Method for manufacturing sheet laminate

A method for manufacturing a sheet laminate to be affixed to an adherent surface of an object, the method comprising preparing a sheet member having a front surface to become a design surface and a rear surface on which an adhesive part has been formed, bending an edge part of the sheet member by sandwiching the sheet member from a front surface side and a rear surface side in a mold, and heating a part of a bent sheet member. The sheet laminate has a flat part spreading out in a flat plate shape, a side surface on which the edge part bent by the bending step is configured, and a connecting surface protruding and curving toward the front surface side between the flat part and the side surface, and in the heating step, the connecting surface is partially heated after the side surface is molded in the bending step.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a national stage filing under 35 U.S.C. 371 of PCT/IB2017/058160, filed Dec. 19, 2017, which claims the benefit of Japan Application No. 2016-255468, filed Dec. 28, 2016, the disclosures of which are incorporated by reference in their entireties herein.

TECHNICAL FIELD

The present invention relates to a method for manufacturing a sheet laminate, a mold for molding a sheet laminate, and a sheet laminate.

BACKGROUND

A molding method called stamping is known as a conventional method for manufacturing a sheet laminate (for example, see Japanese Patent JP 2015-229279). In particular, a processing method for sandwiching a sheet in a heated mold and then bending the sheet is referred to as heat stamping.

SUMMARY OF THE INVENTION

Thus, there is a requirement to bend an edge part of a sheet laminate having an adhesive part on a rear surface and a protective sheet on a front surface. However, this presents a problem in that when heat stamping like that described above is performed with respect to this type of sheet laminate, the adhesive part, a liner, and the protective sheet peel away during molding. There is a demand to resolve this type of problem by manufacturing a bent sheet laminate.

A method for manufacturing a sheet laminate according to an embodiment of the present invention is a method for manufacturing a sheet laminate to be affixed to an adherent surface of an object and is provided with a preparing step for preparing a sheet member having a front surface to become a design surface and a rear surface on which an adhesive part has been formed, a bending step for bending an edge part of the sheet member by sandwiching the sheet member from a front surface side and a rear surface side in a mold, and a partial heating step for heating a part of a bent sheet member, where the sheet laminate has a flat surface part spreading out in a flat plate shape, a side surface on which the edge part bent by the bending step is configured, and a connecting surface protruding and curving toward the front surface side between the flat surface part and the side surface, and in the partial heating step, the connecting surface is partially heated after the side surface is molded in the bending step.

With this kind of embodiment, the sheet laminate has the flat surface part spreading out in a flat plate shape, the side surface on which the edge part bent by the bending step is configured, and the connecting surface protruding and curving toward the front surface side between the flat surface part and the side surface. After the sheet member has been bent into this kind of shape in the bending step, the connecting surface is partially heated in the partial heating step. When the sheet member is molded in a state where the adhesive part has been formed, the adhesive part becomes susceptible to peeling in a position corresponding to the connecting surface that deforms so as to curve in the bending step. Accordingly, distortion in said part can be removed by performing a partial annealing process through partial heating of the connecting surface. Therefore, adhesive part peeling can be prevented and a good quality sheet laminate can be manufactured. A bent sheet laminate can be provided as described above.

With a method for manufacturing a sheet laminate according to another embodiment, a main body part for configuring the flat surface part of the sheet laminate, and a pair of side wall parts extending respectively toward the rear surface side from a pair of mutually intersecting main body part side parts are molded by the bending step, where the side surface has a first side surface corresponding to one side wall part of the pair of side wall parts, a second side surface corresponding to the other side wall part of the pair of side wall parts, and a third side surface forming a roundness having a predetermined curvature formed in a corner part between the first side surface and the second side surface, and the connecting surface has a first connecting surface for connecting the flat surface part and the first side surface, a second connecting surface for connecting the flat surface part and the second side surface, and a third connecting surface for connecting the flat surface part and the third side surface.

In the method for manufacturing a sheet laminate according to another embodiment, the connecting surface is exposed from the mold in the partial heating step, and partial heating is performed by applying heat to the connecting surface from outside the mold.

In the method for manufacturing a sheet laminate according to another embodiment, partial heating is performed in the partial heating step through a part in the mold that makes contact with the connecting surface.

In the method for manufacturing a sheet laminate according to another embodiment, heat going to the flat surface part and the side surface may be insulated in the partial heating step.

In the method for manufacturing a sheet laminate according to another embodiment, the sheet member may also be provided with a release liner covering the adhesive part of the rear surface of the sheet member.

