Patent Description:
Three-dimensional decorative pieces made of a thermoplastic synthetic resin (hereinafter referred to simply as "decorative pieces", if appropriate), such as emblems, appliqués, and stickers, produced through high-frequency dielectric heating have been proposed (see Patent Document <NUM>, for example).

A decorative piece is produced from a decorative piece material that includes a thermoplastic resin sheet, a vapor-deposited metal layer, a foamed resin sheet, and the like. For example, according to Patent Document <NUM>, while a decorative piece material is sandwiched between an engraved die and a flat-plate die, high-frequency dielectric heating is performed, thereby shaping the decorative piece material while heating and welding the material. The engraved die is provided with fusion-cutting blades along outlines of a design of a decorative piece to be produced, so that fusion-cutting can be performed simultaneously with shaping.

In order to produce a decorative piece, it is necessary to soften, shape, and weld a decorative piece material by heating the decorative piece material through high-frequency dielectric heating. However, high-frequency dielectric heating has the property of radio waves being focused on a cutting edge, or a corner portion of a design. Accordingly, if the thickness of a decorative piece material is increased, it is no longer possible for the entire decorative piece material to be heated, and shaping and welding cannot be satisfactorily performed. For this reason, the thickness of decorative pieces that can be produced has been limited to up to about <NUM>.

On the other hand, there is demand for bulky decorative pieces that have an enhanced three-dimensional appearance and an enhanced sense of luxuriousness.

<CIT> describes a laminate-type decorative sheet for use in simultaneous decoration and injection molding, including a base film and at least a decorative layer provided on the base film, the decorative sheet having an elongation at break as measured at <NUM> of <NUM> to <NUM>%, and an elongation at break as measured at <NUM> of <NUM>% or more. The laminate-type decorative sheet exhibits conformability to the molding surface of a mold during the course of preforming, and is less likely to produce wrinkling, blistering, breakage, etc. when laminated on and united with a resin molding through injection molding. In addition, the decorative sheet enables trimming.

<CIT> describes a device and a method for manufacturing an emblem of thermoplastic synthetic resin with an incorporated IC chip by high frequency induction heating without damaging the IC chip. A device for manufacturing and for manufacturing an emblem of thermoplastic synthetic resin with an incorporated IC chip by high frequency induction heating, comprises: an upper metal mold having at least a fusion cutting blade; a support frame disposed along the perimeter and on the upper surface of the table; a slide board disposed on the upper surface of the table so as to be slidable in the axial directions relative to the table; a metal plate arranged on the upper surface of the slide board and wherein pressing the upper layer material by means of the upper metal mold from above and subjecting the upper layer material to high frequency induction heating, the IC chip is placed in an upper position of the recessed section, then the slide board is driven to axially slide so as to be located below the upper metal mold and subsequently a high frequency induction heating operation is executed without any risk of applying pressure onto the IC chip due to the provision of the recessed section and the cushion member.

<CIT> describes a method and an apparatus for producing a three-dimensional decoration piece which do not damage the tacky bonding or adhesion strength of the lower layer material of the decoration piece. The method comprises putting an upper layer material on a first table operating as cathode; lowering an upper mold operating as anode onto the first table to press the upper layer material, emitting a high frequency wave for induction heating, to form a three-dimensionally formed body from the upper layer material by molding and fusion-cutting and temporarily holding the three-dimensionally formed body to the upper mold; stopping the high frequency induction heating; moving a second table carrying a lower layer material having a tacky bonding property to below the upper mold temporarily holding the three-dimensionally formed body; and lowering said upper mold onto the second table to press the three-dimensionally formed body, cutting the lower layer material and tacky bonding the three-dimensionally formed body and the lower layer material.

In the apparatus, the second table or the lower mold is provided on the top surface thereof with recessed sections, each of which being transversally and inwardly separated from a position where an edge of the first machining means contacts, by <NUM> to <NUM>; and a cushion member is arranged in the respective recessed sections.

<CIT> describes a method of manufacturing a three-dimensional decoration piece having a flat rear surface, a method of manufacturing the decoration piece by easily cutting the same by means of a fusion cutter, a method of manufacturing the decoration piece having a bonding or sticking feature on the rear surface and a method of manufacturing a three-dimensional decoration piece without limiting the characteristics of the base member thereof. The three-dimensional decoration piece is manufactured by using an indented mold and high frequency dielectric heating. An indented mold having a second fusion cutter and arranged along an outer periphery of the fusion cutter is used. Firstly, a three-dimensional molded body of upper and intermediate layers having a recessed section on a lower surface thereof is molded by means of an indented mold and a protruding mold, and subsequently a lower layer material is molten by high frequency dielectric heating and made to flow into the recessed section.

An object of the present invention is to provide a method and a device with which a bulky decorative piece made of a thermoplastic synthetic resin can be produced.

The invention provides a method for producing a three-dimensional decorative piece made of a thermoplastic synthetic resin, according to claim <NUM>.

The method can include the features of any of dependent claims <NUM> to <NUM>.

Moreover, the invention provides a device for producing a three-dimensional decorative piece made of a thermoplastic synthetic resin, according to claim <NUM>.

With the method for producing a three-dimensional decorative piece made of a thermoplastic synthetic resin according to the present invention, the entire decorative piece material can be heated and softened by performing high-frequency dielectric heating on the decorative piece material using the flat-plate dies. Since the entire decorative piece material is heated and softened through high-frequency dielectric heating prior to the shaping, the decorative piece material can be shaped using the engraved die in the subsequent shaping step even when the decorative piece material is thick, and thus, a bulky three-dimensional decorative piece made of a thermoplastic synthetic resin that has a three-dimensional appearance and a sense of luxuriousness can be favorably produced.

