U.S. patent application number 14/302033 was filed with the patent office on 2014-11-13 for method and apparatus for producing three-dimensional decoration piece made of thermoplastic synthetic resin.
This patent application is currently assigned to Nobuo Kuroda. The applicant listed for this patent is Nobuo Kuroda, Eiji Kuwahara. Invention is credited to Eiji KUWAHARA.
Application Number | 20140332146 14/302033 |
Document ID | / |
Family ID | 45066301 |
Filed Date | 2014-11-13 |
United States Patent
Application |
20140332146 |
Kind Code |
A1 |
KUWAHARA; Eiji |
November 13, 2014 |
METHOD AND APPARATUS FOR PRODUCING THREE-DIMENSIONAL DECORATION
PIECE MADE OF THERMOPLASTIC SYNTHETIC RESIN
Abstract
A method and an apparatus for producing a three-dimensional
decoration piece that does not damage the tacky bonding or adhesion
strength of the lower layer material of the decoration piece. The
method includes putting an upper layer material on a first table
operating as cathode; lowering an upper mold operating as anode
onto the first table, emitting a high frequency wave for dielectric
heating; stopping the high frequency dielectric heating; moving a
second table carrying a lower layer material having a tacky bonding
property to below the upper mold; and lowering said upper mold onto
the second table. In the apparatus, the second table or the lower
mold is provided on the top surface thereof with recessed sections
that are transversally and inwardly separated from a position where
an edge of the first machining means contacts, by 0.2 mm to 1 mm;
and a cushion member being arranged in the respective recessed
sections.
Inventors: |
KUWAHARA; Eiji; (Osaka-shi,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kuroda; Nobuo
Kuwahara; Eiji |
|
|
US
US |
|
|
Assignee: |
Kuroda; Nobuo
Osaka-shi
JP
Kuwahara; Eiji
Osaka-shi
JP
|
Family ID: |
45066301 |
Appl. No.: |
14/302033 |
Filed: |
June 11, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13698815 |
Nov 19, 2012 |
|
|
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PCT/JP2010/059377 |
Jun 2, 2010 |
|
|
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14302033 |
|
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Current U.S.
Class: |
156/219 ;
156/380.5 |
Current CPC
Class: |
B29C 43/52 20130101;
B29C 66/433 20130101; Y10T 156/1039 20150115; B29C 35/12 20130101;
B29C 59/02 20130101; B29C 66/71 20130101; B29C 66/4724 20130101;
B29C 66/73921 20130101; B29C 65/04 20130101; B29C 65/3676 20130101;
B29C 66/71 20130101; B29C 66/8322 20130101; B29C 43/40 20130101;
B29C 66/30621 20130101; B29C 66/81415 20130101; B29C 66/81431
20130101; B29C 66/1122 20130101; B29C 2035/0811 20130101; B29C
66/71 20130101; B29C 65/366 20130101; B44C 1/005 20130101; B29K
2023/00 20130101; B29K 2075/00 20130101; B29K 2027/06 20130101;
B29K 2067/00 20130101; B29C 66/81457 20130101; B29C 66/72328
20130101; B29C 66/71 20130101; B29C 66/71 20130101; B29L 2031/744
20130101; B29C 59/16 20130101; B29C 65/7441 20130101; B29C 66/81427
20130101; B29L 2031/722 20130101; B29C 59/026 20130101 |
Class at
Publication: |
156/219 ;
156/380.5 |
International
Class: |
B29C 65/04 20060101
B29C065/04; B29C 59/16 20060101 B29C059/16; B29C 59/02 20060101
B29C059/02 |
Claims
1. A method for producing a three-dimensional decoration piece of
thermoplastic synthetic resin comprising: putting an upper layer
material on a first table operating as cathode; lowering an upper
mold operating as anode onto the first table to press the upper
layer material, emitting a high frequency wave for dielectric
heating, to form a three-dimensionally formed body from the upper
layer material by molding and fusion-cutting and temporarily
holding the three-dimensionally formed body to the upper mold;
stopping the high frequency dielectric heating; moving a second
table carrying a lower layer material having a tacky bonding
property to below the upper mold temporarily holding the
three-dimensionally formed body; and lowering said upper mold onto
the second table to press the three-dimensionally formed body
cutting the lower layer material and tacky bonding the
three-dimensionally formed body and the lower layer material, so
that the lower layer material is not subjected to any high
frequency dielectric heating, and is not heated.