A mold for molding the sheet laminate according to an embodiment of the present invention is a mold for molding a sheet laminate to be affixed to an adherent surface of an object. The mold is provided with a first unit for supporting a sheet member, having a front surface to become a design surface and a rear surface where an adhesive part is formed, from a front surface side, and a second unit for supporting the sheet member from a rear surface side; where the first unit and the second unit are able to mold a main body part spreading in a flat plate shape and a pair of side wall parts extending respectively toward a rear surface side from a pair of mutually intersecting main body part side parts by sandwiching the sheet member and bending an edge part of the sheet member; and where, when the front surface has a flat surface part corresponding to the main body part, a first side surface corresponding to one side wall part of the pair of side wall parts, a second side surface corresponding to the other side wall part of the pair of side wall parts, and a third side surface forming a roundness having a predetermined curvature formed in a corner part between the first side surface and the second side surface, a first connecting surface protruding curving toward the front surface side for connecting the flat surface part and the first side surface, a second connecting surface protruding curving toward the front surface side for connecting the flat surface part and the second side surface, and a third connecting surface protruding curving toward the front surface side for connecting the flat surface part and the third side surface; the first unit supports the flat surface part, the first side surface, the second side surface, and the third side surface in a state where the first connecting surface, the second connecting surface and the third connecting surface are exposed.

The mold for molding the sheet laminate according to an embodiment of the present invention is a mold for molding a sheet laminate to be affixed to an adherent surface of an object. The mold is provided with a first unit for supporting a sheet member, having a front surface to become a design surface and a rear surface where an adhesive part is formed, from a front surface side, and a second unit for supporting the sheet member from a rear surface side; where the first unit and the second unit are able to mold a main body part spreading in a flat plate shape sandwich in the sheet laminate and a pair of side wall parts each extending toward a rear surface side from a pair mutually intersecting main body part side parts by sandwiching the sheet member and bending an edge part of the sheet member; and where, when the front surface has a flat surface part corresponding to the main body part, a first side surface corresponding to one of the side wall parts of the pair of side wall parts, a second side surface corresponding to the other of the side wall parts of the pair of side wall parts, and a third side surface forming a roundness having a predetermined curvature formed in a corner part between the first side surface and the second side surface, a first connecting surface protruding curving toward the front surface side for connecting the flat surface part and the first side surface, a second connecting surface protruding curving toward the front surface side for connecting the flat surface part and the second side surface, and a third connecting surface protruding curving toward the front surface side for connecting the flat surface part and the third side surface; the first unit is provided with a heating part for heating a part in contact with the first connecting surface, the second connecting surface and the third connecting surface, and an insulating part for insulating a space between the flat surface part, the first side surface, the second side surface, and the third side surface.

A sheet laminate according to an embodiment of the present invention is a sheet laminate that is to be affixed to an adherent surface of an object and has a flat surface part that spreads out in a flat plate shape, a side surface configured by a bent edge of the flat surface part, and a connecting surface protruding and curving toward a front surface side between the flat surface part and the side surface, where a part configuring the flat surface part, the side surface, and the connecting surface is configured of a base material part having a front surface that is to become a design surface and a rear surface on a side opposite the front surface, an adhesive layer formed on the rear surface of the base material part, and a release liner layer covering the adhesive layer that can be peeled from the adhesive layer.

The sheet laminate according to another embodiment is provided with a main body part for configuring the flat surface part, and a pair of side wall parts extending respectively toward the rear surface side from a pair of mutually intersecting main body part side parts; where the side surface has a first side surface corresponding to one side wall part of the pair of side wall parts, a second side surface corresponding to the other side wall part of the pair of side wall parts, and a third side surface forming a roundness having a predetermined curvature formed in a corner part between the first side surface and the second side surface; and where the connecting surface may have a first connecting surface for connecting the flat surface part and the first side surface, a second connecting surface for connecting the flat surface part and the second side surface, and a third connecting surface for connecting the flat surface part and the third side surface.

With the sheet laminate according to another embodiment, the third side surface forms the aforementioned roundness protruding toward the front surface side, and the curvature of the roundness may have a radius of 1 to 2000 mm. With the sheet laminate according to another embodiment, the third side surface forms the aforementioned roundness protruding toward the rear surface side, and the curvature of the roundness may have a radius of 0.5 to 2000 mm.

In the sheet laminate according to another embodiment, a base material layer may be covered with a biaxially extended protective film layer.

In the sheet laminate according to another embodiment, the release liner layer may be configured using a biaxially extended film.

In the sheet laminate according to another embodiment, the adhesive layer may be configured using an acrylic pressure-sensitive adhesive.

In the sheet laminate according to another embodiment, the base material layer may be configured using a polycarbonate.

