Corona discharge treating method and apparatus for resin moldings

Disclosed is a corona discharge treating method and apparatus for a three-dimensional resin molding having corners, in which a corona discharge electrode at least having a curved surface discharge portion is relatively moved along the shape of the surface of the molding with corona discharge generated in the vicinity of the molding.

BACKGROUND OF THE INVENTION 
1. Field of the Invention. 
The present invention relates to a corona discharge treating method and 
apparatus for improving the quality of surfaces of resin moldings, and 
more particularly, relates to a corona discharge treating method and 
apparatus for three-dimensional resin moldings having corners. 
2. Description of the Related Art 
Generally, polyolefin-series resin such as polypropylene or the like has 
such a property that painting materials, joining materials, printing 
materials or the like are hardly adhered onto the surface thereof, because 
the resin has a little number of polar groups. Accordingly, in the case 
where painting, joining, printing or the like, is applied to the surface 
of the resin, the quality of the surface should be improved by 
pretreatment in order to improve the adhesive property thereof. 
Various methods, such as flame treatment, acid solution treatment, plasma 
treatment, corona discharge treatment and the like, are used as 
pretreatment for improving the adhesive property of the polyolefin-series 
resin with respect to painting materials, joining materials, printing 
materials or the like. 
The plasma treatment is a useful method for activating the almost whole 
surface of a resin molding at once, and accordingly, the plasma treatment 
has produced excellent results as pretreatment before painting or joining 
treatment for automobile bumpers, automobile moldings, etc. 
However, plasma treatment requires a reduced-pressure plasma gas 
atmosphere. Accordingly, plasma treatment has a disadvantage that 
large-scale and high-cost equipments, such as a vacuum tank, a vacuum 
pump, a valve mechanism, a carrier gas and the like, are required as well 
as a large time is required to reduce pressure within the vacuum tank. 
Furthermore, in plasma treatment, manufacturing processes should be made 
by batch processing, so that automatization thereof is difficult. 
Accordingly, plasma treatment has another disadvantage that the vacuum 
condition is interrupted for each manufacturing process to thereby require 
a long time for next reduction of pressure. 
From this point of view, corona discharge treatment which does not require 
such equipments as a vacuum tank and the like, is very advantageous. 
Corona discharge treatment, however, suffers from the limitation that a 
discharge electrode should be always close to a surface to be treated. 
Accordingly, corona discharge treatment has been used only for film-like 
or plate-like resin moldings (hereafter generically referred to as 
two-dimensional resin moldings). There is no report or reference that 
suggests use of corona discharge treatment for resin moldings having 
three-dimensionally uneven surfaces to be treated (hereafter generically 
referred to as three-dimensional resin moldings). 
It is to be understood that realization of corona discharge treatment for 
three-dimensional resin moldings produces a large advantage in the cost of 
equipment and the time required for the treatment. For the realization, 
however, several problems should be solved. One of the problems is the 
lack of uniformity in the state of improved quality. Because the surface 
of a three-dimensional resin molding to be treated is rough, the distance 
between the corona discharge electrode and the surface is changed. The 
power of discharge becomes higher as this distance decreases, while the 
power of discharge becomes lower as this distance increases. Accordingly, 
there is a possibility of producing the lack of uniformity in improved 
quality depending on the positions of the treated surface. 
SUMMARY OF THE INVENTION 
An object of the present invention is to provide a corona discharge 
treating method and apparatus for a three-dimensional resin molding having 
corners, which can improve the adhesive property of the surface thereof 
with respect to painting materials, joining materials, printing materials, 
or the like; which can save the cost and space of equipment required to 
thereby shorten processing time; and which can steadily treat the corners 
making corona discharge treatment difficult. 
Another object of the present invention is to provide a corona discharge 
treating method and apparatus for a resin molding, which can improve 
processing efficiency to thereby shorten processing time. 
A further object of the present invention is to provide a corona discharge 
treating method and apparatus for a resin molding, which can eliminate a 
difficult problem in the lack of uniformity in improved quality to thereby 
realize corona discharge treatment for a three-dimensional molding; and 
accordingly can improve the quality of the treated surface totally and 
uniformly. 
To attain the foregoing objects, according to the present invention, a 
corona discharge electrode at least having a curved surface discharge 
portion is moved relatively along the shape of the surface of a 
three-dimensional resin molding with corona discharge generated in the 
vicinity of the molding. 
Other objects of the present invention will become obvious upon an 
understanding of the illustrative embodiments about to be described or 
will be indicated in the appended claims, and various advantages not 
referred to herein will occur to one skilled in the art upon employment of 
the invention in practice.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
(First Embodiment) 
A first embodiment of the present invention will be described hereunder 
with reference to FIGS. 1 to 7. 
The term "three-dimensional resin molding" used in this specification means 
a three-dimensionally uneven resin molding which is not a flat resin 
molding such as a resin sheet, a resin flat board, or the like. In this 
embodiment, the three-dimensional resin molding to be processed by corona 
discharge is an automobile instrument panel pad 1 formed of PP resin as 
shown in FIG. 1. An outer sheet made of polyvinyl chloride resin is stuck 
to the surface of the instrument panel pad 1 to thereby form an instrument 
panel pad article. 
The instrument panel pad 1 has convex corners 5 with about a 6 mm radius on 
the border between the upper surface 2 and front surface 3, the border 
between the upper surface 2 and the side surface 4, or the like. 
On the left and right sides of the upper surface 2 of the instrument panel 
pad, two shallow saucers 6 and 7 are provided. Accordingly, as shown in 
FIG. 2, convex corners 8 are at the upper edges of the saucers 6 and 7, 
and concave corners 9 are at the bottom edges of the saucers 6 and 7, 
respectively. The respective corners 8 and 9 have a radius of about 6 mm. 
An air-blowing port 10 for side-defroster is formed at the left end of the 
upper surface 2, and two air-blowing ports 11 and 12 for ventilation and 
air-conditioning are formed at the left and right sides of the front 
surface 3, respectively. Each of the air-blowing ports 10, 11 and 12 is 
shaped approximately like a quadrangle and has corners 13 with a radius of 
from 6 to 15 mm at its edges and four corners. 
