U.S. patent application number 15/029129 was filed with the patent office on 2016-09-01 for vacuum forming machine.
The applicant listed for this patent is HITACHI CHEMICAL COMPANY, LTD.. Invention is credited to Kazunori HAYASHI, Takahiro MAENO, Shingo MATSUBARA, Shingo NAKANO, Ryuuta SOUTOME.
Application Number | 20160250799 15/029129 |
Document ID | / |
Family ID | 52992858 |
Filed Date | 2016-09-01 |
United States Patent
Application |
20160250799 |
Kind Code |
A1 |
NAKANO; Shingo ; et
al. |
September 1, 2016 |
VACUUM FORMING MACHINE
Abstract
A vacuum forming method of forming a decorative film in close
contact with a surface of an adherend in a forming space, by using
a vacuum forming machine having the forming space seal-formed by a
lower box and an upper box, includes: a pressure adjusting process
of decompressing a lower division of the forming space sealed to
have a lower pressure than an upper division of the forming space
so as to produce a pressure difference between the divided forming
spaces, thereby setting the pressure in the vicinity of the surface
of the adherend lower pressure than that of the periphery thereof;
a pressure releasing process of releasing the pressure difference
after the forming process; and an extracting process of extracting
a formed product. A lower end portion of the upper box is provided
with a jig which suppresses lifting of the decorative film.
Inventors: |
NAKANO; Shingo; (Tagawa-shi,
Fukuoka, JP) ; HAYASHI; Kazunori; (Tagawa-shi,
Fukuoka, JP) ; MATSUBARA; Shingo; (Chiyoda-ku, Tokyo,
JP) ; MAENO; Takahiro; (Chiyoda-ku, Tokyo, JP)
; SOUTOME; Ryuuta; (Chiyoda-ku, Tokyo, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HITACHI CHEMICAL COMPANY, LTD. |
Chiyoda-ku, Tokyo |
|
JP |
|
|
Family ID: |
52992858 |
Appl. No.: |
15/029129 |
Filed: |
October 20, 2014 |
PCT Filed: |
October 20, 2014 |
PCT NO: |
PCT/JP2014/077868 |
371 Date: |
April 13, 2016 |
Current U.S.
Class: |
156/285 |
Current CPC
Class: |
B29C 51/16 20130101;
B29C 51/10 20130101; B29C 51/44 20130101; B29L 2009/00 20130101;
B29C 51/421 20130101 |
International
Class: |
B29C 51/10 20060101
B29C051/10 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 22, 2013 |
JP |
2013-219122 |
Oct 22, 2013 |
JP |
2013-219123 |
Claims
1. A vacuum forming machine which forms a decorative film in close
contact with a surface of an adherend in a forming space
seal-formed by a lower box opening upward and an upper box opening
downward, wherein the lower box is provided with an accommodation
portion in which the adherend is placed and accommodated, and a
lower end portion of the upper box is provided with a jig which
suppresses lifting of the decorative film.
2. The vacuum forming machine according to claim 1, wherein, in the
lower end portion of the upper box, the jig is provided so as to be
positioned beyond the periphery of the adherend so as to be defined
individually.
3. The vacuum forming machine according to claim 1, wherein the jig
has a wire shape or a thin plate shape.
4. The vacuum forming machine according to claim 3, Wherein the jig
having the wire shape has a diameter of 3 mm to 5 mm and a wire
tension of 50 N to 200 N.
Description
TECHNICAL FIELD
[0001] The present invention relates to a vacuum forming
machine.
BACKGROUND ART
[0002] In a decorating process of an instrument panel, a console
box, and the like in the related art, a water transfer printing
method using a decorative film, a film insert molding method, or
the like is performed. In addition, a vacuum pressure forming
method in which there is a little effect of the outside air to be
imparted is also performed (for example, refer to Patent
Literatures 1 and 2). In the vacuum pressure forming method, a
workpiece to be formed can be heated and formed in a closed off
space by using a vacuum forming machine provided with upper and
lower chamber boxes.
CITATION LIST
Patent Literature
[0003] Patent Literature 1: Japanese Unexamined Patent Publication
No. 2002-079573
[0004] Patent Literature 2: Japanese Unexamined Patent Publication
No. 2012-116094
SUMMARY OF INVENTION
Technical Problem
[0005] Regarding the water transfer printing method and the film
insert molding method, there are problems in formability, adhesion,
scratch resistance, productivity and the like. In addition, even in
the vacuum pressure forming method in the related art in which
formability and the like are improved, as illustrated in FIGS.
10(a) and 10(b), lifting of a decorative film occurs, and there is
a problem in that product defects caused therefrom are easily
generated. In the vacuum pressure forming method in the related
art, in the case of deep drawing, there is a slight problem in
shape followability, and there is also a problem in external
appearance in which parting lines may be seen.
