WO2016186187A1 - 被着体の表面保護方法及び表面装飾方法 - Google Patents
被着体の表面保護方法及び表面装飾方法 Download PDFInfo
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- WO2016186187A1 WO2016186187A1 PCT/JP2016/064950 JP2016064950W WO2016186187A1 WO 2016186187 A1 WO2016186187 A1 WO 2016186187A1 JP 2016064950 W JP2016064950 W JP 2016064950W WO 2016186187 A1 WO2016186187 A1 WO 2016186187A1
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- adherend
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- coating film
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Definitions
- the present invention relates to a surface protection method and a surface decoration method for an adherend having a three-dimensional molded portion on a surface of which a plurality of concave portions and / or convex portions are regularly arranged.
- This adherend includes those used as a moving body whose exposed surface moves, and those used as a relative moving body in which the surface does not move and the fluid flows. Including those used as outer or inner surfaces.
- the adherend in the decoration method includes, in particular, any of the above-mentioned or those used as functional parts that do not move.
- the three-dimensional molded part in which a plurality of concave parts or / and convex parts are regularly arranged includes a dimple molded part in which dimple-like depressions that are partial spherical concave parts are regularly arranged.
- the adherend includes, in particular, one in which a large number of dimples (concave depressions) are applied to the surface of the moving body for the purpose of reducing the dynamic friction coefficient of the traveling body (automobile, motorcycle, ship, aircraft).
- a fluid resistance reduction article a building, a vehicle, or the like having a predetermined shape and a plurality of uneven surfaces on its surface
- Patent Document 1 The concavo-convex portion in the document may be integrally molded with an easy product, or a seal having the concavo-convex portion may be attached to a product.
- fluids such as air and water can be prevented from flowing around the back surface of the article and generating Karman vortices.
- JP 2014-73717 A Japanese Utility Model Publication No. 63-125681
- an object of the present invention is to form a uniform protective layer or decorative layer along the surface of the molded shape by suppressing the change in the depth and shape of the three-dimensional molded shape. It is another object of the present invention to make the sticking to the entire surface having unevenness uniform and to suppress the problem of air retention and poor adhesion.
- the end of the three-dimensionally formed part having the recess, the end of the plate surface having the three-dimensionally formed part, the difference in shrinkage between the film and the adherend and the inside of the film It is an object to suppress the attached sheet from being peeled off due to stress.
- the method for protecting the surface of an adherend of the present invention employs the following means (1) to (5).
- the surface decoration method for an adherend of the present invention employs the following means (6) to (10).
- the method for protecting a surface of an adherend according to the present invention includes the three-dimensionally formed portion of the adherend (W) having a three-dimensionally formed portion in which a plurality of concave portions or / and convex portions are regularly arrayed.
- thermoplastic coating film larger than the area of the adhesion region is integrally adhered to the predetermined adhesion region by a three-dimensional decorative molding procedure, wherein the predetermined adhesion region is , Including all of the three-dimensional molded portion, and over the majority of the adherend (W) in the central cross-sectional view
- the three-dimensional decorative molding procedure is as follows: The adherend is accommodated in one space of the coupled space partitioned by the coating film so that the contact area is integrally exposed, and the adherend is accommodated after both the coupled spaces are decompressed.
- the covering film is integrally adhered over the entire cross-sectional view of the adherend including the adhesion region.
- the phrase “attaching the covering film integrally over the entire circumference in the central sectional view of the adherend (W)” in the present invention appears in the central sectional view of the adherend (W).
- one covering film continuously covers and adheres to the range of the peripheral surface over the majority of the entire peripheral surface (closed figure) extending from the front surface to the back surface.
- the fact that the “cross-sectional view contact length” is more than half of the “cross-sectional view total circumferential length” means that the “cover film over the majority of the cross-section of the adherend (W)” Is in a state of being in close contact.
- the integral adhesion range of the covering film extends from the surface of the adherend (W) to both side surfaces continuous to the left and right as shown in FIGS. When it extends from at least one side surface to the back surface of the adherend (W), it can be said that it is in a state of “the coated film being in close contact with the entire circumference in a cross-sectional view of the adherend (W)”.
- the “adhering body (W) it may not be said that the covering film is in close contact with the entire circumference in a cross-sectional view.
- the adherend (W) has a curved plate-like portion and is a movable body that moves during use, A plurality of dimple-like depressions are exposed and arranged in a portion of the surface of the curved plate-like portion of the adherend (W) where the three-dimensionally shaped portion is subjected to fluid frictional resistance during movement.
- attaches the said coating film is a continuous surface area
- the coupled space is coupled to the upper and lower sides of the covering film with the covering film stretched in the lateral direction as a boundary.
- the adherend is housed in the lower housing space below the coupled space, and the upper housing space above the coupled space is released to atmospheric pressure,
- the coating film (F) is given a predetermined amount of heat to be in a draw-down state close to the three-dimensionally molded part of the adherend, From this drawdown state, the coating film (F) is brought into a close contact state due to the pressure difference between the upper and lower sealed spaces,
- the amount of heat (t1) applied to the central contact-corresponding portion (center area A1) to the three-dimensionally formed portion is the peripheral close-corresponding portion (to the peripheral portion of the three-dimensionally formed portion ( It is preferable to set so as to be lower than the amount of heat (t2) applied to the peripheral area A2).
- molding can be variably adjusted by center area A1 and peripheral part area A2 of a coating film. Specifically, it has a relatively large stretch at the periphery where a stretched area is required and is closely attached, and has a predetermined film thickness at the center where reliable contact is required, and the protrusion or recess is greatly deformed. It can be made to adhere without doing. In particular, peeling of the coating film can be prevented by thinly stretching the peripheral portion.
- step a lower chamber (21) having an accommodation space (S21) opened at the top and accommodating the adherend (W) in the lower accommodation space (S21), and an upper accommodation space (S22) opened at the bottom.
- the upper chamber (22) having the upper and lower storage spaces is combined with the upper chamber (22) in a state of sandwiching the covering film (F) of a size covering both openings, and the coupled space in which the upper and lower accommodation spaces are coupled to each other is sealed.
- the coating film before the adhesion has at least a thickness variable portion formed thinly or thickly in a partial circular shape as compared with other portions.
- a plurality of pre-molded parts corresponding to the close contact range It is preferable that the thickness variable portions are formed at equal intervals with a pitch that is the same as or adjacent to the dimple formation pitch of the three-dimensionally formed portion.
- the adherend (W) having a three-dimensionally molded portion in which a plurality of depressions are regularly arrayed is provided in a predetermined adhesion region including the three-dimensionally molded portion.
- the three-dimensional decorative molding procedure is as follows: The adherend is accommodated in one space of the coupled space partitioned by the coating film so that the contact area is integrally exposed, and the adherend is accommodated after both the coupled spaces are decompressed. By adhering the coating film to the surface of the adherend by releasing the pressure of the other space that is not at atmospheric pressure, The covering film is integrally adhered over the entire cross-sectional view of the adherend including the adhesion region.
- the adherend (W) has a curved plate-like portion and is a moving body that moves during use, A plurality of dimple-like depressions are exposed and arranged in a portion of the surface of the curved plate-like portion of the adherend (W) where the three-dimensionally shaped portion is subjected to fluid frictional resistance during movement.
- attaches the said coating film shall be a continuous surface area
- the coupled space is coupled to the upper and lower sides of the covering film with the covering film stretched in the lateral direction as a boundary.
- the adherend is accommodated in the lower space of the coupled space, and the upper space of the coupled space is released to atmospheric pressure.
- the coating film (F) in the coupled space Before opening the upper space to atmospheric pressure, the coating film (F) in the coupled space is brought into a draw-down state close to the three-dimensionally formed portion of the adherend by applying a predetermined amount of heat, From this drawdown state, the coating film (F) is brought into a close contact state due to the pressure difference between the upper and lower sealed spaces, Of the coated film (F) in the draw down state, the amount of heat (t1) applied to the central contact-corresponding portion (which is the central area A1) to the three-dimensionally formed portion is the peripheral contact-corresponding portion (the peripheral area A2). It is preferable to set so as to be lower than the amount of heat (t2) applied to ().
- (9) In the three-dimensional decorative molding procedure of the adherend surface decoration method, for example, it is preferable to include at least the following steps (A), (B), (C), and (D).
- the upper chamber (22) having the upper and lower storage spaces is combined with the upper chamber (22) in a state of sandwiching the covering film (F) of a size covering both openings, and the coupled space in which the upper and lower accommodation spaces are coupled to each other is sealed.
- a thickness variable portion formed thinly or thickly in a partial circle shape compared to other portions, at least in the adhesion-corresponding range portion A plurality are pre-formed, It is preferable that the thickness variable portions are formed at equal intervals with a pitch that is the same as or adjacent to the dimple formation pitch of the three-dimensionally formed portion.
- the present invention by taking the above-mentioned means, it was possible to suppress a change in the depth and shape of the three-dimensional molded shape and to form a uniform protective layer or decorative layer along the surface of the molded shape. In addition, it is possible to make the sticking to the entire uneven surface uniform, to suppress problems of air retention and adhesion failure, and to prevent the attached film or sheet from peeling off at each part. It was.
