CN102917861B - 热塑性合成树脂制立体装饰片的制造方法和制造装置 - Google Patents

热塑性合成树脂制立体装饰片的制造方法和制造装置 Download PDF

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CN102917861B
CN102917861B CN201080067176.9A CN201080067176A CN102917861B CN 102917861 B CN102917861 B CN 102917861B CN 201080067176 A CN201080067176 A CN 201080067176A CN 102917861 B CN102917861 B CN 102917861B
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workbench
patrix
layer material
primer
machining cell
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CN102917861A (zh
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桑原英二
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Kyoda Takashi
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Kuroda Nobuo
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/04—Dielectric heating, e.g. high-frequency welding, i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/12—Dielectric heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/40—Moulds for making articles of definite length, i.e. discrete articles with means for cutting the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/52—Heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/16—Surface shaping of articles, e.g. embossing; Apparatus therefor by wave energy or particle radiation, e.g. infrared heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3604—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint
    • B29C65/366—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint being a coating or being printed, e.g. being applied as a paint or forming a printed circuit
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3672—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint
    • B29C65/3676—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint being metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7441—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc for making welds and cuts of other than simple rectilinear form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/306—Applying a mark during joining
    • B29C66/3062—Applying a mark during joining in the form of letters or numbers
    • B29C66/30621—Applying a mark during joining in the form of letters or numbers in the form of letters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
    • B29C66/4724—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat said single elements being appliques, e.g. in the form of a text or drawing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81457—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a block or layer of deformable material, e.g. sponge, foam, rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
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    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81415—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being bevelled
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1039—Surface deformation only of sandwich or lamina [e.g., embossed panels]

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  • Oral & Maxillofacial Surgery (AREA)
  • Thermal Sciences (AREA)
  • Toxicology (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明的目的是提供不损害底层材料的粘接强度或粘合强度的立体装饰片的制造方法及装置。热塑性合成树脂制立体装饰片的制造方法为，在作为阴极的第一工作台(31)上载置上层材料(11a、12a)，使作为阳极的上模(21)下降至第一工作台(31)上，在按压上层材料(11a)的同时发射高频进行介质加热，将上层材料(11a)成形，熔断以制成立体赋形体(14b)，并且将立体赋形体(14b)临时固定于上模上，停止高频介质加热，将载置有具有粘合性的底层材料(13a)第二工作台(41)向临时固定有立体赋形体(14b)的上模(21)的下方移动，使所述上模(21)下降到第二工作台(41)上，在按压立体赋形体(14b)和切断底层材料(13a)的同时，使立体赋形体(14b)和底层材料(13a)粘合。此外，本发明的装置为，在所述第二工作台(41)或下模(42)的上表面，且在距离与第一加工单元(22)的刀尖抵接的位置0.2～1mm、邻接的第一加工单元(22)的宽度方向中央侧的区域设有凹部(43)，在该凹部(43)配置有缓冲材料(51)。

Description

热塑性合成树脂制立体装饰片的制造方法和制造装置
技术领域
本发明涉及用粘合剂和粘接剂安装在主要是汽车、双轮车、汽艇、OA设备、家庭用电器、运动用品、机械等上的热塑性合成树脂制立体装饰片的制造方法及制造装置。
背景技术
作为由作为标记等所使用的合成树脂构成的、立体的装饰片的制造方法，提出了使用模具及高频介质加热的各种方法(下述专利文献1、专利文献2、专利文献3)。
但是，专利文献1公开的发明中，由于使用凹模和凸模两者，在凹模和凸模之间制造立体图案片，所以该立体图案片的背面变得不平坦，在背面形成凹部。由此，粘接或粘合在汽车等的被安装物上的面积变小，从而无法得到足够的粘接(粘合)强度。
此外，专利文献2公开的发明中，在利用雕刻模具进行按压和加热时，同时形成赋予聚氨酯膜的上表面的凹凸图案的情况下，由于对装饰片整体加热和加压，所以会损害装饰片背面的粘合剂层的粘附力。
此外，专利文献3公开的发明中，背面的粘合剂层面平坦，但由于高频介质加热的热量和压力而损害原来的粘合力，判明对被安装物的粘接(粘合)强度减半。
