TECHNICAL FIELD
5 [0001] The present invention relates to a film forming apparatus.
BACKGROUND ART
[0002] In conventional spray painting, a spacious facility and an apparatus for
processing paint mist are essential, and a significant amount of energy is required.
10 Technological innovation is necessary to realize carbon neutrality, and, as
decorating methods that replace conventional painting, dry decoration
technologies that use vacuum film formation technologies have been attracting
attention. PTL1 discloses a vacuum forming apparatus that laminates a sheetshaped decorating material onto a resin base material.
15
CITATION LIST
PATENT LITERATURE
[0003]
PTL1: Japanese Patent Laid-Open No. 2008-284771
20
SUMMARY OF INVENTION
TECHNICAL PROBLEM
[0004] However, in the technique disclosed in Patent Literature 1, it is necessary
to replace a jig that supports a resin base material, in accordance with the shape of
25 the resin base material. However, jigs are heavy, and it is often troublesome to
move and replace them. Thus, there is an issue that sheet-shaped decorating
materials cannot be efficiently laminated onto resin base materials having various
shapes, and thus, it is difficult to realize efficient film formation.
[0005] The present invention has been made in light of the aforementioned issue,
30 and aims to provide a technique to realize efficient film formation.
3
SOLUTION TO PROBLEM
[0006] In order to achieve the above aim, the film forming apparatus according to
one aspect of the present invention is characterized by comprising:
5 a first forming line for conveying a target object in a state of being placed
on a jig, and performing a cleaning operation of cleaning the target object, a
lamination operation of laminating a film onto the target object after the cleaning
operation, and a removal operation of removing a portion of the film laminated
onto the target object after the lamination operation; and
10 a jig returning line for returning the jig used on the first forming line from
an exit of the first forming line to an entrance of the first forming line.
ADVANTAGEOUS EFFECTS OF INVENTION
[0007] According to the present invention, it is possible to realize efficient film
15 formation.
[0008] Other features and advantages of the present invention will be apparent
from the following description taken in conjunction with the accompanying
drawings. Note that the same reference numerals denote the same or like
components throughout the accompanying drawings.
20
BRIEF DESCRIPTION OF DRAWINGS
[0009] The accompanying drawings, which are incorporated in and constitute a
part of the specification, illustrate embodiments of the invention and, together
with the description, serve to explain principles of the invention.
25 FIG. 1 is a diagram showing an example of the overall configuration of a
film forming apparatus according to a first embodiment.
FIG. 2 is a diagram showing a configuration example of a control device
according to the first embodiment.
4
FIG. 3A is a flowchart showing a procedure of film forming processing on
a production line according to the first embodiment.
FIG. 3B is a flowchart showing a procedure of film forming processing on
a production line according to the first embodiment.
5 FIG. 4 is a diagram showing an example of the overall configuration of a
film forming apparatus according to a second embodiment.
FIG. 5 is a diagram showing a configuration example of a control device
according to the second embodiment.
FIG. 6A is a diagram showing a control example of vacuum pumps
10 according to the second embodiment (alternating control is not performed).
FIG. 6B is a diagram showing a control example of a vacuum pump
according to the second embodiment (alternating control is performed).
FIG. 7A is a diagram showing a control example of heaters according to
the second embodiment (alternating control is not performed).
15 FIG. 7B is a diagram showing a control example of a heater according to
the second embodiment (alternating control is performed).
DESCRIPTION OF EMBODIMENTS
[0010] Hereinafter, embodiments will be described in detail with reference to the
20 attached drawings. Note, the following embodiments are not intended to limit the
scope of the claimed invention, and limitation is not made to an invention that
requires a combination of all features described in the embodiments. Two or more
of the multiple features described in the embodiments may be combined as
appropriate. Furthermore, the same reference numerals are given to the same or
25 similar configurations, and redundant description thereof is omitted.
First Embodiment
[0011] In the present embodiment, a configuration example of a production line
for performing film formation by laminating a film onto a target object placed on
5
a jig will be described. In the present embodiment, a description will be given in
which a target object onto which a film is laminated is a front bumper or a rear
bumper of a vehicle (such as a four-wheeled vehicle), but the target object is not
limited thereto, and the present invention can be applied to various objects.
5 Decoration processing can be easily performed by changing the color of a film in
accordance with the color of the vehicle.
Overall Configuration of Production Line
[0012] FIG. 1 is a diagram showing an example of the overall configuration of a
10 film forming apparatus according to the present embodiment. The arrows in the
figure each indicate the conveyance direction of a target object 10 alone, a jig 20
on which the target object 10 is placed, or the jig 20 alone. The target object 10
that has been transported on a carriage 30 is gripped by a conveyance apparatus
101 and is placed on the jig 20 at a start position (entrance) of a forming line 1. A
15 first operator 201 checks whether or not the target object 10 is appropriately
placed on the jig 20 and manually wipes the target object 10 placed on the jig 20
to remove grease. If the target object 10 is not appropriately placed, the position
is adjusted.