- FIG. 1 is an external view explanatory diagram of an adherend subjected to surface protection or surface decoration method of Example 1.
- FIG. 2 is an enlarged cross-sectional explanatory view showing a set state before application of a coating film in the ⁇ - ⁇ portion of FIG.
- FIG. 2 is a partial explanatory view of a three-dimensional decoration device showing a set state and a draw-down state before application of a coating film in the ⁇ - ⁇ portion of FIG.
- FIG. 2 is an enlarged cross-sectional explanatory view showing a state after application of a coating film in the ⁇ - ⁇ portion of FIG. FIG.
- Example 3 is an enlarged side view and an enlarged cross-sectional view showing a finished state in an ⁇ - ⁇ portion of Example 1.
- Explanatory sectional explanatory drawing which shows the set state and draw down state before the coating film sticking in the surface protection thru
- FIG. The expanded cross-section explanatory drawing which shows the finishing state after the coating film sticking in the surface protection thru
- FIG. Cross-sectional explanatory drawing before the set state (upper figure) and after the set state (lower figure) in the surface protection or surface decoration method of Example 3.
- BRIEF DESCRIPTION OF THE DRAWINGS FIG. Explanatory sectional explanatory drawing of the set state in the surface protection thru
- FIG. 1 Explanatory sectional explanatory drawing which shows the state after the coating film sticking in the surface protection thru
- FIG. Explanatory sectional explanatory drawing which shows the set state before the coating film sticking in the surface protection thru
- FIG. Explanatory sectional explanatory drawing which shows the finishing state after the coating film sticking in the surface protection thru
- FIG. 6 Explanatory sectional explanatory drawing which shows the set state before the coating film sticking in the surface protection thru
- FIG. The elements on larger scale and sectional drawing of each example of the net-like sheet
- the surface protection method or surface decoration method of the present invention basically uses an adherend (W) having a three-dimensionally formed portion in which a plurality of concave portions or / and convex portions are regularly arranged and formed.
- a coating film (F) having an adhesive surface (A) on the lower surface is adhered to a predetermined adhesion area exposed on the surface of the adherend (W) which is a predetermined three-dimensional decorative molding procedure. is there.
- the procedure of the three-dimensional decorative molding refers to a technique in which the coating film is instantaneously attached to the surface of the adherend in the chamber by releasing the pressure of one of the sealed chambers partitioned through the coating film.
- it refers to a film that is uniform and can provide three-dimensional surface protection and / or surface decoration without wrinkling of the film, which is different from the adhesion of the film by hand attachment or the adhesion of the film by pressing of pressure.
- the adherend includes those used as a moving body in which the exposed surface moves, those used as a relative moving body in which the surface does not move and the fluid flows, and the outer surface of the person or the transporting vehicle that carries the object. Or what is used as an inner surface is included.
- the adherend in the decoration method includes, in particular, any of the above-mentioned or those used as functional parts that do not move.
- the three-dimensional molded part in which a plurality of concave parts or / and convex parts are regularly arranged includes a dimple molded part in which dimple-like depressions that are partial spherical concave parts are regularly arranged.
- the adherend includes, in particular, one in which a large number of dimples (concave depressions) are applied to the surface of the moving body for the purpose of reducing the dynamic friction coefficient of the traveling body (automobile, motorcycle, ship, aircraft).
- the adherend has a three-dimensionally molded portion in which a plurality of concave portions and / or convex portions are regularly arrayed.
- the use of the adherend is not limited, but for example, a moving body that has a curved plate-like part and moves during use, such as an automobile, a train, a bicycle, an airplane, or a ship, or a curved body It includes a moving device such as a traveling part that has a plate-like portion and is moved by the drive mechanism when used.
- the adherend shown as an example among the above is made of an exterior material composed of a plate-like portion in a moving body such as an automobile, a train, a bicycle, an airplane, and a ship that moves when used.
- the solid molded part of the adherend (W) of Example 1 has an overall outline shape that is three-dimensionally molded by a combination of a plurality of surfaces, and has a thickness composed of a plurality of concave portions and / or convex portions on the surface.
- the variable portion (D) is regularly arrayed (FIGS. 1 to 3). As an example of a plurality of concave portions regularly arranged and formed, for example, as shown in FIG.
- partial spherical recesses equal to or less than a quarter are formed in a plurality of rows while being arranged at equal intervals while shifting the position of each row.
- a dimple structure is exemplified.
- the dimple structure is formed on the surface of a traveling body or a moving device, thereby generating a small turbulent region on the surface that generates fluid friction during traveling, and reducing surface friction resistance generated on the traveling surface or moving surface. Has an effect.
- the three-dimensionally formed portion of the adherend (W) of Example 2 and Example 3 is regularly arrayed and formed with a variable thickness portion (D) composed of a plurality of recesses on the surface (FIGS. 6 to 8). ).
- the adherend may be formed by arranging and forming the variable thickness portion (D) including a plurality of concave portions and / or convex portions for the first time after the surface protection method or the surface decoration method of the present invention.
- the three-dimensional molded portion of the adherend before processing does not have the thickness variable portion (D) on the surface (FIGS. 10, 13A, and 14).
- a covering film having a variable thickness portion (D) composed of a plurality of concave portions or / and convex portions is used (FIG. 10), or a net-like sheet is attached to the covering film.
- the variable thickness portion (D) composed of a plurality of recesses is formed for the first time by the surface protection method or the surface decoration method of the present invention. (FIGS. 11, 13B, and 16).
- the covering film (F) is adhered and adhered to the adhesion region on the surface of the adherend (W) for the purpose of protecting the surface of the adherend (W), the purpose of decorating, or the purpose of protecting and decorating.
- the coated film (F) has a larger area than the adherence area of the adherend, and is in a three-dimensional decorative molding state in which the adherend surface is covered so as to include the entire adherence area of the adherend. It becomes. Particularly in the three-dimensional decorative molding state after the close contact, the close contact is made so as to extend over the majority of the entire circumference of the adherend appearing in the central sectional view of the close contact region.
- the surface of the adherend region extends over the majority of the entire circumference of the adherend that appears in the central sectional view of the contact region. , And a range including up to a part of the back surface of the plate. For example, as shown in FIGS.
- the coating film (F) may be one having a flat surface as in Example 1 (FIGS. 2 and 9), and a plurality of concave portions (FD) are regularly formed on the surface as in Examples 2 and 4. (Figs. 6, 10 and 12a).
- the convex part (FA) or the recessed part FD2 may be regularly arranged and formed on the lower surface as in Example 5 (FIGS. 12b, 12c, and 13A). Further, as shown in FIG. 12c, a transparent lenticular lens (LR) having a diameter of several ⁇ m is arranged on the surface with the parallel groove portion (LRD) as a boundary, and a regular pattern PSP is printed on the lower portion of the lenticular lens LR. It is assumed that the enlarged image FD2 in which the regular pattern PSP is three-dimensionally projected on the surface of the covering film is visually recognized so as to be sandwiched between the print sheets PS. As a layer structure of the coating film (F), an adhesive surface (A) is formed on the lower surface of a base material layer made of a thermoplastic resin.
- the adhesive surface (A) on the lower surface of the coating film (F) is stretched in a plane so as to face the adhesion area side of the adherend (W).
- the heaters central heater (220H), peripheral heater (221H), side heater (222H)
- the central area A1 and the peripheral area A2 are drawn down (FIGS. 3, 6, and 10), and the film upper space and the film lower space are set to the same atmospheric pressure from the expanded and drawn down state.
- the material is instantaneously stretched and moved so as to be in close contact with the close contact region on the surface of the adherend (W).
- W the surface of the adherend
- the front surface close contact portion (FF1), the side surface close contact portion (FF2), the back surface close contact portion (FF30), and the remaining close contact portion (FE) covering the surrounding devices are continuously covered (FIG. 4). , FIG. 16).
- the predetermined 3D decorative molding procedure is basically: A dimple (partial spherical depression) shape is formed in one of the sealed coupled spaces (the lower housing space (S21) and the upper housing space (S22)), which is partitioned by the covering film (W) stretched in the lateral direction.
- the three-dimensionally formed portion of the adherend having a close contact region is accommodated, and the close contact region of the adherend is integrally exposed and disposed so as to face the adhesive surface of the coating film, Both are in a reduced pressure state and the coated film (W) is in a draw-down state in which a part of the coating film is heated by a plurality of heaters, and then the other space (the upper accommodation space (S22)) that does not contain the adherend is large.
- W coated film
- S22 the other space
- the covering film is integrated over the entire cross-sectional view of the adherend (in the embodiment, from the entire surface to the cross-sectional view peripheral side surface and the back surface connected thereto). It is made to adhere to.
- the upper chamber (22) having S22) is vertically combined with the covering film (F) of a size covering both openings, and the upper and lower accommodation spaces (S21, 22S) are coupled and sealed. Forming the sealed coupled space (FIG. 2).
- (C) Depressurization and drawdown process The inside of the lower housing space (S21) and the upper housing space (S22) in the sealed coupled space are decompressed while maintaining the same pressure, and a predetermined amount of heat is applied to the coating film (F). Applying and drawing down, the top of the adhesion area of the adherend lifted up by the holding part is the closest to the center of the stretched covering film (FIGS. 3 and 10) ).