2. The method according to claim 1, wherein an intermediate layer
material is put on said first table said upper layer material is
put on the intermediate layer material; and said upper mold is
lowered onto the first table to press said upper layer material and
said intermediate layer material and emitting a high frequency wave
for dielectric heating, to form the three-dimensionally formed body
by fusion bonding said upper layer material and said intermediate
layer material.
3. The method according to claim 1, wherein the lower layer
material having a releasing paper arranged to a rear surface
thereof is put on said second table.
4. The method according to claim 1, wherein after the cutting of
the lower layer material unnecessary parts thereof are removed, an
application film is adhered onto the top surface of the upper
layer.
5. The method according to claim 1, wherein a cushion member is
arranged under the lower layer material in regions located outside
areas where the lower layer material is cut, to absorb the pressure
of the upper mold by the cushion member.
6. An apparatus configured to produce a three-dimensional
decoration piece of thermoplastic synthetic resin according to the
method of claim 1, the apparatus comprising: an upper mold
operating as anode, a first table operating as cathode, and a
second table, said upper mold having a first machining means; the
first machining means fusion-cutting a material at the time of high
frequency dielectric heating between the upper mold and the first
table; said first machining means cutting the material at the time
of pressing between the upper mold and the second table; said upper
mold being provided on a bottom surface thereof with a temporary
holding means; said second table having a flat top surface; said
second table being provided on the top surface thereof with
recessed sections, each of which being transversally and inwardly
separated from a position where an edge of the first machining
means contacts, by 0.2 mm to 1 mm; and a cushion member being
arranged in the respective recessed sections.
7. An apparatus configured to produce a three-dimensional
decoration piece of thermoplastic synthetic resin according to the
method of claim 1, the apparatus comprising: an upper mold
operating as anode, a first table operating as cathode, a second
table, and a lower mold arranged on the second table; said upper
mold having a first machining means; the first machining means
fusion-cutting a material at the time of high frequency dielectric
heating between the upper mold and the first table; the first
machining means cutting the material at the time of pressing
between the upper mold and the second table; said upper mold being
provided on a bottom surface thereof with a temporary holding
means; said lower mold having a flat top surface; said lower mold
being provided on the top surface thereof with recessed sections,
each of which being transversally and inwardly separated from a
position where an edge of the first machining means contacts, by
0.2 mm to m 1 mm; and a cushion member being arranged in the
respective recessed sections.
8. The method according to claim 2, wherein the lower layer
material having a releasing paper arranged to a rear surface
thereof is put on said second table.
9. The method according to claim 2, wherein after the cutting of
the lower layer material unnecessary parts thereof are removed, an
application film is adhered onto the top surface of the upper
layer.
10. The method according to claim 3, wherein after the cutting of
the lower layer material unnecessary parts thereof are removed, an
application film is adhered onto the top surface of the upper
layer.
11. The method according to claim 8, wherein after the cutting of
the lower layer material unnecessary parts thereof are removed, an
application film is adhered onto the top surface of the upper
layer.
12. The method according to claim 2, wherein a cushion member is
arranged under the lower layer material in regions located outside
areas where the lower layer material is cut, to absorb the pressure
of the upper mold by the cushion member.
13. The method according to claim 3, wherein a cushion member is
arranged under the lower layer material in regions located outside
areas where the lower layer material is cut, to absorb the pressure
of the upper mold by the cushion member.
14. The method according to claim 8, wherein a cushion member is
arranged under the lower layer material in regions located outside
areas where the lower layer material is cut, to absorb the pressure
of the upper mold by the cushion member.
Description
[0001] This is a divisional of application Ser. No. 13/698,815
filed Nov. 19, 2012, which is a National Stage Application of
PTC/JP2010/059377 filed Jun. 2, 2010, The entire disclosures of the
prior applications are hereby incorporated by references in their
entirety.
TECHNICAL FIELD
[0002] This invention relates to a method and an apparatus for
producing a three-dimensional decoration piece of thermoplastic
synthetic resin that is to be fitted to, an automobile, a bicycle,
a motor boat, an office automation apparatus, a home electric
appliance, a sporting tool, a machine or the like, by means of a
tacky adhesive agent or a bonding agent.