[0013] Next, in a state of being placed on the jig 20, the target object 10 is
20 conveyed along the forming line 1 to a dust removal area A where a dust removal
apparatus 102 is installed. This conveyance can be performed, for example,
automatically by a belt-conveyor apparatus and/or manually by an operator. In
the dust removal area A, the dust removal apparatus 102 performs a cleaning
operation on the target object 10. The dust removal apparatus 102 is a dust
25 removal apparatus that performs a cleaning operation, for example, by suctioning
waste. For example, a dust removal apparatus having a wiping part such as a mop
wipes the surface of the target object 10 and suctions waste in parallel, thereby
performing a cleaning operation without discharging waste in the space of the dust
removal area A.
6
[0014] After a cleaning operation is performed by the dust removal apparatus
102, the target object 10 placed on the jig 20 is conveyed to a lamination area B
where a vacuum lamination apparatus 103 is disposed. Control is performed such
that a film 35 is unwound and pulled out to cover the upper side of the target
5 object 10 that has been conveyed into the vacuum lamination apparatus 103, and
tension is applied to the film 35 inside the vacuum lamination apparatus 103.
Once the target object 10 is conveyed (slid in) into the vacuum lamination
apparatus 103 and the film 35 is unwound and set at a predetermined position, the
internal space of the vacuum lamination apparatus 103 is evacuated, a heating
10 operation is performed, and a lamination operation of laminating the film 35 onto
the target object 10 is performed. Note that the order of the vacuum operation of
evacuating the internal space of the vacuum lamination apparatus 103 and the
heating operation of heating the internal space of the vacuum lamination
apparatus 103 is not limited. The heating operation may be performed after the
15 vacuum operation, the vacuum operation may be performed after the heating
operation, or the vacuum operation and the heating operation may be performed at
overlapping timings. Furthermore, the method for conveying the target object 10
into the vacuum lamination apparatus 103 is not limited to the sliding-in method.
For example, the target object 10 may be lifted together with the jig 20 using a
20 lifter (not illustrated) or a gripping robot and be conveyed into the vacuum
lamination apparatus 103. In this case, a configuration may be adopted in which a
dividing jig (not illustrated) other than the jig 20 is fixedly disposed inside the
vacuum lamination apparatus 103 in advance, and the jig 20 on which the target
object 10 placed is placed on the divided jig.
25 [0015] The film 35 is used by unwinding a roll film that is in a wound state as
with rolled paper. The roll film can be replaced with films of various colors. For
example, in a case where the target object 10 is a bumper for a red vehicle body, a
red roll film is used, and in a case where the target object 10 is a bumper for a
blue vehicle body, the roll film is replaced with a blue roll film and the blue roll
7
film is used, thereby enabling decoration in a desired color. There is no limitation
to film color variations, and the roll film can also be replaced with various films
having different patterns, three-dimensional textures, and the like, and with
functional films, for example. Once the lamination operation is completed, the
5 target object 10 is conveyed to the outside of the vacuum lamination apparatus
103 (slide-out). Control is performed such that, simultaneously with this slideout, the next target object 10 is slid into the vacuum lamination apparatus 103.
The method for conveying the target object 10 to the outside of the vacuum
lamination apparatus 103 is not limited to the sliding-out method. For example,
10 the target object 10 may be lifted together with the jig 20 using a lifter (not
illustrated) or a gripping robot and be conveyed to the outside of the vacuum
lamination apparatus 103. In this case, the jig 20, which is located on a dividing
jig (not illustrated) and on which the target object 10 is placed, may be conveyed
to the outside of the vacuum lamination apparatus 103.
15 [0016] Through the lamination operation performed by the vacuum lamination
apparatus 103, the film 35 is laminated onto the target object 10, the jig 20, and
surrounding regions thereof. The target object 10 and the jig 20 are conveyed to a
removal area C in this state. Note that a film curing apparatus (e.g., a UV
apparatus) may be provided downstream of the vacuum lamination apparatus 103
20 and upstream of a removal apparatus 104. A configuration may be adopted in
which, after film curing processing is performed by the film curing apparatus, the
target object 10 and the jig 20 are conveyed to the removal area C. Furthermore, a
film finishing apparatus may be provided in place of the film curing apparatus.
The removal apparatus 104 performs a removal operation of removing
25 unnecessary film portions by trimming the target object 10 in this state. For
example, a CO₂ laser may be used to trim the film 35. The target object 10 is then
conveyed to the position of a removal apparatus 105, which collects film scraps
(cut-off pieces of the film generated by the trimming processing). Here, the
removal apparatus 105 performs an operation of peeling off the film scraps
8
generated through trimming, gripping them, and placing them into a waste box.
Note that a release agent is applied in advance to a portion of the jig 20 that
exclude the target object 10, and the surrounding surfaces of the target object 10
and the jig 20 (the placement surface of the jig 20), such that the film can be more
5 easily peeled off by the removal apparatus 105.
[0017] Next, the target object 10 and the jig 20 are further conveyed to the
position of a second operator 202. The second operator 202 performs processing
for manually peeling off film scraps that could not be removed by the removal
apparatus 105, to make the target object 10 and the jig 20 clean, and performs
10 quality check, and, as necessary, repair work and the like. The target object 10
and the jig 20 are then conveyed to the outside of the removal area C, the target
object 10 is gripped by a conveyance apparatus 106, and the target object 10 in a
state of being laminated with the film 35 is placed on a carriage 40.