According to the present invention, a bent sheet laminate can be provided.

DESCRIPTION OF EMBODIMENTS

Detailed descriptions of embodiments according to the present invention are given below with reference to the attached drawings. Note that, in the following descriptions, the same reference symbols have been assigned to elements that are the same or equivalent, and that redundant descriptions thereof have been omitted.

A sheet laminate1according to an embodiment of the present invention will be described with reference toFIG. 1andFIG. 2.FIG. 1is a plan view of a sheet laminate as seen from a design surface side.FIG. 2is a cross sectional view along the Line II-II illustrated inFIG. 1. A sheet laminate1according to the present embodiment is a member to be affixed to an adherent surface of any object. The sheet laminate1has a front surface to become a design surface, and a rear surface to become a sticking surface for the object. This allows the sheet laminate1to cover the object so that the design surface faces outward. Examples of objects to which the sheet laminate can be affixed include a vehicle center pillar, rear pillar, door sash, and the like. A sheet member having the surface to become a design surface and a rear surface on which an adhesive part3is formed is prepared for the sheet laminate1, which is a molded product formed by bending an edge of the sheet member using a mold. The configuration of the sheet laminate1, which is a finished product, will be described here in detail, after that, the method for manufacturing the sheet laminate1, and the mold used in said method, will also be described in detail.

As illustrated inFIG. 1andFIG. 2, the sheet laminate1is provided with a main body part11, and a side wall part12. The main body part11is a part spreading out in a flat plate shape taking any form. In the present embodiment, the main body part11has a rectangular shape when seen from a thickness direction. However, the shape of the main body part11when seen from the thickness direction is not particularly limited, and thus may form a long rectangular shape, a T shape, or a cross shape. InFIG. 1, the main body part11has four side parts11a,11b,11c, and11k. Here, the sides11aand11bare orthogonal to one another, the sides11band11care orthogonal to one another, the sides11kand11aare orthogonal to one another, and the sides11kand11care orthogonal to one another, and the intersecting angles are not particularly limited. Furthermore, a curved part11dis formed by forming a roundness facing outward at a prescribed curvature in a corner where the side part11aand the side part11bintersect. A curved part11eis formed by forming a roundness facing outward at a prescribed curvature in a corner where the side part11band the side part11cintersect.

The side wall part12is a wall part extending toward a rear surface side from each of the side parts11a,11b, and11cof the main body part11. The side wall part12is also formed in positions corresponding to the curved parts11dand11eof the main body part11. Specifically, a side wall part12A is formed in the side part11aof the main body part11, a side wall part12B is formed in the side part11bthereof, and a side wall part12C is formed in the side part11cthereof. Furthermore, a side wall part12D is formed in the curved part11dof the main body, and a side wall part12E is formed in a curved part11ethereof. The side wall parts12A through12E are connected together so as to surround the main body part11in a continuous fashion. That is, the side wall part12A corresponding to the side part11aand the side wall part12D corresponding to the curved part11dare integrally connected. The side wall part12D corresponding to the curved part11dand the side wall part12B corresponding to side part11bare also integrally connected. The side wall part12B corresponding to the side part11band the side wall part12E corresponding to curved part11eare also integrally connected. The side wall part12E corresponding to the curved part11eand the side wall part12C corresponding to side part11care also integrally connected. Note that while no side wall part is formed in a position corresponding to the side part11kin the embodiment ofFIG. 1, such a part may be formed.

Furthermore, a connecting part13is formed between the main body part11and the side wall part12, and curves so as to protrude toward a front surface side. Connecting parts13A,13B,13C,13D, and13E are formed between the main body part11and the side wall parts12A,12B,12C,12D, and12E, respectively. The connecting parts13A,13B,13C,13D, and13E are integrally connected to the main body part11and to the side wall parts12A,12B,12C,12D, and12E.

As illustrated inFIG. 2, the sheet laminate1(also referred to as molded sheet laminate1) is provided with a base material part (base material layer)2, an adhesive part (adhesive layer)3, a release liner (release liner layer)4, and a protective film (protective film layer)6. Furthermore, the sheet laminate1is configured by molding, as-is, a sheet member formed by laminating the base material part2, the adhesive part3, the release liner4, and the protective film6. Accordingly, the main body part11, the side wall part12, and the connecting part13are each provided with the base material part2, the adhesive part3, the release liner4, and the protective film6.

The base material part2is a member that forms a base for the sheet laminate1. The base material part2has a front surface2ato become a design surface, and a rear surface2bon a side opposite the front surface2a. The base material part2is configured from a material, such as polycarbonate, PET, ABS resin, and the like. Furthermore, a thickness of the base material part2is not particularly limited, and thus may be 0.2 to 1.5 mm. Furthermore, a surface treatment using, for example, polyurethane, acrylic, or the like, is applied to the front surface2ato become the design surface.

