface 16b. The protective material 17 in Figure 31 constitutes the front surface 16a of the film assembly 16. The film 15 in Figure 31 constitutes the back surface 16b of the film assembly 16.

[0366] The protective material 17 in Figure 31 includes a base portion 18 and a joint portion 19, arranged in order from the front surface 16a to the back surface 16b of the film assembly 16. The joint portion 19 is located between the base portion 18 and the film 15. The joint portion 19 joins the protective material 17 to the film 15.

[0367] The base portion 18 may be a film. The base portion 18 may be a plate-shaped member. The base portion 18 may contain a synthetic resin. In particular, the base portion 18 may contain a thermoplastic resin. The thermoplastic resin of the base portion 18 may contain one or more of the following: polyethylene terephthalate (PET), (meth)acrylic resin, polyvinyl chloride (PVC), acrylonitrile-butadiene-styrene copolymer synthetic resin (ABS resin), polyolefin resin, polyester resin, urethane resin, fluororesin, polycarbonate, and cellulose resin. Note that the urethane resin includes thermoplastic polyurethane (TPU).

[0368] The joint portion 19 may have the same configuration as the bonding layer 32 of the film 15 described above. The joint portion 19 may have a different configuration from the bonding layer 32. The joint portion 19 may contain an adhesive or tack material. From the viewpoint of facilitating the peeling of the film 15 from the protective material 17, the joint portion 19 preferably contains a tack material. The adhesive included in the joint portion 19 may include one or more acrylic adhesives, rubber adhesives, urethane adhesives, and silicone adhesives. The tack material included in the joint portion 19 may include one or more acrylic adhesives, rubber adhesives, urethane adhesives, silicone adhesives, polyolefin adhesives, ethylene vinyl acetate (EVA) adhesives, and elastomer adhesives. The joint portion 19 may contain an acrylic adhesive mainly composed of methyl methacrylate.

[0369] The peeling force of the film 15 from the protective material 17, that is, the peeling force on the first surface 15a of the film 15, may be less than the peeling force on the second surface 15b of the film 15. As described above, the film 15 is attached to the substrate AB in a state where it has been peeled from the protective material 17. For example, the film 15 can be peeled from the protective material 17 after the film assembly 16 has been attached to the substrate AB. By making the peeling force on the first surface 15a less than the peeling force on the second surface 15b, the film 15 can be maintained in a state where it is attached to the substrate AB, and the film 15 can be stably peeled from the protective material 17. According to this specific example, it is possible to suppress the unintentional peeling of the film 15 from the substrate AB. By suppressing the peeling of the substrate AB from the film 15, it is possible to suppress the mixing of air bubbles between the film 15 and the substrate AB due to the reapplication of the film 15 that has been unintentionally peeled off. Therefore, deterioration of the design of the decorative member 25 can be effectively suppressed.

[0370] Furthermore, when the peeling force on the first surface 15a of the film 15 is set to be relatively low, the film 15 can be easily peeled off the protective material 17 by the fluid 81 supplied from the fluid supply device 80. From this viewpoint as well, it is preferable that the peeling force on the first surface 15a of the protective film 15 is set to be smaller than the peeling force on the second surface 15b of the film 15.

[0371] In the film assembly 16, the peeling force on the first surface 15a of the film 15 represents the magnitude of the force required to peel the film 15 from the protective material 17. The peeling force on the first surface 15a of the film 15 is measured using a sample of the film assembly 16 by the following method. First, a sample of the film assembly 16, having a length of 100 mm in one direction and a length of 25 mm in a direction perpendicular to that direction, is attached to a painted steel plate with a length of 70 mm from the back side. The sample is attached to a portion of the painted steel plate other than the portion that will be held by the chuck described later. The portion of the sample attached to the painted steel plate has a length of 40 mm in the longitudinal direction. The portion of the sample attached to the painted steel plate includes one end of the sample in the longitudinal direction. The portion of the sample not attached to the painted steel plate has a length of 60 mm in the longitudinal direction. The painted steel plate has paint (KINO1210TW Clear, manufactured by Kansai Paint Co., Ltd.) applied to the surface that comes into contact with the sample. When attaching the sample to the painted steel plate, the sample is pressed down by moving a roller (SA-1003-B, manufactured by Tester Industries Co., Ltd.) back and forth once with a load of 2 kilograms-force (kgf).

