EP4595802A1

EP4595802A1 - Can product manufacturing device

Info

Publication number: EP4595802A1
Application number: EP23885576.1A
Authority: EP
Inventors: Yuji Koga; Kenji Takeuchi; Yoji Tsujishita
Original assignee: Brother Industries Ltd
Current assignee: Brother Industries Ltd
Priority date: 2022-11-04
Filing date: 2023-10-24
Publication date: 2025-08-06
Also published as: WO2024095816A1; JPWO2024095816A1

Abstract

Provided is a button product manufacturing device that can automatically manufacture a button product. The button product manufacturing device comprises: a printing unit that prints an image on a printing medium; and a conveyance unit that conveys the printing medium to above the button product. The conveyance unit comprises: a first roller and a second roller that are arranged spaced apart from each other in a direction orthogonal to a first conveyance direction in which the printing medium is conveyed above the button product; a third roller that contacts, among the surfaces of the printing medium, a surface differing from a surface that contacts the first roller; a fourth roller that contacts, among the surfaces of the printing medium, the same surface as the surface that contacts the third roller, the surface thereof differing from the surface that contacts the second roller; and an allowance part that allows bending of the printing medium between the third roller and the fourth roller.

Description

TECHNICAL FIELD

The present invention relates to a button product manufacturing device.

BACKGROUND

In the related art, a device for manufacturing a button product such as a button badge to which a predetermined image is applied is known, and Patent Literature 1 discloses a button product manufacturing device that manufactures a button badge by caulking a front lid to a back lid.

Citation List

Patent Literature

Patent Literature 1: JP2019-136210A

SUMMARY

Technical Problem

In the related art described above, there is a problem in that a user himself/herself needs to place a transparent film on a film placement surface of a lower die, the transparent film being used for caulking together with the front lid against the rear lid supported by the lower die.
[JP0005] Therefore, an object of the present invention is to provide a button product manufacturing device capable of automatically manufacturing a button product.

Solution to Problem

A button product manufacturing device according to the present invention is a device for manufacturing a button product, the device including: a printing unit configured to print an image on a printing medium; and a conveying unit configured to convey the printing medium to above the button product, in which the conveying unit includes a first roller and a second roller disposed at an interval in a direction orthogonal to a first conveying direction in which the printing medium is conveyed above the button product, a third roller configured to come into contact with, among surfaces of the printing medium, a surface different from a surface in contact with the first roller, a fourth roller configured to come into contact with, among the surfaces of the printing medium, a surface different from a surface in contact with the second roller and same as the surface in contact with the third roller, and an allowing part configured to allow bending of the printing medium between the third roller and the fourth roller.

Advantageous Effects Of Invention

According to the present invention, it is possible to provide a button product manufacturing device capable of automatically manufacturing a button product.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating a button product manufacturing device according to the present embodiment.
FIG. 2 is a top view of the button product manufacturing device in FIG. 1.
FIG. 3 is a block diagram illustrating a configuration of a control system of the button product manufacturing device in FIG. 1.
FIG. 4A is a top view of a printing medium.
FIG. 4B is a top view of a white film.
FIG. 5 is a perspective view illustrating a conveying unit.
FIG. 6 is a sectional view of the conveying unit in FIG. 5.
FIG. 7A is a front view of a fifth drive roller and a fifth driven roller.
FIG. 7B is a front view of a sixth drive roller and a sixth driven roller.
FIG. 8A is a diagram in which a conveying path is switched to a first conveying path by a second conveying guide and a third conveying guide.
FIG. 8B is a diagram in which the conveying path is switched to a second conveying path by the second conveying guide and the third conveying guide.
FIG. 9 is a plan view illustrating a lower plate and an upper plate provided on a lower die.
FIG. 10 is a perspective view illustrating a part of a pressing unit.
FIG. 11A is a perspective view of a front member and a back member.
FIG. 11B is a sectional view of a button product produced by connecting the front member and the back member in FIG. 11A.
FIG. 12A is a sectional view of an upper die and two first lower dies for illustrating a caulking step of the front member and the back member.
FIG. 12B is a sectional view of the upper die and the two first lower dies for illustrating the caulking step of the front member and the back member.
FIG. 13A is a sectional view of the upper die and two second lower dies for illustrating the caulking step of the front member and the back member.
FIG. 13B is a sectional view of the upper die and the two second lower dies for illustrating the caulking step of the front member and the back member.
FIG. 14 is a flowchart illustrating a flow of processing by the button product manufacturing device.