BACKGROUND ART
[0003] Various methods employing a metal mold and high frequency
dielectric heating have been proposed as methods for producing a
three-dimensional decoration piece of synthetic resin to be used as
emblem or the like (see, inter alia, Patent Documents Nos. 1, 2 and
3 listed below).
[0004] However, with the invention disclosed in Patent Document No.
1, the three-dimensional decoration piece is produced by using an
indented mold and a protruding mold, and the piece is produced
between the indented mold and the protruding mold. Thus, a rear
surface of the produced piece is not flat but recessed. Therefore,
an area to be bonded or tackily bonded to an object to be decorated
is rather small, and hence does not provide satisfactory bonding
(tacky bonding) strength.
[0005] With the invention disclosed in Patent Document No. 2, when
a three-dimensional pattern on an upper surface of a polyurethane
film is formed by an engraving die, the engraving die heats and
presses the three-dimensional decoration piece entirely, so as to
damage the tacky adhesive effect of the adhesive layer formed on
the rear surface of the decoration piece.
[0006] The invention disclosed in Patent Document No. 3 provides a
flat adhesive layer on the rear surface of the decoration piece to
be produced. However, it has been found that the original tacky
adhesive force is degraded under pressure, to reduce the tacky
adhesion strength relative to the object to which the decoration
piece is fitted almost by half.
[0007] A number of experiments have proved that a tacky adhesive
material and a tacky adhesive agents are degraded by heat, and a
tacky adhesion strength is further reduced when pressure is applied
thereto.
LIST OF PRIOR ART DOCUMENTS
Patent Documents
[0008] Patent Document No. 1: JP-B-H07-102620
[0009] Patent Document No. 2: JP-B-3235943
[0010] Patent Document No. 3: JP-B-4227587
SUMMARY OF THE INVENTION
Problem to Be Solved by the Invention
[0011] Therefore, the object of the present invention is to provide
a method and an apparatus for producing a three-dimensional
decoration piece that do not damage the tacky bonding or adhesion
strength of the lower layer material of the decoration piece.
Means for Solving the Problem
[0012] In the first aspect of the present invention, there is
provided a method for producing a three-dimensional decoration
piece of thermoplastic synthetic resin comprising:
[0013] putting an upper layer material on a first table operating
as cathode;
[0014] lowering an upper mold operating as anode onto the first
table to press the upper layer material, emitting a high frequency
wave for dielectric heating, to form a three-dimensionally formed
body from the upper layer material by molding and fusion-cutting
and temporarily holding the three-dimensionally formed body to the
upper mold;
[0015] stopping the high frequency dielectric heating;
[0016] moving a second table carrying a lower layer material having
a tacky bonding property to below the upper mold temporarily
holding the three-dimensionally formed body; and
[0017] lowering said upper mold onto the second table to press the
three-dimensionally foamed body, cutting the lower layer material
and tacky bonding the three-dimensionally formed body and the lower
layer material (Embodiment 1).
[0018] Preferably, an intermediate layer material is put on said
first table;
[0019] said upper layer material is put on the intermediate layer
material; and
[0020] said upper mold is lowered onto the first table to press
said upper layer material and said intermediate layer material and
emitting a high frequency wave for dielectric heating, to form the
three-dimensionally fanned body by fusion bonding said upper layer
material and said intermediate layer material (Embodiment 2).
[0021] Preferably, the lower layer material having a releasing
paper arranged to a rear surface thereof is put on said second
table (Embodiment 3).
[0022] Preferably, after the cut the lower layer material,
unnecessary parts thereof are removed, and an application film is
adhered onto the top surface of the upper layer (Embodiment 4).
[0023] Preferably, a cushion member is arranged under the lower
layer material in regions located outside areas where the lower
layer material is cut, to absorb the pressure of the upper mold by
the cushion member (Embodiment 5).