As described above, the instrument panel pad 1 is featured in that it is a 
three-dimensional molding and that it has a lot of corners 5, 8, 9 and 13. 
An apparatus for applying corona discharge treatment to the instrument 
panel pad 1 will be now described hereunder. 
The corona discharge treating apparatus of first embodiment, as shown in 
FIG. 2, mainly comprises a jig member 301 (including a moving mechanism 
for the jig member 301, and a counter electrode) for fixing the instrument 
panel pad 1, a first treating unit 302 (disposed to the left side in FIG. 
2) for treating the instrument panel pad 1 with corona discharge through a 
discharge electrode having a rod-like discharge portion, and a second 
treating unit 303 (disposed to the right side in FIG. 2) for treating the 
instrument panel pad 1 with corona discharge through a discharge electrode 
at least having a curved surface at the top thereof. 
The parts 301 to 303 will be described in detail and in order hereunder. 
[Jig Member 301] 
The jig member 301 has a base leg 21 which can be suitably moved back and 
forth and right and left on a floor by sliding means 26 (which can be 
general means such as a rail, a roller, etc.) provided on the floor and 
can be suitably moved up and down by a hydraulic cylinder 27 provided 
under the base leg 21. 
As shown in FIGS. 3 and 4, a jig body 22 formed from epoxy resin so as to 
agree with the inside shape of the instrument panel pad 1 is mounted onto 
the base leg 21 to thereby support the instrument panel pad 1 from the 
inside thereof. The jig body 22 can be easily formed like a shell by 
reactively hardening epoxy resin poured to the inside of the instrument 
panel pad 1. 
A counter electrode 23 for corona discharge treatment is formed on the 
surface of the jig body 22 by any one of coating methods, such as a metal 
plating method, a vacuum evaporating method, a sputtering method, a 
conductive paint coating method, an aluminum foil sticking method, etc. 
The surface of the counter electrode 23 is made to substantially abut on 
the inner surface of the instrument panel pad 1. 
The jig body 22 is provided with about 6 mm deep recess portions 24 formed 
at the positions corresponding to the air-blowing ports 10, 11 and 12 of 
the instrument panel pad 1. For generating uniform corona discharge, the 
counter electrode 23 is formed on the surfaces of the recess portions 24 
and about 6 mm thick buffering plates 25 formed of a dielectric material, 
such as hyperon rubber, epoxy resin, or the like, are inserted into the 
recess portions 24. If the counter electrode 23 is directly formed at a 
position on the jig body 22 corresponding to the airblowing ports which 
are through-holes, the counter electrode 23 will be exposed with respect 
to a discharge electrode to be described later to thereby disturb corona 
discharge. 
[First Treating Unit 302] 
The first treating unit 302 comprises a discharge electrode 31 having a 
rod-like discharge portion, a moving mechanism 32 for moving the discharge 
electrode 31 to cause it approach the instrument panel pad 1 and for 
further moving the discharge electrode 31 along the respective surfaces of 
the instrument panel pad 1, and high-frequency energy applying means 33 
for applying high frequency energy to the counter electrode 23 and the 
discharge electrode 31 to thereby generate corona discharge. 
The discharge electrode 31 disposed in the air is formed by bending a 
stainless steel bar of a diameter of 14 mm into a U-shape. The discharge 
electrode 31 is constituted by three portions of: (1) a gripped portion 34 
gripped by the moving mechanism 32; (2) a rod-like discharge portion 35 
substantially parallel to the instrument panel pad 1; and (3) a terminal 
portion 36 for preventing the concentration of corona discharge onto the 
end of the discharge portion 35 to produce corona discharge uniformly at 
the whole of the discharge portion 35; the three portions being at right 
angles to each other in order from the base end thereof. 
The radius of the discharge electrode 31 is 7 mm which is larger than the 
radius (6 mm) of each of the main corners 5, 8 and 9 in the instrument 
panel pad 1. 
A computer controlled robot is used in the moving mechanism 32 and various 
types of industrial robots (e.g., multipurpose working robot, Model: 
PW-10II, HITACHI Ltd.) are applicable thereto. In the first embodiment, 
the moving mechanism 32 is of the articulated or revolute type and 
constructed as follows. A support base 38 is rotatably pivoted on the 
upper portion of a base leg 37, and first and second arms 39 and 40 are 
independently rotatably pivoted to the upper portion of the support base 
38. 
On the upper portions of the two arms 39 and 40, a third arm is rotatably 
pivoted at its base end. A cylindrical acting portion 42 is rotatably 
pivoted on the top end of the third arm 41. The acting portion 42 is 
formed so as to rotate about its central axis, and a gripping member 43 
for gripping the gripped portion 34 of the discharge electrode 31 is 
attached to the top end of the acting portion 42. 
All the operations, such as rotation of the support base 38, motion of each 
of the arms 39 to 41, rotation of the acting portion 42, and the like, are 
controlled by a computer not shown. Through the operations by executing a 
computer program, the electrode 31 is caused to approach the instrument 
panel pad 1 up to a distance of about 10 mm toward each of the upper 
surface 2, the front surface 3 and the side surfaces 4 of the instrument 
panel pad 1 and then to move along each of these surfaces. 
The counter electrode 23 of the jig member 301 and the rod-like discharge 
electrode 31 are connected to high-frequency energy applying means 33 
constituted by a high-frequency oscillator 45 and a high-voltage 
transformer 46. The counter electrode 23 is grounded. As a measure to 
counter high-frequency noises, the high-frequency oscillator 45 is also 
directly grounded. 
As the high-frequency oscillator 45, used is a product made by Tantec 
(trade name HVO5-2), for generating high frequency energy of 20-30 kHz and 
350 W maximum power output. As the highvoltage transformer 46, used is a 
product made by Tantec (trade name SUPER C), for raising the 
high-frequency output voltage of the high-frequency oscillator 45 to 
impress a high voltage onto the electrodes 23 and 31. 