DETAILED DESCRIPTION

Hereinafter, a button product manufacturing device according to an embodiment of the present invention will be described with reference to the drawings. The button product manufacturing device to be described below is merely an embodiment of the present invention. Accordingly, the present invention is not limited to the following embodiment, and can be added, deleted, or modified without departing from the scope of the present invention.

Overall Configuration

A button product manufacturing device 100 according to an embodiment of the present invention is a device for manufacturing a button product 200 by connecting a front member SE in which a white film F and a printing medium W are laminated and a back member BE as illustrated in the example of FIG. 11B. The button product manufacturing device 100 includes a printing unit 1, a conveying unit 2, a die unit 3, a front member feed unit 4, a back member feed unit 5, a pressing unit 6, a take-out unit 7, a collection box 8, and a button product container 9, as illustrated in the example of FIG. 1. The printing medium W, the white film F, the button product 200, and each part of the button product manufacturing device 100 will be described later. As illustrated in the example of FIG. 1, directions orthogonal to one another are referred to as a front-rear direction Dx, a left-right direction Dy, and an up-down direction Dz, but an arrangement direction of the button product manufacturing device 100 is not limited thereto.
The button product manufacturing device 100 further includes a control device 110, as illustrated in the example of FIG. 3. The control device 110 includes an interface 111, a calculation unit 112, and a storage unit 113. The interface 111 receives various data such as image data from an external device 114 such as a computer, a camera, a communication network, a recording medium, a display, and a printer. The control device 110 may be implemented by a single device, or may have a configuration in which a plurality of devices are arranged in a distributed manner and cooperate with one another to operate the button product manufacturing device 100.
The storage unit 113 is a memory accessible from the calculation unit 112 and includes a RAM and a ROM. The RAM temporarily stores various data including data received from the external device 114 such as image data, data converted by the calculation unit 112, and the like. The ROM stores a button product manufacturing program for performing various processes, predetermined data, and the like. The button product manufacturing program may be stored in an external storage medium that is different from the storage unit 113 and that is accessible from the calculation unit 112, such as a CD-ROM.
The calculation unit 112 includes at least one circuit, for example, a processor such as CPU, and an integrated circuit such as ASIC. The calculation unit 112 executes the button product manufacturing program stored in the storage unit 113 or the like to control each part of the button product manufacturing device 100.
The control device 110 is connected, via a first drive circuit 115, to an ejection head 10 and a conveying motor 11 provided in the printing unit 1. The first drive circuit 115 causes the ejection head 10 to eject ink droplets and causes the conveying motor 11 to convey the printing medium W in a predetermined direction based on a control signal of the control device 110. In this way, the first drive circuit 115 alternately or simultaneously performs an ejection operation and a conveying operation, so that an image based on the image data is printed on the printing medium W.
The control device 110 is connected, via a fourth drive circuit 118, to a pusher motor 46 provided in the front member feed unit 4. The fourth drive circuit 118 drives the pusher motor 46 based on the control signal of the control device 110 to feed the front member SE to the die unit 3.
The control device 110 is connected, via a second drive circuit 116, to a conveying motor 23 provided in the conveying unit 2. The second drive circuit 116 drives the conveying motor 23 based on detection results of a first conveying sensor S1, a second conveying sensor S2, and a third conveying sensor S3 and the control signal of the control device 110. Accordingly, the printing medium W printed by the printing unit 1 and the white film F are conveyed to above a front surface of the front member SE fed by the front member feed unit 4.
The control device 110 is connected, via a sixth drive circuit 120, to a pressing motor 60 provided in the pressing unit 6. The sixth drive circuit 120 drives the pressing motor 60 based on the control signal of the control device 110. Accordingly, the printing medium W or the white film F conveyed by the conveying unit 2 is pressed against the front member SE.
The control device 110 is connected, via a fifth drive circuit 119, to a pusher motor 56 provided in the back member feed unit 5. The fifth drive circuit 119 drives the pusher motor 56 based on the control signal of the control device 110 to feed the back member BE to the die unit 3.
The control device 110 is connected, via a third drive circuit 117, to an upper die lifting motor 34 and a lower die moving motor 140 provided in the die unit 3. The third drive circuit 117 drives the upper die lifting motor 34 and the lower die moving motor 140 based on the control signal of the control device 110. Accordingly, the button product 200 is produced by deforming the front member SE, the back member BE, or both the front member SE and the back member BE such that a part of the printing medium W is clamped between a back surface of the front member SE and the back member BE fed by the back member feed unit 5, in a state where the front surface of the front member SE is covered with the printing medium W.
The control device 110 is connected, via a seventh drive circuit 150, to a take-out motor 70 provided in the take-out unit 7. The take-out motor 70 drives the take-out motor 70 based on the control signal of the control device 110 to take out, from the die unit 3, the button product 200 manufactured by the die unit 3.