各种实验证明粘合材料或粘合剂因加热而劣化，再施加压力的话，粘合强度进一步被损害。
现有技术文献 
专利文献1:日本专利特公平07-102620号公报
专利文献2:日本专利第3235943号公报
专利文献3:日本专利第4227587号公报
发明内容
发明所要解决的技术问题
本发明的目的是提供不损害底层材料的粘接强度或粘合强度的立体装饰片的制造方法及装置。
解决技术问题所采用的技术方案
根据本发明的第一个方面，提供一种热塑性合成树脂制立体装饰片的制造方法，该方法包括在作为阴极的第一工作台上载置上层材料，使作为阳极的上模下降至第一工作台上，在按压上层材料的同时发射高频进行介质加热，将上层材料成形、熔断以制成立体赋形体，并且将立体赋形体临时固定于上模上，停止高频介质加热，将载置有具有粘合性的底层材料的第二工作台向临时固定有立体赋形体的上模的下方移动，使上述上模下降到第二工作台上，在按压立体赋形体和切断底层材料的同时，使立体赋形体和底层材料进行粘合(权利要求1)。
较好是，在上述第一工作台上载置中间层材料，在该中间层材料上载置上述上层材料，使上述上模下降到第一工作台上，在按压上述上层材料及中间层材料的同时发射高频进行介质加热，使上层材料和中间层材料熔接，从而制成立体赋形体(权利要求2)。
此外，较好是，在上述第二工作台上载置背面配置有脱模纸的底层材料(权利要求3)。
此外，较好是，将底层材料切断后，除去不需要部分，将应用贴膜粘贴在上层的上表面(权利要求4)。
更好是，通过在上述底层材料的、切断部位以外的部分的下方配置缓冲材料，使缓冲材料吸收上模的按压力(权利要求5)。
根据本发明的第二个方面，提供一种热塑性合成树脂制立体装饰片的制造装置，其由作为阳极的上模、作为阴极的第一工作台、和第二工作台构成，上述上模具有第一加工单元，该第一加工单元在上模和第一工作台之间进行高频介质加热时，将材料熔断，上述第一加工单元在上模和第二工作台之间进行按压时，将材料切断，在上述上模的下表面设置有临时固定单元，上述第二工作台的上表面平坦，在上述第二工作台的上表面，且在距离与第一加工单元的刀 尖抵接的位置0.2～1mm的、邻接的第一加工单元的宽度方向中央侧的区域设有凹部，在该凹部配置有缓冲材料(权利要求6)。
此外，提供一种热塑性合成树脂制立体装饰片的制造装置，其由作为阳极的上模、作为阴极的第一工作台、第二工作台和配置在第二工作台上的下模构成，上述上模具有第一加工单元，该第一加工单元在上模和第一工作台之间进行高频介质加热时将材料熔断，上述第一加工单元在上模和第二工作台之间进行按压时将材料切断，在上述上模的下表面设置有临时固定单元，上述下模的上表面平坦，在上述下模的上表面且在距离与第一加工单元(22)的刀尖抵接的位置0.2～1mm、邻接的第一加工单元的宽度方向中央侧的区域设有凹部，在该凹部配置有缓冲材料(权利要求7)。
发明效果
根据权利要求1～3、5～7中记载的发明，具有粘合性的底层材料没有进行高频介质加热而未被加热，因此，能够防止底层材料的粘合性的劣化。
根据权利要求5中记载的发明，由于在底层材料的下方配置有缓冲材料，因此能够防止因按压底层材料而引起的粘合性的劣化，除上述效果外，还可以进一步有效地防止上述粘合性的劣化。
此外，由于在底层材料的切断部位的下方没有配置缓冲材料，因此容易完成底层材料的切断。
根据权利要求6中记载的发明，由于在第二工作台的上表面的所述位置配置有缓冲材料，因此能够防止因按压底层材料引起的粘合性的劣化。此外，由于在底层材料的切断部位的下方没有配置缓冲材料，因此容易完成底层材料的切断。
根据权利要求7中记载的发明，除上述效果外，还具有即使在改变立体装饰片的图案的情况下，也只需仅另外制作下模即可的效果。
附图的简单说明
图1是上模21的示意仰视图。
图2是示意地示出第一工序的高频介质加热前的状态的图1中M-M线剖视图。
图3是示意地示出第一工序的高频介质加热中的状态的图1中M-M线剖视图。
图4是图3中将N部分放大后的剖视图。
图5是示意地示出第一工序的高频介质加热后的状态的图1中M-M线剖视图。
图6是下模42的示意俯视图。
图7是下模42的图6中P-P线剖视图。
图8是示意地示出第二工序的按压前的状态的图，显示了下模42的图6中P-P线剖面，和上模、立体赋形体、底层材料的同样的剖面。
图9是示意地示出第二工序的按压中的状态的图，显示了下模42的图6中P-P线剖面，和上模、立体赋形体、底层材料的同样的剖面。
图10是除去立体赋形体和底层材料的将图9中的X部分放大后的剖视图。
图11是示意地示出第二工序的按压后的状态的图，显示了下模42的图6中P-P线剖面，和上模、立体赋形体、底层材料的同样的剖面。
图12是利用本发明的方法所制得的立体图案片的俯视图。
图13是图12中的Y-Y线剖视图。
具体实施方式
<立体装饰片>