[0018] Note that the second operator 202 may be positioned in a working
15 environment space that is separate from the removal apparatus 104 and the
removal apparatus 105. That is, the removal area C may be divided by defining,
as a removal area C1, the space in which the removal apparatuses 104 and 105 are
disposed, and defining, as a separate removal area C2, the space in which the
second operator 202 is disposed. In that case, the removal areas C1 and C2 may
20 be in fluid communication with each other along the forming line 1. At this time,
control may be performed such that the pressure in the removal area C1 is lower
than that in the removal area C2, thereby achieving a configuration in which air is
prevented from flowing from the removal area C1 into the removal area C2.
Accordingly, the second operator 202 can be isolated from dust, smoke, and the
25 like generated by the operations of the removal apparatuses 104 and 105, and thus
the working environment can be improved.
[0019] On the other hand, after the target object 10 is gripped and moved by the
conveyance apparatus 106, only the jig 20 remains. This jig 20 is returned along a
jig returning line 2 to be reused. The jig 20 is conveyed to the position of a third
9
operator 203 along the jig returning line 2. The third operator 203 cleans the
waste remaining after trimming. The third operator 203 also applies a release
agent to the jig 20. Note that a configuration may be adopted in which the
operation of cleaning the waste and the operation of applying a release agent are
5 automatically performed by a robot. The jig 20 is then further conveyed to the
position of a conveyance apparatus 107 along the jig returning line 2. The
conveyance apparatus 107 performs an operation of replacing the jig 20 in
accordance with the type of target object 10. When the replacement operation is
necessary, the conveyance apparatus 107 grips the jig 20, moves the jig 20 out
10 from the jig returning line 2, and moves a different jig onto the jig returning line 2
from outside. The jig 20 is then conveyed along the jig returning line 2 to the start
position (entrance) of the forming line 1, where the target object 10 is placed on
the jig 20. From this point on, the same operations are repeated.
[0020] In FIG. 1, a vacuum pump 301 is disposed in a pump chamber 31. The
15 vacuum pump 301 is connected to the vacuum lamination apparatus 103 and
evacuates a predetermined space inside the vacuum lamination apparatus 103
under the control of a control device 302. The control device 302 is disposed in a
control chamber 32. In the control chamber 32, an operator (not illustrated)
monitors the overall control of the production line performed by the control
20 device 302.
[0021] In FIG. 1, an air supply apparatus 401 supplies air into the dust removal
area A and the lamination area B such that the pressures in the dust removal area
A and the lamination area B become positive relative to atmospheric pressure. In
addition, an exhaust apparatus 402 exhausts air such that the pressure in the
25 removal area C becomes negative relative to the atmospheric pressure. Note that
the space where the first operator 201 is located is in fluid communication with
the dust removal area A. Similarly, the dust removal area A and the lamination
area B are in fluid communication with each other, the lamination area B and the
removal area C are in fluid communication with each other, and the removal area
10
C and the space where the conveyance apparatus 106 is located are in fluid
communication with each other. Note that the dust removal area A and the
lamination area B are partitioned by a partition 50, but the spaces thereof are in
fluid communication with each other.
5
Configuration of Control Device
[0022] Next, a configuration example of the control device according to the
present embodiment will be described with reference to FIG. 2. The control
device 302 includes a pressure control unit 3021, a lamination operation control
10 unit 3022, a vacuum control unit 3023, a conveyance operation control unit 3024,
a dust removal operation control unit 3025, and a removal operation control unit
3026. The control device 302 operates using one or more CPUs (Central
Processing Units), and various operations are executed by the one or more CPUs
reading and executing computer programs stored in one or more memories (not
15 illustrated). In addition, the control device 302 may include a display unit such as
a liquid crystal display, a notification unit such as a speaker, and an input unit
such as a keyboard and a switch. A configuration may be adopted in which an
operator in the control chamber 32 can monitor the status of the production line
using these units, and stop the operation of the line in accordance with the
20 situation.
[0023] The pressure control unit 3021 controls the pressures in the spaces of the
dust removal area A, the lamination area B, and the removal area C by controlling
the operations of the air supply apparatus 401 and/or the exhaust apparatus 402.
In the present embodiment, the pressure control unit 3021 performs control so as
25 to achieve positive pressures in the dust removal area A and the lamination area B
by controlling the air supply apparatus 401 to supply clean air into these areas
from the outside. The air in the cleanroom is discharged from the dust removal
area A toward the upstream side of the line (the first operator 201 side) along the
forming line 1 via an opening portion (not illustrated) of the entrance of the dust
11
removal area A for conveying the target object 10. Furthermore, the air in the
cleanroom is discharged along the forming line 1 from the lamination area B
toward the downstream side of the line (the removal area C side) via an opening
portion (not illustrated) provided between the areas B and C for conveying the
5 target object 10. Accordingly, the interiors of the dust removal area A and the
lamination area B can be formed as a cleanroom.
[0024] The pressure control unit 3021 also controls the exhaust apparatus 402 to
exhaust air such that the pressure in the removal area C becomes negative relative
to the atmospheric pressure. Therefore, air flows along the forming line 1 from
10 the lamination area B toward the downstream side of the line (the removal area C
side) via the opening portion (not illustrated) between the areas B and C for
conveying the target object 10. Also, air flows from the space in which the
conveyance apparatus 106 is positioned toward the upstream side of the line (the
removal area C side) along the forming line 1 via an opening portion (not
15 illustrated) on the exit side of the area C, the opening portion being for conveying
the target object 10.