Button Product

The button product 200 is, for example, a button badge, and is produced by the front member SE, the back member BE, the white film F, and the printing medium W, as illustrated in the example of FIG. 11B. The front member SE and the back member BE are formed of a magnetic material such as a tin-plated steel plate, as illustrated in the example of FIG. 11A. The front member SE and the back member BE each have a circular shape in a plan view. The front member SE has a circular front surface portion SEb and an annular peripheral edge portion SEa protruding downward from an outer peripheral edge of the front surface portion SEb. The back member BE has a circular back surface portion BEb and an annular peripheral edge portion BEa protruding upward from an outer peripheral edge of the back surface portion BEb.
As illustrated in the example of FIG. 11B, a cover portion Fb of the white film F is disposed on the front surface of the front member SE, and a cover portion Wb of the printing medium W is disposed on the white film F. Of the cover portions Wb and Fb, a portion protruding from a front surface of the front surface portion SEb is bent downward from the outer peripheral edge of the front surface portion SEb to cover a front surface of the peripheral edge portion SEa, and a portion protruding from the front surface of the peripheral edge portion SEa is bent upward from a lower end of the peripheral edge portion SEa to be clamped between a back surface of the peripheral edge portion SEa and the peripheral edge portion BEa of the back member BE. Then, the button product 200 is formed by deforming (for example, caulking) at least one of the front member SE and the back member BE in a state where the cover portions Wb and Fb are clamped between the peripheral edge portion SEa and the peripheral edge portion BEa of the back member BE facing each other. The front member SE may be covered with only the printing medium W without using the white film F in the button product 200.

Printing Medium

The printing medium W is a rectangular transparent sheet, as illustrated in the example of FIG. 4A. The printing medium W has a trailing end We1 which is a downstream end in a first conveying direction Dc1 when being conveyed toward the die unit 3 by the conveying unit 2, and a leading end We2 which is an upstream end in the first conveying direction Dc1. The printing medium W includes the cover portion Wb covering the front member SE, a remaining portion Wa different from the cover portion Wb, and a coupling portion Wc coupling the cover portion Wb and the remaining portion Wa.
The cover portion Wb has, for example, a circular shape in a plan view, and is unevenly distributed closer to the trailing end We1 than to the leading end We2 in the printing medium W. The cover portion Wb is equal to or larger than the cover portion Fb of the white film F. The cover portion Wb has a first front portion Wf1 covering the front surface of the front surface portion SEb of the front member SE, a second front portion Wf2 covering the front surface of the peripheral edge portion SEa, and a clamped portion Wg clamped between the back surface of the peripheral edge portion SEa and the peripheral edge portion BEa of the back member BE.
The remaining portion Wa includes a linear weak portion Wd that surrounds the cover portion Wb and extends in the front-rear direction from the cover portion Wb to the trailing end We1. The coupling portion Wc and the linear weak portion Wd are weak portions having lower strength than the cover portion Wb and the remaining portion Wa, such as perforations. The coupling portion Wc and the linear weak portion Wd are cut by the cover portion Wb being pressed by the pressing unit 6 in the die unit 3 and the remaining portion Wa being conveyed in a second conveying direction Dc2 by the conveying unit 2 in a state where the cover portion Wb is pressed by the pressing unit 6, so that the cover portion Wb and the remaining portion Wa are separated.