- the three-dimensional decorative molding apparatus of the embodiment shown in FIGS. 2 to 4, 6, and 7 is The lower chamber (21) and the upper chamber (22) which are close to or away from each other are composed of a vacuum forming machine capable of forming a coupled space sealed up and down with the coating film (F) interposed therebetween.
- the lower chamber (21) has a lower accommodating space (S21) opened upward, and a lower sandwiched portion (31) made of a hard elastic material for sandwiching the film to be deposited is embedded inside the upper edge of the frame.
- the upper chamber (22) has an upper accommodating space (S22) opened downward, and an upper sandwiched portion (32) made of a hard elastic material that sandwiches the film to be attached is attached to and detached from the inside of the upper edge of the frame.
- the upper chamber (22) is supported upward by an arm (22A) so as to be vertically movable.
- the adherend (W) is accommodated in the lower chamber (21), the covering film (F) is placed in the upper opening, and the lower sandwiched portion (31) and the upper sandwiched portion (32) are the deposited film (F).
- the upper chamber (22) moves downward with the chamber sandwiched between them, and the chambers are combined vertically, and the coupled space in which the spaces are vertically coupled with the coating film (F) sandwiched is hermetically formed.
- the pressed state is set. In this set state, a pulling force that spreads the coating film (F) toward the periphery is applied (FIG. 2).
- a holding portion (120) for holding the adherend (W) from the back surface (WB) is supported downward by an arm (11A) having a fitting body (11) at the upper end ( FIG. 2, FIG. 9).
- the holding part (120) is formed by a continuous holding surface formed along the back surface (WB) of the adherend (W) and a recessed surface formed in the downward direction from the periphery of the holding surface.
- a rising portion (120S) is formed so as to project upward from the periphery of the recessed surface.
- the rising portion (120S) fits in the cutout frame of the adherend and projects upward from the cutout frame of the adherend while being held.
- the rising portion (120S) of Example 2 is formed so as to be in contact with the inner side surface of the lower chamber (21) (FIGS. 6 and 7).
- the holding portion (120) of the embodiment is in a state in which the adherend (W) is brought into surface contact with the holding surface protruding in the center and the adherend (W) is held, and the lower portion is fitted by the fitting body (11). Supported.
- the arm (11A) connected to the lower side of the fitting body (11) is moved upward by the drive mechanism (10)
- the holding portion (120) is moved upward, and the covering film (F) and the adherend ( W) is brought into close proximity with the central portion of the contact surface (FIG. 2).
- the lower chamber (21) and the upper chamber (22) are configured to communicate with pressure control means for controlling the pressure of the upper and lower spaces constituting the coupling space.
- the pressure control means includes a lower communication pipe (41) communicating with the side of the lower chamber, an upper communication pipe (42) communicating with the side of the upper chamber, the lower communication pipe (42) and the upper communication pipe.
- a connecting pipe (44) for connecting the communicating pipe (42), an upper connecting pipe (45) for connecting the connecting pipe (44) to the vacuum chamber (6) at the upper front part thereof, and a connecting pipe (44) for the lower part thereof It has a pipe structure consisting of an upper connection pipe (45) connected to the pressure control mechanism (5) at the tip, and further, a pressure control mechanism (5) and a vacuum chamber (6) are connected to this pipe structure. (FIG. 6).
- a predetermined partially molded portion (WP) is formed of a concave-shaped container covering the side periphery from the inside of the portion, and the upper end of the receiving die extends along the upper opening edge of the lower chamber (21).
- a receiving jig (consisting of a bottom frame plate (11) and a side frame plate (31)), In a state where the adherend (W) is accommodated in the accommodation space, the receiving jig that covers a part of the predetermined molding portion (WP) of the adherend (W) can be disposed close to the upper opening.
- the lower chamber (21) is disposed so as to be movable up and down above the upper space. In the lowest position, the lower opening of the housing space is brought into contact with the upper opening of the lower chamber (21) with the covering film (F) interposed therebetween.
- An upper chamber (22) combined together; Pressure control means for controlling the pressure of the upper storage space (S22) in the upper chamber (22) and the lower space (11S) in the receiving jig disposed and fixed in the lower chamber (21). Is done.
- the upper end of the receiving die of the receiving jig that covers a part of the adherend (W) is disposed close to the upper opening, so that the lower chamber (21) is treated.
- Dividing into a lower space (11S) and a storage space (S21) in the tool The lower space (11S) in the partitioned receiving jig and the upper accommodation space (S22) in the upper chamber (22) are hermetically coupled vertically with the covering film (F) interposed therebetween, After decompressing each of the lower space (11S) and the upper storage space (S22) of the sealed container, only the upper storage space (S22) is released by pressure, A covering film (F) is overlaid on a part of the adherend (W) covered with the receiving jig (FIG. 8).
- the amount of heat (t1) given to the central contact equivalent part (central area A1) which covers the surface central part (topmost part of the set state) of the adherend among the coated film (F) in the draw-down state that has undergone this step ) Is lower than the amount of heat (t2) applied to the peripheral contact-corresponding portion (peripheral area A2) that covers the surface peripheral portion, side surface, or back surface (peripheral portion excluding the topmost portion in the set state) of the adherend. (Fig. 3).
- the heater for performing radiant heating is a central heater (220H) disposed at the center of the inner top surface of the upper chamber (22) and a corner near the center of the inner top surface of the upper chamber (22).
- the adjacent peripheral heaters (221H) or the radiant heating ranges of the peripheral heater (221H) and the side heater (222H) are set to overlap each other (FIG. 3).
- the peripheral contact equivalent portion (peripheral area A2) that overlaps the radiant heating range where the peripheral heater (221H) and the side heater (222H) overlap is a predetermined peripheral heat amount (t2). Heated by radiation.
- the radiant heating ranges of the adjacent central heater (220H) and peripheral heater (221H) are set so as not to overlap (FIG. 3).
- the central contact equivalent portion (central area A1) that overlaps the radiant heating range of the central heater (220H) has a predetermined central heat quantity (t1) in the radiant heating range of the central heater (220H).
- heat amount (t1) is set so that it may become lower than the said peripheral part calorie
- the lower chamber (21) can accommodate the entire adherend (W) in the internal accommodation space, and a receiving jig that covers a predetermined molding portion WP of the adherend (W) is attached to the adherend. At the same time, it can be accommodated in the internal accommodation space (S21), and the receiving jig can be disposed close to the upper opening.
- the adherend (W) is three-dimensionally molded by a three-dimensional molded plate and has a plurality of aperture molding portions, and the side surface (WS) is exposed by any one of the aperture molding portions. Further, the front surface (WF) and the back surface (WB) are exposed continuously to the side surface (WS).
- the covering film (F) is in close contact with the back surface (WB) from the front surface (WF) to the side surface (WS).
- the side surface (WS) and the back surface (WB) are formed as a thin film portion that has a large amount of stretched film by three-dimensional decoration and becomes thinner toward the back surface. By cutting this thin film portion with a cut line (CL), the adhesion on the back side of the molded portion can be improved.
- the pressure adjusting step includes a depressurization step for depressurizing the upper and lower molding spaces partitioned by the covering film (F) covering the adherend (W), and a pressurization step for pressurizing only the upper molding space after the depressurization step. And have.
- the heating process heats the coating film (F) from the upper molding space in the former decompression step.
- the table is raised from the lower molding space in the latter pressurizing step, and the covering film (F) is placed on the adherend (W).
- the present invention is provided with the heaters 2201H, 221H, and 222H composed of a plurality of heating elements aligned on the inner surface of the upper chamber (22), so that it is a vacuum forming apparatus that is hardly affected by the outside air.
- the adherend (W) is a moving body that moves in use, and the dimple (partial spherical depression) -shaped three-dimensionally molded portion receives a fluid frictional resistance during movement in the entire surface area. It is preferable to be formed so as to be exposed to air in order to surely exhibit the air resistance reduction.
- the covering film (F) before adhesion is brought into a draw-down state as shown in FIG. 3 by applying a predetermined amount of heat. From this drawdown state, the coating film (F) is brought into a close contact state due to the pressure difference between the upper and lower sealed spaces, Of the coating film (F) in the draw-down state, the amount of heat (t1) applied to the central contact-corresponding portion (center area A1) to the dimple processed portion is applied to the peripheral contact-corresponding portion (circumferential area A2). It is set to be lower than the amount of heat (t2). Thereby, a thermoplastic reaction becomes larger in the side peripheral part than in the central part, and the elongation percentage of the film in the side peripheral part after the three-dimensional decorative molding increases.
- the coating film before contact of Example 2 includes a plurality of concave portions FD, which are thin portions thicker or thicker than the other portions, at least in the contact-corresponding range portion.
- Each of the variable thickness portions is formed and arranged in a dimple shape smaller than the dimple (D) as the concave portion of the three-dimensional molded portion, and the pitch of the dimple (D) as the concave portion of the three-dimensional molded portion is formed. Are formed at equal intervals with a small pitch.