[0025] The lamination operation control unit 3022 controls the lamination
operation of the film 35 by controlling the vacuum lamination apparatus 103.
Specifically, an operation of unwinding and stretching out the film 35 over the
20 target object 10, which has been slid into the vacuum lamination apparatus 103, is
performed. The lamination operation control unit 3022 further performs control
so as to lower a chamber (not illustrated) in a state where the film 35 is stretched
out, and the vacuum control unit 3023 evacuates the interior of the vacuum
lamination apparatus 103 and performs heating processing. The vacuum control
25 unit 3023 controls the pressure in the vacuum lamination apparatus 103 and create
a vacuum state by controlling the vacuum pump 301. Note that, as described
above, the order of the vacuum operation and the heating operation is not limited.
Accordingly, the operation of laminating the film 35 onto the target object 10 is
12
performed. The chamber is then lifted, and the target object 10, which has been
laminated with the film 35, is slid out from the vacuum lamination apparatus 103.
[0026] The conveyance operation control unit 3024 controls various conveyance
operations. The conveyance operation control unit 3024 controls operations of the
5 conveyance apparatus 101 to perform an operation of gripping the target object 10
and moving the target object 10 to the starting point of the forming line 1 (the
point where the first operator 201 performs operations = the entrance of the
forming line 1). The conveyance operation control unit 3024 also controls
operations of a belt-conveyor apparatuses (not illustrated) provided on at least a
10 portion of the forming line 1 and the jig returning line 2. The conveyance
operation control unit 3024 also controls operations of the conveyance apparatus
106 and the conveyance apparatus 107. The dust removal operation control unit
3025 controls operations of the dust removal apparatus 102. The removal
operation control unit 3026 controls operations of the removal apparatus 104 and
15 the removal apparatus 105.
Processing
[0027] Next, a procedure of film forming processing on the production line
according to the present embodiment will be described with reference to the
20 flowcharts in FIGS. 3A and 3B. Note that the pressures in the dust removal area
A, the lamination area B, and the removal area C are controlled as described with
reference to FIG. 1.
[0028] In S301, the conveyance operation control unit 3024 controls the
conveyance apparatus 101 to grip the target object 10 placed on the carriage 30,
25 move the target object 10 to the start position (entrance) of the forming line 1, and
place the target object 10 on the jig 20 that has been conveyed to the start
position. The first operator 201 checks whether the target object 10 is
appropriately placed on the jig 20, and if there is any misalignment, performs an
13
adjustment operation. The first operator 201 also manually wipes the target object
10 placed on the jig 20 to remove grease.
[0029] In S302, the conveyance operation control unit 3024 controls the beltconveyor apparatus (not illustrated) to convey the jig 20, on which the target
5 object 10 is placed, into the dust removal area A. Note that the apparatus used
here is not limited to the belt-conveyor apparatus, and may instead be a roller
conveyor, a linear conveyor, a roller-top conveyor, or the like. In S303, the dust
removal operation control unit 3025 controls the dust removal apparatus 102 to
perform a cleaning operation. In S304, the conveyance operation control unit
10 3024 controls the belt-conveyor apparatus (not illustrated) to convey the jig 20, on
which the target object 10 is placed, into the lamination area B, and further into
the vacuum lamination apparatus 103 (slide-in).
[0030] In S305, the lamination operation control unit 3022 controls the vacuum
lamination apparatus 103, and the vacuum control unit 3023 controls the vacuum
15 pump 301, thereby performing a lamination operation of the film 35. In S306, the
conveyance operation control unit 3024 controls the belt-conveyor apparatus (not
illustrated) to convey the jig 20, on which the target object 10 is placed, to the
outside of the vacuum lamination apparatus 103 (slide-out).
[0031] In S307, the conveyance operation control unit 3024 controls the belt20 conveyor apparatus (not illustrated) to convey the jig 20, on which the target
object 10 (laminated with the film 35) is placed, into the removal area C. In S308,
the removal operation control unit 3026 controls the removal apparatus 104 to
perform a removal operation of removing unnecessary portions of the film 35 by
trimming the film 35 laminated onto the target object 10 placed on the jig 20.
25 [0032] In S309, the conveyance operation control unit 3024 controls the beltconveyor apparatus (not illustrated) to convey the jig 2010, on which the target
object 10 is placed and which has been subjected to trimming performed by the
removal apparatus 104, to the removal apparatus 105. In S310, the removal
operation control unit 3026 controls the removal apparatus 105 to perform a
14
collection operation of peeling off the film scraps generated through trimming
performed by the removal apparatus 104, gripping them, and putting them into a
waste box.
[0033] In S311, the conveyance operation control unit 3024 controls the belt5 conveyor apparatus (not illustrated) to convey the jig 20, which has been
subjected to the removal operation performed by the removal apparatus 104 and
the removal apparatus 105, and on which the target object 10 is placed, to the
position where the second operator 202 is located. The second operator 202
performs processing for manually peeling off film scraps that could not be
10 removed by the removal apparatus 105, to make the target object 10 and the jig 20
clean. The second operator 202 also performs quality check by visual inspection,
and, as necessary, repair work and the like.