[0372] Next, the film is removed from the portion of the film assembly sample that is not attached to the painted steel plate. The film is removed by pressing the cutter against the back of the film assembly and moving it in the width direction. As a result of this operation, the film assembly sample contains film only in the portion attached to the painted steel plate. The film assembly sample does not contain film in the portion that is not attached to the painted steel plate.

[0373] Next, 30 minutes after the film assembly sample is attached to the painted steel plate, a 180-degree peel strength test is performed as follows: The edge of the painted steel plate is clamped in one chuck. The portion of the sample not attached to the painted steel plate is folded back 180 degrees relative to the portion attached to the painted steel plate. A 24 mm wide cellophane tape (manufactured by Nichiban Co., Ltd.: CT405AP-24) is attached to the folded portion of the sample, and this cellophane tape is clamped in the other chuck. The sample in this state is pulled at a tensile speed of 200 mm / min under 25°C conditions, and the average stress is measured from 10 mm to 30 mm in length as the sample peels off from the painted steel plate. By measuring this average stress for five samples, five measurement values ​​are obtained. In the above 180-degree peel strength test, it is confirmed that the protective material 17 has peeled off from the film 15. In a 180-degree peel strength test, if the protective material 17 does not peel from the film 15 but the film 15 peels from the painted steel plate, the measured value of that test will not be used to calculate the peeling force of the protective material 17 from the film 15.

[0374] If it is difficult to fold the film assembly sample back to 180 degrees, in the 180-degree peel strength test, the film assembly sample is placed in one chuck instead of the painted steel plate. The film peeled from the film assembly sample is placed in the other chuck. The sample in this state is pulled at a tensile speed of 200 mm / min under 25°C conditions, and the average stress is measured from 10 mm to 30 mm in length as the film peeled from the protective material is extended. By measuring this average stress for five samples, five measurement values ​​are obtained. "If it is difficult to fold the film assembly sample back to 180 degrees" includes cases where the protective material 16 does not have enough flexibility to be folded back to 180 degrees.

[0375] The peel force on the first surface 15a of the film 15 is determined as the average value of the three measurements obtained by excluding the largest and smallest measurements from the five measurements described above. The peel force on the first surface 15a of the film 15 is measured in accordance with JIS Z 0237:2009 under conditions other than those described above. The peel force on the first surface 15a of the film 15 may be 1 N / 25 mm or more and 2 N / 25 mm or less.

[0376] As shown in Figures 32 and 33, the protective material 17 may be provided with through holes 170 that penetrate through the protective material 17. In the film assembly 16, the film 15 may be exposed at the location where the through holes 170 of the protective material 17 are provided.

[0377] The through-hole 170 may be provided at a position where the fluid supply device 80 supplies the fluid 81. The through-hole 170 may be provided in a portion of the film assembly 16 held by the holding device 50 that protrudes in the first direction D1 due to its own weight. For example, the through-hole 170 may be provided in the central portion of the film assembly 16 held by the holding device 50 in the second direction D2 and in the central portion in the third direction D3.

[0378] The film assembly 16 may contact the holding device 50 from the front surface 16a side, as shown in Figures 32 and 33. The film assembly 16 may also close the opening 51hb of the frame 51 from the front surface 16a side, as shown in Figures 32 and 33. Unlike in Figures 331 and 33, the film assembly 16 may also contact the holding device 50 from the back surface 16b side. The film assembly 16 may also close the opening 51hb of the frame 51 from the back surface 16b side.

[0379] The film application device 40 may further include a sealing device 58 and a depressurization device 65, as shown in Figure 30, etc. The sealing device 58 seals the second space S2 that the second surface 15b of the film 15 faces. The depressurization device 65 depressurizes the second space S2 sealed by the sealing device 58.

[0380] "Sealing" by the sealing device 58 means that the sealing device 58 closes the second space S2 to the extent that it can maintain the pressure in the second space S2 at a level different from the external pressure. For example, the sealing device 58 that seals the second space S2 closes the second space S2 to the extent that it can maintain the pressure in the second space S2 at a level lower than the external pressure.