[0024] In a second aspect of the present invention, there is
provided an apparatus for producing a three-dimensional decoration
piece of thermoplastic synthetic resin, comprising:
[0025] an upper mold operating as anode, a first table operating as
cathode and a second table,
[0026] said upper mold having a first machining means;
[0027] the first machining means fusion-cutting a material at the
time of high frequency dielectric heating between the upper mold
and the first table;
[0028] said first machining means cutting the material at the time
of pressing between the upper mold and the second table;
[0029] said upper mold being provided on a bottom surface thereof
with a temporary holding means;
[0030] said second table having a flat top surface;
[0031] said second table being provided on the top surface thereof
with recessed sections, each of which being transversally and
inwardly separated from a position where an edge of the first
machining means contacts, by 0.2 mm to 1 mm;
[0032] a cushion member being arranged in the respective recessed
sections (Embodiment 6).
[0033] There is also provided an apparatus for producing a
three-dimensional decoration piece of thermoplastic synthetic
resin, comprising:
[0034] an upper mold operating as anode, a first table operating as
cathode, a second table, and a lower mold arranged on the second
table;
[0035] said upper mold having a first machining means;
[0036] the first machining means fusion-cutting a material at the
time of high frequency dielectric heating between the upper mold
and the first table;
[0037] the first machining means cutting the material at the time
of pressing between the the upper mold and the second table;
[0038] said upper mold being provided on a bottom surface thereof
with a temporary holding means;
[0039] said lower mold having a flat top surface;
[0040] said lower mold being provided on the top surface thereof
with recessed sections, each of which being transversally and
inwardly separated from a position where an edge of the first
machining means contacts, by 0.2 mm to 1 mm;
[0041] a cushion member being arranged in the respective recessed
sections (Embodiment 7).
ADVANTAGES OF THE INVENTION
[0042] According to the inventions as defined in Embodiments 1
through 3 and 5 through 7, the lower layer material having a tacky
bonding property is not subjected to any high frequency dielectric
heating, and hence it is not heated. Therefore, the tacky bonding
property of the lower layer material is prevented from being
degraded.
[0043] According to the invention as defined in Embodiment 5, since
the cushion member is arranged under the lower layer material, the
tacky bonding property of the lower layer material is prevented
from being degraded under pressure, so as to further prevent the
tacky bonding property from being degraded effectively.
[0044] Since the cushion member is not arranged below the lower
layer material at a portion where the lower layer material is cut,
the lower layer material can be easily cut.
[0045] According to the invention as defined in Embodiment 6, since
the cushion member is arranged at the above defined position on the
top surface of the second table, the tacky bonding property of the
lower layer material is prevented from being degraded under
pressure. Additionally, since no cushion member is arranged under
the cutting positions of the lower layer material, the lower layer
material can be easily cut.
[0046] The invention as defined in Embodiment 7 provides an
additional advantage that only the lower mold needs to be prepared
separately when the pattern of the three-dimensional decoration
piece is changed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 is a schematic bottom view of an upper mold 21.
[0048] FIG. 2 is a schematic sectional view taken along line M-M in
FIG. 1 that schematically illustrates a state before the high
frequency dielectric heating of the first step.
[0049] FIG. 3 is a schematic sectional view taken along line M-M in
FIG. 1 that schematically illustrates a state during the high
frequency dielectric heating of the first step.
[0050] FIG. 4 is an enlarged schematic sectional view of part N in
FIG. 3.
[0051] FIG. 5 is a schematic sectional view taken along line M-M in
FIG. 1 that schematically illustrates a state after the high
frequency dielectric heating of the first step.
[0052] FIG. 6 is a schematic plan view of a lower mold 42.
[0053] FIG. 7 is a schematic sectional view taken along line P-P of
the lower mold 42 in FIG. 6.
[0054] FIG. 8 is a schematic illustration of a state before
pressing of the second step, specifically cross sectional views
taken along line P-P of the lower mold 42 and corresponding
respective sectional views of the upper mold, a three-dimensionally
formed body and a lower layer material.
[0055] FIG. 9 is a schematic illustration of a state during the
pressing of the second step, specifically a sectional view taken
along line P-P of the lower mold 42 and corresponding respective
sectional views of the upper mold, the three-dimensionally formed
body and the lower layer material.
[0056] FIG. 10 is an enlarged selective of part X in FIG. 9 from
which the three-dimensionally formed body and the lower layer
material are not shown,
[0057] FIG. 11 is a schematic illustration of a state after the
pressing of the second step, specifically a sectional view taken
along line P-P of the lower mold 42 and corresponding respective
cross sectional views of the upper mold, the three-dimensionally
formed body and the lower layer material.