The high-frequency energy applying means 33 and the computer control 
mechanism of the moving mechanism 32 are disposed at a considerable 
distance from each other and are independently energized by separate power 
sources for the purpose of preventing operation errors of the computer 
owing to high-frequency noises leaking out of the high-frequency applying 
means 33. Further, for the same purpose, it is necessary to securely 
shield cords for connecting the high-frequency oscillator 45, the 
high-voltage transformer 46 and the discharge electrode 31. 
[Second Treating Unit 303] 
The second treating unit 303 is constituted by a discharge electrode 51 
having a spherical discharge top end portion, a moving mechanism 52 for 
moving the discharge electrode 51 to approach the instrument panel pad 1 
and for further moving the discharge electrode 51 three-dimensionally 
along the shape of the instrument panel pad 1, and high-frequency energy 
applying means 53 for applying high frequency energy to the counter 
electrode 23 and the discharge electrode 51 to thereby generate corona 
discharage. 
The discharge electrode 51 disposed in the air is constituted by a rod-like 
gripped portion 54 of a diameter of about 2 mm formed of stainless steel 
to be gripped by the moving mechanism 52, and a spherical discharge 
portion 55 formed of stainless steel and attached to the top end of the 
gripped portion 54 to substantially perpendicularly correspond to the 
instrument panel pad 1. 
The radius of the spherical discharge portion 55 is 2.5 mm which is smaller 
than the radius (6-15 mm) at each of the corners 5, 8, 9 and 13 of the 
instrument panel pad 1. Accordingly, corona discharge from the discharge 
portion 55 is made densely with respect to each of the corners 5, 8, 9 and 
13. 
Preferably, a mesh-like shielding cylinder 60 formed of stainless steel or 
the like is provided around the discharge electrode 51 as shown in FIG. 7 
for the purpose of preventing radiation of high-frequency noises generated 
from the discharge electrode 51 during corona discharge. 
The same structure as used for the moving mechanism 32 of the first 
treating unit 302 is used for the moving mechanism 52. 
Accordingly, operations, such as rotation of the support base 38, motion of 
each of the arms 39 to 41, rotation of the acting portion 42, and the 
like, are made with the execution of a program on a computer not shown, so 
that the discharge 51 is caused to approach the instrument panel pad 1 up 
to a distance of about 10 mm substantially perpendicularly to the cut 
surface of each of the corners 5, 8, 9 and 13 and the air-blowing ports 
10, 11 and 12 of the instrument panel pad 1 and then to move 
three-dimensionally along the shape of each of the cut surfaces. 
The counter electrode 23 of the jig member 301 and the discharge electrode 
51 having a spherical discharge top end are connected to high-frequency 
energy applying means 53 constituted by a high-frequency oscillator 56 and 
a high-voltage transformer 57, as shown in FIG. 7. The same products as 
used in the first treating unit 302 are used for the high-frequenty 
oscillator 56 and the high-voltage transformer 57. 
Description will now be made as to a method for applying corona discharge 
treatment to the instrument panel pad 1 by use of the corona discharge 
treating apparatus having such a construction as described above. 
First, in the case where the molded instrument panel pad 1 is stained with 
parting agents or owing to handwork, preferably the stain is removed by 
pretreatment with trichloroethane or the like for the purpose of surely 
performing corona discharge treatment. However, in the case where it is 
little stained with parting agents or owing to handwork, such pretreatment 
is of course unnecessary. 
Next, the instrument panel pad 1 is fitted to the jig body 22 of the jig 
member 301 as shown in FIGS. 3 and 4 so that contact is made between the 
surface of the counter electrode 23 and the inner surface of the 
instrument panel pad 1. In this case, although there may occur portions of 
the instrument panel pad which are not in contact with the counter 
electrode 23 due to manufacturing errors of the instrument panel pad 1, 
the corona discharge is not so affected as long as the distance 
therebetween at those non-contact portions is within about 2 to 3 mm. The 
jig member 301 is moved to the front of the first treating unit 302 by the 
sliding means 26. 
Next, the main portions of the instrument panel pad 1 are treated with 
corona discharge by the first treating unit 302. Upon actuation of the 
moving mechanism 32, the discharge portion 35 of the rod-like discharge 
electrode 31 is arranged to extend in the frontward/rearward direction 
over the upper surface 2 of the instrument panel pad 1 as shown in FIG. 4 
and is disposed about the left end of the upper surface 2 at a distance of 
about 10 mm, as shown in FIG. 3. 
At this time, the high-frequency oscillator 45 of the high-frequency energy 
applying means 33 is actuated to operate, the high-frequency output 
voltage thereof is raised by the high-voltage transformer 46 so that 
high-frequency energy of 28 kV is impressed across the counter electrode 
23 and the rod-like discharge electrode 31. Upon the impression of high 
frequency energy, corona discharge occurs in the air between the upper 
portion 2 and a portion of the discharge portion 35 opposite to the upper 
surface 2, so that corona discharge treatment for the upper surface 2 
starts to thereby improve the adhesive property with respect to an 
adhesive agent, or the like. Improvement of wetting property owing to the 
corona discharge treatment of the first embodiment is substantially the 
same as that owing to a frame treatment. 
The phenomenon in the corona discharge treatment is considered to be 
induced by the fact that a flow of electrons generated by discharge 
collide with synthetic resin (which is PP in the first embodiment) so that 
the collision energy thereof partially breaks carbon-hydrogen bonds to 
activate the surface of the synthetic resin with oxidation and ionization. 
The rod-like discharge electrode 31 is gradually moved to the right of the 
upper surface 2 by the moving mechanism 32, while generating the corona 
discharge. The moving speed can be suitably set within a range of 1 to 250 
mm/sec under the above-described discharge conditions. In the first 
embodiment, the moving speed is set to be 150 mm/sec, on the balance of 
satisfactory results with shortening of necessary time for the treatment. 