首先，对利用本发明的方法及装置制造的立体装饰片进行说明。
图12是利用本发明的方法及装置制造的立体装饰片的正视图，图13是图12中Y-Y线剖视图。
如图13所示，立体装饰片由成形为立体形状的上层11、配置在上述上层11的下方且具有粘合功能的底层13、配置在上层11的上表面的应用贴膜15和配置在底层13的下表面的脱模纸16构成。
如后述那样，由于底层13具有粘合性，因此配置脱模纸16。
作为应用贴膜15，可例举例如在背面(下表面)配置有粘合材料的透明树脂膜或纸。通过粘贴这种应用贴膜等，可保护立体装饰片，并且在如图示实施例那样的构成要素(图示实施例的情况下，为N、E、O、-、X各文字)隔离的图案的情况下，能够保持这些构成元素的相对位置。
利用本发明的方法及装置所制得的立体装饰片能够安装在各种物品上，例如能够用于汽车、摩托车、汽艇、自行车、OA设备、家庭用电器、运动用品、机械等的内外装饰。
<上层>
立体图案片的上层11被赋形为立体形状。此外，也可以是通过印刷等让装饰片的表面变得看起来美观。上层11由表面层材料11a和中间层材料12a制成，如后述那样，在立体图案片的制造中，表面层材料11a和中间层材料12a熔接成为一体。此外，在后述的图示实施例中，上层材料由表面层材料11a和中间层材料12a构成。但是，如果仅由表面层材料11a充满上模21的腔内(仅由表面层材料11a获得立体装饰片的厚度)时，则无需中间层材料12a。
<表面层材料>
表面层材料11a是用于使立体装饰片的表面看起来美观的材料，可使用热塑性合成树脂膜，也可使用作为合成树脂制装饰片的材料的公知的材料。例如，可以使用聚氯乙烯膜、聚氨酯膜、聚酯膜、聚烯烃膜等。热塑性合成树脂膜也可以是层叠膜。
此外，也可以利用公知技术在热塑性合成树脂膜上蒸镀金属，来制成金属制的立体装饰片那样的装饰片，例如，可以使用金属蒸镀过的聚氯乙烯膜、金属蒸镀过的聚氨酯膜、金属蒸镀过的聚酯膜、金属蒸镀过的聚烯烃膜等。作为金属，可使用公知的金属，可例举例如铝、铬、银、锡等。
可根据所要制造的立体装饰片来适当选择上述的表面层材料11a。此外，可以利用公知技术在其表面进行印刷。
<中间层材料>
中间层材料12a是即赋予立体装饰片以厚度，又可防止在装饰片内形成空洞，使立体装饰片不凹陷的层，可使用热塑性合成树脂，可例举例如聚氯乙烯片、聚氨酯片、聚烯烃片等。
<底层及底层材料>
底层13是用于将上层11安装在汽车等被安装物上的层，它具有粘接功能或粘合功能，由底层材料13a制成。
底层材料13a由具有粘接功能或粘合功能的材料构成，可以使用作为用于安装合成树脂制装饰片的材料的公知的材料。可例举例如具有基材的双面胶粘带、不具有基材的双面胶粘带，但本发明不局限于此。这种底层材料13a可根据制造的装饰片及被安装物来适当选择。
<制造装置>
根据本发明， 
(1)利用第一工作台31和上模21对上述材料进行高频介质加热，以形成立体赋形体14b(第一工序)；
(2)利用第二工作台41和上模21对该立体赋形体14b进行按压，切断底层材料13a，以制成立体装饰片1。
以下，对本发明中所使用的制造装置进行说明。
本发明的制造装置由第一工序及第二工序中所使用的上模21、第一工序中所使用的第一工作台31和第二工序中所使用的第二工作台41构成。
第一工序中，上模21起到阳极的作用，第一工作台31起到阴极的作用。另一方面，在第二工序中，上模21不发挥作为阳极的功能。
虽然没有图示，第一工作台31和第二工作台41能够移动，交替地位于上模21的下方的位置(工作台滑动式)。此外，能够利用转台将第一工作台31和第二工作台41移动，也能够使用公知的技术。
上模21形成有腔以形成立体装饰片的表面。腔的剖面形状不局限于图示实施例，当然也可以是山形、穹顶形、梯形或者其他的任意形状。
上模21设置有第一加工单元22及第二加工单元23。
第一加工单元22在进行高频介质加热的第一工序中起到熔断刀的作用，将表面层材料11a及中间层材料12a熔断，在不进行高频介质加热而进行按压的第二工序中起到切断刀的作用，对底层进行切断。
第二加工单元23在第一工序中起到按压刀的作用。第二加工单元23根据需要设置，不是必需的。
此外，图4中，虽然示出了第一加工单元22等的尺寸，但本发明不局限于该尺寸。
如图1所示，在上模21的下表面设置有临时固定单元25。临时固定单元 25将上述第一工序中制造的立体赋形体14b临时固定于上模21上。作为临时固定单元25，可例举例如粘合带。
上模21设置有位置对准用销孔24。将销钉(未图示)***位置对准用销孔24和后述的第二工作台41的位置对准用销孔45内，从而完成上模21和第二工作台41的位置对准。 
第一工作台31在第一工序中作为阴极使用，但在第二工序中未作为阴极使用。第一工作台31的上表面为平坦面。