[0058] FIG. 12 is a schematic plan view of a three-dimensional
decoration piece produced by a method according to the present
invention.
[0059] FIG. 13 is a schematic sectional view taken along line Y-Y
in FIG. 12.
PREFERRED EMBODIMENT OF THE INVENTION
Three-Dimensional Decoration Piece
[0060] Firstly, a three-dimensional decoration piece which is
produced by a method and an apparatus according to the present
invention will be described.
[0061] FIG. 12 is a schematic elevation of a three-dimensional
decoration piece produced by a method and an apparatus according to
the present invention. FIG. 13 is a schematic cross sectional view
taken along line Y-Y in FIG. 12.
[0062] As shown in FIG. 13, the three-dimensional decoration piece
comprises an upper layer 11 molded to show a three-dimensional
shape, a lower layer 13 arranged under the upper layer 11 and
having a tackily bonding function, an application film 15 arranged
on a top surface of the upper layer 11 and a releasing paper 16
arranged under a bottom surface of the lower layer 13.
[0063] Since the lower layer 13 has an tackily bonding property,
the releasing paper 16 is arranged under the lower layer 13, as
will be described later.
[0064] The application film 15 may be a transparent resin film or a
sheet of paper, a rear surface (bottom surface) of which a tackily
bonding material is arranged. The three-dimensional decoration
piece is protected by the applied application film. In addition,
even if components (in the illustrated example, characters or
symbols of N, E, O, - and X) are separated from one another, the
relative positions of the components can be maintained.
[0065] A three-dimensional decoration piece produced by a method
and an apparatus according to the present invention can be applied
to any of various articles including automobiles, motor bicycles,
motorboats, bicycles, office automation apparatus, electric home
appliances, sporting tools and machines in order to decorate
it.
[0066] <Upper Layer>
[0067] The upper layer 11 of a three-dimensional decoration piece
is provided with a three-dimensional shape. The surface of the
upper layer may be further decorated by, such as printing. The
upper layer 11 is formed by a surface layer material 11 and an
intermediate layer material 12a. As will be described later, the
surface layer material 11a and the intermediate layer material 12a
are fusion-bonded each other in the process of producing the
three-dimensional decoration piece. In the illustrated example as
explained below, the upper layer material comprises a surface layer
material 11a and an intermediate layer material 12a. However, the
intermediate layer material 12a is not essential, if a cavity of an
upper mold 21 is filled with the surface layer material 11a (and
hence the surface layer material 11a alone can provide the
thickness of the three-dimensional decoration piece)
[0068] <Surface Layer Material>
[0069] The surface layer material 11a is a material to be used to
make the surface of the three-dimensional decoration piece
aesthetically appealing, and thermoplastic synthetic resin can be
used for it. Any of known thermoplastic synthetic resin materials
can be used for a three-dimensional decoration piece according to
the present invention. Examples of known thermoplastic synthetic
resin materials that can be used for the surface layer material
include polyvinylchloride film, polyurethane film, polyester film
and polyolefin film. The thermoplastic synthetic resin film to be
used for the purpose of the present invention may be a laminate
film.
[0070] Metal may be deposited on the thermoplastic synthetic resin
film by evaporation by means of a known technique to provide an
appearance like a metal-made three-dimensional decoration piece.
Examples of metal deposited films that can be used for the purpose
of the present invention include metal deposited polyvinylchloride
film, metal deposited polyurethane film, metal deposited polyester
film and metal deposited polyolefin film. Any known metal can be
used for the purpose of the present invention, for example,
aluminum, chromium, silver and tin.
[0071] The surface layer material 11a is appropriately selected
depending on the three-dimensional decoration piece to be produced.
The surface layer material may be further decorated by printing of
a known technique.
[0072] <Intermediate Layer Material>
[0073] The intermediate layer material 12a is a layer for providing
the three-dimensional decoration piece with a certain thickness and
for preventing one or more than one voids from being formed in the
decoration piece. Thermoplastic synthetic resin can be used for the
intermediate layer material, for example, polyvinylchloride sheets,
polyurethane sheets and polyolefin sheets etc. <Lower Layer and
Lower Layer Material>
[0074] The lower layer 13 is a layer for fitting the upper layer 11
onto an object to be decorated such as a car, and hence has an
adhesive function or a tackily bond function. The lower layer is
made of a lower layer material 13a.