The adhesive part3is a member for joining the sheet laminate1to an object by adhering to said object. The adhesive part3is laminated onto the rear surface2bof the base material part2. The adhesive part3is laminated onto the rear surface2bof the base material part2so as to cover nearly the entire surface thereof. Of the surfaces of the adhesive part3, an adhesive surface3afunctions as a surface on a side opposite the base material part2. The adhesive part3is configured from a material, such as acrylic, rubber, and the like. More specifically, the adhesive layer may be configured using an acrylic pressure-sensitive adhesive. Furthermore, a thickness of the adhesive part3is not particularly limited, and thus may be 0.005 to 0.4 mm.

The release liner4is a member for protecting the adhesive part3. The release liner4covers the entire surface of the adhesive surface3aof the adhesive part3. When the sheet laminate1is adhered to an object, the release liner4is peeled from the adhesive part3to thus expose the adhesive part3. The release liner4may be configured using a biaxially extended film. For example, the release liner4is provided with a release layer of silicone, and the like, on a biaxially extended material, such as PET, PEN, or the like, and a polyolefin layer of PE, or the like, may also be provided there between. Furthermore, a thickness of the release liner4is not particularly limited, and thus may be 0.01 to 0.3 mm.

Because the protective film6covers the front surface2aof the base material part2, said film serves as a member for protecting the front surface2a, which is the design surface. The protective film6is a biaxially extended film. That is, while the front surface2ain the connecting part13of the base material part2deforms so as to stretch somewhat when the sheet laminate1is molded from a sheet member state, there is only a small degree of following. The material of the protective film6is configured from PET, PEN, or the like. Furthermore, a thickness of the protective film6is not particularly limited, and thus may be 0.005 to 0.3 mm.

A surface configuration of the design surface (that is, the front surface2aof the base material part2) of the sheet laminate1will be described next. The sheet laminate1has a flat surface part20spreading out in a flat plate shape, a side surface21on which a bent edge part of the flat surface part20is configured, and a connecting surface22protruding and curving toward the front surface2aside between the flat surface part20and the side surface21. The flat surface part20is formed on a part corresponding to the main body part11portion of the front surface2a. The side surface21is formed on a part corresponding to the side wall parts12A through12E portion of the front surface2a. The connecting surface22is formed on parts corresponding to the connecting parts13A through13E portion of the front surface2a.

The surface configuration of the sheet laminate1is described in further detail below with reference toFIG. 3 (a). Note that whileFIG. 3 (a)illustrates a configuration in the vicinity of the side wall part12C, the side wall part12B, and the side wall part12E, the same gist holds for descriptions of different parts so long as a pair of mutually intersecting side walls12is provided.

As illustrated inFIG. 3 (a), the flat surface part20corresponds to the main body part11, and forms a primary surface, that is, a flat surface. The side surface21has a first side surface21B corresponding to the side wall part12B, which is one of the pair made up of the side wall parts12B and12C, a second side surface21C corresponding to the side wall part12C, which is the other of said pair, and a third side surface21E corresponding to the side wall part12E that forms a roundness. The first side surface21B and the second side surface21C form a primary surface, that is, a flat surface. The third side surface21E is formed in a corner between the first side surface21B and the second side surface21C, and is a surface for forming a roundness having a predetermined curvature. The third side surface21E forms a secondary surface, that is, a curved surface having a component bent with reference to a single axis. When seen from a thickness direction of the main body part11, the third side surface21E forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 1 to 2000 mm. The connecting surface22has a first connecting surface22B for connecting the flat surface part20and the first side surface21B, a second connecting surface22C for connecting the flat surface part20and the second side surface21C, and a third connecting surface22E for connecting the flat surface part20and the third side surface21E. The first connecting surface22B is a secondary surface corresponding to a connecting part13B. When seen from a thickness direction of the side wall part12C, the first connecting surface22B forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 0.5 to 200 mm. The second connecting surface22C is a secondary surface corresponding to a connecting part13C. When seen from a thickness direction of the side wall part12B, the second connecting surface22C forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 0.5 to 200 mm. The third connecting surface22E is a tertiary surface corresponding to a connecting part13E. The tertiary surface forms a curved surface having a component bent with reference to two axes. The third connecting surface22E has a curved component of the third side surface21E and a curved component of the first connecting surface22B and the second connecting surface22C.