Moreover, with the device for producing a three-dimensional decorative piece made of a thermoplastic synthetic resin according to the present invention, it is possible to shape the decorative piece material using the engraved die and/or the engraved die with the fusion-cutting blade immediately after softening the decorative piece material using the flat-plate die, by sliding the dies after the softening.

Hereinafter, a three-dimensional decorative piece <NUM> made of a thermoplastic synthetic resin of the present invention and a method for producing the three-dimensional decorative piece <NUM> will be described with reference to the drawings. Note that, in the drawings, the thicknesses of the decorative piece <NUM> and layers of a decorative piece material <NUM>, projections and recesses of dies, the thicknesses of the dies, and the like are shown exaggerated to facilitate the explanation. Also, the shapes, the designs, and the like of the decorative piece <NUM> and the decorative piece material <NUM> are given by way of example only, and can be changed as appropriate.

<FIG> is a cross-sectional view of the decorative piece material <NUM>. As shown in <FIG>, the decorative piece material <NUM> includes an upper layer <NUM> and a lower layer <NUM>.

The upper layer <NUM> is a laminated film including a thermoplastic synthetic resin film that can be molded through high-frequency dielectric heating, a vapor-deposited metal layer, and the like. The thermoplastic synthetic resin film may be made of a soft thermoplastic synthetic resin, such as polyvinyl chloride or polyurethane, for example. The upper layer <NUM> can be formed by, for example, forming the vapor-deposited metal layer on the thermoplastic synthetic resin film that is located on the upper surface side through metal vapor deposition. Note that the upper layer <NUM> may also have a configuration in which a migration preventing film is provided on a lower surface of the vapor-deposited metal layer via an adhesive layer, if necessary, and furthermore a thermoplastic synthetic resin film may be provided thereunder via an adhesive layer.

An example of the migration preventing film is an ethylene-vinyl alcohol copolymer (EVOH) film. The migration preventing film prevents a dye of a garment or the like to which the decorative piece <NUM> is attached from migrating to a front surface side of the decorative piece material <NUM>.

A desired design can also be printed in a desired color onto an upper surface of the upper layer <NUM> using a transparent color ink, a matte ink, a glossy ink, or the like. Furthermore, a fine line design can also be added by screen printing an ultraviolet-curable transparent UV ink or the like onto the above-described printing, so that a sense of luxuriousness such as that of braided embroidery, an aura of substance, elaborateness, a depth of color, and a metallic appearance, and furthermore, minute projections and depressions, and the like can also be expressed.

A soft sheet of a thermoplastic synthetic resin or a foamed resin sheet can be used as the lower layer <NUM>, and the lower layer <NUM> may be made of a thermoplastic synthetic resin, such as soft polyvinyl chloride (PVC), for example.

In the present invention, a material in which a foamed resin sheet or the like is thicker than that of a conventional material can be used as the decorative piece material <NUM>. For example, the decorative piece material <NUM> may have a total thickness of greater than <NUM>, and the shaping of a decorative piece material having such a thickness has been difficult with a conventional method. The decorative piece material <NUM> has a thickness of preferably about <NUM> to <NUM>, but the present invention is also applicable to a decorative piece material having a greater thickness.

A feature of the present invention is that the decorative piece material <NUM> is softened through high-frequency dielectric heating in advance, and then high-frequency dielectric heating is performed again to thereby perform shaping and fusion-cutting.

As illustrated in <FIG>, the step of softening the decorative piece material <NUM> can be performed by performing high-frequency dielectric heating while the decorative piece material <NUM> is sandwiched between a first flat-plate die <NUM> and a second flat-plate die <NUM>, which serve as electrodes. Specifically, the decorative piece material <NUM> is placed on top of the first flat-plate die <NUM> as illustrated in <FIG>, the second flat-plate die <NUM> is brought closer to the first flat-plate die <NUM> as illustrated in <FIG>, and high-frequency dielectric heating is performed. Thus, insulators of the upper layer <NUM> and the lower layer <NUM> of the decorative piece material <NUM> generate heat and fuse, allowing both layers to be softened in their entirety and welded to each other. After the high-frequency dielectric heating, the second flat-plate die <NUM> is separated from the decorative piece material <NUM> as illustrated in <FIG>.

According to a first embodiment, after the softening step, the decorative piece material <NUM> is shaped as illustrated in <FIG> (shaping step), and subsequently the shaped decorative piece material <NUM> is fusion-cut as illustrated in <FIG> (fusion-cutting step).

In the shaping step, as illustrated in <FIG>, the first flat-plate die <NUM> is used, and an engraved die <NUM> is used in place of the second flat-plate die <NUM> in <FIG>. As illustrated in <FIG>, the engraved die <NUM> is a die in which recesses <NUM> of a design to be formed in the decorative piece material <NUM> are formed. While the decorative piece material <NUM> that is in a softened state due to the softening step is still placed on top of the first flat-plate die <NUM>, the engraved die <NUM> is brought closer to the first flat-plate die <NUM> as illustrated in <FIG>, and high-frequency dielectric heating is performed. Thus, the decorative piece material <NUM> is shaped in conformity with the recesses <NUM> of the engraved die <NUM> as illustrated in <FIG>. In the shaping step, since the decorative piece material <NUM> that is softened in its entirety in advance is shaped, the shaping can be performed even when the decorative piece material <NUM> is thick. Note that, after the shaping, the decorative piece material <NUM> is cooled to fix its shape.