White Film

The configuration of the white film F is basically the same as the configuration of the printing medium W. The white film F has the same size as the printing medium W and has a rectangular shape, as illustrated in the example of FIG. 4B. The white film F has a trailing end Fe1, a leading end Fe2, a cover portion Fb, a remaining portion Fa, a coupling portion Fc, and a linear weak portion Fd. The trailing end Fe1 corresponds to the trailing end We1, the leading end Fe2 corresponds to the leading end We2, the cover portion Fb corresponds to the cover portion Wb, the remaining portion Fa corresponds to the remaining portion Wa, the coupling portion Fc corresponds to the coupling portion Wc, and the linear weak portion Fd corresponds to the linear weak portion Wd. A first front portion Ff1, a second front portion Ff2, and a clamped portion Fg of the cover portion Fb are the same as the first front portion Wf1, the second front portion Wf2, and the clamped portion Wg of the cover portion Wb, respectively. A color of the white film is not limited to white.

Printing Unit

The printing unit 1 is disposed below the die unit 3, the front member feed unit 4, the back member feed unit 5, the pressing unit 6, and the take-out unit 7, as illustrated in the examples of FIGS. 1 and 2. The printing unit 1 is, for example, an inkjet printer that prints an image on the printing medium W. The printing unit 1 includes the ejection head 10 and the conveying motor 11, as illustrated in the example of FIG. 3. An image is printed on the printing medium W by ink droplets being ejected from the ejection head 10 onto the printing medium W and the printing medium W being conveyed by the conveying motor 11. The ejection head 10 may be of a serial head type or a line head type. In the present embodiment, an example in which the printing unit 1 is an inkjet printer has been described, but without being limited thereto, the printing unit 1 may be another printer such as a laser printer or a thermal printer.
The printing unit 1 further includes a first sheet holder 28 that holds the printing medium W, and a second sheet holder 29 that is different from the first sheet holder 28 and holds the white film F, as illustrated in the example of FIG. 1. In this case, the white film F from the second sheet holder 29 is fed to the conveying unit 2 without being printed by the printing unit 1, and the printing medium W from the first sheet holder 28 is fed to the conveying unit 2 after a predetermined image is printed by the ejection head 10 of the printing unit 1. The predetermined image is an image inverted to be a normal image when a user views the image from a surface opposite to a surface on which the image is printed among the surfaces of the printing medium W. The printing unit 1 may include a sheet holder that holds a plurality of printing media W and a plurality of white films F, and the printing media W and the white films F may be held on the sheet holder as a bundle in which the printing media W and the white films F are alternately stacked, and may be alternately conveyed.

Front Member Feed Unit

The front member feed unit 4 feeds the front member SE to a first lower die 30 provided in the die unit 3, as illustrated in the examples of FIGS. 1 and 2. The front member feed unit 4 is disposed above the printing unit 1 and to the right of the die unit 3. The front member feed unit 4 includes a front member stocker 40, a front member slope 43, a pusher 45, and the pusher motor 46 (FIG. 3). The front member stocker 40 has a cylindrical shape, and accommodates a plurality of front members SE having, for example, a circular shape in a plan view in a state of being stacked in the up-down direction Dz. The front member slope 43 extends from a position below the front member stocker 40 to the first lower die 30 disposed at a first die position P1.
The pusher 45 is connected to the pusher motor 46 via a rack gear, and reciprocates along the front member slope 43 in a space between a lower end of the front member stocker 40 and an upper surface of the front member slope 43 by rotational drive of the pusher motor 46. The pusher 45 moves in a direction approaching the first lower die 30 to push the front member SE on the front member slope 43 in the space toward the first lower die 30. On the other hand, the pusher 45 retreats from the space below the front member stocker 40 in a direction away from the first lower die 30, so that one front member SE is fed from the front member stocker 40 onto the front member slope 43.

Back Member Feed Unit

The back member feed unit 5 feeds the back member BE to the second lower die 31 provided in the die unit 3. The back member feed unit 5 is disposed above the printing unit 1 and to the left of the die unit 3. The back member feed unit 5 includes a back member stocker 50, a back member slope 53, a pusher 55, and a pusher motor 56 (FIG. 3). The back member stocker 50 has a cylindrical shape, and accommodates a plurality of back members BE having, for example, a circular shape in a plan view in a state of being stacked in the up-down direction Dz. The back member slope 53 extends from a position below the back member stocker 50 to the second lower die 31 disposed at the first die position P1.
The pusher 55 is connected to the pusher motor 56 via a rack gear, and reciprocates along the back member slope 53 in a space between a lower end of the back member stocker 50 and an upper surface of the back member slope 53 by rotational drive of the pusher motor 56. The pusher 55 moves in a direction approaching the second lower die 31 to push the back member BE on the back member slope 53 in the space toward the second lower die 31. On the other hand, the pusher 55 retreats from the space below the back member stocker 50 in a direction away from the second lower die 31, so that one back member BE is fed from the back member stocker 50 onto the back member slope 53.