Note that “first side surface” and “second side surface” are expedient names for clearly describing a structure and thus may be a first side surface21C and a second side surface21B. Accordingly, these are sometimes referred to in the following description simply as “side surface” without distinguishing between “first side surface” and “second side surface.” Furthermore, “first connecting surface” and “second connecting surface” are also expedient names for clearly describing a structure and thus may be a first connecting surface22C and a second connecting surface22B. Accordingly, these are sometimes referred to in the following description simply as “connecting surface” without distinguishing between “first connecting surface” and “second connecting surface.”

A structure in a case where a third side surface protrudes toward the front surface side and thus draws a so-called positive curve was described usingFIG. 3 (a). However, this may also be a structure where the third side surface protrudes toward the rear surface side and thus draws a so-called negative curve. Specifically, the structure illustrated inFIG. 3 (b)may be used. As illustrated inFIG. 3 (b), a side wall part12H forming a roundness so as to protrude toward the rear surface side is formed by a corner between a pair of side wall parts12E and12G that extend straight from said corner. Furthermore, connecting parts13F,13G, and13H are formed between the main body part11and the side wall parts12F,12G and12H, respectively.

In the configuration ofFIG. 3 (b), the side surface21has a first side surface21F corresponding to the side wall part12F, which is one of the pair made up of the side wall parts12F and12G, a second side surface21G corresponding to the side wall part12G, which is the other of said pair, and a third side surface21H corresponding to the side wall part12H that forms a roundness. The first side surface21F and the second side surface21G form a primary surface, that is, a flat surface. The third side surface21H is formed in a corner between the first side surface21F and the second side surface21G, and is a surface for forming a roundness having a predetermined curvature. The third side surface21H forms a secondary surface, that is, a curved surface having a component bent with reference to a single axis. When seen from a thickness direction of the main body part11, the third side surface21H forms a roundness protruding toward the rear surface side. A radius of a curvature of the roundness is 0.5 to 2000 mm. The connecting surface22has a first connecting surface22F connecting the flat surface part20and the first side surface21F, a second connecting surface22G connecting the flat surface part20and the second side surface21G, and a third connecting surface22H connecting the flat surface part20and the third side surface21H. The first connecting surface22F is a secondary surface corresponding to a connecting part13F. When seen from a thickness direction of the side wall part12G, the first connecting surface22F forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 0.5 to 200 mm. The second connecting surface22G is a secondary surface corresponding to a connecting part13G. When seen from a thickness direction of the side wall part12F, the second connecting surface22G forms a roundness protruding toward the front surface side. A radius of a curvature of the roundness is 0.5 to 200 mm. The third connecting surface22H is a tertiary surface corresponding to a connecting part13H. The tertiary surface forms a curved surface having a component bent with reference to two axes. The third connecting surface22H has a curved component of the third side surface21H and a curved component of the first connecting surface22F and the second connecting surface22G.

The method for manufacturing the sheet laminate1according to the present embodiment and a mold100for molding the sheet laminate1are described next with reference toFIG. 4throughFIG. 10.

A configuration of the mold100for molding the sheet laminate1will be described first. The mold100is a mold for molding the sheet laminate1to be affixed to an adherent surface of an object. As illustrated inFIG. 5, the mold100is provided with a first unit110a second unit120. The first unit is a unit for supporting a sheet member50, having a front surface50ato become a design surface and a rear surface50bon which the adhesive part3is formed, from the front surface50aside. The second unit120is a unit for supporting the sheet member50from the rear surface50bside. The first unit110and the second unit120are able to mold the main body part11spreading in a flat plate shape portion of the sheet laminate1, and the side wall parts12extending respectively toward the rear surface50bside from mutually intersecting side parts of the main body part11by sandwiching the sheet member and bending an edge part of the sheet member50. Note that what is described here is the mold100for molding the sheet laminate1having the shape illustrated inFIG. 1. That is, this is a description of the mold100for molding the sheet laminate1having the side wall parts12A through12F. However, because the form of the sheet laminate1is not particularly limited, the configuration of the mold100can be changed appropriately to match the form of the sheet laminate1.

The first unit110is provided with a first piece111for supporting the flat surface part20of the main body part11, and a second piece112for supporting each surface of the side wall part12. When seen from a thickness direction, the first piece111is configured as a block forming a rectangular shape to match the form of the flat surface part20of the main body part11(seeFIG. 6). An upper surface of the first piece111is configured as a supporting surface113for making contact with and thus supporting the flat surface part20of the main body part11. When seen from a thickness direction, the second piece112is configured as a frame member having an opening that matches the form of the side surface21of the side wall part12(seeFIG. 6). A third piece121of the second piece112and of the second unit120to be described later is provided inside the opening of the second piece112.