Although the bulk of the upper surface 2 can be treated with corona 
discharge with the movement of the discharge electrode 31, positions, such 
as the corners 5 of the upper surface 2, the cut end surfaces and corners 
13 of the air-blowing ports 10, 11 and 12, the corners 8 and 9 of the 
saucers 6 and 7, and the like, are difficult to be treated. It is 
considered that potential distribution changes at these positions to make 
the surface to be treated out of perpendicular to the direction of 
discharge, so that corona discharge is pulled to the surface other than 
these positions and does not act on these positions effectively. 
If the discharge electrode 31 would come into direct opposition to the 
counter electrode 23 when the electrode 31 passes above of the air-blowing 
port 10, severe discharge would occur to therefore result in defective 
articles. However, according to the first embodiment, the buffering plates 
25 of a dielectric material are interposed as described above to thereby 
make the discharge relaxed and uniform. In the other positions of the 
upper surface 2, the instrument panel pad 1 itself is a dielectric 
functioning as a buffering member, so that uniform discharge occurs. 
If a buffering member of a dielectric material would be provided wholly on 
the inside of the instrument panel pad 1, corona discharge would become 
uniform but would become weak all over the surfaces of the instrument 
panel pad 1 to thereby reduce the treating efficiency. However, in the 
first embodiment, the buffering plates 25 are provided only at the insides 
of the air-blowing ports 10-12 which are through-holes. 
After the completion of the corona discharge treatment for the upper 
surface 2 in such a manner as described above, the discharge electrode 31 
is automatically moved by the moving mechanism 32 so as to be arranged to 
extend vertically (in the up/down direction) in the vicinity of the front 
surface 3 of the instrument panel pad 1 as shown in FIG. 4. In succession, 
the discharge electrode 31 is moved from the left end front portion of the 
front surface 3 to the right end front portion of the same, (keeping at a 
distance of about 10 mm similar to that in the case of the upper surface 
2) while maintaining the corona discharge. Thus, corona discharge 
treatment for the front surface 3 is perfected. 
Similarly to the case of the air-blowing port 10, the cut end surfaces and 
the corners 13 of the air-blowing ports 11 and 12 are difficult to be 
treated and corona discharge is kept uniform under the influence of the 
buffering plates 25 when the discharge electrode 31 passes the front of 
the air-blowing ports 11 and 12. 
After the completion of the corona discharge treatment for the front 
surface 3, the discharge electrode 31 is automatically moved by the moving 
mechanism 32 so as to be arranged to extend vertically (in the up/down 
direction) in the vicinity of the side surface 4 of the instrument panel 
pad 1 as shown in FIG. 3. In succession, the discharge electrode 31 is 
moved from the side of the rear end of the side surface 4 to the side of 
the front end of the same. Thus, corona discharge treatment for the side 
surfaces 4 is perfected. 
The total time required for the corona discharge treatment for the upper 
surface 2, the front surface 3 and the opposite side surfaces 4 by means 
of the first treating unit 302 is about 25 sec. 
Although the above-described treatment shows the case where the discharge 
electrode 31 is moved relative to the instrument panel pad 1 only by the 
moving mechanism 32, only the instrument panel pad 1 may be moved by both 
the sliding means 26 and the hydraulic cylinder 27 or both the discharge 
electrode 31 and the instrument panel pad 1 may be moved. 
As described above, according to the first treating unit 302, large-scale 
equipment, such as a vacuum tank, a vacuum pump, a valve mechanism, a 
carrier gas and the like, and preparatory time to be reduce pressure 
within the vacuum tank, as required in the plasma treatment, becomes 
unnecessary. Furthermore, it is made possible to improve the quality of 
the surface of the PP resin only by moving corona discharge generated in 
the air by the rod-like discharge electrode 31 or the like. Accordingly, 
it is possible to save the cost and space of equipment greatly as well as 
to shorten the time required for the treatment. 
In addition, because the rod-like discharge electrode 31 is moved along the 
surface of the instrument panel pad 1, a wide surface to be treated can be 
treated at once to make treating efficiency very high. 
After the corona discharge treatment according to the first treating unit 
is perfected, the high-frequency oscillator 45 is turned off to stop the 
corona discharge, and the jig member 301, together with the instrument 
panel pad 1, is moved to the front of the second treating unit 303 by the 
sliding means 26. 
In succession, the corners 5, 8, 9 and 13 and the like not fully treated 
with corona discharge by the first treating unit 302 can be treated by the 
second treating unit 303. The moving mechanism 52 is operated and the 
spherical discharge portion 55 of the discharge electrode 51 is disposed 
at a distance of about 10 mm with respect to the corners 5 of the 
instrument panel pad 1 as shown in FIG. 5. 
At this time, the high-frequency oscillator 56 of the high-frequency energy 
applying means 53 is operated and high frequency energy of 28 kV is 
impressed across the counter electrode 23 and the discharge electrode 51 
so that corona discharge is generated between the discharge portion 55 and 
the corners 5. 
The corona discharge generated from the discharge portion 55 has a very 
uniform discharge pattern as shown in FIG. 5, and accordingly, the surface 
treatment for the instrument panel pad 1 at a time is of a relatively wide 
range and a range within a circle of a diameter of 10-15 mm can be treated 
sufficiently. This is because the discharge portion 55 is spherical and 
hence the discharge top end is shaped to be a curved surface so that 
corona discharge is uniformly distributed without concentration onto one 
point (such as a sharp point, a corner point, or the like). 
Furthermore, because the discharge top end is shaped to be a curved 
surface, the corona discharge is little influenced by the changes in 
potential distribution at the corners 5 or the angles of the surface to be 
treated with respect to the direction of discharge and, accordingly, the 
corona discharge effectively acts on the corners 5. Particularly, because 
the radius of the discharge portion 55 in the discharge electrode 51 of 
this embodiment is smaller than the radius at each of the corners 5, 8, 9 
and 13, the above-described influences are negligible. Accordingly, the 
corners 5 not fully treated by the first treating unit 302 can be fully 
treated herein. 
The discharge electrode 51 is gradually moved three-dimensionally over all 
the corners 5 by the moving mechanism 52, while generating corona 
discharge. The moving speed can be suitably set to be a value within a 
range of 1 to 250 mm/sec under the above-described discharge conditions. 