Conveying Unit

Regarding the conveying unit 2, a part of the conveying unit 2 is disposed in front of the printing unit 1, and the entire conveying unit 2 is disposed in front of the die unit 3. The conveying unit 2 conveys the printing medium W and the white film F conveyed from the printing unit 1 onto the front member SE, which is fed prior to the first lower die 30, along the first conveying direction Dc1 toward the die unit 3. The conveying unit 2 conveys the remaining portion Wa of the printing medium W and the remaining portion Fa of the white film F, which are separated at the die unit 3, to the collection box 8 along the second conveying direction Dc2, and the remaining portions Wa and Fa are collected in the collection box 8 as waste portions. In the present embodiment, the white film F is conveyed prior to the printing medium W such that the white film F is placed on the front member SE, which is held by the first lower die 30, prior to the printing medium W. Since the method for conveying the printing medium W by the conveying unit 2 is the same as the method for conveying the white film F, the conveyance of the printing medium W will be representatively described below.
Specifically, the conveying unit 2 includes a right support plate 20 and a left support plate 22, as illustrated in the examples of FIGS. 5 and 6. The support plates 20 and 22 have a flat plate shape extending in the up-down direction Dz. The right support plate 20 and the left support plate 22 are arranged in parallel to be spaced apart from each other in the left-right direction Dy, and are coupled by a plurality of plate coupling shafts 24 extending in the left-right direction Dy.
The conveying unit 2 further includes the conveying motor 23 and drive rollers Rk1 to Rk6. The conveying motor 23 and the drive rollers Rk1 to Rk6 are arranged between the pair of support plates 20 and 22. The first drive roller Rk1, the second drive roller Rk2, the third drive roller Rk3, the fourth drive roller Rk4, and the fifth drive roller Rk5 are arranged upward in this order. The drive rollers Rk2 to Rk4 are arranged in the up-down direction in front of the first drive roller Rk1 and the fifth drive roller Rk5 and behind the sixth drive roller Rk6. The fifth drive roller Rk5 and the sixth drive roller Rk6 are arranged in the front-rear direction. The conveying motor 23 is disposed in front of the drive rollers Rk1 to Rk6 between the first drive roller Rk1 and the second drive roller Rk2 in the up-down direction.
The first drive roller Rk1 includes the first drive roller Rk1 on the right side and the first drive roller Rk1 on the right side, which are provided on a first drive shaft Sk1. The second drive roller Rk2 includes the second drive roller Rk2 on the right side and the second drive roller Rk2 on the left side, which are provided on a second drive shaft Sk2. The third drive roller Rk3 includes the third drive roller Rk3 on the right side and the third drive roller Rk3 on the left side, which are provided on a third drive shaft Sk3. The fourth drive roller Rk4 includes the fourth drive roller Rk4 on the right side and the fourth drive roller Rk4 on the left side, which are provided on a fourth drive shaft Sk4. The fifth drive roller Rk5 includes the fifth drive roller Rk5 on the right side and the fifth drive roller Rk5 on the left side, which are provided on a fifth drive shaft Sk5. The sixth drive roller Rk6 includes the sixth drive roller Rk6 on the right side and the sixth drive roller Rk6 on the left side, which are provided on a sixth drive shaft Sk6. The drive shafts Sk1 to Sk6 are shafts extending in the left-right direction, and the drive rollers Rk1 to Rk6 are rotatably supported by the support plates 20 and 22.
The conveying unit 2 further includes a drive gear Ga1 and drive gears Gb1 to Gb6. The drive gear Ga1 is connected to a rotary shaft of the conveying motor 23. The first drive gear Gb1 is connected to the first drive shaft Sk1, the second drive gear Gb2 is connected to the second drive shaft Sk2, the third drive gear Gb3 is connected to the third drive shaft Sk3, the fourth drive gear Gb4 is connected to the fourth drive shaft Sk4, the fifth drive gear Gb5 is connected to the fifth drive shaft Sk5, and the sixth drive gear Gb6 is connected to the sixth drive shaft Sk6.