- Example 3 In the molding apparatus of Example 3 shown in FIG. 8, a lower chamber (21) having an upper opening and an upper chamber (22) having a lower opening are vertically combined with a covering film (F) sandwiched therebetween, so A molding space in which the members 21S and 22S are coupled is hermetically formed, and pressure control is performed on the upper and lower sides of the molding space, so that a covering film (F) is formed on a part of the adherend (W) accommodated in the molding space. ) Under reduced pressure.
- the lower chamber (21) is composed of a concave receiving jig that covers a predetermined partial molding portion WP of the adherend (W) from the inside to the side of the portion, and only the portion enclosed in the receiving jig is enclosed.
- the bottom frame plate 11 is formed of a plate-like body formed on the stepped portion 11E with thin front and rear ends, and is formed on the plate surface of the bottom frame plate 11 so as to protrude into a three-dimensional shape corresponding to the three-dimensional shape of the protruding portion.
- a mold 12 is formed to protrude.
- the molding die 12 contacts the back side of the predetermined molding portion WP.
- the opening bottom hole 50 is vertically connected to the bottoms of the two upper openings 10. Other configurations and molding methods not specifically mentioned are the same as those in the first embodiment.
- Example 4 Similarly to Example 3, the coating films of Examples 4 and 5 shown in FIGS. 10 to 13B also have a thickness variable portion formed in a partial circular shape that is thinner or thicker than the other portions on the coating film before adhesion. , At least a plurality of the contact-corresponding range portions are formed in advance.
- Example 4 as shown in FIG. 10, a coating film in which concave portions FD composed of fine depressions are regularly arranged and formed only on the surface is used, and the concave film itself of the concave portions FD is heated by heating from above.
- the peripheral area A2 is radiantly heated so as to extend more thinly and wider than the central area A1, and has a state of being drawn down in two stages with a boundary between the central area A1 and the peripheral area A2. ing.
- Example 5 uses the coating film of FIG. 12c, and this coating film has convex portions formed only on the adhesive surface FA on the lower surface, and a lenticular lens LR is formed on the surface.
- the covering film is deformed along the surface of the adherend by the three-dimensional decorative molding procedure shown in FIGS. 13A and 13B.
- the protrusions FT having a size corresponding to the protrusions on the lower surface are regularly arranged and formed on the surface of the covering film that adheres closely to the surface of the adherend, without impairing the shape of the lenticular lens LR. (FIG. 13B).
- FIG. 13B shows that adheres closely to the surface of the adherend, without impairing the shape of the lenticular lens LR.
- Example 6 The surface decoration method for an adherend of Example 6 shown in FIGS. 14 to 16 is performed by applying a thermoplastic coating film larger than the area of the adhesion area to a predetermined adhesion area of the adherend by three-dimensional decoration molding.
- a method for decorating the surface of an adherend that is integrally adhered by a procedure Between the covering film and the adherend, by three-dimensional decorative molding sandwiching a mesh sheet (N) in which a plurality of openings NH are regularly arrayed, The covering film (F) is integrally adhered over the entire cross-sectional view of the adherend including the adhesion region, A solid molded portion in which a plurality of concave portions corresponding to the openings of the mesh sheet are regularly arranged is formed in at least a part of the close contact region. According to this, since the thickness variable portion is formed along the sheet thickness of the sandwiched net sheet and the opening shape of the opening NH, it is possible to control the size of the thickness variable portion formed by surface decoration or surface protection. It becomes easy.
- the concave portions are arranged on the surface of the covering film as in Example 4 (FIG. 10), the depth and size of the concave portions are limited by the base material of the covering film and are deeper than the thickness of the covering film. It becomes difficult to form the variable thickness portion. Further, in the variation of the coating film used in Example 5 (FIGS. 13A and 13B) and Example 5 (FIG. 12abc), the thermoplastic reaction of the convex portion FT is partially inferior, and the stretch adhesion at the convex portion is May become unstable.
- the control of the drawdown amount is divided for each area such as the central part or the central part.
- FIG. 17 the form example (variation) of the net-like sheet
- the octagonal openings NH are arranged in a honeycomb shape by shifting by half width and half height, and the network connecting the openings NH has a circular cross section.
- the rounded corner openings NH are uniformly arranged vertically and horizontally, and the net connecting the openings NH has a trapezoidal chevron-shaped cross section whose front side is narrower than the back side.
- a partial spherical circular opening NH is formed in a flat original sheet with a predetermined distance therebetween, and the net connecting the openings NH is a wave-shaped (sine curve-shaped) mountain shape.
- the net connecting the openings NH is a wave-shaped (sine curve-shaped) mountain shape.
- only the predetermined range VA in the mesh sheet N of FIG. 17a is hollowed out, and other mesh sheets N as shown in FIGS. 17b and 17c are cut out according to the predetermined range VA and combined to obtain the predetermined range VA.
- the shape, size, and number of the predetermined aperture group VHA can be freely controlled.
- FIG. 18 shows another embodiment in which the surface decoration method of the present invention is adopted in each part of an automobile.
- the predetermined height range including the A pillar, the B pillar, and the C pillar is a non-decorative range (FA) that is partially excluded from the file decoration range, but the embodiment of FIG.
- the A pillar, the B pillar, and the C pillar are included in the decoration range, and further, the surface of the automobile window glass, the transparent cover of the headlight, and the wheel cover are also included in the decoration range.
- a polarizing fluoroscopic film that can be seen only from one side is used as the covering film. After the polarizing fluoroscopic film is decorated on the window glass, it cannot be seen through by reflection from the outside of the vehicle, and can be seen only from the inside of the vehicle on the back side.
- Three-dimensional decorative molding of a “flat” coating film along a concave portion on the surface of the adherend surface with a mesh sheet N having a desired thickness variable portion (depressurizing one side of a double sealed space across the film)
- the film is fixed in a thermoplastic state by the method of adhering the film by the adhesive method.
- a coating film “with a variable thickness portion consisting of fine irregularities formed on the surface” is applied to the dimple surface by three-dimensional decorative molding. Thereby, the surface protective layer can be uniformly formed while improving the dimple effect. 4).
- the weather resistance is secured by protecting the adherend with a predetermined thickness by the peripheral part of the convex part or concave part by fixing the covering film with the variable thickness part by decorative molding for the purpose of surface protection. can do. 5.
- the surface of the adherend has a predetermined uneven pattern by the formation of the convex part or the concave part or the surface processing of the covering film.
- the adherend can be integrated with the adherend, and the adherend can be formed integrally with a variable thickness portion that has an unprecedented regular arrangement or a combination of a plurality of types of regular arrangements. 6).
- By controlling the size of the thickness variable portion it is possible to meet a demand for a predetermined surface shape adjustment such as reduction or increase of air resistance during high-speed traveling, and uneven processing of only a part.
- the present invention is not limited to the above-described embodiments, and within the scope of the present invention, extraction of some elements, replacement with elements or substitutes of other embodiments, deletion, or configurations between the embodiments Various modifications such as a superimposing combination of the above are possible.