In the first embodiment, the moving speed is set to be 150 mm/sec, on the 
balance of satisfactory results with the shortening of necessary time for 
the treatment. 
After the completion of treatment for the corners 5, the discharge 
electrode 51 is automatically moved above the respective corners 8 and 9 
of the saucers 6 and 7 by the moving mechanism 52 and treats the corners 8 
and 9 while three-dimensionally moving. After the treatment for the 
corners 8 and 9, the discharge electrode 51 is similarly moved to the 
air-blowing ports 10, 11 and 12 in order and treats the cut end surfaces 
and corners 13 of the ports. 
The total time required for the corona discharge treatment for the corners 
and the like according to the second treating unit 303 is about 30 sec. 
After the treatment is completed, the corona discharge stops. 
Although the above-described treatment shows the case where the discharge 
electrode 51 is moved relative to the instrument panel pad 1 only by the 
moving mechanism 52, only the instrument panel pad 1 may be moved by both 
the sliding means 26 and the hydraulic cylinder 27 or both the discharge 
electrode 51 and the instrument panel pad 1 may be moved. In the case 
where the instrument panel pad 1 is moved, it is preferable to form the 
instrument panel pad 1 to be slantingly movable so as to make it possible 
to adjustably change the angle between the discharge electrode 51 and the 
surface to be treated. 
As described above, according to the second treating unit 303, similarly to 
the first treating unit 302, improvement in quality of the surface of the 
PP resin instrument panel pad 1 can be made only by moving the discharge 
electrode 51 or the like with corona discharge generated in the air. 
Accordingly, it is possible to save the cost and space of equipment 
greatly as well as to shorten the time required for the treatment. 
Furthermore, because the discharge electrode 51 at least having a curved 
surface discharge top end is moved along the surface of the instrument 
panel pad 1, the corners 5, 8, 9 and 13 difficult to be treated by the 
rod-like electrode 31 can be surely treated. 
As described above, according to the first embodiment, because short-time 
treatment for the main portions of the instrument panel pad 1 by the first 
treating unit 302 is combined with treatment for the corners 5, 8, 9 and 
13 of the instrument panel pad 1 by the second treating unit 303, it is 
possible to improve treating efficiency greatly as a whole and shorten 
treating time greatly. 
It is to be understood that the first embodiment is not limited to the 
above-described specific construction, and that changes or modifications 
may be made as follows. 
(1) Generally, in order to generate corona discharge, a high-frequency 
voltage or a high voltage is impressed between two adjacent electrodes 
(for example, the counter electrode 23 and the discharge electrode 31/51), 
as described in the foregoing embodiment. 
However, by use of atmospheric electricity, corona discharge can be 
generated from only a discharge electrode without use of a counter 
electrode. Particularly, in the case of the discharge electrode 51 having 
a spherical discharge portion 55 at the top end, relatively strong and 
uniform corona discharge can be generated without use of the counter 
electrode 23 because the corona discharge concentrates onto the sphere 
portion thereof. 
Accordingly, a treating method without use of the counter electrode 23 is 
applicable to the second treating unit 303, though the use of the counter 
electrode 23 contributes to strengthening discharge and enlarging 
discharge range. 
(2) The treating procedure according to the first treating unit 302 and the 
treating procedure according to the second treating unit 303 may be made 
in reverse order, or either or both may be repeated twice or more or may 
be suitably combined. 
(3) The whole surface of the instrument panel pad can be treated by use of 
only the second treating unit 303, though combination with the first 
treating unit 302 makes treating time short because the plane portions of 
the instrument panel pad 1 are treated more efficiently by use of the 
rod-like discharge electrode 31. 
(4) Preferably, the jig member 301 and the units 302 and 303 are installed 
in a room maintained at constant temperature and humidity, because corona 
discharge is affected by ambient temperature and humidity. 
(5) Either the high-frequency energy applying means 33 of the first 
treating unit 302 or the high-frequency energy applying means 53 of the 
second treating unit 303 may be used in common to serve a double purpose. 
In this case, the cost of equipment can be more reduced but the conditions 
for corona discharge in the discharge electrodes 31 and 51 cannot be set 
independently and freely. 
(6) The discharge portion 55 of the discharge electrode 51 is not limited 
to the spherical shape, but any shape, for example, a hemispherical one or 
a spheroidal one, can be employed as long as at least the discharge top 
end is shaped to be a curved surface. 
However, it is considered that the spherical shape is optimum from the 
point of view of uniformity of corona discharge. 
(7) The rod-like discharge electrode 31 can be replaced by a plane-like 
discharge electrode which is moved to approach to the instrument panel pad 
1 by the moving mechanism 32. 
(Second Embodiment) 
A second embodiment of the present invention will be described hereunder 
with reference to FIGS. 8 to 13. The resin molding used in the second 
embodiment is the same as that used in the first embodiment. 
The corona discharge treating apparatus of the second embodiment, which is 
provided on a base rack 80 formed of a two-stage metal framing, mainly 
comprises: 
(1) counter electrode means 401 disposed at the first stage of the base 
rack 80 for fixing the instrument panel pad 1 and bring a counter 
electrode into contact with the rear surface thereof; 
(2) a discharge electrode 90 and moving means 402 disposed at the second 
stage of the base rack 80 for moving the discharge electrode 90 and the 
instrument panel pad 1 relative to each other while maintaining the 
distance between the discharge electrode 90 and the surface of the 
instrument panel pad 1 to be treated substantially constant; 
(3) high-frequency energy applying means 403 disposed on a shelf 84 at the 
left side of the base rack 80 for applying high-frequency energy to the 
discharge electrode 90 and having discharge power output control means for 
maintaining discharge power output constant in spite of the changes in 
distance between the surface of the instrument panel pad 1 to be treated 
and the discharge electrode 90; and 
(4) a control unit 404 disposed at the right side of the base rack 80 for 
controlling the moving means 402. 
The parts 401 and 404 will be described in detail hereunder. 