[0075] The lower layer material 13a is a material having an
adhesive function or a tackily bond function. Any known materials
that can be used for fitting a three-dimensional decoration piece
to the object to be decorated can be used for the purpose of the
invention, for example, double sided tapes having a base member and
double sided tapes having no base member, although the invention is
not limited to these materials. The lower layer material 13a is
selected in view of the decoration piece and the object to be
decorated.
[0076] <Apparatus for Producing Decoration Piece>
[0077] According to the present invention, a three-dimensional
decoration piece 1 is produced by
[0078] (1) high frequency dielectric heating the above described
materials by means of a first table 31 and an upper mold 21, to
produce a three-dimensionally formed body 14b (1st Step); and
[0079] (2) pressing the three-dimensionally formed body 14b by
means of a second table 41 and the upper mold 21 (2nd Step) to cut
the lower layer material 13a, so as to Bonn the three-dimensional
decoration piece 1.
[0080] Now, the apparatus used in the present invention will be
described below.
[0081] The apparatus according to the present invention comprises
an upper mold 21 to be used in the first step and the second step,
a first table 31 to be used in the first step, and a second table
41 to be used in the second step.
[0082] In the first step, the upper mold 21 functions as anode,
while the first table 31 functions as cathode. In the second step,
on the other hand, the upper mold 21 does not function as
anode.
[0083] Although not shown, the first table 31 and the second table
41 may be made movable so as to be alternately placed below the
upper mold 21 (table sliding method). Alternatively, a turn table
may be used to make the first table 31 and the second table 41
movable. Any known method for moving the first table 31 and the
second table 41 can be used for the purpose of the present
invention.
[0084] The upper mold 21 is provided with cavities for defining a
surface profile of the three-dimensional decoration piece. Cross
sectional views of the cavities are not limited to the illustrated
examples, and may show the shape of an inverted V, a semi-circle, a
trapezoid or any other shape.
[0085] The upper mold 21 is provided with a first machining means
22 and a second machining means 23.
[0086] The first machining means 22 functions as a fusion-cutting
blade in the first step so as to fusion-cut the surface layer
material 11a and the intermediate layer material 12a, and functions
as a cutting blade in the second step of applying pressure without
high frequency dielectric heating, so as to simply cut the lower
layer.
[0087] The second machining means 23 functions as a pressing blade
in the first step. The second machining means 23 is arranged when
necessary. In other words, it is not essential. While some of the
dimensions of the first machining means 22 and other members are
shown in FIG. 4, the present invention is not limited to the
dimensional values shown in FIG. 4.
[0088] As shown in FIG. 1, the upper mold 21 is provided on a lower
surface thereof with a temporary holding means 25. The temporary
holding means 25 temporarily holds the three-dimensionally formed
body 14b produced in the first step to the upper mold 21. The
temporary holding means 25 may be, for example, an tackily bonding
tape.
[0089] The upper mold 21 is provided with an aligning hole 24. A
pin (not shown) are driven into the respective aligning holes 24
and the corresponding aligning holes 45 of the second table 41,
which will be described hereinafter, in order to align the upper
mold 21 and the second table 41.
[0090] The first table is operated as cathode in the first step,
but it is not operated as such in the second step. A top surface of
the first table is 31a flat surface.
[0091] The upper mold 21 and the first table 31 operate for high
frequency dielectric heating. Any known ones can be used for the
purpose of the present invention.
[0092] The second table 41 is not used in the first step. In other
words, it is used only in the second step. A top surface of the
second table 41 is flat. The second table 41 is provided on the
surface thereof with a recessed section.
[0093] Alternatively, as shown in the illustrated example, a lower
mold 42 may be placed on the second table 41. The lower mold 42 has
a flat top surface and a recessed section 43 on the top surface.
This arrangement is convenient for instances where the current
design of three-dimensional decoration piece is replaced by some
other design, because only the lower mold needs to be replaced and
it is not necessary to replace the second table 41.