上模21和第一工作台31都是高频介质加热装置，可以使用公知的装置。
在第一工序中没有使用第二工作台41，而在第二工序中使用了第二工作台41。第二工作台41的上表面平坦。第二工作台41的上表面设有凹部。
作为替代，如图示实施例所示，也可以在第二工作台41上载置上表面平坦、在上表面设有凹部43的下模42。在改变立体装饰片的图案的情况下，只要制作另外的下模即可。
在各凹部43内配置有缓冲材料51以使下模42的上表面平坦。作为缓冲材料，可例举例如橡胶等的能够吸收按压力的物质。通过这样配置缓冲材料51，在利用上模21按压配置在下模42上的底层材料13a的情况下，在与缓冲材料51接触的部分，按压力被缓冲材料吸收。因此，在与缓冲材料51接触的部分，底层材料13a的粘合力不会劣化。
但是，如果在与第一加工单元22的刀尖抵接的位置配置有缓冲材料的话，由于按压力被缓冲材料吸收，不能用第一加工单元22对底层材料13a进行切断。因此，缓冲材料51的位置和凹部43的位置重要。
凹部43是邻接的第一加工单元22的宽度方向(图10中的U方向)中央侧的区域，且位于距离与第一加工单元22的刀尖抵接的位置441和442为0.2mm～1mm的中央侧的位置443和444。即，点441和点443的距离为0.2mm～1mm。如果在距离该抵接位置441和442不到0.2mm的位置存在凹部43(缓冲材料51)，则上模21和下模42(第二工作台41)的相对位置稍微错位时，第一加工单元22的刀尖就位于缓冲材料51的位置上，导致不能切断底层材料13a。如果在距离该抵接位置441和442超过1mm的位置存在凹部43(缓冲材料51)，则对底层材料13a施加压力的面积增大，导致其粘合性能劣化。
此外，优选凹部43的深度为1～5mm。图10中，将凹部43的深度设为2mm，但本发明并不局限于2mm。如果凹部43的深度(即，缓冲材料51的厚度)小于1mm，则不能充分吸收按压力。如果超过5mm，则缓冲材料51因按压力而塌陷，在与底层材料13a之间产生间隙。因此，有时会导致底层材料13a的下表面变得不平坦。
换言之，通过在底层材料13a的、切断部位以外的部分的下方配置缓冲材料51，可以将上模21的按压力吸收，防止底层材料13a的粘合性能的劣化。
下模42(或者第二工作台41)设有位置对准用销孔45。将销钉(未图示)***第二工作台41的位置对准用销孔45和位置对准用销孔24内，从而完成上模21和下模42(第二工作台41)的位置对准。 
<制造方法>
根据本发明，使用如上所述的装置，进行如下操作来制造立体装饰片。
图示实施例中，如图2所示，在第一工作台31上载置中间层材料12a，在中间层材料12a上载置表面层材料11a。该阶段中，不载置底层材料13a。
图示实施例中，采用了在中间层材料12a上载置表面层材料11a的方式，但也可以将预先将中间层材料12a和表面层材料11a层叠一体化所形成的物质载置在第一工作台31上。此外，如果表面层材料11a具有充满上模21的腔内的厚度，则也可以没有中间层材料12a。
接着，如图3所示，使上模21下降，按压表面层材料11a及中间层材料12a，将上模21作为阳极，将第一工作台31作为阴极，发射高频。将表面层材料11a和中间层材料12a加热、熔融。表面层材料11a及中间层材料12a经加热而熔融，流入上模21的腔中而被赋形。接着，表面层材料11a和中间层材料12a熔接，形成立体赋形体14b。
立体赋形体14b(表面侧材料11a及中间层材料12a)被第一加工单元22熔断。
所形成的立体赋形体14b被上模21赋形。此外，如上所述，第一工作台31的上表面平坦，因此立体赋形体14b的下表面变得平坦。因此，利用本发明的方法制造的立体装饰片的粘接或粘合面积增大，可获得足够的粘接强度或粘合强度。
此外，立体赋形体14b被临时固定单元25临时固定于上模21上。临时固定单元25为粘合带的情况下，通过上模21的按压力和临时固定单元25的粘合力将立体赋形体14b临时固定于上模21上。
一旦立体赋形体14b形成，被临时固定于上模21上，就停止高频介质加热。
在第二工作台41上载置底层材料13a。图示实施例中，在第二工作台41上载置下模42。图示实施例中，在下模42上载置背面配置有脱模纸16的底层材料13a(图8)。
接着，使配置在上模21的下方的第一工作台31移动，而将第二工作台41移动至上模21的下方。较为便利的是形成第一工作台31和第二工作台41能够滑动，能够向上模21的下方进行移动的结构。
图示实施例中，首先，将立体赋形体14b和上模21同时提起(图5)，使第一工作台31移动，然后使第二工作台41及下模42向上模21的下方移动(图8)。此时，立体赋形体14b被临时固定单元25临时固定于上模21上。
如图9所示，使上模21下降，按压立体赋形体14b和底层材料13a。此时，不发射高频。