After the shaping step, the decorative piece material <NUM> is fusion-cut along the design. In the fusion-cutting step, first, as illustrated in <FIG>, the decorative piece material <NUM> with a piece of release paper <NUM> disposed on or attached to the lower layer <NUM> side thereof via a piece of double-sided tape <NUM> is placed on top of the first flat-plate die <NUM>. The double-sided tape <NUM> is used to attach the produced decorative piece <NUM> to various products and the like.

In the fusion-cutting step, as also illustrated in <FIG>, an engraved die <NUM> with fusion-cuttings blade is used in place of the engraved die <NUM>. The engraved die <NUM> with the fusion-cutting blades is a die in which fusion-cutting blades <NUM> are formed at peripheral edges of recesses <NUM> along outlines of the design to be formed in the decorative piece material <NUM>. If the fusion-cutting blades <NUM> come into surface contact with the decorative piece material <NUM> that has been shaped using the engraved die <NUM>, the dielectric heating efficiency decreases, resulting in a deformation or the like of the already shaped decorative piece material <NUM>. For this reason, it is desirable that, as illustrated in <FIG>, the fusion-cutting blades <NUM> have a sharper angle than the engraved die <NUM> so as not to come into surface contact with the decorative piece material <NUM>. In a state in which the decorative piece material <NUM> that has been shaped through the shaping step is placed on top of the first flat-plate die <NUM>, with the double-sided tape <NUM> and the release paper <NUM> disposed on or attached to the decorative piece material <NUM>, the engraved die <NUM> with the fusion-cutting blades is brought closer to the first flat-plate die <NUM> as illustrated in <FIG>, and high-frequency dielectric heating is performed. Thus, the decorative piece material <NUM> and the double-sided tape <NUM> are fusion-cut or cut by the fusion-cutting blades <NUM> as illustrated in <FIG>. The release paper <NUM> is not cut by the fusion-cutting blades <NUM>.

As a result of the above-described fusion-cutting step, the shaped and fusion-cut design and unnecessary portions of the decorative piece material <NUM> remain on the release paper <NUM> in a state in which the design and the unnecessary portions are separately attached to the double-sided tape <NUM>. After that, the unnecessary portions are eliminated, and an application film is attached to the upper layer <NUM> side of the decorative piece material <NUM> so as to prevent displacement of the design. Thus, a decorative piece <NUM> can be obtained. Examples of the application film include, but are not limited to, sheets in which an acrylic pressure-sensitive adhesive is applied to a polyester film or paper.

The obtained decorative piece <NUM> can be affixed to a product by peeling off the release paper <NUM> and attaching the decorative piece <NUM> to the product via the double-sided tape <NUM> in a state in which the application film or the like is attached to the decorative piece <NUM>, and then peeling off the application film or the like.

According to the first embodiment of the present invention, a decorative piece <NUM> can be produced by performing the shaping step and the fusion-cutting step by replacing the dies after the softening step.

As described above, replacement of the dies is needed when producing the decorative piece <NUM>. Hereinafter, a production device <NUM> with which a decorative piece <NUM> can be produced by favorably replacing the dies will be described.

<FIG> and <FIG> show an example of the production device <NUM> that can be used in the present embodiment. The production device <NUM> may be constituted by a first jig <NUM> shown in <FIG> and a second jig <NUM> shown in <FIG>. The first jig <NUM> and the second jig <NUM> constitute the production device <NUM> in which, as shown in <FIG>, which will be described later, the first jig <NUM> is arranged on the lower side and the second jig <NUM> is arranged on the upper side.

In the first jig <NUM>, as shown in <FIG>, a rectangular first frame <NUM> is mounted on an upper surface of a rectangular bottom plate <NUM>. As shown in <FIG>, the first frame <NUM> includes first guide members <NUM> on an inner surface side thereof in a left-right direction, which is a width direction, the first guide members <NUM> extending parallel to each other.

A first slide plate <NUM> is slidably engaged with the first guide members <NUM>. The first slide plate <NUM> has a length that is <NUM>/<NUM> of the length of the first frame <NUM> (first guide members <NUM>). A plurality of tapped holes <NUM> to which a die, which will be described later, is to be fastened are formed in the first slide plate <NUM>, and two dies can be mounted on the first slide plate <NUM> in a length direction.

Also, pin holes <NUM> for achieving alignment with the second jig <NUM> are formed at a plurality of locations in the first frame <NUM>.

Means for preventing displacement such as magnets <NUM> and <NUM> are arranged in end faces in the length direction of the first frame <NUM> and the first slide plate <NUM>, and when the first slide plate <NUM> is slid and abutted against the first frame <NUM>, the magnets <NUM> and <NUM> are attracted to each other, thereby restraining the first slide plate <NUM> from moving freely.

The first jig <NUM> is configured such that one wire (lower board) of a high-frequency molding machine, which is not shown, can be connected to the center of a lower surface of the bottom plate <NUM>, and high-frequency dielectric heating is applied to a portion indicated by the oblique lines in <FIG>. The region that is subjected to the high-frequency dielectric heating is a region that occupies <NUM>/<NUM> of the first slide plate <NUM> in the length direction and <NUM>/<NUM> of the first frame <NUM> in the length direction and is located centrally in the length direction of the first frame <NUM>.