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Abstract
Description
またほかに、従来のシート貼付けによる凹凸形成技術も開示されるが、均一な貼付が困難という問題があった。また空気溜り、接着の部分不良の問題があった。特に凹部の端部、凹部を有する立体成形部の端部、立体成形部を有する板面の端部では、貼り付けた後にフィルムと被着体との収縮率の違いや、フィルムの内部応力によって、貼り付けたシートが剥がれ易いという問題があった。
(1)本発明の被着体の表面保護方法は、複数の凹部又は/及び凸部が規則的に配列成形された立体成形部を有する被着体(W)の、前記立体成形部を含む所定の密着領域に、密着領域の面積よりも大きい熱可塑性の被覆フィルムを、三次元加飾成形の手順によって一体的に密着させる被着体の表面保護方法であって、前記所定の密着領域は、前記立体成形部の全てを含み、かつ、被着体(W)の中央断面視にて過半周に亘るものであり、
前記三次元加飾成形の手順は、
被覆フィルムによって区画した連成空間の一方の空間に被着体を収容して前記密着領域が一体的に露出するように配置し、連成空間内を共に減圧状態としてから、被着体を収容していない他方の空間を大気圧に圧力開放することで被着体の表面に被覆フィルムを密着させることで、
前記密着領域を含む被着体の断面視過半周に亘って、被覆フィルムを一体的に密着させることを特徴とする。
ここで、本発明にいう「被着体(W)の中央断面視にて過半周に亘って、被覆フィルムを一体的に密着させる」とは、被着体(W)の中央断面視において表れる、表面から裏面に亘る全周面(閉じた図形)のうち、過半部に亘る周面の範囲に、一枚の被覆フィルムが、連続的に覆って密着される状態をいう。すなわち、立体成形表面の中央を横断する断面視においては、被着体(W)の表面から裏面に亘る全周面(表面、裏面、及びこれらの左右側部に連なる左右の側面)が、扁平四角形や円形などの閉じた図形線として表れる。この図形線の全ての長さを「断面視全周長さ」とし、また、この図形線のうち、被着体(W)の表面を一体的に覆って密着する被覆フィルムの密着範囲の長さを、「断面視密着長さ」とする。このとき、前記「断面視密着長さ」が、「断面視全周長さ」の半分超となっていることを、「被着体(W)の断面視にて過半周に亘って被覆フィルムが密着された」状態とする。例えば、図4,5のように、被覆フィルムの一体的な密着範囲が、図4,図5のように被着体(W)の表面からその左右に連なる両側面にまで亘るか、或いは被着体(W)の少なくとも片側面から裏面にまで亘るとき、前記「被着体(W)の断面視にて過半周に亘って被覆フィルムが密着された」状態であるといえる。逆に、被覆フィルムの一体的な密着範囲が、表面からその左右に連なるいずれの側面にも亘らず、断面において表れる表面の一部にしか至らないとき、前記「被着体(W)の断面視にて過半周に亘って被覆フィルムが密着された」状態とはいえない場合がある。
前記立体成形部が、被着体(W)の前記湾曲した板状部の板表面のうち、移動の際に流体摩擦抵抗を受ける部分に、複数のディンプル状の窪みが露出して配列形成されたものであり、
前記被覆フィルムを密着させる密着領域は、前記板表面、板表面の周部に連なる板側面、及び板側面に連なる板裏面の一部を含む、連続した面領域であることが好ましい。
連成空間は、横方向に張設した被覆フィルムを境界としてこの被覆フィルムの上下に連成され、
連成空間のうちの下方の下収容空間に被着体を収容し、連成空間のうちの上方の上収容空間を大気圧に圧力開放するものであり、
前記上収容空間を大気圧に開放する前に、被覆フィルム(F)は、所定の熱量を付与されることで、被着体の立体成形部と近接したドローダウン状態とされ、
このドローダウン状態から被覆フィルム(F)の上下の密閉空間の圧力差によって密着状態とされるものであり、
前記ドローダウン状態の被覆フィルム(F)のうち、立体成形部への中央密着相当部(中央エリアA1)へ付与される熱量(t1)が、立体成形部の周部への周辺密着相当部(周部エリアA2)へ付与される熱量(t2)よりも低くなるように設定することがこのましい。
このようなものであれば、加飾成形の密着工程における延伸量を、被覆フィルムの中央エリアA1と周部エリアA2とで可変調整することができる。具体的には、延伸面積が必要となる周部において比較的大きく延伸させつつ密着させると共に、確実な密着が必要となる中央部において所定のフィルム厚さを有し、凸部または凹部が大きく変形することなく密着させることができる。特に、周部において薄く延伸させることで、被覆フィルムの剥がれを防止することができる。
(A)密閉工程:上部開口した収容空間(S21)を有すると共にこの下収容空間(S21)内に被着体(W)を収容した下チャンバー(21)と、下部開口した上収容空間(S22)を有する上チャンバー(22)とを、両開口を覆う大きさの被覆フィルム(F)を挟んだ状態で上下に組み合わせて、上下各収容空間同士S21,S22が連成した連成空間を密閉形成する工程。
(B)リフトアップ工程:収容空間(S21)内に収容した被着体(W)を、前記立体成形部を含む密着領域、及びその周囲縁部に連なる側周部のいずれからも外れた保持部で接触保持し、保持部の駆動によって、被着体(W)を上収容空間側へリフトアップする工程。
(C)減圧及びドローダウン工程:密閉した連成空間の下収容空間(S21)内、上収容空間(S22)内を互いに同圧のまま減圧すると共に、被覆フィルム(F)に所定の熱量を付与してドローダウン状態とし、保持部によってリフトアップされた被着体の前記密着領域の最頂部が、張設された被覆フィルムの中央部に最も近接した状態とする工程。
(D)密着工程:減圧された上下各収容空間内のうち上収容空間(S22)内のみを大気圧開放することで、被着体(W)の前記密着領域ないし前記側周部に被覆フィルム(F)を一体的に密着させる工程。
上記課題を解決すべく、本発明の被着体の表面装飾方法は、以下(1)~(5)の特徴を有するものとしている。
この厚さ可変部は、立体成形部の隣接するディンプル形成ピッチと同じであるかあるいは前記ディンプル形成ピッチよりも小さいピッチで等間隔に離間形成されることが好ましい。
(6)本発明の被着体の表面装飾方法は、複数の窪みが規則的に配列成形された立体成形部を有する被着体(W)の、前記立体成形部を含む所定の密着領域に、密着領域の面積よりも大きい熱可塑性の被覆フィルムを、三次元加飾成形の手順によって一体的に密着させる被着体の表面装飾方法であって、前記所定の密着領域は、前記立体成形部の全てを含み、かつ、被着体(W)の中央断面視にて過半周に亘るものであり、
前記三次元加飾成形の手順は、
被覆フィルムによって区画した連成空間の一方の空間に被着体を収容して前記密着領域が一体的に露出するように配置し、連成空間内を共に減圧状態としてから、被着体を収容していない他方の空間を大気圧に圧力開放することで被着体の表面に被覆フィルムを密着させることで、
前記密着領域を含む被着体の断面視過半周に亘って、被覆フィルムを一体的に密着させることを特徴とする。
前記立体成形部が、被着体(W)の前記湾曲した板状部の板表面のうち、移動の際に流体摩擦抵抗を受ける部分に、複数のディンプル状の窪みが露出して配列形成されたものであり、
前記被覆フィルムを密着させる密着領域は、前記板表面、板表面の周部に連なる板側面、及び板側面に連なる板裏面の一部を含む、連続した面領域であるものとすることが好ましい。
連成空間は、横方向に張設した被覆フィルムを境界としてこの被覆フィルムの上下に連成され、
連成空間のうちの下方の空間に被着体を収容し、連成空間のうちの上方の空間を大気圧に圧力開放するものであり、
前記上方の空間を大気圧に開放する前に、連成空間内の被覆フィルム(F)は、所定の熱量の付与によって、被着体の立体成形部と近接したドローダウン状態とされ、
このドローダウン状態から被覆フィルム(F)の上下の密閉空間の圧力差によって密着状態とされるものであり、
前記ドローダウン状態の被覆フィルム(F)のうち、立体成形部への中央密着相当部(である中央エリアA1)へ付与される熱量(t1)が、周辺密着相当部(である周部エリアA2)へ付与される熱量(t2)よりも低くなるように設定することが好ましい。
(A)密閉工程:上部開口した収容空間(S21)を有すると共にこの下収容空間(S21)内に被着体(W)を収容した下チャンバー(21)と、下部開口した上収容空間(S22)を有する上チャンバー(22)とを、両開口を覆う大きさの被覆フィルム(F)を挟んだ状態で上下に組み合わせて、上下各収容空間同士S21,S22が連成した連成空間を密閉形成する工程。
(B)リフトアップ工程:収容空間(S21)内に収容した被着体(W)を、前記立体成形部を含む密着領域、及びその周囲縁部に連なる側周部のいずれからも外れた保持部で接触保持し、保持部の駆動によって、被着体(W)を上収容空間側へリフトアップする工程。
(C)減圧及びドローダウン工程:密閉した連成空間の下収容空間(S21)内、上収容空間(S22)内を互いに同圧のまま減圧すると共に、被覆フィルム(F)に所定の熱量を付与してドローダウン状態とし、保持部によってリフトアップされた被着体の前記密着領域の最頂部が、張設された被覆フィルムの中央部に最も近接した状態とする工程。
(D)密着工程:減圧された上下各収容空間内のうち上収容空間(S22)内のみを大気圧開放することで、被着体(W)の前記密着領域ないし前記側周部に被覆フィルム(F)を一体的に密着させる工程。