[Counter Electrode Means 401] 
As shown in FIGS. 8, 10, 11 and 13, a hollow electrode stand 61 is disposed 
at the first stage of the base rack 80. A shelllike electrode base 62 
formed of epoxy resin so as to be agree with the three-dimensional inside 
shape of the instrument panel pad 1 is supported on the upper portion of 
the electrode stand 61 in order to support the instrument panel pad 1 from 
the inside thereof. 
A thin-film counter electrode 63 is formed on the surface of the electrode 
base 62 corresponding to the inner surface of the instrument panel pad 1 
by a suitable coating method, such as a metal plating method, a vacuum 
evaporating method, a sputtering method, a conductive paint coating 
method, an aluminum-foil sticking method, or the like, so that contact is 
made between the surface of the counter electrode 63 and the inner surface 
of the instrument panel pad 1. 
As shown in FIGS. 10 and 13, the electrode base 62 is provided with recess 
portions 64 formed in positions corresponding to the air-blowing ports 10, 
11 and 12 of the instrument panel pad 1, so that the recess portions 64 is 
coated with the counter electrode 63. 
A buffering member 65 made of a dielectric material, such as hyperon 
rubber, epoxy resin, or the like, is inserted into each of the recess 
portions 64 to be coated over the counter electrode 63 within the recess 
portions 64. Accordingly, when a discharge electrode described later is 
caused to approach the counter electrode 63 to which the instrument panel 
pad 1 is fitted, it is not apprehended that the counter electrode 63 
within the recess portions 64 is exposed to the discharge electrode 
through the air-blowing ports 10, 11 and 12. 
If the counter electrode 63 is exposed to the discharge electrode, corona 
discharge between the two electrodes may be disturbed or spark discharge 
may occur. 
[Moving Means 402] 
As shown in FIGS. 9, 11 and 12, the moving means 402 is constituted by an 
X-direction moving means 100 for moving a corona discharge electrode 90 in 
the direction of the X-axis (in the left/right direction), Y-direction 
moving means 110 for moving the discharge electrode 90 in the direction of 
the Y-axis (in the back/forth direction), and Z-direction moving means 120 
for moving the discharge electrode 90 in the direction of the Z-axis (in 
the up/down direction). 
In the X-direction moving means 100, two guide rods 128 horizontally 
extending in parallel to each other are attached to the base rack 80. A 
turntable 126 for supporting the Y-direction moving means 110 is provided 
on the guide rods 128 so as to be slidably movable in the direction of the 
X-axis. That is to say, supports 123 are attached to the lower surface of 
the turntable 126 and the two guide rods 128 are inserted into the 
supports 123 to thereby make the turntable 126 slidably movable. 
Furthermore, screw joints 129 are attached on the left and right sides of 
the supports 123 at the lower surface of the turntable 126, and a screw 
shaft 127 is rotatably and longitudinally displaceably screw-engaged with 
the screw joints 129. A gear 121a is attached to the right end of the 
screw shaft 127, and the gear 121a engages with a gear 121b of a 
servo-motor 125 attached to the right end of the base rack 80. 
Accordingly, the screw shaft 127 rotates through the gears 121a and 121b as 
the servo-motor 125 rotates, so that the turntable 126 moves in the 
direction of the X-axis together with the screw joints 129 engaged with 
the screw shaft 127. 
In the Y-direction moving means 110, as shown in FIG. 12, two pairs of 
bearings 135 are provided at the opposite sides of the upper surface of 
the turntable 126. Two screw shafts 131 extending horizontally parallelly 
to each other are attached between the respective pairs of right and left 
bearings 135, the two screw shafts 131 being rotatable but not 
displaceable longitudinally. Gears 136a are attached on the rear ends of 
the screw shafts 131 and engaged with a gear 136b of a servo-motor 132 
attached to the rear end of the base rack 80. 
A screw joint 134 is extended across and screw-engaged with the two shafts 
131, and the rear end of a Y-axis arm 133 extending forward is attached to 
the center of the screw joint 134. The Z-direction moving means 120 is 
fixed to the front end of the Y-axis arm 133. 
Accordingly, also in the Y-direction moving means 110, rotation of the 
servo-motor 132 is transmitted to the gears 136, the screw shafts 131 and 
the screw joint 134 in the order, so that the Z-direction moving means 120 
can move in the direction of the Y-axis. 
In the Z-direction moving means 120, a stationary table 141 is vertically 
fixed to the front end of the Y-axis arm 133. Two guide rods 142 are fixed 
on the front surface of the stationary table 141, and the rods 142 
vertically extend in parallel to each other. 
A sliding member 144 is extended across the two guide rods 142 to be 
attached thereto, and a female screw portion (not shown) is formed at the 
center of the sliding member 144. A screw shaft 146 extending upward is 
screw-engaged with the female screw portion of sliding member 144, and 
directly connected to a rotary shaft 147 of a servo-motor 145 mounted on 
the upper portion of the stationary table 141. 
On the other hand, a Z-axis arm 143 is fixed at its upper end at the center 
of the sliding member 144 so as to extend downward therefrom, and the 
discharge electrode 90 for corona discharge is gripped by the lower end of 
the Z-axis arm so as to always extend substantially vertically downward. 
Accordingly, the screw shaft 146 rotates as the servo-motor 145 rotates, so 
that the Z-axis arm 143 and discharge electrode 90 are caused to come 
up/down by the sliding member 144. 
The discharge electrode 90 disposed in the air is constituted by a rod-like 
gripped portion 91 of a diameter of about 2 mm formed of stainless steel, 
and a spherical discharge top end portion 92 of a diameter of about 6 mm 
formed of stainless steel and attached to the top end of the gripped 
portion 91. The gripped portion 91 is gripped by the Z-axis arm 143 as 
described above so as to be maintained substantially vertically. 
Accordingly, the gripped portion 91 is not inclined even when moved by the 
respective moving means 100, 110 and 120. 
[High-frequency Energy Applying Means 403] 
As shown in FIGS. 8 and 9, the high-frequency energy applying means 403 is 
electrically connected across the counter electrode 63 and the discharge 
electrode 90. 
The arrangement of the high-frequency applying means 403 will be described 
hereunder. 