[0034] In S312, the conveyance operation control unit 3024 controls the beltconveyor apparatus (not illustrated) to convey the jig 20, on which the target
15 object 10 is placed, to the outside of the removal area C. In S313, the conveyance
operation control unit 3024 controls the conveyance apparatus 106 to grip the
target object 10 that has been laminated with the film 35 and has reached the end
position (exit) of the forming line 1, and to convey the target object 10 onto the
carriage 40.
20 [0035] In S314, the conveyance operation control unit 3024 controls the beltconveyor apparatus (not illustrated) to move the jig 20 from the forming line 1 to
the jig returning line 2, and convey the jig 20 to the position where the third
operator 203 is located. The third operator 203 cleans waste remaining after the
removal operation performed by the removal apparatus 104 and the removal
25 apparatus 105. The third operator 203 also applies a release agent to the jig 20.
Note that a configuration may be adopted in which the operation of cleaning
waste and the operation of applying a release agent are automatically performed
by a robot.
15
[0036] In S315, the conveyance operation control unit 3024 controls the beltconveyor apparatus (not illustrated) to convey the jig 20 to the position of the
conveyance apparatus 107 along the jig returning line 2.
[0037] In S316, the conveyance operation control unit 3024 controls the
5 conveyance apparatus 107 to perform an operation of replacing the jig 20 in
accordance with the type of target object 10. For example, when the target object
10 is changed from a front bumper to a rear bumper, a jig for the front bumper is
replaced with a jig for the rear bumper. Note that, when the jig 20 does not need
to be replaced, this step is skipped.
10 [0038] In S317, the conveyance operation control unit 3024 controls the beltconveyor apparatus (not illustrated) to convey the jig 20 to the start position
(entrance) of the forming line 1.
[0039] In S318, the conveyance operation control unit 3024 determines whether
or not to end a series of processing. For example, when film forming processing
15 on a predetermined number of target objects 10 is complete, it can be determined
that the procedure is to be ended. If determination is made as Yes in this step, the
procedure is ended. On the other hand, if determination is made as No in this
step, the procedure returns to S301, where the procedure is repeated. This
describes a series of processing in FIGS. 3A and 3B.
20 [0040] As described above, the present embodiment provides a film forming
apparatus including: a forming line for conveying a target object in a state of
being placed on a jig, and performing a cleaning operation of cleaning the target
object, a lamination operation for laminating a film onto the target object after the
cleaning operation, and a removal operation of removing a portion of the film
25 laminated onto the target object after the lamination operation; and a jig returning
line for returning the jig used on the forming line, from the exit of the forming
line to the entrance.
[0041] Accordingly, the target object can be efficiently decorated, and efficient
film formation can be realized.
16
Variation of First Embodiment
[0042] In the first embodiment above, a description has been given in which the
dust removal apparatus 102 is a dust removal apparatus that performs a cleaning
5 operation by suctioning waste. However, the dust removal apparatus 102 may be
a dust removal apparatus that performs a cleaning operation by blowing away
waste (such as a static-eliminating air blower). In that case, the partition 50
separates the dust removal area A and the lamination area B, and the interior of
the lamination area B is formed as a cleanroom. An opening portion lies along the
10 forming line 1 between the dust removal area A and the lamination area B, which
are thereby in fluid communication with each other along the forming line 1.
Control is performed through an operation performed by the air supply apparatus
401 in the lamination area B such that the pressure inside the lamination area B is
positive relative to atmospheric pressure, while an exhaust apparatus (not
15 illustrated) is separately provided in the dust removal area A to perform control
such that the pressure in the dust removal area A is negative relative to the
atmospheric pressure. Accordingly, the dust removal area A has a negative
pressure, the lamination area B has a positive pressure, and the removal area C has
a negative pressure, enabling the lamination area B to be formed as a cleanroom.
20 Alternatively, the entire area including the dust removal area A and the lamination
area B in FIG. 1 may be configured as a single cleanroom (a single lamination
area), with the dust removal apparatus 102 being provided outside these areas
(e.g., at a position on the upstream side of the line relative to the dust removal
area A in FIG. 1).
25
Second Embodiment
[0043] In the first embodiment, a film forming apparatus that includes one
forming line and one jig returning line has been described. In contrast, in the
present embodiment, a film forming apparatus that includes two forming lines and
17
one jig returning line will be described. By sharing the jig returning line, space
saving and cost reduction can be realized. Also in the present embodiment, a
target object to which a film is to be laminated is described as a front bumper or
rear bumper of a vehicle (such as a four-wheeled vehicle), but, similarly, the
5 target object is not limited to these, and the present invention can be applied to
various objects.
Overall Configuration of Production Line
[0044] FIG. 4 is a diagram showing an example of the overall configuration of a
10 film forming apparatus according to the present embodiment. In the present
embodiment, two forming lines share one jig returning line. The basic
configuration is similar to the configuration described in the first embodiment
with reference to FIG. 1. Note that, in the present embodiment, a pump chamber
61 and a vacuum pump 601 are disposed between a first forming line 1 and a
15 second forming line 3, and a control chamber 62 and a control device 602 are
disposed between the first forming line 1 and the second forming line 3.