Therefore, the first jig <NUM> is configured such that, when the first slide plate <NUM> is slid in a direction indicated by the arrows in <FIG>, the first slide plate <NUM> can be slid to the front side, which is the lower side in the paper plane, as shown in <FIG> and positioned by the magnets <NUM> and <NUM> attracting each other. Moreover, in the case where the first slide plate <NUM> is slid to the back side, which is the upper side in the paper plane, as well, the first slide plate <NUM> can be positioned by the magnets <NUM> and <NUM> attracting each other.

In the second jig <NUM>, as shown in <FIG>, a rectangular second frame <NUM> is mounted on a lower surface of a rectangular top plate <NUM>. The second frame <NUM> includes second guide members <NUM> on an inner surface side thereof in the left-right direction, which is the width direction, the second guide members <NUM> extending parallel to each other. The second guide members <NUM> are formed so as to extend in the same direction as the first guide members <NUM>.

A second slide plate <NUM> is slidably engaged with the second guide members <NUM>. The second slide plate <NUM> has a length that is <NUM>/<NUM> of the length of the second frame <NUM> (second guide members <NUM>). A plurality of tapped holes <NUM> to which a die, which will be described later, is to be fastened are formed in the second slide plate <NUM>, and two dies can be mounted on the second slide plate <NUM> in the length direction.

Also, pin holes <NUM> for achieving alignment with the first jig <NUM> are formed at a plurality of locations in the second frame <NUM>.

Means for preventing displacement such as magnets <NUM> and <NUM> are arranged in end faces in the length direction of the second frame <NUM> and the second slide plate <NUM>, and when the second slide plate <NUM> is slid and abutted against the second frame <NUM>, the magnets <NUM> and <NUM> are attracted to each other, thereby restraining the second slide plate <NUM> from moving freely.

In the second jig <NUM>, a cross-shaped bar 51a in which a plurality of screw holes are formed is mounted on an upper surface of the top plate <NUM>, so that the second jig <NUM> can be fastened to an upper board (not shown) of the high-frequency molding machine, which is not shown, using a bolt or the like. In the second jig <NUM>, high-frequency dielectric heating is performed on a portion indicated by the oblique lines in <FIG>. The region that is subjected to the high-frequency dielectric heating is a region that occupies <NUM>/<NUM> of the second slide plate <NUM> in the length direction and <NUM>/<NUM> of the second frame <NUM> in the length direction and is located centrally in the length direction of the second frame <NUM>. This region opposes the high-frequency dielectric heating region of the first jig <NUM> shown in <FIG>.

Therefore, the second jig <NUM> is configured such that, when the second slide plate <NUM> is slid in a direction indicated by the arrows in <FIG>, the second slide plate <NUM> can be slid to the back side, which is the lower side in the paper plane, as shown in <FIG>, and positioned by the magnets <NUM> and <NUM> attracting each other. Moreover, in the case where the second slide plate <NUM> is slid to the front side, which is the upper side in the paper plane, as well, the second slide plate <NUM> can be positioned by the magnets <NUM> and <NUM> attracting each other.

In the first jig <NUM> and the second jig <NUM> described above, dies are mounted on the first slide plate <NUM> and the second slide plate <NUM>.

<FIG> shows the first jig <NUM> to which dies <NUM> and <NUM> are mounted, and <FIG> shows the dies <NUM> and <NUM> that are to be mounted to the first jig <NUM>. The dies <NUM> and <NUM> can be mounted on the first slide plate <NUM> by fastening screws <NUM> to the tapped holes <NUM>. The dies to be fastened to the first jig <NUM> may be the first flat-plate die <NUM> shown in <FIG> and the first engraved die <NUM> with fusion-cutting blades shown in <FIG>. The first flat-plate die <NUM> is a die that has a flat upper surface, and the first engraved die <NUM> with the fusion-cutting blades is a die in which fusion-cutting blades <NUM> are formed along the outlines of the design of the decorative piece material <NUM>.

<FIG> shows the second jig <NUM> to which dies <NUM> and <NUM> are mounted, and <FIG> shows the dies <NUM> and <NUM> that are to be mounted to the second jig <NUM>. The dies <NUM> and <NUM> can be mounted on the second slide plate <NUM> by fastening screws <NUM> to the tapped holes <NUM>. The dies to be fastened to the second jig <NUM> may be the second flat-plate die <NUM> shown in <FIG> and the second engraved die <NUM> shown in <FIG>. The second flat-plate die <NUM> is a die that has a flat lower surface, and the second engraved die <NUM> is a die in which recesses <NUM> of the design of the decorative piece material <NUM> are formed. For example, recesses <NUM> that constitute inverted alphabet letters "CHRO" are formed in the second engraved die <NUM> shown in <FIG>.

Then, the first jig <NUM> and the second jig <NUM> on which the dies <NUM> and <NUM> and the dies <NUM> and <NUM> are respectively mounted are fastened to a high-frequency dielectric heating device, which is not shown, such that the first jig <NUM> is located on the lower side and the second jig <NUM> is located on the upper side. In order for the first jig <NUM> and the second jig <NUM> to be fastened correctly relative to each other in the vertical direction, the positions of both jigs are adjusted by inserting pins (not shown) into the pin holes <NUM> and <NUM>.