An inner circumferential surface of the opening of the second piece112is configured as a supporting surface114for supporting the side surface21of the side wall part12. Furthermore, an arranging part116for arranging the previously molded sheet member50is formed near an upper edge of the opening of the second piece112. The arranging part116faces an end part of an outer circumferential side of the sheet member50, and has an aligning surface117for performing alignment in a plane direction of the sheet member50. The arranging part116also has a guide surface118for smoothly guiding (seeFIG. 7) the side wall part12toward the supporting surface114side when an edge part of the sheet member50is bent during molding. Note that while the guide surface118is a curved surface curved so as to protrude outward in the present embodiment, said surface may be an inclined surface extending in a straight manner.

The second unit120is provided with a third piece121for pressing the sheet member50from the rear surface50bside toward the front surface50aside. A lower surface of the third piece121is configured as a supporting surface122for pressing the rear surface side of the main body part11of the sheet laminate1. Furthermore, an outer circumferential surface of the third piece121is configured as a supporting surface123for making contact with and thus supporting the rear surface side (surface on the opposite side of the side surface21) of the side wall part12of the sheet laminate1. During molding, the side wall part12is sandwiched by the supporting surface114of the second piece112and the supporting surface123of the third piece121(seeFIG. 8). Accordingly, a dimension in a horizontal direction gap between the supporting surface114and the supporting surface123is set to a thickness dimension of the side wall part12.

At least during the execution of a partial heating step to be described later, the first unit110supports the flat surface part20and the side surface21(first side surface, second side surface, and third side surface), in a state where the connecting surface22(first connecting surface, second connecting surface, and third connecting surface) of the sheet laminate1is exposed. That is, inFIG. 3 (a), the connecting surfaces22B,22C, and22E are exposed from the first unit110, and the flat surface part20and the side surfaces21B,21C, and21E are supported by the first unit110.

A manufacturing step of the method for manufacturing the sheet laminate1will be described next with reference toFIG. 4. As illustrated inFIG. 4, the method for manufacturing the sheet laminate1includes a preparing step S10, a bending step S20, a partial heating step S30, and an extracting step S40.

The preparing step S10is a step for preparing the sheet member50. In the preparing step S10, the sheet member50is pre-cut to a form that matches the mold100. Furthermore, the prepared sheet member50is provided in the arranging part116of the second piece112of the mold100(seeFIG. 5).

The bending step S20is a step for bending an edge part of the sheet member50by sandwiching the sheet member50from the front surface50aside and the rear surface50bside. By lowering the third piece121of the second unit120downward in the bending step S20, the rear surface50bof the sheet member50is pressed downward by the supporting surface122(seeFIG. 7). At this time, the front surface50aof the sheet member50may be supported by the supporting surface113of the first piece111of the first unit110. At this time, an edge part of the sheet member50abuts with the guide surface118of the arranging part116, which guides said member toward the supporting surface114side while thus bending said part toward the rear surface50bside.

When the third piece121is lowered all the way down, an edge part of the sheet member50is sandwiched between the supporting surface114of the first piece111of the first unit and the supporting surface123of the third piece121of the second unit (seeFIG. 8). This forms the side wall part12of the sheet laminate1. Furthermore, the rear surface50bof the sheet member50is sandwiched between the supporting surface122of the third piece and the supporting surface113of the second piece112. This forms the main body part11of the sheet laminate1. Furthermore, by pressing a curved part of a corner of the third piece, a corner between the main body part11and the side wall part12forms the bent connecting part13. In this state, the first unit110is supporting the flat surface part20and the side surface21in a state where the connecting surface22of the sheet laminate1is exposed.

The partial heating step S30is a step for heating part of the bent sheet member50. The partial heating step S30heats the connecting surface22exposed from the first unit110but does not heat the flat surface part20or the side surface21being supported and covered by the first unit110(seeFIG. 9). This anneals the bent connecting part13, which was significantly bent in the bending step, to thus remove distortion produced in said part. A predetermined heating device140is provided with respect to the connecting part13, and the heating device140supplies heat. The heating device140may heat the connecting surface22by supplying, for example, infrared rays (IR), heated air, high pressure steam, or heated liquid. Or, a heating pad itself may be pressed against the connecting surface22, or housed inside a heating furnace for each mold.

After the partial heating step S30has completed, the extracting step S40extracts the sheet laminate1from the mold100by raising the third piece121together with the sheet laminate1(seeFIG. 10). Note that after the partial heating step S30has completed, the connecting surface22may be cooled through contact with cooling air, a cooling liquid, or a cooling pad. Or, the connecting surface22may be cooled naturally by letting said surface stand. The manufacturing step illustrated inFIG. 4is complete when the extracting step S40ends.