[0045] Moreover, a jig returning line 4 according to the present embodiment is
provided to extend through a higher position than the pump chamber 61 and the
control chamber 62, between the forming line 1 and a forming line 3. That is to
20 say, the jig returning line 4 is disposed above the heights at which the forming line
1 and the forming line 3 are disposed, between the forming line 1 and the forming
line 3. Therefore, when moving the jig 20 from an end position (exit) 501 of the
forming line 1 to a position 503, the jig 20 is lifted by a lifting apparatus (not
illustrated). Also, when moving the jig 20 from an end position (exit) 502 of the
25 forming line 3 to the position 503, the jig 20 is lifted by the lifting apparatus (not
illustrated). The jig 20 conveyed from the forming line 1 and the jig 20 conveyed
from the forming line 3 is lifted using the one lifting apparatus.
[0046] In addition, the jig 20 conveyed to a position 504 along the jig returning
line 4 is moved to a start position (entrance) 505 of the forming line 1 or a start
18
position (entrance) 506 of the forming line 3. At that time, the jig 20 is lowered
by a lifting apparatus (not illustrated). The jig 20 that is to be conveyed to the
forming line 1 and the jig 20 that is to be conveyed to the forming line 3 is
lowered using the one lifting apparatus.
5 [0047] As shown in FIG. 4, on the forming line 1, a conveyance apparatus 101a, a
dust removal apparatus 102a, a vacuum lamination apparatus 103a, a removal
apparatus 104a, a removal apparatus 105a, the conveyance apparatus 106a, and
the like are provided. Similarly to the first embodiment, the dust removal area A,
the lamination area B, and the removal area C are provided. Furthermore, on the
10 forming line 3, a conveyance apparatus 101b, a dust removal apparatus 102b, a
vacuum lamination apparatus 103b, a removal apparatus 104b, a removal
apparatus 105b, a conveyance apparatus 106b, and the like are provided so as to
be symmetrical with respect to the jig returning line 4 relative to the
corresponding apparatuses. Similarly to the first embodiment, a dust removal area
15 D, a lamination area E, and a removal area F are provided. In FIG. 4, the forming
line 1 and the forming line 3 are arranged in a symmetrical layout with respect to
the jig returning line 4, and the conveyance apparatus 107 is shared between the
two forming lines. The operators are also arranged in a similar manner. Note
that, as a matter of course, there is no need to adopt a completely symmetrical
20 layout, and a partially asymmetrical layout may be adopted.
[0048] By the two forming lines sharing the pump chamber 61, the control
chamber 62, the lifting apparatuses (not illustrated), and the conveyance apparatus
107 in this manner, the overall manufacturing cost of the production line can be
reduced. In addition, space saving can be realized.
25
Configuration of Control Device
[0049] Next, a configuration example of the control device 602 according to the
present embodiment will be described with reference to FIG. 5. Similarly to the
first embodiment, the control device 602 includes a pressure control unit 6021, a
19
lamination operation control unit 6022, a vacuum control unit 6023, a conveyance
operation control unit 6024, a dust removal operation control unit 6025, and a
removal operation control unit 6026.
[0050] The pressure control unit 6021 controls the pressures in the spaces of the
5 dust removal area A, the lamination area B, and the removal area C by controlling
operations of an air supply apparatus 401a and/or an exhaust apparatus 402a.
Details of the control content are the same as those of the first embodiment. The
pressure control unit 6021 also controls the pressures in the spaces of the dust
removal area D, the lamination area E, and the removal area F by controlling
10 operations of an air supply apparatus 401b and/or an exhaust apparatus 402b. The
pressures in the dust removal area D, the lamination area E, and the removal area
F are respectively controlled in a similar manner to the pressures in the dust
removal area A, the lamination area B, and the removal area C.
[0051] The lamination operation control unit 6022 controls the vacuum
15 lamination apparatus 103a and the vacuum lamination apparatus 103b to control
lamination operations of the film 35 on the forming line 1 and the forming line 3.
Details of the control content are the same as those of the first embodiment. The
vacuum control unit 6023 controls the vacuum pump 601 to bring the pressure in
the vacuum lamination apparatus 103a or 103b into a vacuum state to ensure that
20 the lamination operation on the forming line 1 or the lamination operation on the
forming line 3 is performed in a vacuum state. Details of the control content are
the same as those of the first embodiment.
[0052] The conveyance operation control unit 6024 controls various conveyance
operations. The conveyance operation control unit 6024 controls operations of the
25 conveyance apparatus 101a to perform an operation of gripping the target object
10 and moving the target object 10 to the start point (entrance) of the forming line
1. The conveyance operation control unit 6024 also controls operations of the
conveyance apparatus 101b to perform an operation of gripping the target object
10 and moving the target object 10 to the start point (entrance) of the forming line
20
3. The conveyance operation control unit 6024 also controls operations of a beltconveyor apparatus (not illustrated) provided in at least a portion of the forming
line 1, the forming line 3, and the jig returning line 4. Also, the conveyance
operation control unit 6024 controls operations of the conveyance apparatus 106a,
5 the conveyance apparatus 106b, and the conveyance apparatus 107. Details of the
control content are the same as those of the first embodiment.
[0053] The dust removal operation control unit 6025 controls operations of the
dust removal apparatus 102a and the dust removal apparatus 102b. Details of the
control content are the same as those of the first embodiment. The removal
10 operation control unit 6026 controls operations of the removal apparatus 104a, the
removal apparatus 104b, the removal apparatus 105a, and the removal apparatus
105b. Details of the control content are the same as those of the first embodiment.