この厚さ可変部は、立体成形部の隣接するディンプル形成ピッチと同じであるかあるいは前記ディンプル形成ピッチよりも小さいピッチで等間隔に離間形成されることが好ましい。
・複数の凹部又は/及び凸部が規則的に配列形成された表面の貼り付け箇所全体に、三次元加飾成形によって被覆フィルムを均一に貼り付けるため、三次元成形部の形状を大きく変化させることなく、均一に表面保護層を形成できる。
・ディンプル成形された移動体の板部材の表面の周囲側面を介して裏面まで連なる部分を一体的に三次元加飾成形することで、立体的形状へのフィルム貼り付けによるエアだまりや接着不良といった問題、端部で剥がれ易いといった問題を回避することができる。
・ドローダウン状態における熱量を立体成形部とその周囲とで変えることで、周囲のフィルムの薄化による影響をおさえることができ、貼り付け不良を抑制することができる。
被着体は露出表面が移動する移動体として使用するもの、それ自体は移動せず表面を流体が流れる相対移動体として使用するものを含み、また、ヒト又はものを運搬する運搬走行体の外面又は内面として使用するものを含む。装飾方法における被着体は、特に、前記のいずれか又は移動しない機能部品として使用するものを含む。また複数の凹部又は/及び凸部が規則的に配列形成された立体成形部は、部分球状の凹部であるディンプル状の窪みが規則配列されたディンプル成形部を含む。また被着体は、特に、走行体(自動車、二輪車、船舶、航空機)の動摩擦係数の低減を目的として、移動体の表面に多数のディンプル加工(凹部窪み)を施したものを含む。いずれにおいても被着体は複数の凹部又は/及び凸部が規則的に配列成形された立体成形部を外面に有する。被着体の用途は限定するものではないが、例えば、自動車、列車、自転車、飛行機、船等の、湾曲した板状部を有して使用の際に移動を伴う移動体、或いは、湾曲した板状部を有し、駆動機構によって使用の際に移動を伴う走行部品等の移動機器が含まれる。
実施例1の被着体(W)の立体成形部は全体が複数の面の組み合わせによって立体的に成形された全体概形を有し、その表面に複数の凹部又は/及び凸部からなる厚さ可変部(D)が規則的に配列成形される(図1~図3)。規則的に配列成形された複数の凹部の例としては例えば、図5aに示すような、四分の一以下の部分球面窪みが等間隔に並んで各列ごとの位置をずらしながら複数列成形された、ディンプル構造が挙げられる。前記ディンプル構造は、走行体や移動機器の表面に形成されることで、走行時の流体摩擦を生じる表面に微小な乱流領域を発生させ、走行面又は移動面に生じる表面摩擦抵抗を軽減する効果を有する。実施例2、実施例3の被着体(W)の立体成形部も同様にその表面に複数の凹部からなる厚さ可変部(D)が規則的に配列成形される(図6~図8)。
但し、この被着体は本発明の表面保護方法ないし表面装飾方法の後に初めて複数の凹部又は/及び凸部からなる厚さ可変部(D)が配列成形されるものでも良い。例えば実施例4~6では、加工前の被着体の立体成型部は厚さ可変部(D)を表面に有していない(図10.図13A、図14)。ところが、三次元加飾成形の手順において、複数の凹部又は/及び凸部からなる厚さ可変部(D)を有する被覆フィルムを使用する(図10)か、あるいは網状シートを被覆フィルムと被着体の表面との間に介在させる(図14、図15)ことで、本発明の表面保護方法ないし表面装飾方法によって初めて複数の凹部からなる厚さ可変部(D)が配列成形されるものとなっている(図11、図13B、図16)。
被覆フィルム(F)は前記被着体(W)の表面を保護する目的、装飾する目的、或いは保護及び装飾する目的で被着体(W)の表面の密着領域に密着貼付される。被覆フィルム(F)は被着体の密着領域の面積よりも大きい面積を有し、被着体の密着領域全てを含むように被着体表面を覆って密着された、三次元加飾成形状態となる。密着後の三次元加飾成形状態においては特に、密着領域の中央断面視にて表れる被着体の全周の過半部以上に亘るように密着される。密着領域の中央断面視にて表れる被着体の全周の過半部以上に亘るとは、例えば板状の被着体(W)の板表面全体を密着領域の主要領域としたとき、板側面、及び板裏面の一部までを含む範囲までを密着領域とする意味である。例えば図4、図5、図7に示すように、一枚の被覆フィルム(F)によって、被着体(W)の中央断面視過半周以上の範囲を一体的に覆って密着することで、密着領域内に複数の凹部/凸部またはその両方が形成された立体成形部を含む場合でも、立体成形の形状によって密着性が劣ったり密着後の定着性が劣ったりすることを回避することができる。
被覆フィルム(F)は、実施例1のように表面が平坦面からなるもの(図2、図9)でもよく、実施例2、4のように表面にあらかじめ複数の凹部(FD)が規則的に配列形成されたものでもよい(図6、10、図12a)。また実施例5のように下面に凸部(FA)又は凹部FD2が規則的に配列形成されたものでもよい(図12b、図12c、図13A)。さらに図12cに示すように表面に数μm径の透明のレンチキュラーレンズ(LR)を並行溝部(LRD)を境として列設すると共に、レンチキュラーレンズLRの下部に、規則模様PSPがプリントされた平坦なプリントシートPSを挟み込んで、被覆フィルムの表面に規則模様PSPが立体的に映し出された拡大像FD2が浮かび上がるように視認されるものとしている。被覆フィルム(F)の層構成としては、熱可塑性樹脂からなる基材層の下面に接着剤面(A)が形成される。
所定の三次元加飾成形の手順は、基本的に、
横方向に張り拡げた被覆フィルム(W)によって区画された、密閉式の連成空間(下収容空間(S21)、上収容空間(S22))の一方の空間に、ディンプル(部分球状窪み)状の立体成形部の密着領域を有する被着体を収容して、被着体の前記密着領域が一体的に露出するとともに被覆フィルムの接着剤面と対向するように配置し、連成空間内を共に減圧状態とすると共に被覆フィルム(W)を複数のヒーター加熱によって一部分が重複加熱されたドローダウン状態としてから、被着体を収容していない他方の空間(上収容空間(S22))を大気圧に圧力開放することで被着体の表面に被覆フィルムを瞬間的に延伸密着させる、いわゆる三次元加飾成形方法の工程からなる。
(A)密閉工程:上部開口した下収容空間(S21)を有すると共にこの下収容空間(S21)内に被着体(W)を収容した下チャンバー(21)と、下部開口した上収容空間(S22)を有する上チャンバー(22)とを、両開口を覆う大きさの被覆フィルム(F)を挟んだ状態で上下に組み合わせて、上下各収容空間同士(S21,22S)が連成して密閉した密閉連成空間を形成する工程(図2)。
(B)リフトアップ工程:ディンプル(部分球状窪み)状の立体成形部を有する被着体(W)を、収容空間(S21)内に収容して、ディンプル(部分球状窪み)状の立体成形部、及びその周囲縁部に連なる側周部のいずれからも外れた保持部(120)で接触保持し、保持部(120)を収容空間側へリフトアップすることで、被着体(W)の立体成形部とその周囲縁部に連なる側周部が収容空間(S21)内で一体的に露出し、被覆フィルムに近接した状態とする工程(図省略)。
(C)減圧及びドローダウン工程:密閉した連成空間の下収容空間(S21)内、上収容空間(S22)内を互いに同圧のまま減圧すると共に、被覆フィルム(F)に所定の熱量を付与してドローダウン状態とし、保持部によってリフトアップされた被着体の前記密着領域の最頂部が、張設された被覆フィルムの中央部に最も近接した状態とする工程(図3、図10)。
(D)密着工程:連成空間内の上下各収容空間内を互いに同圧のまま減圧し、次いで上収容空間内のみを大気圧開放することで、被着体(W)の前記立体成形部ないし側周部までに被覆フィルム(F)を一体的に密着させる工程。
(E)余密着部(FE)排除工程:裏面の裏面密着部(FF30)を所定のカットライン(CL)でカットし、カットされた周囲の裏面密着部(FF30)及びこれに連なる余密着部(FE)を排除することで、表面密着部(FF1)、側面密着部(FF2)、及び裏面カット密着部(FF3)のみからなる被覆状態に加工する工程(図5、図7、図11)。
図2~図4、図6、図7に示す実施例の三次元加飾成形装置は、
互いに近接乃至離間する下チャンバー(21)と上チャンバー(22)とによって、被覆フィルム(F)を挟んで上下に密閉された連成空間を形成可能な真空成形機からなる。
特に、実施例2の立ち上げ部(120S)は、下チャンバー(21)の内部側面に接するように形成される(図6、図7)。
被着体(W)のうち所定の部分成形部分(WP)を当該部分の内側から側周囲を覆う凹型形状の容体からなると共に、受け型上端が前記下チャンバー(21)の上部開口縁に沿って開口した受け治具(底枠板(11),側枠板(31)からなる)と、
被着体(W)を収容空間内に収容した状態で、被着体(W)の前記所定の成形部分(WP)の一部分を覆った前記受け治具を、上部開口に近接配置し得る下チャンバー(21)と、
下チャンバー(21)の上部空間の上方にて昇降可能に配置され、最下降状態において、収容空間の下部開口を、被覆フィルム(F)を挟んで下チャンバー(21)の上部開口に当接させて組み合わされる上チャンバー(22)と、
上チャンバー(22)内の上収容空間(S22)、及び、下チャンバー(21)内に配置固定した受け治具内の下空間(11S)を圧力制御する圧力制御手段と、を具備して構成される。