Then, first, the softening step (see <FIG>) of softening the decorative piece material <NUM> is performed using the production device <NUM>. As illustrated in <FIG>, in both the first jig <NUM> and the second jig <NUM>, the slide plates <NUM> and <NUM> are positioned such that the flat-plate dies <NUM> and <NUM> are located centrally (in the portions indicated by the oblique lines in <FIG> and <FIG>), and the decorative piece material <NUM> is placed on top of the first flat-plate die <NUM>. In this state, the second jig <NUM> is moved downward, and while the decorative piece material <NUM> is thereby pressed, high-frequency dielectric heating is performed using the flat-plate dies <NUM> and <NUM> as electrodes, thereby softening and welding the entire decorative piece material <NUM>. When the softening is completed, the second jig <NUM> is moved upward.

Subsequently, with the first jig <NUM> left as it is, the second slide plate <NUM> of the second jig <NUM> is slid to the back side, thereby moving the second engraved die <NUM> to the center (the portion indicated by the oblique lines in <FIG>) as illustrated in <FIG>. Then, the second jig <NUM> is moved downward, and while the decorative piece material <NUM> is thereby pressed, high-frequency dielectric heating is performed using the first flat-plate die <NUM> and the second engraved die <NUM> as electrodes (shaping step in <FIG>). Since the entire decorative piece material <NUM> is softened due to the softening step, the decorative piece material <NUM> is shaped in conformity with the recesses <NUM> of the second engraved die <NUM> through high-frequency dielectric heating, and thus the design is formed therein as projections and recesses. When the shaping is completed, the decorative piece material <NUM> is temporarily cooled to fix the shape.

Next, as illustrated in <FIG>, the first slide plate <NUM> of the first jig <NUM> is slid to the back side, thereby moving the first engraved die <NUM> with the fusion-cutting blades to the center (the portion indicated by the oblique lines in <FIG>), and the second slide plate <NUM> of the second jig <NUM> is slid to the front side, thereby moving the second flat-plate die <NUM> to the center (the portion indicated by the oblique lines in <FIG>). Then, the decorative piece material <NUM> is disposed, with its surface that has served as the lower surface in the shaping step facing upward, such that the shaped design is fitted into the first engraved die <NUM> with the fusion-cutting blades. The double-sided tape <NUM> to which the release paper <NUM> is attached is placed on or attached to the decorative piece material <NUM> from above such that the release paper <NUM> is located on the upper side. In this state, the second jig <NUM> is moved downward, and while the decorative piece material <NUM> is thereby pressed, high-frequency dielectric heating is performed using the first engraved die <NUM> with the fusion-cutting blades and the second flat-plate die <NUM> as electrodes (fusion-cutting step in <FIG>). Thus, the decorative piece material <NUM> and the double-sided tape <NUM> are fusion-cut along the outlines of the design by the fusion-cutting blades <NUM>. After that, the second jig <NUM> is moved upward, and the decorative piece material <NUM> is removed.

Since the removed decorative piece material <NUM> is attached to the release paper <NUM> via the double-sided tape <NUM>, the decorative piece material <NUM> can be removed from the production device <NUM> without positional displacement occurring. In this state, unnecessary portions are eliminated from the decorative piece material <NUM>, and the application film <NUM> is attached to a surface of the decorative piece material <NUM> on the opposite side to the release paper <NUM>. Thus, a decorative piece <NUM> can be obtained as illustrated in <FIG>.

The obtained decorative piece <NUM> can be affixed to a product without positional displacement occurring, by peeling off the release paper <NUM>, attaching the decorative piece <NUM> to the product via the double-sided tape <NUM>, and then peeling off the application film <NUM>.

In the above-described embodiment, the slide plates <NUM> and <NUM> are respectively disposed in the first jig <NUM> and the second jig <NUM>, and different types of dies are fastened to these slide plates <NUM> and <NUM>. Therefore, replacement of the dies can be achieved simply by sliding the slide plates <NUM> and <NUM>, and the softening step (<FIG>), the shaping step (<FIG>), and the fusion-cutting step (<FIG>) can be performed immediately one after another using the same device.

Moreover, since the softening step allows the entire decorative piece material <NUM> to be softened in advance even when the decorative piece material <NUM> is thick, the above-described embodiment is particularly preferable for the production of a bulky decorative piece <NUM> having a three-dimensional appearance and a sense of luxuriousness. For example, if a decorative piece material <NUM> that is <NUM> to <NUM> thick is used, a decorative piece <NUM> having a thickness of <NUM> to <NUM> can be produced.

In a second embodiment, after the softening step, shaping and fusion-cutting are performed in one step. Note that, unless otherwise specified, the same reference numerals as those of the first embodiment denote the same or similar members, and a description thereof is omitted as appropriate.

As is the case with the first embodiment, the decorative piece material <NUM> is subjected to the softening step illustrated in <FIG>.

Then, the decorative piece material <NUM> that is softened in its entirety is subjected to a shaping and fusion-cutting step illustrated in <FIG>. The shaping and fusion-cutting step can be performed by performing high-frequency dielectric heating using the flat-plate die <NUM> on one hand and the engraved die <NUM> with the fusion-cutting blades, in which the recesses <NUM> of the design are formed and the fusion-cutting blades <NUM> are formed along the outlines of the design, on the other hand. The engraved die <NUM> with the fusion-cutting blades shown in <FIG> is a die in which the recesses <NUM> are formed to have a depth that is greater than the thickness of a decorative piece <NUM> to be obtained.