Control of Production Line
15 [0054] In the present embodiment, a configuration is adopted in which the two
forming lines (the forming line 1 and the forming line 3) share the one vacuum
pump 301. That is to say, the vacuum pump 601 used for the lamination
operation performed on the forming line 1 is also used for the lamination
operation performed on the forming line 3. In view of this, the vacuum control
20 unit 6023 according to the present embodiment controls the vacuum pump 601
such that a timing at which the lamination operation is performed on the forming
line 1 differs from a timing at which the lamination operation is performed on the
forming line 3. In this manner, by adopting a configuration in which the vacuum
lamination apparatus 103a and the vacuum lamination apparatus 103b are, for
25 example, alternatingly operated, efficient lamination operations can be realized
using one vacuum pump. In addition, by making a timing of a lamination
operation different between the forming lines, a timing at which the jig 20 is
conveyed from each forming line to the position 503 can be made different. This
21
makes it possible to shorten the takt time. Therefore, the production efficiency
can be improved.
[0055] Here, a control example of the vacuum pump according to the present
embodiment will be described with reference to FIGS. 6A and 6B. FIG. 6A
5 shows a control example in which alternating control is not performed, and FIG.
6B shows a control example in which alternating control is performed. A case
will be described in which the cycle time of a forming operation is two minutes.
In addition, the power consumption of a single vacuum pump is assumed to be
0.75 kW. As shown in FIG. 6A, in a case where alternating vacuum control is not
10 performed, a vacuum pump needs be provided for each of the vacuum lamination
apparatuses 103a and 103b. In this case, two vacuum pumps are required,
resulting in a total power consumption of 1.5 kW. On the other hand, as shown in
FIG. 6B, in a case where alternating vacuum control is performed as in the present
embodiment, a single vacuum pump 601 is operated alternately for the vacuum
15 lamination apparatuses 103a and 103b. For example, the vacuum control unit
6023 controls the vacuum pump 601 to evacuate the interior of the vacuum
lamination apparatus 103a during a period of 0 to 1 minute based on a reference
clock time, evacuate the interior of the vacuum lamination apparatus 103b during
a period of 1 to 2 minutes, and evacuate the interior of the vacuum lamination
20 apparatus 103a again during a period of 2 to 3 minutes. Accordingly, it is
possible to increase the operating rate of the vacuum pump while reducing the
power consumption of the vacuum pump. Furthermore, since the number of
pumps can be reduced, cost reduction can be achieved.
[0056] As described above, in the present embodiment, by the two forming lines
25 sharing the pump chamber 61 (the vacuum pump 601), the control chamber 62
(the control device 602), the lifting apparatuses (not illustrated), and the
conveyance apparatus 107, the overall manufacturing cost of the production line
can be reduced. In addition, if operation timings of vacuum lamination
apparatuses on the respective forming lines are made different, efficient
22
lamination operations can be realized, and the takt time can be shortened to
improve the production efficiency. Therefore, the target object can be efficiently
decorated, and efficient film formation can be realized.
[0057] Furthermore, by disposing the jig returning line 4 above the pump
5 chamber 61 and the control chamber 62, it is possible to reduce the area (space)
required for the entire production line. Therefore, a compact production line can
be provided even in a limited site area.
Variation of Second Embodiment
10 [0058] In the second embodiment, an example has been described in which the jig
returning line 4 is positioned above the heights of the forming line 1 and the
forming line 3, but there is no limitation thereto. Similarly to the first
embodiment, the height of the jig returning line 4 may be the same as the heights
of the forming line 1 and the forming line 3. In that case, for example, the jig
15 returning line 4 may be provided between the forming line 1 and the pump
chamber 61 and control chamber 62. Alternatively, the jig returning line 4 may be
provided between the forming line 3 and the pump chamber 61 and control
chamber 62.
[0059] In addition, in the second embodiment, an example has been described in
20 which two forming lines share a vacuum pump, but what is shared is not limited
to a vacuum pump. Although a heating operation is also executed inside the
vacuum lamination apparatuses, a power supply for heating heaters (not
illustrated) in the respective vacuum lamination apparatuses may be shared
between the two forming lines.
25 [0060] Here, a control example of a heater according to the present embodiment
will be described with reference to FIGS. 7A and 7B. FIG. 7A shows a control
example in which alternating control is not performed, and FIG. 7B shows a
control example in which alternating control is performed. A case will be
described in which the cycle time of a forming operation is two minutes. In
23
addition, the power consumption of a single heater is assumed to be 0.5 kW. As
shown in FIG. 7A, in a case where alternating control is not performed, there is a
need to supply power to both the heater of the vacuum lamination apparatus 103a
and the heater of the vacuum lamination apparatus 103b. In this case, the power
5 supply is equivalent to that of two units, and the total power consumption is 1.0
kW. On the other hand, in a case where a control example in which alternating
control is performed as shown in FIG. 7B, power is alternatingly supplied to the
heater of the vacuum lamination apparatus 103a and the heater of the vacuum
lamination apparatus 103b. For example, the lamination operation control unit
10 6022 controls a power supply (not illustrated) of the control device 602 to heat the
interior of the vacuum lamination apparatus 103a during a period of 0 to 1 minute
based on a reference clock time, heat the interior of the vacuum lamination
apparatus 103b during a period of 1 to 2 minutes, and heat the interior of the
vacuum lamination apparatus 103a again during a period of 2 to 3 minutes. In this
15 case, the power consumption of the power supply is 0.5 kW. Accordingly, it is
possible to increase the operating rate of the power supply while reducing the
power consumption of the power supply. In addition, since a high-output power
supply is not required, the cost can be reduced.