[0381] The sealing device 58 shown in Figure 30 is positioned between the retaining device 50 and the adherend AB in a first direction D1. The sealing device 58 may include a sheet 58A and a tape 58B that joins the sheet 58A. The sealing device 58 may be connected to the retaining device 50 at the end of the first side S11 in the first direction D1. The sealing device 58 may be connected to the adherend AB at the end of the second side S12 in the first direction D1. Alternatively, the sealing device 58 may be connected around the adherend AB at the end of the second side S12 in the first direction D1. As an example, when the adherend AB is a roof 11, the sealing device 58 may be connected to the front window, side windows, rear window, and pillar 12 of the roof.

[0382] The material of sheet 58A only needs to be able to stably seal the second space S2. For example, sheet 58A may contain a synthetic resin. In particular, sheet 58A may contain a thermoplastic resin. Sheet 58A may contain one or more of the following as thermoplastic resins: (meth)acrylic resin, polyvinyl chloride (PVC), acrylonitrile-butadiene-styrene copolymer synthetic resin (ABS resin), polyolefin resin, polyester resin, urethane resin, fluororesin, polycarbonate, and cellulose resin. Note that urethane resin includes thermoplastic polyurethane (TPU).

[0383] The sealing device 58 may include tape 58B for joining the sheet 58A, as shown in Figure 34. In Figure 34, tape 58B joins the sheet 58A to the frame 51 of the retaining device 50 at the end of the first side S11 in the first direction D1. Tape 58B joins the sheet 58A to the retaining device 50 to the extent that it can seal the second space S2. In Figure 34, tape 58B joins the sheet 58A to the front window, side windows, rear window, and pillar 12 around the adherend AB (roof 11) at the end of the second side S12 in the first direction D1. Tape 58B presses the sheet 58A around the roof 11 to the extent that it can seal the second space S2.

[0384] Various tapes capable of securely joining the sheet 58A to other components can be used as tape 58B. For example, tape 58B may be packing tape.

[0385] The pressure reducing device 65 may include a hose 66 and a pump 67 connected to the hose 66, as shown in Figure 30. The second space S2 may be depressurized as a result of the air in the second space S2 being sucked out by the pump 67 through the hose 66. The pressure in the second space S2 may become lower than atmospheric pressure as a result of the operation of the pressure reducing device 65. In the film application apparatus 40, the pressure difference between the first space S1 and the second space S2 may be increased by a combination of pressurizing the first space S1 by the pressurizing device 60 and depressurizing the second space S2 by the pressure reducing device 65. As described above, the pressurizing device 60 makes the pressure in the first space S1 greater than the pressure in the second space S2 by pressurizing the first space S1.

[0386] The operation of the film application device 40 shown in Figure 30 will be explained below, mainly by referring to Figures 32 and 33. Specifically, an example of a method for applying a film 15 to an object AB using the film application device 40 of Figure 30 (first application step STP1) will be described. In the following explanation, the first application step STP1 includes a fluid supply step STP27 between the placement step STP22 and the moving step STP23, as shown in Figure 38. The first application step STP1 in Figure 38 includes a holding step STP21, a placement step STP22, a fluid supply step STP27, a first moving step STP23, and a second moving step STP28 in this order.

[0387] <Placement Process STP22> The holding device 50 is placed on the adherend AB while holding the film assembly 16. The film assembly 16 may be placed on the holding device 50 by the suction device 56 described above. The film assembly 16 placed on the holding device 50 may have its relative movement to the holding device 50 restricted by the fixing member 53 described above. As described above, the film assembly 16 may come into contact with the holding device 50 from the surface 16a side.

[0388] As a result of the holding device 50 being positioned on the adherend AB, the film assembly 16 held by the holding device 50 is positioned on the adherend AB. When positioned on the adherend AB, the film assembly 16 may protrude in the first direction D1 toward the adherend AB due to its own weight. In the film assembly 16 held by the holding device 50, the back surface 16b, which is made up of film 15, faces the adherend AB. The film 15, as in the example described above, faces the adherend AB on its second surface 15b.

[0389] <Fluid Supply Process STP27> Next, as shown in Figure 32, the fluid supply device 80 supplies fluid 81 onto the film assembly 16. The fluid supply device 80 in Figure 32 supplies the fluid 81 at a position that overlaps with the through hole 170 provided in the protective material 17. The fluid 81 supplied from the fluid supply device 80 is placed between the film 15 and the protective material 17. The opening of the through hole 170 constitutes the inlet IL for the fluid 81 to flow between the film 15 and the protective material 17.