Further, the conveying unit 2 includes endless drive belts Be1 to Be6. The first drive belt Be1 is stretched over the drive gear Ga1 and the first drive gear Gb1, the second drive belt Be2 is stretched over the first drive gear Gb1 and the second drive gear Gb2, the third drive belt Be3 is stretched over the second drive gear Gb2 and the third drive gear Gb3, the fourth drive belt Be4 is stretched over the third drive gear Gb3 and the fourth drive gear Gb4, the fifth drive belt Be5 is stretched over the fourth drive gear Gb4 and the fifth drive gear Gb5, and the sixth drive belt Be6 is stretched over the fifth drive gear Gb5 and the sixth drive gear Gb6. Accordingly, a driving force by the conveying motor 23 is transmitted to the drive rollers Rk1 to Rk6 via the first drive belts Be1 to Be6. Therefore, when the conveying motor 23 is rotatably driven in one direction, the drive rollers Rk1 to Rk6 normally rotate, and the printing medium W is conveyed in the first conveying direction Dc1. On the other hand, when the conveying motor 23 is rotationally driven in the other direction, the drive rollers Rk1 to Rk6 reversely rotate, and the printing medium W is conveyed in the second conveying direction Dc2.
The conveying unit 2 further includes driven rollers Ro1 to Ro6. The first driven roller Ro1 faces the first drive roller Rk1 disposed below the first driven roller Ro1, and includes the first driven roller Ro1 on the right side and the first driven roller Ro1 on the left side, which are provided on a first driven shaft So1. The second driven roller Ro2 faces the second drive roller Rk2 disposed in front of the second driven roller Ro2, and includes the second driven roller Ro2 on the right side and the second driven roller Ro2 on the left side, which are provided on a second driven shaft So2. The third driven roller Ro3 faces the third drive roller Rk3 disposed in front of the third driven roller Ro3, and includes the third driven roller Ro3 on the right side and the third driven roller Ro3 on the left side, which are provided on a third driven shaft So3. The fourth driven roller Ro4 includes the fourth driven roller Ro4 on the right side and the fourth driven roller Ro4 on the left side, which are provided on a fourth driven shaft So4 and arranged behind the fourth drive roller Rk4 and the fourth drive roller Rk4 disposed in front of the fourth driven roller Ro4. The fifth driven roller Ro5 faces the fifth drive roller Rk5 disposed above the fifth driven roller Ro5, and includes the fifth driven roller Ro5 on the right side and the fifth driven roller Ro5 on the left side, which are provided on a fifth driven shaft So5. The sixth driven roller Ro6 faces the sixth drive roller Rk6 disposed above the sixth driven roller Ro6, and includes the sixth driven roller Ro6 on the right side and the sixth driven roller Ro6 on the left side, which are provided on a sixth driven shaft So6. The driven shafts So1 to So6 are shafts extending in the left-right direction, and the driven rollers Ro1 to Ro6 are rotatably supported by the support plates 20 and 22. The printing medium W is clamped and conveyed between the drive rollers Rk1 to Rk6 and the driven rollers Ro1 to Ro6 facing each other.
The conveying unit 2 further includes conveying guides 21 and 25 to 27 that guide the printing medium W. The first conveying guide 21, the second conveying guide 25, and the third conveying guide 27 constitute a first conveying path Cp1 along which the printing medium W is conveyed to the first lower die 30 of the die unit 3 in the first conveying direction Dc1. The fourth conveying guide 26 and the third conveying guide 27 constitute a second conveying path Cp2 along which the remaining portion Wa of the printing medium W is conveyed from the first lower die 30 of the die unit 3 to the collection box 8 in the second conveying direction Dc2. Further, the second conveying guide 25 and the third conveying guide 27 constitute a switching unit that switches between the first conveying path Cp1 and the second conveying path Cp2.
The first conveying guide 21 includes the first conveying guide 21 on the right side protruding leftward from a left surface of the support plate 20 on the right side and the first conveying guide 21 on the left side protruding rightward from a right surface of the support plate 22 on the left side. An interval E is formed between the first conveying guide 21 on the right side and the first conveying guide 21 on the left side in the left-right direction. That is, the conveying unit 2 includes, for example, the first conveying guide 21 on the right side and the first conveying guide 21 on the left side as two conveying guides disposed at an interval in a direction orthogonal to the first conveying direction Dc1 and that guide the printing medium W conveyed in the first conveying direction Dc1.