[0061] The invention is not limited to the foregoing embodiments, and various
20 variations/changes are possible within the spirit of the invention.
[0062] This application claims priority from Japanese Patent Application No.
2023-059020 filed March 31, 2023, which is hereby incorporated by reference
herein.
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WE CLAIM :
1. A film forming apparatus characterized by comprising:
5 a first forming line for conveying a target object in a state of being placed
on a jig, and performing a cleaning operation of cleaning the target object, a
lamination operation of laminating a film onto the target object after the cleaning
operation, and a removal operation of removing a portion of the film laminated
onto the target object after the lamination operation; and
10 a jig returning line for returning the jig used on the first forming line from
an exit of the first forming line to an entrance of the first forming line.
2. The film forming apparatus according to claim 1, characterized in that
the first forming line includes a first area where the cleaning operation is
15 performed, a second area where the lamination operation is performed, and a third
area where the removal operation is performed.
3. The film forming apparatus according to claim 2, characterized by further
comprising
20 pressure control means for performing control such that a pressure in the
second area is positive relative to atmospheric pressure, and for performing
control such that a pressure in the third area is negative relative to the atmospheric
pressure,
wherein the second area and the third area are in fluid communication with
25 each other.
4. The film forming apparatus according to claim 2, characterized by further
comprising
pressure control means for performing control such that a pressure in the
30 second area is positive relative to atmospheric pressure,
wherein the second area forms a cleanroom.
25
5. The film forming apparatus according to claim 4, characterized by further
comprising
a dust removal apparatus that performs the cleaning operation by blowing
5 away waste,
wherein the dust removal apparatus is disposed in the first area.
6. The film forming apparatus according to claim 2, characterized by further
comprising
10 pressure control means for performing control such that pressures in the
first area and the second area are positive relative to atmospheric pressure,
wherein the first area and the second area form one cleanroom.
7. The film forming apparatus according to claim 6, characterized by further
15 comprising
a dust removal apparatus that performs the cleaning operation by
suctioning waste,
wherein the dust removal apparatus is disposed in the first area.
20 8. The film forming apparatus according to any one of claims 1 to 7,
characterized by further comprising
vacuum control means for performing control such that the lamination
operation on the first forming line is performed in a vacuum state.
25 9. The film forming apparatus according to claim 8, characterized by further
comprising
a vacuum lamination apparatus that performs the lamination operation,
wherein the vacuum control means performs control so as to evacuate the
vacuum lamination apparatus.
26
10. The film forming apparatus according to any one of claims 1 to 7,
characterized by further comprising
a second forming line for conveying a target object in a state of being
5 placed on a jig, and performing a cleaning operation of cleaning the target object,
a lamination operation for laminating a film onto the target object after the
cleaning operation, and a removal operation for removing a portion of the film
laminated onto the target object after the lamination operation, the second forming
line being disposed along the first forming line,
10 wherein it is possible to return the jig used on the first forming line and the
jig used on the second forming line from an exit of the first forming line or an exit
of the second forming line to an entrance of the first forming line or an entrance of
the second forming line, using the jig returning line.
15 11. The film forming apparatus according to claim 10, characterized in that
the jig returning line is disposed between the first forming line and the
second forming line.
12. The film forming apparatus according to claim 10 or 11, characterized by
20 further comprising
vacuum control means for performing control such that the lamination
operation on the first forming line or the lamination operation on the second
forming line is performed in a vacuum state.
25 13. The film forming apparatus according to claim 12, characterized by further
comprising:
a first vacuum lamination apparatus that performs the lamination operation
on the first forming line; and
27
a second vacuum lamination apparatus that performs the lamination
operation on the second forming line,
wherein the vacuum control means performs control so as to evacuate one
of the first vacuum lamination apparatus and the second vacuum lamination
5 apparatus.
14. The film forming apparatus according to any one of claims 10 to 13,
characterized in that
a vacuum pump that is used for the lamination operation on the first
10 forming line is used for the lamination operation on the second forming line.
15. The film forming apparatus according to any one of claims 10 to 14,
characterized in that
a timing at which the lamination operation on the first forming line is
15 performed differs from a timing at which the lamination operation on the second
forming line is performed.
16. The film forming apparatus according to any one of claims 10 to 15,
characterized in that
20 the first forming line and the second forming line are symmetrical with
respect to the jig returning line.
17. The film forming apparatus according to any one of claims 10 to 16,
characterized in that
25 the jig returning line is disposed above heights at which the first forming
line and the second forming line are disposed.
18. The film forming apparatus according to any one of claims 10 to 17,
characterized in that
28
a timing at which an operation of heating a film is performed in the
lamination operation on the first forming line differs from a timing at which an
operation of heating a film is performed in the lamination operation on the second
forming line.
5
Dated this 10th day of September 2025

10 ABHISHEK SEN
IN/PA No. 980
of S. MAJUMDAR & CO.
Applicant’s Agent
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