The operations and effects of the method for manufacturing the sheet laminate1, the mold100for molding the sheet laminate1, and the sheet laminate1according to the present invention will be described next. Note that the part illustrated inFIG. 3 (a)will be used as an example for describing the “flat surface part,” “first side surface,” “second side surface,” “third side surface,” “first connecting surface,” “second connecting surface,” and “third connecting surface” in the following description. However, the same operations and effects can be obtained for other parts having the same gist in the sheet laminate1.

A method for manufacturing a sheet laminate according to a comparative example will be described first. Examples of methods for manufacturing according to the comparative example include heat stamping which sandwiches a sheet in a heated mold, and then bends the sheet. However, in cases where an edge part of a sheet member having an adhesive part on a rear surface is bent, a problem occurs when heat stamping is performed where the adhesive part peels during molding.

By contrast, with the method for manufacturing the sheet laminate1according to the present embodiment, the sheet laminate1has the flat surface part20spreading out in a flat plate shape, the side surface21on which an edge part bent by the bending step is configured, and the connecting surface22protruding and curving toward the front surface side between the flat surface part20and the side surface21. After the sheet member50has been bent into this kind of shape in the bending step, the connecting surface22is partially heated in the partial heating step. When the sheet member50is molded in a state where the adhesive part3or the protective film6has been formed, the adhesive part3or the protective film6become susceptible to peeling in a position corresponding to the connecting surface22that deforms so as to curve in the bending step. Accordingly, distortion in said part can be removed by partially removing stress (performing an annealing process) through partial heating of the connecting surface22. Therefore, the sheet laminate1can be manufactured with good quality while preventing peeling of the adhesive part3and the protective film6.

The merits of partially heating the connecting surface22will be described here. For example, if stamping is done in a state where the adhesive part3, the protective film6, and the release liner4have been heated and softened, the adhesive part3and the protective film6may displace due to a shear force between molds, which can lead to peeling (the impact from displacement caused by the adhesive part3is particularly significant). To prevent this, heating is performed in a static state after stamping has been performed without heating. Additionally, movement of a peripheral part (here this is a flat surface part or side surface of a periphery of the connecting surface22), other than a major curved part where stress is to be relaxed by heating, is suppressed by keeping said part sandwiched between molds, and this part is also not softened through heating. This makes it possible to prevent layers from peeling due to the displacement of a part (that is a part corresponding to the connecting surface22) to be partially heated sandwiched in the peripheral part.

The method for manufacturing the sheet laminate1molds the main body part11for configuring the flat surface part20portion of the sheet laminate1, and the pair of side wall parts12B and12C extending respectively toward the rear surface side from the pair of mutually intersecting side parts11band11cof the main body part11. In the example inFIG. 3 (a), the side surface21has the first side surface21B corresponding to the side wall part12B, the second side surface21C corresponding to the side wall part12C, and the third side surface21E formed in the corner between the first side surface21B and the first side surface21C forming a roundness having a predetermined curvature. The connecting surface22may have the first connecting surface22B connecting the flat surface part20and the first side surface21B, the second connecting surface22C connecting the flat surface part20and the second side surface21C, and the third connecting surface22E connecting the flat surface part20and the third side surface21E.

The connecting surface22is exposed from the mold100in the partial heating step, and partial heating is performed by applying heat to the connecting surface22from outside the mold100. This enables the connecting surface to be partially heated using a simple configuration.

The sheet member50is also provided with the release liner4for covering the adhesive part3of the rear surface50bof the sheet member50. This enables molding to be performed in a state where the adhesive part3is protected.

The mold100for molding the sheet laminate1is the mold100for molding the sheet laminate1to be affixed to the adherent surface of an object, and is provided with the first unit110for supporting the sheet member50, having the front surface50ato become the design surface and the rear surface50bin which the adhesive part3has been formed, from the front surface50aside, and the second unit120for supporting the sheet member50from the rear surface50bside. The first unit110and the second unit120are able to mold the main body part11spreading in a flat plate shape portion of the sheet laminate1, and the pair of side wall parts12B and12C extending respectively toward the rear surface50bside from the pair of mutually intersecting side parts11band11cof the main body part11by sandwiching the sheet member50and then bending the sheet member50. When the front surface is formed on the flat surface part20corresponding to the main body part11, the first side surface21B corresponding to the side wall part12B, the second side surface21C corresponding to the side wall part12C, and in a corner between the first side surface21B and the second side surface21C; and has the third side surface21E forming a roundness having a predetermined curvature, the first connecting surface22B protruding and curving toward the front surface side for connecting the flat surface part20and the first side surface21B, the second connecting surface22C protruding and curving toward the front surface side for connecting the flat surface part20and the second side surface21C, and the third connecting surface22E protruding and curving toward the front surface side for connecting the flat surface part20and the third side surface21E, the first unit110supports the flat surface part20, the first side surface21B, the second side surface21C, and the third side surface21E in a state where the first connecting surface22B, the second connecting surface22C, and the third connecting surface22E are exposed.