In the left-right direction, the interval E between the two first conveying guides 21 is, for example, larger than a width of the cover portion Wb of the printing medium W. Therefore, the remaining portion Wa to the right of the cover portion Wb is guided by the first conveying guide 21 on the right side, and the remaining portion Wa to the left of the cover portion Wb is guided by the first conveying guide 21 on the left side. In this case, the cover portion Wb passes between a left end of the first conveying guide 21 on the right side and a right end of the first conveying guide 21 on the left side. Accordingly, since the printing medium W is conveyed without the image printed on the cover portion Wb coming into contact with the first conveying guide 21, it is possible to reduce damage to the image caused by the contact with the first conveying guide 21 at the time of conveying the printing medium W.
The first conveying guide 21 includes a first guide piece 21a and a second guide piece 21b. The first guide piece 21a has, for example, a plate shape, and has a lower portion curved obliquely upward from a lower end of the first guide piece 21a toward the front, a middle portion extending upward from a front end of the lower portion, and an upper portion curved obliquely upward from an upper end of the middle portion toward the rear. The second guide piece 21b has, for example, a plate shape, and has a lower portion curved obliquely upward from a lower end of the second guide piece 21b toward the front, and a middle portion extending upward from a front end of the lower portion. A space between the lower portion of the first guide piece 21a and the lower portion of the second guide piece 21b disposed below the first guide piece 21a is provided as a lower groove, and a space between the middle portion of the first guide piece 21a and the middle portion of the second guide piece 21b disposed in front of the first guide piece 21a is provided as a middle groove. An end portion of the printing medium W in the left-right direction Dy passes through the lower groove and the middle groove, and the printing medium W is guided by the first conveying guide 21.
The first driven roller Ro1 is disposed behind the lower end of the first guide piece 21a, and the first drive roller Rk1 is disposed behind the lower end of the second guide piece 21b. The printing medium W discharged from the printing unit 1 is clamped between the first driven roller Ro1 and the first drive roller Rk1 and is conveyed forward along the lower groove.
The middle portion of the first guide piece 21a and the middle portion of the second guide piece 21b are disposed between the second to fourth drive shafts Sk2 to Sk4 and the second to fourth driven shafts So2 to So4, respectively. Each of the first guide piece 21a and the second guide piece 21b is provided with a notch Ng. A part of the driven rollers Ro2 to Ro4 protrudes forward via the notch Ng of the first guide piece 21a, and a part of the drive rollers Rk2 to Rk4 protrudes rearward via the notch Ng of the second guide piece 21b. Accordingly, the printing medium W conveyed by the lower portion of the guide pieces 21a and 21b is clamped between the driven rollers Ro2 to Ro4 and the drive rollers Rk2 to Rk4 in the middle groove and is conveyed upward.
The second conveying guide 25 includes the second conveying guide 25 on the right side facing the upper portion of the first guide piece 21a on the right side and the second conveying guide 25 on the left side facing the upper portion of the first guide piece 21a on the left side. The second conveying guide 25 is disposed above the upper portion of the first guide piece 21a and the middle groove. The second conveying guide 25 has a plate shape, extends obliquely upward and rearward from a front end thereof, is curved, and extends rearward. A space between the second conveying guide 25 and the upper portion of the first guide piece 21a is provided as an upper groove, and the upper groove is in communication with the middle groove. The end portion of the printing medium W in the left-right direction Dy passes through the upper groove from the middle groove, and the printing medium W is guided by the first conveying guide 21 and the second conveying guide 25.
The front end of the second conveying guide 25 is fixed to the support plates 20 and 22, and the second conveying guide 25 is pivotable about the front end. The third conveying guide 27 is disposed above the second conveying guide 25 and between the second conveying guide 25 on the right side and the second conveying guide 25 on the left side. The third conveying guide 27 has a plate shape, has flexibility, and is made of, for example, resin. A front end of the third conveying guide 27 is fixed to the support plates 20 and 22, and a rear end of the third conveying guide 27 is deflectable in the up-down direction. A rear portion 27a of the third conveying guide 27 is bent at the same height as an upper end of the fifth driven roller Ro5 and the second conveying guide 25 or slightly below the upper end.