The engraved die <NUM> with the fusion-cutting blades is used in place of the second flat-plate die <NUM> used in the softening step (see <FIG>), and as illustrated in <FIG>, the decorative piece material <NUM> that is in the softened state due to the softening step is placed on top of the flat-plate die <NUM>, with the release paper <NUM> disposed on the lower layer <NUM> side of the decorative piece material <NUM>, or attached to the decorative piece material <NUM>, via the double-sided tape <NUM>. Then, as illustrated in <FIG>, the engraved die <NUM> with the fusion-cutting blades is brought closer to the flat-plate die <NUM>, and high-frequency dielectric heating is performed. Thus, the decorative piece material <NUM> is shaped as illustrated in <FIG>. In the present embodiment, since the recesses <NUM> of the engraved die <NUM> with the fusion-cutting blades are formed to have a depth that is greater than the thickness of the decorative piece <NUM>, a top portion of the decorative piece <NUM> is shaped without abutting against a bottom surface of the die. As a result, a decorative piece <NUM> with a design having a slightly round-shaped curve can be obtained. Moreover, the decorative piece material <NUM> is fusion-cut or cut together with the double-sided tape <NUM> by the fusion-cutting blades <NUM> as illustrated in <FIG>.

After that, unnecessary portions of the decorative piece material <NUM> are eliminated, and the application film <NUM> is attached to the upper layer <NUM> side of the decorative piece material <NUM> so as to prevent displacement of the design, and thus, a decorative piece <NUM> can be obtained.

According to the second embodiment of the present invention, a decorative piece <NUM> can be produced by performing the shaping and fusion-cutting step by replacing the die after the softening step.

As described above, replacement of the die is needed when producing the decorative piece <NUM>. Hereinafter, a production device <NUM> with which a decorative piece <NUM> can be produced by favorably replacing the die will be described.

In the present embodiment, the production device <NUM> shown in <FIG> and <FIG> is used in which dies different from those of the first embodiment are mounted as the production device <NUM>. Specifically, in the first jig <NUM>, as illustrated in <FIG>, only the first flat-plate die <NUM> is mounted on the first slide plate <NUM>, while in the second jig <NUM>, the second flat-plate die <NUM> illustrated in <FIG> and a second engraved die <NUM> with fusion-cutting blades are mounted on the second slide plate <NUM>. Note that the second engraved die <NUM> with the fusion-cutting blades has recesses <NUM> having a depth that is greater than the thickness of the decorative piece <NUM> to be obtained, and includes fusion-cutting blades <NUM> at peripheral edges of the recesses <NUM>.

Then, the first jig <NUM> and the second jig <NUM> to which the die <NUM> and the dies <NUM> and <NUM> are respectively mounted are fastened to a high-frequency dielectric heating device, which is not shown, such that the first jig <NUM> is located on the lower side and the second jig <NUM> is located on the upper side.

Then, as is the case with the first embodiment, the softening step (see <FIG>) of softening the decorative piece material <NUM> is performed using the production device <NUM>. As illustrated in <FIG>, in both the first jig <NUM> and the second jig <NUM>, the slide plates <NUM> and <NUM> are positioned such that the flat-plate dies <NUM> and <NUM> are located centrally, and the decorative piece material <NUM> is placed on top of the first flat-plate die <NUM>. In this state, the second jig <NUM> is moved downward, and while the decorative piece material <NUM> is thereby pressed, high-frequency dielectric heating is performed using the flat-plate dies <NUM> and <NUM> as electrodes, thereby softening and welding the entire decorative piece material <NUM>. When the softening is completed, the second jig <NUM> is moved upward.

Subsequently, with the first jig <NUM> left as it is, the second slide plate <NUM> of the second jig <NUM> is slid, thereby moving the second engraved die <NUM> with the fusion-cutting blades to the center as illustrated in <FIG>. Then, the double-sided tape <NUM> to which the release paper <NUM> is attached is disposed on the first flat-plate die <NUM> of the first jig <NUM> or attached to the decorative piece material <NUM>, and the decorative piece material <NUM> is placed thereon with the upper layer <NUM> facing upward. Subsequently, the second jig <NUM> is moved downward, and while the decorative piece material <NUM> is thereby pressed, high-frequency dielectric heating is performed using the first flat-plate die <NUM> and the second engraved die <NUM> with the fusion-cutting blades as electrodes (shaping step in <FIG>). Since the entire decorative piece material <NUM> is softened due to the softening step, the decorative piece material <NUM> is shaped within the recesses <NUM> of the second engraved die <NUM> with the fusion-cutting blades through high-frequency dielectric heating, and thus, a design with a slightly round-shaped surface is formed. Moreover, the decorative piece material <NUM> and the double-sided tape <NUM> are fusion-cut along the outlines of the design by the fusion-cutting blades <NUM>. After that, the second jig <NUM> is moved upward, and the decorative piece material <NUM> is removed.

In the above-described production device <NUM>, the slide plates <NUM> and <NUM> are respectively disposed in the first jig <NUM> and the second jig <NUM>, and different types of dies are fastened to these slide plates <NUM> and <NUM>. However, in the first jig <NUM>, the first flat-plate die <NUM> may be disposed non-slidably.

In the present embodiment as well, replacement of the die can be achieved simply by sliding the second slide plate <NUM>, and the softening step (<FIG>), the shaping and fusion-cutting step (<FIG>) can be performed immediately one after the other using the same device.

In a third embodiment, after the softening step, a shaping step and a fusion-cutting step are performed as is the case with the first embodiment. Note that, unless otherwise specified, the same reference numerals as those of the first embodiment and the second embodiment denote the same or similar members, and a description thereof is omitted as appropriate.