前記区画した受け治具内の下空間(11S)と、上チャンバー(22)内の上収容空間(S22)とを、被覆フィルム(F)を挟んで上下に密閉連成し、
密閉された容体内の下空間(11S)、上収容空間(S22)のそれぞれを減圧したのちに上収容空間(S22)のみを圧力開放することで、
受け治具で覆った被着体(W)の一部に被覆フィルム(F)をオーバーレイ成形する(図8)。
減圧及びドローダウン工程においては、密閉した連成空間の下収容空間(S21)内、上収容空間(S22)内を互いに同圧のまま減圧すると共に、被覆フィルム(F)に所定の熱量を付与してドローダウン状態とし、保持部によってリフトアップされた被着体の前記密着領域の最頂部が、張設された被覆フィルムの中央部に最も近接した状態とする。本工程によって、密着前の被覆フィルム(F)は、所定の熱量の付与によって熱延伸したドローダウン状態(DD)とされる。
なお、成形工程において、セットした被着体(W)の周囲外方に、被着体(W)の最大高さよりも高い突出高さで被覆フィルム(F)の近接方向に突出した立ち上げ部(120E)が設けられ、前記立ち上げ部(120E)が、被着体(W)よりも先に被覆フィルム(F)と接触し、被着体(W)の周囲外方にて被覆フィルム(F)を押し上げて張り拡げた枠接触状態となり、この枠接触状態の次に、被着体(W)が前記張り拡げられた被覆フィルム(F)の表面に密着する。この場合、セットした被着体(W)の成形部分WPの周囲外方に、被着体(W)の最大高さよりも高い突出高さで被覆フィルム(F)の近接方向に突出した立ち上げ枠が形成されるため、前記立ち上げ枠が、被覆フィルム(F)を近接させる際に被着体(W)よりも先に被覆フィルム(F)と接触し、被着体(W)の周囲外方にて被覆フィルム(F)を押し上げて張り拡げた状態となる。
下チャンバー(21)は、被着体(W)の全部を内部の収容空間に収容可能であり、被着体(W)のうち所定の成形部分WPを覆った受け治具を、被着体と共に内部の収容空間(S21)に収容し、受け治具を上部開口に近接配置し得る。
圧力調整工程は、被着体(W)上を覆う被覆フィルム(F)によって仕切られた上下の成形空間をそれぞれ減圧する減圧ステップと、減圧ステップの後に上部の成形空間のみを加圧する加圧ステップとを有する。
加熱工程は、前者の減圧ステップにおいて上部の成形空間内から被覆フィルム(F)を加熱するものである。また成形工程は、後者の加圧ステップにおいて下部の成形空間内からテーブルを上昇させて被覆フィルム(F)を被着体(W)上に被せるものである。
前記被着体(W)が、使用の際に移動を伴う移動体であって、ディンプル(部分球状窪み)状の立体成形部が、全表面範囲のうち移動の際に流体摩擦抵抗を受ける部分に露出して形成されることが、空気抵抗の低減性の確実な発揮のため好ましい。
密着前の被覆フィルム(F)は、所定の熱量の付与によって図3に示すようなドローダウン状態とされ、
このドローダウン状態から被覆フィルム(F)の上下の密閉空間の圧力差によって密着状態とされるものであり、
前記ドローダウン状態の被覆フィルム(F)のうち、ディンプル加工部への中央密着相当部(中央エリアA1)へ付与される熱量(t1)が、周辺密着相当部(周部エリアA2)へ付与される熱量(t2)よりも低くなるように設定されている。これにより中央部よりも側周部のほうが熱可塑反応が大きくなり、三次元加飾成形後の側周部のフィルムの伸び率が大きくなる。
図5,6に示す実施例2の密着前の被覆フィルムには、他の部分と比べて部分円形状に薄く又は厚く形成した厚さ部である凹部FDを、少なくとも前記密着相当範囲部分に複数個予め成形してあり、この厚さ可変部は、立体成形部の凹部たるディンプル(D)よりも小さいディンプル形状に配置形成されるとともに、立体成形部の凹部たるディンプル(D)の形成ピッチよりも小さいピッチで等間隔に離間形成される。
図8に示す実施例3の成形装置では、上部開口した下チャンバー(21)と下部開口した上チャンバー(22)とを、被覆フィルム(F)を挟んだ状態で上下に組み合わせて、上下収容空間同士21S,22Sが連成した成形空間を密閉形成し、この成形空間内の上下をそれぞれ圧力制御することで、成形空間内に収容した被着体(W)の一部表面に被覆フィルム(F)を減圧密着させる。下チャンバー(21)は、被着体(W)のうち所定の部分成形部分WPを当該部分の内側から側周囲を覆う凹型形状の受け治具からなり、受け治具内で囲った部分だけを部分真空成形する。
底枠板11は前後端が薄い段差状部11Eに形成された板状体からなり、底枠板11の板面上に、突出部分の三次元形状に対応して三次元形状に突出した成形型12が突出形成されてなる。この受け治具が凹型形状内にて前記所定の成形部分WPを纏めて覆った第二セット状態(SB1)で、前記成形型12が所定の成形部分WPの裏側に当接する。また開口底孔50は、二つの上方開口部10の底部にそれぞれ連なって上下貫通している。特記しない他の構成及び成形方法は実施例1と同様である。
図10~図13Bに示す実施例4、5の被覆フィルムも実施例3と同様に、密着前の被覆フィルムに、他の部分と比べて部分円形状に薄く又は厚く形成した厚さ可変部を、少なくとも前記密着相当範囲部分に複数個予め成形してある。特に実施例4では図10に示すように表面にのみ微細窪みからなる凹部FDが規則的に配置形成された被覆フィルムを使用しており、この被覆フィルムは上方からの加熱によって凹部FDの凹面自体が熱可塑状態となるため、加熱熱量の影響を受け易く、被覆フィルムの中央エリアA1と周囲エリアA2とでドローダウンの程度に変化をつけることができる。図10では、周部エリアA2のほうが中央エリアA1よりも薄く広く延伸するように輻射加熱され、中央エリアA1と周部エリアA2との境界を有して二段階にドローダウンされた状態となっている。
また、実施例5における異なる被覆フィルムの例を示す図12bでは、厚さ可変部として、被覆フィルムの裏面と表面にそれぞれ、複数の大凸部FT1,複数の小凸部FT2が配列される。これらの厚さ可変部は、互いに重ならないように互い違いにかつ規則的に配列成形される。
図14~図16に示す実施例6の被着体の表面装飾方法は、被着体の所定の密着領域に、密着領域の面積よりも大きい熱可塑性の被覆フィルムを、三次元加飾成形の手順によって一体的に密着させる、被着体の表面装飾方法であって、
被覆フィルムと被着体との間に、複数の開口部NHが規則的に配列成形された網状シート(N)を挟んで三次元加飾成形することで、
前記密着領域を含む被着体の断面視過半周に亘って、被覆フィルム(F)を一体的に密着させると共に、
前記密着領域の少なくとも一部に、網状シートの開口部に対応する複数の凹部が規則的に配列された立体成形部を形成することを特徴とする。
これによれば、挟んだ網状シートのシート厚さと開口部NHの開口形状に沿って厚さ可変部が形成されるため、表面装飾又は表面保護によって形成する厚さ可変部の大きさのコントロールが容易となる。例えば、前記実施例4(図10)のように被覆フィルムの表面に凹部を配列形成する場合、凹部の深さや大きさは被覆フィルムの基材の制限を受けてしまい、被覆フィルム厚さよりも深い厚さ可変部を形成することが困難となる。また、前記実施例5(図13A,B)や実施例5にて使用する被覆フィルムのバリエーション(図12abc)においては、凸部FTの熱可塑反応が部分的に劣り、凸部における延伸密着性が不安定になる可能性がある。これらに対し、網状シートNを被覆フィルムの下面又は被着体の上面に配置して三次元加飾成形の手順を行うことで、ドローダウン量のコントロールを、中央部ないし中部といったエリアごとに分けて確実に行うことができ(図15)、また、厚さ可変部を中央エリアだけに部分形成するといった、厚さ可変部の形成範囲のコントロールを自由に行うことができる(図15、図16)。
また、例えば図17aの網状シートNにおける所定範囲VAのみをくりぬいて、図17bや図17cに示すような他の網状シートNをこの所定範囲VAに合わせて切り出し、組み合わせることで、当該所定範囲VA内の所定開口群VHAの形状、大きさ、個数を自在にコントロールすることができる。
1.表面に多数のディンプル加工(数mm径の凹部窪み)が施された三次元形状の外板に、被覆フィルム/被覆フィルムをドローダウン量のコントロールを伴う三次元加飾成形の手順によって定着させ、定着状態において規則的な厚さ可変部を形成する。これにより吹き付けのような樹脂溜まりが生じず、均一に表面保護層を形成できる。また、規則的な厚さ可変部を形成することで、表面の空気摩擦抵抗を削減し、流麗な外観を形成することができる。
2.”平坦な”被覆フィルムを、所望の厚さ可変部を有する網状シートN又は被着体表面の凹部に沿って三次元加飾成形(フィルムを挟んだ2連の密閉空間の片側を減圧させることによるフィルムの密着貼付工法)によって熱可塑状態で定着する。これによりディンプル形状を変形させることなく均一に所定の大きさ、数、深さの厚さ可変部を有した表面保護層を形成できる。
3.“表面に微細凹凸からなる厚さ可変部が形成された”被覆フィルムを、三次元加飾成形によってディンプル表面に貼り付ける。これによりディンプル効果を向上させつつ均一に表面保護層を形成できる。
4.表面保護を目的として加飾成形によって厚さ可変部を伴った被覆フィルムの固定を行うことで、凸部又は凹部の周辺部分によって被着体を所定の厚さで保護することで耐候性を確保することができる。