[0390] In the portion where the fluid 81 is supplied, the combined weight of the film 15 and the weight of the fluid 81 act upon it. Therefore, as shown in Figure 32, the amount of the film 15 protruding in the first direction D1 toward the adherend AB increases in the portion of the film 15 where the fluid 81 is supplied compared to the portion of the film 15 where the fluid 81 is not supplied.

[0391] Furthermore, in the film application apparatus 40 shown in Figure 32, the fluid 81 is relatively hot. The temperature of the fluid 81 is higher than the softening temperature of the base layer 31, at least immediately after it is supplied from the fluid supply device 80. In this specific example, in the region where the fluid 81 and the film 15 overlap, the fluid 81 heats the base layer 31 above its softening temperature. As a result of the base layer 31 being heated above its softening temperature, the base layer 31 softens. The softening of the base layer 31 promotes the deformation of the film 15, specifically its protrusion in the first direction D1 toward the adherend AB. Note that "immediately after it is supplied from the fluid supply device 80" means within one minute after it is supplied from the fluid supply device 80.

[0392] Furthermore, in the film assembly 16 shown in Figure 32, the protective material 17 includes a joint 19 that joins the film 15 to the protective material 17. In this specific example, joining the film 15 to the protective material 17 via the joint 19 suppresses the protrusion of the film 15 in the first direction D1 toward the adherend AB. On the other hand, in the portion where fluid 81 is supplied from the fluid supply device 80, the film 15 peels away from the protective material 17. As a result, in the film assembly 16, the relative amount of protrusion of the portion of the film 15 that has peeled away from the protective material 17 increases with respect to the portion where the protective material 17 and the film 15 are joined. As the relative amount of protrusion of the film 15 increases, the angle between the adherend AB and the film 15 increases, as shown in Figure 32.

[0393] <Moving Process STP23> Next, the film 15 is moved in the first direction D1 toward the adherend AB from the state shown in Figure 32. In the following example, moving process STP23 includes the first moving process STP23 and the second moving process STP28 in this order. The first moving process STP23 is a process of moving the film 15 by the operation of at least one of the moving device 42 and the pressurizing device 60. The first moving process STP23 may also include the pre-application moving process STP24 and the post-application moving process STP25 described above in this order. The film 15 is attached to the adherend AB by the first moving process STP23 with respect to the adherend AB at the portion that protrudes in the first direction D1 toward the adherend AB, as shown in Figure 33. The second moving process STP28 is a process of moving the film 15 by the operation of the depressurizing device 65. The film 15 is attached to the adherend AB by the second moving step STP28, in the peripheral portion located around the portion that protrudes toward the adherend AB in the first direction D1.

[0394] In the first moving step STP23, the moving device 42 moves the holding device 50 toward the adherend AB in the first direction D1, as described above. The film 15 moves toward the adherend AB in the first direction D1 together with the holding device 50 that holds the film 15.

[0395] In the first moving step STP23, the pressurizing device 60 moves the film 15 by pressurizing the first space S1. The first space S1 may be the space in which the first surface 15a of the film 15 faces the other layers of the film assembly 16. In Figures 32 and 33, the first surface 15a of the film 15 faces the first space S1 via the protective material 17. When the film 15 is moved using the pressurizing device 60, the opening 51h of the frame 51 is closed after the fluid supply step STP27 described above.

[0396] The film 15 protrudes in a first direction D1 toward the adherend AB by the fluid supply process STP27. The film 15 is attached to the adherend AB in the portion that protrudes in the first direction D1 toward the adherend AB by the first moving process STP23. As shown in Figure 32, the amount of protrusion of the film 15 in the portion to which the fluid 81 is supplied increases by the fluid supply process STP27. As a result, the occurrence of wrinkles in the film 15 attached to the adherend AB can be suppressed more effectively compared to the above example. Therefore, the film application device 40 of Figure 30 can effectively suppress the deterioration of the design of the decorative member 25.

[0397] Furthermore, as described above, the amount of protrusion of the film 15 in the first direction D1 toward the adherend AB increases further when the film application device 40 satisfies one or more of the following conditions (A) to (C). Therefore, the deterioration of the design of the decorative member 25 can be more effectively suppressed when one or more of the following conditions (A) to (C) are satisfied. (A): The temperature of the fluid 81 is higher than the softening temperature of the base layer 31. (B): The temperature of the fluid 81 is higher than the softening temperature of the film 15. (C): The film 15 and the protective material 17 are bonded together.