[0006] In order to solve the problems, an object of the present
invention is to provide a vacuum forming machine which provides
good formability, adhesion, productivity, and the like without
lifting of a decorative film.
Solution to Problem
[0007] A vacuum forming machine according to an aspect of the
present invention forms a decorative film in close contact with a
surface of an adherend in a forming space seal-formed by a lower
box opening upward and an upper box opening downward. The lower box
is provided with an accommodation portion in which the adherend is
placed and accommodated. A lower end portion of the upper box is
provided with a jig which suppresses lifting of the decorative
film.
[0008] In addition, in the lower end portion of the upper box, the
jig may be provided so as to be positioned beyond the periphery of
the adherend so as to be defined individually.
[0009] In addition, the jig may have a wire shape or a thin plate
shape.
[0010] In addition, the jig having the wire shape may have a
diameter of 3 mm to 5 mm and a wire tension of 50 N to 200 N.
Advantageous Effects of Invention
[0011] In the aspect of the present invention, it is possible to
provide a vacuum forming machine which provides good formability,
adhesion, productivity, and the like without lilting of a
decorative film.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is an explanatory view of a placing process of a
vacuum forming method using a vacuum forming machine of an
embodiment.
[0013] FIG. 2 is an explanatory view of a decorative film placing
process of the vacuum forming method using the vacuum forming
machine of the embodiment.
[0014] FIG. 3 is an explanatory view of a heating process and a
sealing process of the vacuum forming method using the vacuum
forming machine of the embodiment.
[0015] FIG. 4 is an explanatory view of a forming process of the
vacuum forming method using the vacuum forming machine of the
embodiment.
[0016] FIG. 5 is an explanatory view of a pressure adjusting
process of the vacuum forming method using the vacuum forming
machine of the embodiment.
[0017] FIG. 6 is an explanatory view of an extracting process of
the vacuum forming method using the vacuum forming machine of the
embodiment.
[0018] FIG. 7 is a perspective view illustrating a lower end
portion of an upper box of the vacuum forming machine of the
embodiment.
[0019] FIG. 8 is a perspective view illustrating a lower end
portion of the upper box of the vacuum forming machine of the
embodiment.
[0020] FIG. 9(a) is an explanatory view of the forming process of
the vacuum forming method using the vacuum forming machine of the
embodiment, and FIG. 9(b) is an explanatory view of the pressure
adjusting process.
[0021] FIG. 10(a) is an explanatory view of a forming process of a
vacuum forming method using a vacuum forming machine in the related
art, and FIG. 10(b) is an explanatory view of a pressure adjusting
process.
DESCRIPTION OF EMBODIMENTS
[0022] A vacuum forming machine according to an aspect of the
present invention forms a decorative film in close contact with a
surface of an adherend in a forming space seal-formed by a lower
box opening upward and an upper box opening downward, in which the
lower box is provided with an accommodation portion in which the
adherend is placed and accommodated, and a lower end portion of the
upper box is provided with a jig which suppresses lifting of the
decorative film.
[0023] Hereinafter, an embodiment of the vacuum forming machine
according to the aspect of the present invention will be described
in detail with reference to the drawings.
[0024] In a vacuum forming method, basically, the decorative film
is formed in close contact with the surface of the adherend by
using a vacuum forming machine M of this embodiment in which a
sealed forming space or an open state is formed by the lower box
and the upper box which approach each other or become distant from
each other.
[0025] The adherend is a resin molding. For example, the adherend
is used as an instrument panel, a console box, or the like for a
vehicle. The decorative film is a transparent or translucent resin
film decorated by printing, coating, vacuum deposition, coloring,
or the like. The material of the decorative film is not
particularly limited. Specifically, as the material of the
decorative film, an acrylic resin, a polyester-based resin, a
polyolefin-based resin, a polycarbonate based resin, a fluororesin,
and the like may be employed.
[0026] In order to enhance adhesion to the decorative film, it is
preferable that an adhesion acceleration treatment such as a primer
treatment or a flame treatment is performed on the surface of the
adherend. As the adhesion acceleration treatment, a flame treatment
such as a flame treatment, a corona treatment, or an, ITRO
treatment is preferable, and a frame treatment is particularly
preferable.
[0027] As illustrated in FIG. 1, in the vacuum forming machine M of
this embodiment, a lower box 1 is provided with an accommodation
portion 3 in which an adherend 4 is placed and accommodated, and
the lower and portion of an upper box 6 is provided with a jig 8
which suppresses lifting of a decorative film 5 (see FIG. 2).
[0028] FIGS. 7 and 8 are perspective views illustrating the lower
end portion of the upper box of the vacuum forming machine of this
embodiment. As illustrated in FIG. 7, a lower end portion 9a of the
upper box 6 is provided with a wire-shaped jig 8a which suppresses
lifting of the decorative film 5. Otherwise, as illustrated in FIG.