此外，此时通过将销钉(未图示)***上模21的位置对准用销孔24和下模42的位置对准用销孔45内，以完成上模21和下模42的位置对准。此外，将上模21和下模42固定后，拔出销钉。
通过按压，通过底层材料13a的粘合力将立体赋形体14b和底层材料13a粘合，从而成为一体。
此外，按压时，底层材料13a被上模的第一加工单元22切断。该情况下，在图示实施例中，由于在下模42的与第一加工单元22的刀尖抵接的位置上不存在缓冲材料51，所以容易进行切断。另一方面，在存在缓冲材料51的部分，按压力被缓冲材料51吸收。因此，在存在缓冲材料51的部分，底层材料13a的粘合力不会劣化。底层材料13a的粘合力因按压力而劣化，但根据本发明，就能够防止该劣化。
即，较好是通过在底层材料13a的切断部位以外的部分的下方配置缓冲材料51，就能够使缓冲材料51吸收上模21的按压力，进一步防止底层13的粘 合力的劣化。
此外，脱模纸16不被第一加工单元22切断，只伸长了少许。
然后，将上模21提起(图11)。
将成为一体的立体赋形体14b和底层材料13a从上模21取出，除去不需要部分。
然后，将应用贴膜15粘贴在上层11的上表面。 

Claims (7)

1.一种热塑性合成树脂制立体装饰片的制造方法，其特征在于，
在作为阴极的第一工作台(31)上载置表面层材料(11a)，
使作为阳极的上模(21)下降至第一工作台(31)上，在按压表面层材料(11a)的同时发射高频进行介质加热，将表面层材料(11a)成形和熔断以制成立体赋形体(14b)，并且将立体赋形体(14b)临时固定于上模上，
停止高频介质加热，
将载置有具有粘合性的底层材料(13a)的第二工作台(41)向临时固定有立体赋形体(14b)的上模(21)的下方移动，
使所述上模(21)下降到第二工作台(41)上，不进行高频介质加热，在按压立体赋形体(14b)和切断底层材料(13a)的同时，使立体赋形体(14b)和底层材料(13a)进行粘合。
2.如权利要求1所述的方法，其特征在于，
在所述第一工作台(31)上载置中间层材料(12a)，
在该中间层材料(12a)上载置所述表面层材料(11a)，
使所述上模(21)下降到第一工作台(31)上，在按压所述表面层材料(11a)及中间层材料(12a)的同时发射高频进行介质加热，使表面层材料(11a)和中间层材料(12a)熔接，从而制成立体赋形体(14b)。
3.如权利要求1或2所述的方法，其特征在于，在所述第二工作台(41)上载置背面配置有脱模纸(16)的底层材料(13a)。
4.如权利要求1或2所述的方法，其特征在于，将底层材料(13a)切断后，除去不需要部分，将应用贴膜(15)粘贴在上层(11)的上表面。
5.如权利要求1或2所述的方法，其特征在于，通过在所述底层材料(13a)的切断部位以外的部分的下方配置缓冲材料(51)，使缓冲材料(51)吸收上模(21)的按压力。
6.一种热塑性合成树脂制立体装饰片的制造装置，其特征在于，
其由作为阳极的上模(21)、作为阴极的第一工作台(31)、和第二工作台(41)构成，
所述上模(21)具有第一加工单元(22)，
该第一加工单元(22)在上模(21)和第一工作台(31)之间进行高频介质加热时，将表面层材料(11a)和中间层材料(12a)熔断，
所述第一加工单元(22)在上模(21)和第二工作台(41)之间进行按压时，不进行高频介质加热，将底层材料(13a)切断，
在所述上模(21)的下表面设置有临时固定单元(24)，
所述第二工作台(41)的上表面平坦，
在所述第二工作台(41)的上表面，且在距离与第一加工单元(22)的刀尖抵接的位置0.2～1mm的、邻接的第一加工单元(22)的宽度方向中央侧的区域设有凹部(43)，
在该凹部(43)配置有缓冲材料(51)。
7.一种热塑性合成树脂制立体装饰片的制造装置，其特征在于，
其由作为阳极的上模(21)、作为阴极的第一工作台(31)、第二工作台(41)和配置在第二工作台(41)上的下模(42)构成，
所述上模(21)具有第一加工单元(22)，
该第一加工单元(22)在上模(21)和第一工作台(31)之间进行高频介质加热时，将表面层材料(11a)和中间层材料(12a)熔断，
所述第一加工单元(22)在上模(21)和第二工作台(41)之间进行按压时，不进行高频介质加热，将底层材料(13a)切断，
在所述上模(21)的下表面设置有临时固定单元(24)，
所述下模(42)的上表面平坦，
在所述下模(42)的上表面，且在距离与第一加工单元(22)的刀尖抵接的位置0.2～1mm、邻接的第一加工单元的(22)宽度方向中央侧的区域设有凹部(43)，
在该凹部(43)配置有缓冲材料(51)。
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