[0398] In particular, with respect to the above-mentioned condition (C), it is preferable that the film 15 is easily peeled off from the protective material 17 by the fluid 81 flowing between the film 15 and the protective material 17. For example, the peeling force from the protective material 17 on the first surface 15a of the film 15 may be greater than the peeling force on the second surface 15b of the film 15. In this specific example, the protective material 17 can be easily peeled off from the film 15 by the fluid 81 supplied from the fluid supply device 80.

[0399] In the first moving step STP23 described above, at least a portion of the film 15 is attached to the adherend AB. As a result of the first moving step STP23, the film 15 is attached to the adherend AB at least in the portion that protrudes most in the first direction D1 toward the adherend AB.

[0400] After at least a portion of the film 15 has been attached to the adherend AB by the first moving step STP23, the removal device 82 may remove the fluid 81. The removal device 82 may also use a pump 84 to suck up the fluid 81 with one end of the hose 83 connected to the fluid 81 on the film 15. By removing the fluid 81 on the film 15 with the removal device 82, it is possible to prevent the fluid 81 from flowing to unintended locations. As a result, the film application device 40 can stably attach the film 15 to the adherend AB using the fluid 81.

[0401] Prior to the second moving step STP28, a sealing device 58 is installed between the holding device 50 and the adherend AB. As described above, the sealing device 58 may be a sheet 58A. One end of the sheet 58A in the first direction D1 may be attached to the film 15 or the holding device 50. The other end of the sheet 58A in the first direction D1 may be attached to the adherend AB. Alternatively, the other end of the sheet 58A in the first direction D1 may be attached around the adherend AB.

[0402] The sheet 58A may be attached before the first moving step STP23. The sheet 58A can be deformed when the holding device 50 moves in the first direction D1 relative to the adherend AB during the first moving step STP23. The deformation of the sheet 58A allows the sealing device 58 to maintain the second space S2 in a sealed state.

[0403] As shown in Figure 34, the sheet 58A may be provided with a through hole 58H that connects to the second space S2. A pressure reducing device 65 may be connected to the through hole 58H. A hose 66 of the pressure reducing device 65 may be connected to the through hole 58H. The second space S2 may be connected to the pump 67 of the pressure reducing device 65 via the through hole 58H provided in the sheet 58A.

[0404] In the second moving step STP28, the pump 67 of the depressurizing device 65 sucks air from the second space S2. The second space S2 is depressurized by the pump 67 sucking in air. The pressure in the second space S2 becomes lower than the pressure in the first space S1 due to the depressurization. The pressure difference between the first space S1 and the second space S2 increases due to the depressurization. In the second moving step STP28, the film 15 moves toward the adherend AB due to the pressure difference between the first space S1 and the second space S2. In the second moving step STP28, the film 15 is attached to the adherend AB from the portion that protrudes toward the adherend AB in the first direction D1.

[0405] In the second moving step STP28 described above, the peripheral portion of the film 15 is attached to the adherend AB from the portion that protrudes toward the adherend AB in the first direction D1. The peripheral portion of the film 15 is the portion located around the portion that was attached to the adherend AB in the first moving step STP23. According to this specific example, the occurrence of wrinkles in the peripheral portion attached to the adherend AB can be suppressed.

[0406] The first application process STP1 is completed when the second transfer process STP28 is completed. The film 15 is attached to the adherend AB in the same order as in the example described above by performing the molding process STP2 and the second application process STP4 in the same order as in the example described above. The decorative member 25 is manufactured by the adherend AB and the film 15 attached to the adherend AB.

[0407] As described above, the film application device 40 in Figure 30 applies a film 15 having a first surface 15a and a second surface 15b to the adherend AB by moving the film 15 in a first direction D1, starting from the second surface 15b. The film application device 40 includes a holding device 50 and a fluid supply device 80. The holding device 50 holds the film 15. The fluid supply device 80 supplies fluid 81 onto the first surface 15a of the film 15 held by the holding device 50. The fluid 81 causes the film 15 to protrude in the first direction D1 toward the adherend AB. In this specific example, in the region where the film 15 and the fluid 81 overlap, the weight of the fluid 81 causes the film 15 to move in the first direction D1 toward the adherend AB. The fluid 81 increases the amount of protrusion of the film 15 in the first direction D1 toward the adherend AB. In the region of the film 15 that overlaps with the fluid 81, the increase in the amount of protrusion in the first direction D1 suppresses pulling in a direction perpendicular to the first direction D1 when the film is attached to the adherend AB. This suppresses the formation of wrinkles in the film 15 when it is attached to the adherend AB. Therefore, the film application device 40 can suppress deterioration of the design of the decorative member 25 composed of the adherend AB and the film 15.