As is the case with the first embodiment and the second embodiment, the decorative piece material <NUM> is subjected to the softening step illustrated in <FIG>.

After the softening step, in the third embodiment, the decorative piece material <NUM> is shaped as illustrated in <FIG> (shaping step), and subsequently the shaped decorative piece material <NUM> is fusion-cut as illustrated in <FIG> (fusion-cutting step).

In the shaping step, as illustrated in <FIG>, the first flat-plate die <NUM> used in the softening step in <FIG> is used, and the engraved die <NUM> with the fusion-cutting blades is used in place of the second flat-plate die <NUM>. As illustrated in <FIG>, the engraved die <NUM> with the fusion-cutting blades is a die in which the recesses <NUM> of the design are formed and the fusion-cutting blades <NUM> are formed along the outlines of the design. While the decorative piece material <NUM> that is in the softened state due to the softening step is still placed on top of the first flat-plate die <NUM>, the engraved die <NUM> with the fusion-cutting blades is brought closer to the first flat-plate die <NUM> as illustrated in <FIG>, and high-frequency dielectric heating is performed. Thus, the decorative piece material <NUM> is shaped in conformity with the recesses <NUM> of the engraved die <NUM> with the fusion-cutting blades. At this time, the decorative piece material <NUM> is partially fusion-cut by the fusion-cutting blades <NUM>. In the shaping step, since the decorative piece material <NUM> that is softened in its entirety in advance is shaped, the shaping can be performed even when the decorative piece material <NUM> is thick. After the shaping, the decorative piece material <NUM> is held on the engraved die <NUM> with the fusion-cutting blades using gummed tape or the like, and in this state, the engraved die <NUM> with the fusion-cutting blades is moved upward as illustrated in <FIG>. Then, the procedure proceeds to the fusion-cutting step.

In the fusion-cutting step, the first flat-plate die <NUM> is replaced with a flat-plate die <NUM> with cushioning materials in which, as illustrated in <FIG>, cushioning material recesses <NUM> are formed at positions corresponding to respective portions of the design, the cushioning material recesses <NUM> being smaller than the respective portions of the design by about <NUM> to <NUM>, and cushioning materials <NUM> are arranged in the cushioning material recesses <NUM>. The cushioning materials <NUM> may be made of cellular rubber, for example, and has such a thickness that the cushioning materials <NUM> protrude from the cushioning material recesses <NUM> for about <NUM> to <NUM>.

Then, as illustrated in <FIG>, the release paper <NUM> is disposed on the lower layer <NUM> side of the decorative piece material <NUM>, on top of the flat-plate die <NUM> with the cushioning materials in <FIG>, with the double-sided tape <NUM> located on the upper side.

Subsequently, as illustrated in <FIG>, the engraved die <NUM> with the fusion-cutting blades on which the decorative piece material <NUM> is held is brought closer to the flat-plate die <NUM> with the cushioning materials, and high-frequency dielectric heating is performed. Due to the repulsive force of the cushioning materials <NUM>, the decorative piece material <NUM> is strongly pressed against and hence attached to the double-sided tape <NUM>, and is also fusion-cut or cut by the fusion-cutting blades <NUM>. Note that the release paper <NUM> is not cut by the fusion-cutting blades <NUM>.

After that, unnecessary portions of the decorative piece material <NUM> are eliminated, and the application film <NUM> is attached to the upper layer <NUM> side of the decorative piece material <NUM> so as to prevent displacement of the design. Thus, a decorative piece <NUM> can be obtained.

According to the third embodiment of the present invention, a decorative piece <NUM> can be produced by performing the shaping and fusion-cutting step by replacing the dies after the softening step.

As described above, replacement of the dies is needed when producing a decorative piece <NUM>. Hereinafter, a production device <NUM> with which a decorative piece <NUM> can be produced by favorably replacing the dies will be described.

In the present embodiment, the production device <NUM> shown in <FIG> and <FIG> is used in which dies different from those of the first embodiment are mounted as the production device <NUM>. Specifically, in the first jig <NUM>, as illustrated in <FIG>, the first flat-plate die <NUM> and a flat-plate die <NUM> with cushioning materials (see <FIG>) are mounted on the first slide plate <NUM>. Note that the flat-plate die <NUM> with the cushioning materials is a die in which cushioning material recesses <NUM> are formed at positions corresponding to and inward of respective portions of the design as described above and cushioning materials <NUM> are arranged in the cushioning material recesses <NUM>. In the second jig <NUM>, the second flat-plate die <NUM> shown in <FIG> and the second engraved die <NUM> with the fusion-cutting blades (see <FIG>) are mounted on the second slide plate <NUM>. Moreover, in the present embodiment, the design to be applied to the decorative piece <NUM> is "SUPER".

Then, the first jig <NUM> and the second jig <NUM> to which the dies <NUM> and <NUM> and the dies <NUM> and <NUM> are respectively mounted are fastened to a high-frequency dielectric heating device, which is not shown, such that the first jig <NUM> is located on the lower side and the second jig <NUM> is located on the upper side.