A rectifier 71 is electrically connected to an input three-phase AC power 
source. The DC output of the rectifier 71 is connected to an oscillator 72 
constituted by an inverter circuit using a thyristor. High-speed switching 
is made in the oscillator 72 so as to generate a rectangular wave of about 
25 kHz. 
A tuning circuit 73 is electrically connected to the output of the 
oscillator 72. The tuning circuit 73 removes harmonic components from the 
rectangular wave so as to permit a sinusoidal wave of about 25 kHz to pass 
therethrough. 
A primary coil 75 of a high-voltage transformer 74 is electrically 
connected to the output of the tuning circuit 73, and a secondary coil 76 
of the same is connected to both the discharge electrode 90 and the 
counter electrode 63. The counter electrode side of the secondary coil 76 
is grounded. 
At the wiring portion between the tuning circuit 73 and the primary coil 
75, a detecting circuit 77 for detecting a high-frequency voltage and a 
high-frequency current impressed to the primary coil 75 is connected in 
parallel to the primary coil 75. An oscillation-output control circuit 78 
is connected between the detecting circuit 77 and the oscillator circuit 
72 in order to control the output of the oscillator circuit 72 on the 
basis of the values of the high-frequency voltage and current detected by 
the detecting circuit 77. 
In the second embodiment, these detecting circuit 77 and the 
oscillation-output control circuit 78 constitute discharge-output control 
means for maintaining the discharge output constant regardless of the 
change in distance between the surface of the instrument panel pad 1 to be 
treated and the discharge electrode 90 
[Control Unit 404] 
A control circuit (not shown) using a computer or the like is installed in 
the control unit 404. The control circuit is taught in advance programs, 
such as (1) a drive program for controlling the operations of the X-, Y- 
and Z-direction moving means 100, 110 and 120 to move the discharge 
electrode while maintaining the distance between the discharge electrode 
90 and the surface of the instrument panel pad 1 to be treated 
substantially constant, and (2) a program for controlling the turning 
on-off of the high-frequency energy applying means 403, and the like. 
As shown in FIG. 11, exhaust means 405 for exhausting gas such as ozone or 
the like generated during corona discharge treatment is disposed behind 
the counter electrode means 401 in the rear of the base rack 80. 
A corona discharge treating method for an instrument panel pad 1, using the 
corona discharge treating apparatus having such an arrangement as 
described above, will be described hereunder. 
As shown in FIGS. 8, 10, 11 and 13, the instrument panel pad 1 is fitted to 
the electrode base 62 and counter electrode 63 of the counter electrode 
means 401. At this time, the almost whole surface of the counter electrode 
63 is brought in direct contact with the whole rear surface of the 
instrument panel pad 1, because the surface of the counter electrode 63 or 
the whole thereof is shaped to agree with the three-dimensional shape of 
the rear side of the instrument panel pad 1. 
Accordingly, the instrument panel pad 1 is electrically effectively 
connected to the counter electrode 63 to thereby make it easy to generate 
corona discharge from the discharge electrode 90. 
Next, after the exhaust means 405 is turned on, the control unit 404 is 
turned on and each of the X-, Y- and Z-direction moving means 100, 110 and 
120 of the moving means 402 is set in a starting position for corona 
discharge treatment. At this time, the gripped portion 91 of the discharge 
electrode 90 is supported to always extend vertically, and the discharge 
top end portion 92 is located above the front edge left end of the 
instrument panel pad 1 at a distance of about 10 mm therebetween. 
Next, upon actuation of the high-frequency energy applying means 403, a 
rectangular wave of 25 kHz is generated from the oscillator circuit 72 and 
harmonic components are removed from the rectangular wave in the tuning 
circuit 73, so that only a sinusoidal wave is allowed to pass through the 
tuning circuit 73. The sinisoidal wave is raised by the high-voltage 
transformer 74 so that a high-frequency voltage of 28 kV is produced to be 
impressed across the counter electrode 63 and the discharge electrode 90. 
At this time, corona discharge occurs in the air between the upper surface 
2 and the opposite portion of the discharge top end portion 92 so as to 
initiate the corona discharge treatment for the upper surface 2. 
The X-, Y- and Z-direction moving means 100, 110 and 120 are moved in the 
respective directions by the rotations of the servomotors 125, 132 and 145 
operated on the basis of the control signal generated from the control 
unit 404, so that the discharge electrode 90 is moved in the vicinity of 
the surface of the instrument panel pad 1 to be treated. 
The displacement of the discharge electrode 90 is as follows. 
(1) First, the discharge electrode 90 is moved right from the left end of 
the front edge of the instrument panel pad to the right end of the same. 
(2) Next, the discharge electrode 90 is moved a little backward so that it 
is located at the right side of the right side surface 4 of the instrument 
panel pad 1. Then, the discharge electrode 90 is moved up to a portion 
above the right end of the front surface 3, moved left to a portion above 
the left end of the front surface 3, and then moved down to the left side 
of the left side surface 4 again. 
(3) Further, the discharge electrode 90 is moved a little backward, moved 
upward to a portion above the left end of the upper surface 2, moved right 
to a portion above the right end of the upper face 2, and the moved 
downward to the right side of the right side surface 4 again as shown in 
FIG. 13. 
(4) Furthermore, the discharge electrode 90 is reciprocatingly moved while 
moving backward. 
In such displacement of the discharge electrode 90, the distance between 
the discharge electrode 90 and the surface of the instrument panel pad 1 
to be treated is maintained substantially constant, that is, about 10 mm. 
For example, as shown in FIG. 13, when the discharge electrode 90 passes 
through over the air-blowing ports 10, 11 and 12 and saucers 6 and 7, the 
discharge electrode 90 is moved down by the respective depth thereof. 
Accordingly, the discharge power output from the discharge electrode 90 is 
maintained substantially constant with respect to the whole surface of the 
instrument panel pad to be treated, so that the quality of the treated 
surface can be improved substantially uniformly. 