[0094] Cushion members 51 are arranged in the respective recessed
sections 43 to make the top surface of the lower mold 42 flat. A
material that can absorb pressure such as rubber is employed for
the cushion members. Because cushion members 51 are arranged, when
the lower layer material 13a arranged on the lower mold 42 is
pressed by the upper mold 21, the pressure is absorbed by the
cushion members in the areas where the lower layer material 13a
contacts with the cushion members 51. Therefore, the adhesive force
of the lower layer material 13a is not degraded in the areas where
the lower layer material 13a contacts with the cushion members
51.
[0095] If the cushion members are arranged at the positions where
edge (s) of the first machining means 22 contacts them, the first
machining means 22 can no longer cut the lower layer material 13a,
because the pressure applied by the first machining means 22 is
absorbed by the cushion members. Therefore, the positions of the
cushion members and the positions the recessed sections 43 are
important.
[0096] Each of the recessed sections 43 is arranged between a point
443 and a point 444. The edge of the blade of the first machining
means 22 contacts with the top surface of the lower mold 42 at
points 441, 442. Each of the points 443 and 444 is positioned
transversally (in a direction indicated by an arrow U in FIG. 10)
and inwardly separated from the points 441, 442 by 0.2 mm to 1 mm.
In other words, a distance between the point 441 and the point 443
is between 0.2 mm and 1 mm. If the recessed section 43 (the cushion
member 51) is arranged in a region separated from the positions
441, 442 only by less than 0.2 mm, the edge of the first machining
means 22 may be positioned above the cushion member 51, in case
that the upper mold 21 and the lower mold 42 (second table 41) are
relatively displaced from each other a little. In such a case, the
edge can no longer cut the lower layer material 13a. If, contrary,
the recessed section 43 (the cushion member 51) is arranged in a
region separated from the positions 441, 442 by more than 1 mm, the
area to which the lower layer material 13a applies pressure becomes
large, to consequently degrade the tacky bonding properties of the
lower layer material 13a.
[0097] A depth of the recessed sections 43 is preferably between 1
mm and 5 mm. While FIG. 10 shows the depth of the recessed sections
43 is 2 mm, the depth is not limited to 2 mm. When the depth of the
recessed sections 43 (and hence the thickness of the cushion
members 51) is less than 1 mm, the cushion member 51 cannot
sufficiently absorb the pressure applied to them. When, on the
other hand, the depth is more than 5 mm, the cushion member 51 is
depressed to produce a gap between the cusion member 51 and the
lower layer material 13a. Then, the bottom surface of the lower
layer material 13a may not be fiat.
[0098] In other words, the pressure applied by the upper mold 21 is
absorbed, and the tacky bonding properties of the lower layer
material 13a is prevented from being degraded, by arranging the
cushion member 51 in regions other than a portion where the lower
layer material 13a is cut.
[0099] The lower mold 42 (or the second table 41) is provided with
an aligning hole 45. The pin (not shown) is arranged into the
aligning hole 45 of the second table 41 and the corresponding
aligning holes 24 of the upper mold 21, to align the upper mold 21
and the lower mold 42 (second table 41).
[0100] <Method for Producing the Decoration Piece>
[0101] According to the present invention, the three-dimensional
decoration piece is produced by means of an apparatus as described
above in a manner as described below.
[0102] In the illustrated example, the intermediate layer material
12a is put on the first table 31, and the surface layer material
11a is put on the intermediate layer material 12a, as shown in FIG.
2. In this stage, the lower layer material 13a is not put.
[0103] While the surface layer material 11a is put on the
intermediate layer material 12a in the illustrated example, the
surface layer material 11a may be laid on the intermediate layer
material 12a in advance to integrally combine the two materials to
produce a layered set of materials, which is then on the first
table 31. The intermediate layer material 12a may be omitted, if
the surface layer material 11a has a thickness sufficient for
filling the cavity of the upper mold 21.
[0104] Then, as shown in FIG. 3, the upper mold 21 is lowered to
press the surface layer material 11a and the intermediate layer
material 12a, and a high frequency wave is transmitted by using the
upper mold 21 and the first table 31 respective as anode and
cathode. The surface layer material 11a and the intermediate layer
material 12a are heated and molten. The surface layer material 11a
and the intermediate layer material 12a are molten as a result of
being heated, and then flow into the cavity of the upper m,old 21
so as to take the designed shape. The surface layer material 11a
and the intermediate layer material 12a are fusion-bonded to make a
three-dimensionally formed body 14b.