Using a mold like the mold100makes it possible to execute a manufacturing method like that described above, and to obtain the same operation and effect.

The sheet laminate1is the sheet laminate1that is to be affixed to an adherent surface of an object and has the flat surface part20that spreads out in a flat plate shape, the side surface21configured by a bent edge of the flat surface part20, and the connecting surface22protruding and curving toward the front surface side between the flat surface part20and the side surface21, where the part configuring the flat surface part20, the side surface21, and the connecting surface22is configured of the base material part2having the front surface that is to become the design surface, and the rear surface on the side opposite the front surface, an adhesive part3formed on the rear surface of the base material part2, and the release liner4covering the adhesive part3that can be peeled from the adhesive part3.

Using a laminate like the sheet laminate1enables achieving an operation and effect during manufacture having the same gist as the manufacturing method described above.

The sheet laminate1is provided with the main body part11for configuring the flat surface part20, and the pair of side wall parts12B and12C extending respectively toward the rear surface side from the pair of mutually intersecting side parts11band11cof the main body part11. The side surface21has the first side surface21B corresponding to the side wall part12B, the second side surface21C corresponding to the side wall part12C, and the third side surface21E formed in the corner between the first side surface21B and the second side surface21C forming a roundness having a predetermined curvature. The connecting surface22has a first connecting surface22B for connecting the flat surface part20and the first side surface21B, a second connecting surface22C for connecting the flat surface part20and the second side surface21C, and a third connecting surface22E for connecting the flat surface part20and the third side surface21E. The manufacturing method according to the present embodiment becomes particularly noteworthy when the sheet laminate1having this type of configuration is manufactured.

The third side surface21E forms a roundness protruding toward the front surface side, and the curvature of the roundness has a radius of 1 to 2000 mm.

In the example inFIG. 3 (b), the third side surface21H forms a roundness protruding toward the rear surface side, and the curvature of the roundness has a radius of 0.5 to 2000 mm.

The base material part2is covered by the biaxially extended protective film6. This makes it possible to protect a front surface of the base material part2.

The release liner4is configured using a biaxially extended film. This makes it possible to reduce an impact on the release liner4during partial heating of the connecting surface.

For example, the adhesive part3is configured using an acrylic pressure-sensitive adhesive. For example, the base material part is configured using a polycarbonate.

The present invention is not intended to be limited to the embodiments described above.

In the embodiments described above, the sheet member50is provided in the mold100after having been cut beforehand. However, an un-cut sheet member that is not cut until it is supplied in the mold may also be used. For example, a cutting member210may be provided on an outer circumferential side of the third piece121of the first unit110, as illustrated inFIG. 11andFIG. 12. For example, a base material250of a sheet member is cut by the cutting member210simultaneous to pressurization in the third piece121to thus form the sheet member50in a desired shape. Note that the cutting member210is retracted upward after the cutting, as illustrated inFIG. 12.

Note that in the embodiments described above, the connecting surface to be partially heated was exposed from the mold. In addition, the first unit has a piece for supporting the connecting surface, and may partially heat the connecting surface through said piece. Specifically, as illustrated inFIG. 13, in a mold300, the first unit110is provided with a heating part310provided with a fourth piece115that makes contact with the connecting surface (first connecting surface, second connecting surface, and third connecting surface)22, for heating the part making contact, an insulating part302for insulating a space between the flat surface part20and the heating part310, and an insulating part301for insulating a space between the side surface (first side surface, second side surface, and third side surface)21and the heating part310, and for insulating the insulating part301. The heating part310may be configured using a flow path, and the like, of a heating medium such as a heating wire, a liquid, a gas, or the like.

According to the description above, in the method for manufacturing the sheet laminate1, partial heating is performed in the partial heating step through a part (the fourth piece115) in the mold300that makes contact with the connecting surface22. Furthermore, heat going to the flat surface part20and the side surface21is insulated in the partial heating step. This kind of configuration allows partial heating to be performed while a shape is sustained because the connecting surface22is supported by the fourth piece115. Note that if the fourth piece115does not have the heating part310, the fourth piece115is retracted during the partial heating step, and partial heating may be performed by exposing the connecting surface22.