5.表面装飾を目的として加飾成形によって厚さ可変部を伴った被覆フィルムの固定を行うことで、凸部又は凹部の形成ないし被覆フィルムの表面加工によって被着体を所定の凹凸模様を有した携帯で被着体と一体化させ、今までにない規則的な配置からなる、あるいは複数種類の規則的な配置を組み合わせた厚さ可変部を有した被着体を一体形成できる。
6.厚さ可変部の大きさをコントロールすることで、高速走行時の空気抵抗の削減や増加、一部分だけの凹凸加工といった所定の表面形状調整の要望に応えることができる。
22S 上収容空間
F 被覆フィルム
WP 成形部分
W 被着体
D 厚さ可変部
A1 中央エリア(中央密着相当部)
A2 周部エリア(周辺密着相当部)
21 下チャンバー
22 上チャンバー
Claims (12)
- 被着体の所定の密着領域に、密着領域の面積よりも大きい熱可塑性の被覆フィルムを、三次元加飾成形の手順によって一体的に密着させる、被着体の表面保護方法であって、
被覆フィルムと被着体との間に、複数の開口部が規則的に配列成形された網状シートを挟んで三次元加飾成形することで、
前記密着領域を含む被着体の断面視過半周に亘って、被覆フィルムを一体的に密着させると共に、
前記密着領域の少なくとも一部に、網状シートの開口部に対応する複数の凹部が規則的に配列された立体成形部を形成することを特徴とする、被着体の表面保護方法。 - 前記所定の密着領域は、前記立体成形部の全てを含み、かつ、被着体の中央断面視にて過半周に亘るものであり、
前記三次元加飾成形の手順は、
被覆フィルムによって区画した連成空間の一方の空間に被着体を収容して前記密着領域が一体的に露出するように配置し、連成空間内を共に減圧状態としてから、被着体を収容していない他方の空間を大気圧に圧力開放することで被着体の表面に被覆フィルムを密着させることで、
前記密着領域を含む被着体の断面視過半周に亘って、被覆フィルムを一体的に密着させる、請求項1記載の被着体の表面保護方法。 - 前記被着体が、湾曲した板状部を有して使用の際に移動を伴う移動体であって、
前記立体成形部が、被着体の前記湾曲した板状部の板表面のうち、移動の際に流体摩擦抵抗を受ける部分に、複数のディンプル状の窪みが露出して配列形成されたものであり、
前記被覆フィルムを密着させる密着領域は、前記板表面、板表面の周部に連なる板側面、及び板側面に連なる板裏面の一部を含む、連続した面領域である、請求項1又は2記載の被着体の表面保護方法。 - 前記三次元加飾成形の手順において、
連成空間は、横方向に張設した被覆フィルムを境界としてこの被覆フィルムの上下に連成され、
連成空間のうちの下方の下収容空間に被着体を収容し、連成空間のうちの上方の上収容空間を大気圧に圧力開放するものであり、
前記上収容空間を大気圧に開放する前に、被覆フィルムは、所定の熱量を付与されることで、被着体の立体成形部と近接したドローダウン状態とされ、
このドローダウン状態から被覆フィルムの上下の密閉空間の圧力差によって密着状態とされるものであり、
前記ドローダウン状態の被覆フィルムのうち、立体成形部への中央密着相当部へ付与される熱量が、立体成形部の周部への周辺密着相当部へ付与される熱量よりも低くなるように設定する、請求項1、2、又は3のいずれか記載の被着体の表面保護方法。 - 前記三次元加飾成形の手順は、少なくとも以下の各工程を含むことを特徴とする、請求項1、2、3、又は4のいずれか記載の被着体の表面保護方法。
密閉工程:上部開口した収容空間を有すると共にこの下収容空間内に被着体を収容した下チャンバーと、下部開口した上収容空間を有する上チャンバーとを、両開口を覆う大きさの被覆フィルムを挟んだ状態で上下に組み合わせて、上下各収容空間同士が連成した連成空間を密閉形成する工程。
リフトアップ工程:収容空間内に収容した被着体を、密着領域及びその周囲縁部に連なる側周部のいずれからも外れた保持部で接触保持し、保持部の駆動によって、被着体を上収容空間側へリフトアップする工程。
減圧及びドローダウン工程:密閉した連成空間の下収容空間内、上収容空間内を互いに同圧のまま減圧すると共に、被覆フィルムに所定の熱量を付与してドローダウン状態とし、保持部によってリフトアップされた被着体の前記密着領域の最頂部が、張設された被覆フィルムの中央部に最も近接した状態とする工程。
密着工程:減圧された上下各収容空間内のうち上収容空間内のみを大気圧開放することで、被着体の前記密着領域ないし前記側周部に被覆フィルムを一体的に密着させる工程。 - 前記密着前の被覆フィルムには、他の部分と比べて部分円形状に薄く又は厚く形成した厚さ可変部を、少なくとも前記密着相当範囲部分に複数個予め成形してあり、
この厚さ可変部は、網状シートに規則的に配列成形された複数の開口部の配列ピッチと同じであるかあるいは前記配列ピッチよりも小さいピッチで規則的に配列成形される、請求項1ないし4のいずれか記載の被着体の表面保護方法。 - 被着体の所定の密着領域に、密着領域の面積よりも大きい熱可塑性の被覆フィルムを、三次元加飾成形の手順によって一体的に密着させる、被着体の表面装飾方法であって、
被覆フィルムと被着体との間に、複数の開口部が規則的に配列成形された網状シートを挟んで三次元加飾成形することで、
前記密着領域を含む被着体の断面視過半周に亘って、被覆フィルムを一体的に密着させると共に、
前記密着領域の少なくとも一部に、網状シートの開口部に対応する複数の凹部が規則的に配列された立体成形部を形成することを特徴とする、被着体の表面装飾方法。 - 前記所定の密着領域は、前記立体成形部の全てを含み、かつ、被着体の中央断面視にて過半周に亘るものであり、
前記三次元加飾成形の手順は、
被覆フィルムによって区画した連成空間の一方の空間に被着体を収容して前記密着領域が一体的に露出するように配置し、連成空間内を共に減圧状態としてから、被着体を収容していない他方の空間を大気圧に圧力開放することで被着体の表面に被覆フィルムを密着させることで、
前記密着領域を含む被着体の断面視過半周に亘って、被覆フィルムを一体的に密着させる、請求項7記載の被着体の表面装飾方法。 - 前記被着体が、湾曲した板状部を有して使用の際に移動を伴う移動体であって、
前記立体成形部が、被着体の前記湾曲した板状部の板表面のうち、移動の際に流体摩擦抵抗を受ける部分に、複数のディンプル状の窪みが露出して配列形成されたものであり、
前記被覆フィルムを密着させる密着領域は、前記板表面、板表面の周部に連なる板側面、及び板側面に連なる板裏面の一部を含む、連続した面領域である、請求項7又は8記載の被着体の表面装飾方法。 - 前記三次元加飾成形の手順において、
連成空間は、横方向に張設した被覆フィルムを境界としてこの被覆フィルムの上下に連成され、
連成空間のうちの下方の下収容空間に被着体を収容し、連成空間のうちの上方の上収容空間を大気圧に圧力開放するものであり、
前記上収容空間を大気圧に開放する前に、被覆フィルムは、所定の熱量を付与されることで、被着体の立体成形部と近接したドローダウン状態とされ、
このドローダウン状態から被覆フィルムの上下の密閉空間の圧力差によって密着状態とされるものであり、
前記ドローダウン状態の被覆フィルムのうち、立体成形部への中央密着相当部へ付与される熱量が、立体成形部の周部への周辺密着相当部へ付与される熱量よりも低くなるように設定する、請求項7、8、又は9のいずれか記載の被着体の表面装飾方法。 - 前記三次元加飾成形の手順は、少なくとも以下の各工程を含むことを特徴とする、請求項7、8、9、又は10のいずれか記載の被着体の表面装飾方法。
密閉工程:上部開口した収容空間を有すると共にこの下収容空間内に被着体を収容した下チャンバーと、下部開口した上収容空間を有する上チャンバーとを、両開口を覆う大きさの被覆フィルムを挟んだ状態で上下に組み合わせて、上下各収容空間同士が連成した連成空間を密閉形成する工程。
リフトアップ工程:収容空間内に収容した被着体を、密着領域及びその周囲縁部に連なる側周部のいずれからも外れた保持部で接触保持し、保持部の駆動によって、被着体を上収容空間側へリフトアップする工程。
減圧及びドローダウン工程:密閉した連成空間の下収容空間内、上収容空間内を互いに同圧のまま減圧すると共に、被覆フィルムに所定の熱量を付与してドローダウン状態とし、保持部によってリフトアップされた被着体の前記密着領域の最頂部が、張設された被覆フィルムの中央部に最も近接した状態とする工程。
密着工程:減圧された上下各収容空間内のうち上収容空間内のみを大気圧開放することで、被着体の前記密着領域ないし前記側周部に被覆フィルムを一体的に密着させる工程。 - 前記密着前の被覆フィルムには、他の部分と比べて部分円形状に薄く又は厚く形成した厚さ可変部を、少なくとも前記密着相当範囲部分に複数個予め成形してあり、
この厚さ可変部は、網状シートに規則的に配列成形された複数の開口部の配列ピッチと同じであるかあるいは前記配列ピッチよりも小さいピッチで規則的に配列成形される、請求項7ないし10のいずれか記載の被着体の表面装飾方法。
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HK18113240.1A HK1263395A1 (zh) | 2015-05-19 | 2018-10-16 | 粘附體的表面保護方法以及表面裝飾方法 |
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