Then, as is the case with the first embodiment, the softening step (see <FIG>) of softening the decorative piece material <NUM> is performed using the production device <NUM>. As illustrated in <FIG>, in both the first jig <NUM> and the second jig <NUM>, the slide plates <NUM> and <NUM> are positioned such that the flat-plate dies <NUM> and <NUM> are located centrally, and the decorative piece material <NUM> is placed on top of the first flat-plate die <NUM> such that the upper layer <NUM> faces upward. In this state, the second jig <NUM> is moved downward, and while the decorative piece material <NUM> is thereby pressed, high-frequency dielectric heating is performed using the flat-plate dies <NUM> and <NUM> as electrodes, thereby softening and welding the entire decorative piece material <NUM>. When the softening is completed, the second jig <NUM> is moved upward.

Subsequently, with the first jig <NUM> left as it is, the second slide plate <NUM> of the second jig <NUM> is slid, thereby moving the second engraved die <NUM> with the fusion-cutting blades to the center as illustrated in <FIG>. Then, the second jig <NUM> is moved downward, and while the decorative piece material <NUM> is thereby pressed, high-frequency dielectric heating is performed using the first flat-plate die <NUM> and the second engraved die <NUM> with the fusion-cutting blades as electrodes (shaping step in <FIG>). Since the entire decorative piece material <NUM> is softened due to the softening step, the decorative piece material <NUM> is shaped in conformity with the recesses <NUM> of the second engraved die <NUM> with the fusion-cutting blades through high-frequency dielectric heating. Moreover, the decorative piece material <NUM> is partially fusion-cut by the fusion-cutting blades <NUM>. After that, the decorative piece material <NUM> is cooled. The cooling may be performed through natural cooling, for example, or may be performed through water-cooling or the like of the dies or the like with use of a chiller in order to shorten the cooling time.

In this state, the decorative piece material <NUM> is held on the second engraved die <NUM> with fusion-cutting blades using gummed tape or the like, and the second jig <NUM> is moved upward as illustrated in <FIG>.

Next, as illustrated in <FIG>, the first slide plate <NUM> of the first jig <NUM> is slid to the back side, thereby moving the flat-plate die <NUM> with the cushioning materials to the center (a portion indicated by the oblique lines in <FIG>). Then, the double-sided tape <NUM> to which the release paper <NUM> is attached is placed on top of the flat-plate die <NUM> with the cushioning materials such that the release paper <NUM> is located on the lower side. In this state, the second jig <NUM> is moved downward, and while the decorative piece material <NUM> is thereby pressed, high-frequency dielectric heating is performed again using the flat-plate die <NUM> with the cushioning materials and the second engraved die <NUM> with the fusion-cutting blades as electrodes (fusion-cutting step in <FIG>). The cushioning materials <NUM> allow the decorative piece material <NUM> to be strongly attached to the double-sided tape <NUM>, and the decorative piece material <NUM> and the double-sided tape <NUM> are fusion-cut by the fusion-cutting blades <NUM> along the outlines of the design by the fusion-cutting blades <NUM>. After that, the second jig <NUM> is moved upward, and the decorative piece material <NUM> is removed.

Since the removed decorative piece material <NUM> is attached to the release paper <NUM> via the double-sided tape <NUM>, the decorative piece material <NUM> can be removed from the production device <NUM> without positional displacement occurring. In this state, unnecessary portions are eliminated from the decorative piece material <NUM>, and the application film <NUM> is attached to a surface of the decorative piece material <NUM> on the opposite side of the release paper <NUM>. Thus, a decorative piece <NUM> can be obtained as illustrated in <FIG>.

The foregoing description is given merely to describe the present invention, and therefore should not be construed as limiting the invention recited in the appended claims or narrowing the scope of the present invention. Also, the constituent elements of the present invention are not limited to those described in the embodiments above, and it is of course possible to make various modifications within the technical scope defined in the appended claims.

It is also possible to combine the dies of the foregoing first to third embodiments. Moreover, the types of the dies that are mounted to the first jig <NUM> and the second jig <NUM> are not limited to those described above in the embodiments, and it is of course also possible to exchange the positions of the upper and lower dies, for example. Furthermore, regarding the shape of the recesses of the dies, any shapes, such as a mountain shape, a trapezoidal shape, and a round shape, and combinations of these shapes can be adopted.

In the embodiments, a plurality of dies are mounted to the first jig <NUM> and the second jig <NUM> in order to simplify the die replacement. However, it is of course also possible to realize the present invention in a manner in which dies are replaced as appropriate, or dies are respectively mounted on a plurality of high-frequency induction heating devices.

Claim 1:
A method for producing a decorative piece (<NUM>) made of a thermoplastic synthetic resin, comprising the following steps, in order:
a step of preparing a decorative piece material (<NUM>) including an upper layer (<NUM>) that has a thermoplastic synthetic resin film and a lower layer (<NUM>) that includes a thermoplastic synthetic resin sheet;
a step of disposing the decorative piece material (<NUM>) on a flat-plate die (<NUM>) serving as an electrode;
a softening step of softening the decorative piece material (<NUM>) by bringing a flat-plate die (<NUM>) serving as another electrode closer to the flat-plate die (<NUM>) serving as the electrode, and performing high-frequency dielectric heating while pressing the decorative piece material (<NUM>);
a step of disposing the softened decorative piece material (<NUM>) on a flat-plate die (<NUM>) serving as an electrode such that the lower layer side of the decorative piece material abuts against the flat-plate die; and
a shaping step of shaping the softened decorative piece material (<NUM>) by bringing an engraved die (<NUM>), the engraved die serving as an electrode and having a recess (<NUM>) of a design to be formed in the decorative piece material (<NUM>), closer to the flat-plate die (<NUM>) on which the decorative piece material is disposed, and performing high-frequency dielectric heating while pressing the decorative piece material.