8, a lower end portion 9b of the upper box 6 is provided with a
thin plate-shaped jig 8b which suppresses lifting of the decorative
film 5.
[0029] As illustrated in FIGS. 7 and 8, in the lower end portions
9a and 9b of the upper box 6, each of the jigs 8a and 8b which
suppress lifting of the decorative film 5 is provided so as to be
positioned beyond the periphery of the adherend 4 so as to be
defined individually. "So as to be defined individually" means that
the jig 8 which suppresses lifting of the decorative film 5 is
provided between at least two adjacent adherends 4 in a case where
a plurality of adherends 4 are placed and accommodated in the
accommodation portion 3 on a movable table 2 provided in, the lower
box 1.
[0030] It is preferable that the jig 8 is provided so as to be
positioned in the vicinity of the adherend 4 and beyond the
periphery of the adherend 4. In a case where the adherend 4 is a
quadrilateral, the jig 8 may be in the vicinity of the outside of
the periphery of at least one side, preferably two or more sides of
the quadrilateral.
[0031] The material, shape, and the like of the jig 8 which
suppresses lifting of the decorative film 5 are not particularly
limited as long as the jig 8 has a function of suppressing lifting
of the decorative film 5. It is preferable that the jig 8 has a
wire shape or a thin plate shape. In the case of the jig 8a having
the wire shape, the diameter thereof is 3 mm to 5 mm, and the
material thereof is stainless steel. In the case of the jig 8b
having the thin plate shape, the thickness thereof is 3 mm to 5 mm,
the width thereof is 20 mm to 50 mm, and the material thereof is
aluminum or stainless steel.
[0032] Regarding the jig 8a having the wire shape, the wire tension
thereof is 50 N to 200 N in order to suppress a reaction force of
the decorative film 5. When the wire tension is less than 50 N,
there is concern that lifting of the decorative film 5 may occur.
In a case where the wire tension is higher than 200 N, the
decorative film 5 enters an unnecessarily excessively stretched
state, and there is concern that winkles may be generated in the
decorative film. Regarding the jig 8a having the wire shape, since
the diameter thereof is in a range of 3 mm to 5 mm, the reaction
force of the decorative film 5 is suppressed, and lifting of the
decorative film 5 does not occur.
[0033] As illustrated in FIG. 1, in the vacuum forming machine M of
this embodiment, a heater 7 is assembled in the upper box 6. The
heater 7 heats the decorative film 5 in a forming space formed by
joining the upper box 6 and the lower box 1.
[0034] The upper box 6 and the lower box 1 can be joined to each
other and be separated from each other. That is, the upper box 6 is
provided with a driving device 10 such that the upper box 6 can be
lifted and lowered. The table 2 is disposed in the lower box 1, and
the table 2 can be lifted and lowered by a driving device 11. As
each of the driving devices 10 and 11, for example, an air
cylinder, a hydraulic cylinder, a servomotor, and the like can be
used. In addition, a vacuum circuit is laid out in the lower box 1.
A vacuum circuit and a compressed air circuit are laid out in the
upper box 6.
[0035] A vacuum forming method using the vacuum forming machine M
of this embodiment includes a placing process, a sealing process, a
heating process, a forming process, a pressure adjusting process, a
pressure releasing process, and an extracting process. Hereinafter,
each of the processes of the vacuum forming method using the vacuum
forming machine M of this embodiment will be described.
[0036] As illustrated in FIG. 1, in the placing process, the
adherend 4 is placed and accommodated in the accommodation portion
3 on the movable table 2 provided in the lower box 1. The
accommodation portion 3 which accommodates the adherend 4
beforehand may be moved onto the table 2 and placed thereon.
Otherwise, the accommodation portion 3 may be placed on the table 2
and the adherend 4 may be accommodated therein.
[0037] As illustrated in FIG. 2, in the sealing process, the
movable table 2 on which the adherend 4 is placed and accommodated
in the accommodation portion 3 is lowered, and thereafter the
decorative film 5 is placed on the upper portion of the lower box 1
so as to vertically divide the forming space by the decorative film
5 as a boundary. Accordingly, the forming space is vertically
divided by the decorative film 5 as the boundary, and the table 2
and the adherend 4 are sealed in the lower division of the forming
space.
[0038] Thereafter, as illustrated in FIG. 3, in the heating
process, the decorative film 5 is heated. Here, by lowering the
upper box 6 so as to be in close contact with the lower box 1, the
table 2 and the adherend 4 are sealed in the lower division of the
forming space. Subsequently, the heater 7 is started up to heat the
decorative film 5. Furthermore, both of the lower box 1 and the
upper box 6 are decompressed to a vacuum state using a vacuum pump
(not illustrated) or the like. A sealed state is a state in which
the decorative film 5 is placed on the upper portion of the lower
box 1, and the lower box 1 and the upper box 6 are in close contact
with each other.