[0105] The three-dimensionally formed body 14b (the surface layer
material 11a and the intermediate layer material 12a) is fusion-cut
by the first machining means 22. The formed three-dimensionally
formed body 14b has the designed shape by the upper mold 21. Since
the top surface of the first table 31 is flat as described above, a
bottom surface of the three-dimensionally formed body 14b is flat.
Therefore, the three-dimensionally formed body produced by the
method of the present invention has a large area that can be used
for adhesion or tackily bonding, to consequently provide a
sufficient adhesion or tackily bonding strength.
[0106] Additionally, the three-dimensionally formed body 14b is
temporarily held to the upper mold 21 by the temporary holding
means 25. If the temporary holding means 25 is a tacky bond tape,
the three-dimensionally formed body 14b is temporarily held to the
upper mold 21 by the pressure applied by the upper mold 21 and the
tackily bonding force of the temporary holding mean 25.
[0107] When the three-dimensionally formed body 14 is made to take
the designed shape and temporarily held to the upper mold 21, the
high frequency dielectric heating is stopped.
[0108] The lower layer material 13a is put on the second table 41.
In the illustrated example, the lower mold 42 is placed on the
second table 41. In the illustrated example, the lower layer
material 13a having a sheet of release paper 16 fitted to the rear
surface thereof is put on the lower mold 42 (FIG. 8).
[0109] Then, the first table 31 arranged below the upper mold 21 is
moved away, and the second table 41 is moved to below the upper
mold 21. It is convenient that the first table 31 and the second
table 41 are slidable, and can be moved to and away from below the
upper mold 21.
[0110] In the illustrated example, firstly the upper mold 21 is
pulled up with the three-dimensionally formed body 14b (FIG. 5),
and the first table is moved away. Subsequently, the second table
41 and the lower mold 42 is moved to below the upper mold 21 (FIG.
8). Note that the three-dimensionally formed body 14b is
temporarily held to the upper mold 21 by the temporary holding
means 25.
[0111] As shown in FIG. 9, the upper mold 21 is lowered to press
the three-dimensionally formed body 14b and the lower layer
material 13a. In this case, high frequency wave is not emitted.
[0112] Since pins (not shown) are driven into the respective
aligning holes 24 of the upper mold 21 and the aligning holes 45 of
the lower mold 42 at this time, the upper mold 21 and the lower
mold 42 are aligned. After the upper mold 21 and the lower mold 42
are anchored, the pins are pulled away.
[0113] As a result of the pressing, the three-dimensionally formed
body 14b and the lower layer material 13a are tackily bonded to
each other and integrally combined due to the tacky adhesive force
of the lower layer material 13a.
[0114] Due to the pressing, the lower layer material 13a is cut by
the first machining means 22 of the upper mold 21. In the
illustrated example, no cushion members 51 are found at the
positions where the edges of the blades of the first machining
means 22 contact the lower layer material 13a, so that the lower
layer material 13a can be cut with ease. On the other hand, the
applied pressure is absorbed by the cushion members 51 in the
regions where the cushion members 51 are placed. Therefore, the
tacky adhesive force of the lower layer material 13a is not
degraded in the regions where the cushion members 51 are placed.
While the tacky adhesive force of the lower layer material 13a is
degraded as pressure is applied thereto, such degradation can be
prevented according to the present invention.
[0115] Thus, preferably cushion members 51 are arranged in the
regions located outside the areas where the lower layer material
13a is cut. The cushion members 51 absorb the pressure applied by
the upper mold 21, to prevent the tacky adhesive force of the lower
layer 13 from being degraded further.
[0116] The releasing paper 16 is not cut by the first machining
means 22, but stretched to a slight extent.
[0117] Thereafter, the upper mold 21 is pulled up (FIG. 11)
[0118] The three-dimensionally formed body 14b and the lower layer
material 13a that are now integrally combined is moved away from
the upper mold 21, and unnecessary parts thereof are removed.
[0119] Subsequently, the application film 15 is attached to the top
surface of the upper layer 11.
* * * * *