There is however a possibility of dimensional errors in the instrument 
panel pad 1 or warp transformation of the same after molding. Accordingly, 
the distance between the discharge electrode 90 and the surface of the 
instrument panel pad 1 to be treated may change in practice in spite of 
the operation of the moving means 402, so that also the discharge power 
output may be changed more or less in practice. 
In this embodiment, however, even if the distance is changed, the detecting 
circuit 77 and oscillation-output control circuit 78 constituting the 
discharge-output control means provided for the high-frequency energy 
applying means 403 can maintain the discharge power output constant in 
such a manner as follows. 
Assuming now that the distance between the discharge electrode 90 and the 
surface of the instrument panel pad 1 to be treated becomes less than a 
standard value of 10 mm, the discharge power output between the counter 
electrode 63 and the discharge electrode 90 becomes more than a standard 
power output. With the increase of the discharge power output, a 
high-frequency current flowing in the primary coil 75 of the high-voltage 
transformer 74 increases. The detecting circuit 77 detects the 
high-frequency current, so that the oscillation-output control circuit 78 
reduces the oscillation power output of the oscillator circuit 72. 
Accordingly, the discharge power output is controlled to be reduced to the 
standard power output. 
Reversely, assuming that the distance between the discharge electrode 90 
and the surface of the instrument panel pad 1 to be treated becomes larger 
than the standard value 10 mm, the discharge power output becomes less 
than the standard power output. With the decrease of the discharge power 
output, the high-frequency current flowing in the primary coil 75 
decreases. The detecting circuit 77 detects the high-frequency current, so 
that the oscillation-output control circuit 78 increases the oscillation 
power output of the oscillator circuit 72. Accordingly, the discharge 
power output is controlled to be increased to the standard power output. 
The quality of the treated surface of the instrument panel pad 1 can be 
improved uniformly by corona discharge with the above-mentioned 
reciprocating motion to thereby improve the adhesive property with respect 
to painting materials, joining materials, printing materials, etc. 
Although the moving speed of the discharge electrode 90 can be suitably set 
to a value within a range of 1 to 250 mm/sec under the above-mentioned 
discharge conditions, this embodiment shows the case of 150 mm/sec. 
According to the moving speed, one instrument panel pad 1 can be treated 
in about 50 sec. 
In addition, this embodiment has the advantage of being free from the 
influences of changes in potential distribution at the corners 5, 8, 9 and 
13 and changes in angles at the treated surface with respect to the 
direction of discharge due to the shape of the curved surface of the 
discharge top end portion 92. 
It is to be understood that the second embodiment is not limited to the 
above-described specific arrangement, but changes or modifications may be 
made as follows. 
(1) The X-, Y- and Z-direction moving means 100, 110 and 120 of the moving 
means 402 may be modified in arrangement or may be replaced by revolute 
robots or the like. 
(2) Although the second embodiment shows the case where the discharge 
electrode 90 is provided with the moving means 402 for moving the 
discharge electrode 90, moving means may be provided on the counter 
electrode means 401 for moving the instrument panel pad 1. In short, any 
moving means may be used as long as it can move the discharge electrode 90 
and the instrument panel pad 1 relative to each other while maintaining 
the distance between the discharge electrode 90 and the surface of the 
instrument panel pad 1 to be treated substantially constant. 
(3) The discharge-output control means may be modified in arrangement. For 
example, the discharge-output control means may be made up of detecting 
means for directly detecting the distance between the discharge electrode 
90 and the instrument panel pad 1, and the above-mentioned 
oscillation-output control circuit 78. 
(4) The shape of the discharge top end portion 92 of the discharge 
electrode 90 is not limited to the spherical one, but any shape, for 
example, a hemispherical one, a spheroidal one, or the like, can be 
employed as long as at least the discharge top end portion is shaped to be 
a curved surface. However, it is considered that the spherical shape is 
optimum from the point of view of uniformity of corona discharge, 
particularly from the point of view of uniformity of corona discharge in 
the case where the discharge electrode is moved without inclination with 
respect to the surface to be treated as shown in this embodiment. 
(5) Furthermore, the discharge electrode 31 can be replaced by a rod-like 
or plane-like discharge electrode which is moved to approach a surface of 
the resin molding to be treated in parallel thereto. In the case where the 
shape of a surface to be treated is simple or a little rough, the use of 
the rod-like or plane-like electrode is advantageous in more shortening 
the time required for corona discharge treatment. 
In addition, treatment with the discharge electrode 90 according to the 
embodiment may be suitable combined with treatment with the rod-like or 
plane-like discharge electrode. 
It is to be understood that the present invention is not limited to the 
first and second embodiments, but changes or modifications may be made as 
follows. 
(1) Although the embodiments show the case where the present invention is 
applied to an instrument panel pad 1, the invention is applicable to any 
other three-dimensional resin moldings, such as an automobile bumper, an 
automobile molding, an autobicycle fender, various types of industrial 
appliances and home appliances, etc., which need painting, joining, 
printing or the like after molding. 
(2) The discharge portion 55 or discharge top end portion 92 of the 
discharge electrode 51 or 90 may have a curved surface including concavity 
and convexity. For example, the concavity may be shaped like a groove or 
like a hole, and the convexity may be shaped like a semispherical 
projection. In this case, electric collection is made at the convexity so 
that an electronic avalanche effect easily generates from the convexity, 
particularly from the edges thereof to thereby make corona discharge 
stable and make the range of discharge wide. 
(3) The distance between the top end of the discharge electrode 51 or 90 
and the surface of the resin molding 1 to be treated may be 50 mm or less, 
and the relatively moving speed therebetween may be 500 mm/sec or less. In 
this case, the quality of the surface of the molding 1 can be improved 
more effectively. 
(4) A rod-like nonconductive distance control member which extends toward 
the surface of the molding 1 to be treated may be mounted to the discharge 
electrode 51/90 or one of the members connected thereto to thereby 
maintain the distance between the discharge electrode 51 or 90 and the 
surface to be treated constant. 
As many apparently widely different embodiments of the present invention 
may be made without departing from the spirit and scope thereof, it is to 
be understood that the invention is not limited to the specific 
embodiments thereof except as defined in the appended claims.