[0408] In the film application device 40 shown in Figure 30, the pressure device 60 may be omitted. In the film application device 40 in which the pressure device 60 is omitted, the cover 52 of the holding device 50 may also be omitted. The film assembly 16 may contact the holding device 50 from the first side S11 in the first direction D1 instead of the cover 52.

Claims

1. A film forming apparatus comprising a first type and a second type, wherein the edge of a film partially attached to a substrate is heated to form the edge sandwiched between the first type and the second type.

2. The film molding apparatus according to claim 1, wherein at least one of the first type and the second type heats the edge portion.

3. A film forming apparatus comprising a first type and a second type, wherein at least one of the first type and the second type heats the edge of the film, thereby forming the edge sandwiched between the first type and the second type.

4. The film molding apparatus according to claim 2 or 3, wherein at least one of the molds generates heat.

5. The film molding apparatus according to claim 2 or 3, wherein the film includes a bonding layer for bonding the film to the adherend, and the material of at least one of the molds is a fluororesin, a silicone resin, and an olefin resin in the portion that contacts the bonding layer.

6. The film molding apparatus according to claim 2 or 3, wherein the material of at least one of the molds is aluminum.

7. The film molding apparatus according to claim 1 or 3, wherein the portion in contact with the edge is made of a coating containing a release agent.

8. The film forming apparatus according to claim 1 or 3, wherein the film includes a corner portion in which a plurality of edges are connected to one another, and the apparatus forms the corner portion sandwiched between the first mold and the second mold.

9. The film forming apparatus according to claim 1 or 3, wherein one of the first and second molds is provided with a recess for accommodating the other of the first and second molds, and the edge portion is bent in the recess.

10. The film forming apparatus according to claim 1 or 3, wherein the first type and the second type are connected to each other so as to be swingable.

11. The film forming apparatus according to claim 1 or 3, wherein the first mold includes a recess for accommodating the second mold, the recess includes a first bottom surface and a first side surface extending from the first bottom surface in a direction nonparallel to the first bottom surface, the first side surface includes a first portion and a second portion extending in directions nonparallel to each other, the second mold includes a second bottom surface and a second side surface extending from the second bottom surface in a direction nonparallel to the second bottom surface, the second side surface includes a first portion and a second portion extending in directions nonparallel to each other, and the edge is heated while sandwiched between the first bottom surface and the second bottom surface, between the first portion of the first side surface and the first portion of the second side surface, and between the second portion of the first side surface and the second portion of the second side surface.

12. The film forming apparatus according to claim 1 or 3, wherein the first type includes a first body and a first handle connected to the first body, and the second type includes a second body and a second handle connected to the second body, and the edge is sandwiched between the first body and the second body.

13. The film forming apparatus according to claim 1 or 3, wherein the first type includes a first body, the second type includes a second body, the first body includes a recess for housing the second body, at least one of the first body and the second body generates heat when the second body is housed in the recess, and the at least one body is provided with holes through which a cooling fluid flows to cool the heated at least one body.

14. The film molding apparatus according to claim 13, wherein the hole opens in a portion that does not come into contact with the film.

15. The film forming apparatus according to claim 13, wherein the holes open at multiple locations on the second main body.

16. The film molding apparatus according to claim 1 or 3, wherein the adherend has a three-dimensional shape.

17. A method for manufacturing a decorative member, comprising: a first application step of partially attaching a film to an adherend; a molding step of forming the edge of the film using a film molding apparatus according to claim 1 or 3; and a second application step of attaching the edge to the adherend.

18. The method for manufacturing a decorative member according to claim 17, wherein the film includes a positioning portion at its edge for positioning at least one of the first type and the second type.

19. The method for manufacturing a decorative member according to claim 17, wherein the film includes a base layer, and the base layer includes thermoplastic polyurethane.

20. The method for manufacturing a decorative member according to claim 17, wherein the 3% strain tensile stress of the film is 1 N / 10 mm or more and 40 N / 10 mm or less in an environment of 25°C.

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