[0039] As illustrated in FIG. 4, in the forming process, the table
2 on which the adherend 4 is placed in the placing process is
allowed to approach the lower side of the decorative film 5 heated
in the heating process and the decorative film 5 is formed in close
contact with the surface of the adherend. 4. When the temperature
of the heated decorative film 5 reaches 100.degree. C. to
150.degree. C., the table 2 on which the adherend 4 is placed is
lifted, and the decorative film 5 comes into contact with (covers)
a portion of the surface of the adherend 4. At this time, lifting
of the decorative film 5 on the outside of the periphery of the
adherend 4 is suppressed by the jig 8 provided in the lower end
portion of the upper box 6.
[0040] As illustrated in FIG. 5, in the pressure adjusting process,
the pressure in the lower division of the forming space sealed by
the sealing process is reduced compared to that of the upper
division of the forming space to produce a pressure difference
between the divided forming spaces. Accordingly, the pressure in
the vicinity of the surface of the adherend 4 set on the table 2 is
lower than that of the periphery thereof. Specifically, as
illustrated in FIG. 5, with the table 2 and the decorative film 5
acting as the boundary, the lower division of the forming space is
maintained in a decompressed state, and the upper division of the
forming space is pressurized or is open to the atmosphere to
neutralize the decompressed state. At this time, the upper division
of the forming space may be in any of a pressurized state or a
state at atmospheric pressure. Heating of the decorative film 5 is
stopped.
[0041] When a pressure difference is produced in the forming space,
by stopping the heating of the decorative film 5, the excessively
stretched state of the decorative film 5 due to the heating is
relieved. Accordingly, the decorative film 5 appropriately follows
the shape of the adherend 4, and loosening of the decorative film 5
which is a cause of lifting of the decorative film 5 does not
occur.
[0042] When the lower division (the lower box 1) of the forming
space is decompressed to have a lower pressure than the upper
division (the upper box 6) of the forming space and a pressure
difference between the divided forming spaces can be produced, the
lower division (the lower box 1) of the forming space is maintained
in the decompressed state (vacuum state), and the upper division
(the upper box) of the forming space is not open to the atmosphere
but the decompressed state (vacuum state) is relieved to enter a
state at a pressure lower than the atmospheric pressure.
[0043] As illustrated in FIGS. 5 and 9(b), the decorative film 5 is
pressed against the adherend 4 to be overlaid (to be formed) by
releasing the vacuum in the upper division of the forming space
(the upper box 6). By supplying compressed air into the upper
division of the forming space (the upper box 6) from a compressed
air tank (not illustrated) (pressurized state), the decorative film
5 can be allowed to come into close contact with the adherend 4
with a greater force.
[0044] The pressure in the vicinity of the surface of the adherend
4 set on the table 2 is lower than that of the periphery thereof,
and furthermore, as illustrated in FIGS. 4 and 9(a), when the table
2 is lifted, lifting of the decorative film 5 on the outside of the
periphery of the adherend 4 is suppressed by the jig 8b provided in
the lower end portion of the upper box 6. Therefore, the decorative
film 5 follows the surface of the adherend 4 and reliably comes
into close contact therewith. Particularly, since lifting of the
decorative film 5 is suppressed, even in the case of deep drawing,
there is no problem in shape followability. In addition, since the
edges of the decorative film 5 are reliably wound and parting lines
are not seen, external appearance is also enhanced.
[0045] In the vacuum forming method using the vacuum forming
machine M of this embodiment, the pressure adjusting process may be
performed after the forming process or may be performed
simultaneously with the forming process. By simultaneously
performing the pressure adjusting process and the forming process,
the decorative film 5 is uniformly adhered to the surface of the
adherend 4 at a time, which is effective in solving problems
(winkles or the like) in external appearance and is thus
preferable.
[0046] As illustrated in FIG. 6, in the pressure releasing process,
the pressure difference produced in the pressure adjusting process
is released. In the extracting process, a formed product is
extracted while releasing the pressure. The lower division of the
forming space and the upper division of the forming space are open
to the atmosphere, thereby releasing the pressure difference.
Thereafter, the upper box 6 is lifted, and the adherend 4 having
the decorative film 5 (the formed product) is extracted.
REFERENCE SIGNS LIST
[0047] 1: lower box [0048] 2: table [0049] 3: accommodation portion
[0050] 4: adherend [0051] 5: decorative film [0052] 6: upper box
[0053] 7: heater [0054] 8, 8a, 8b: jig [0055] 9a, 9b: lower end
portion of upper box [0056] 10, 11: driving device [0057] M: vacuum
forming machine
* * * * *