After left and right ends of the printing medium W are conveyed upward along the middle groove, the left and right ends are conveyed rearward along the upper groove. Here, a central portion of the printing medium W in the left-right direction is along the third conveying guide 27. Therefore, the second conveying guide 25 and the third conveying guide 27 are pressed upward by the printing medium W, a rear end of the second conveying guide 25 is separated from the first guide piece 21a, a rear end of the upper groove is opened, and the printing medium W is conveyed rearward from the upper groove via the opening at the rear end, as illustrated in the examples of FIGS. 6 and 8A. Accordingly, the second conveying guide 25 allows the conveyance of the printing medium W from the fourth drive roller Rk4 and the fourth driven roller Ro4 to the fifth drive roller Rk5 and the fifth driven roller Ro5.
The fifth driven roller Ro5 and the fifth drive roller Rk5 arranged in the up-down direction are disposed behind the upper groove. The printing medium W conveyed rearward from the upper groove is clamped between the fifth driven roller Ro5 and the fifth drive roller Rk5 and is conveyed to the first lower die 30 of the die unit 3 at the rear side along the first conveying direction Dc1. Here, since the upper portion of the first guide piece 21a is curved obliquely upward toward the rear, the printing medium W conveyed along the upper portion of the first guide piece 21a is conveyed obliquely upward toward the rear, and is conveyed to above the first lower die 30 without hitting the first lower die 30. Further, since the third conveying guide 27 is located slightly below the second conveying guide 25, as illustrated in the example of FIG. 8A, the center portion of the printing medium W is pressed downward by the third conveying guide 27, so that the printing medium W is stretched to be horizontal, and the trailing end We1 of the printing medium W does not hang down, and thus the printing medium W is conveyed to above the first lower die 30 without hitting the first lower die 30. As described above, the first conveying path Cp1 of the printing medium W toward the first lower die 30 of the die unit 3 is implemented by the first conveying guide 21, the second conveying guide 25, and the third conveying guide 27.
On the other hand, when the printing medium W is conveyed onto the first lower die 30, the printing medium W is located behind the second conveying guide 25 and the third conveying guide 27. Therefore, the second conveying guide 25 is lowered by its own weight, the rear end of the second conveying guide 25 comes into contact with the first guide piece 21a, and the opening at the rear end of the upper groove is closed, as illustrated in the example of FIG. 8B. The rear end of the third conveying guide 27 is located below the rear end of the second conveying guide 25. In this way, the second conveying guide 25 and the third conveying guide 27 block the conveyance of the printing medium W to the first conveying path Cp1 and guide the conveyance of the printing medium W to the second conveying path Cp2. Therefore, the remaining portion Wa of the printing medium W is conveyed to the second conveying path Cp2 on the second conveying guide 25 and the third conveying guide 27 without moving backward to the first conveying path Cp1.
The third conveying guide 27 is disposed between the fifth driven roller Ro5 and the sixth driven roller Ro6, as illustrated in the examples of FIGS. 5 and 6. The fourth conveying guide 26 is disposed between the fifth drive roller Rk5 and the sixth drive roller Rk6 above the third conveying guide 27. The fourth conveying guide 26 has a substantially plate shape and extends rearward from the rear end of the third conveying guide 27, and an extending portion 26a is curved obliquely upward toward the rear. The remaining portion Wa of the printing medium W is clamped between the fifth drive roller Rk5 and the fifth driven roller Ro5 in a state where the cover portion Wb is pressed by the pressing unit 6 in the die unit 3. The remaining portion Wa is separated from the cover portion Wb and conveyed in the second conveying direction Dc2 by rotating the fifth drive roller Rk5. Here, the remaining portion Wa comes into contact with the upper surface of the second conveying guide 25 and the upper surface of the third conveying guide 27 to be guided to the second conveying path Cp2, and is conveyed toward the sixth drive roller Rk6 and the sixth driven roller Ro6. In this case, since the rear end of the second conveying guide 25 and the rear portion 27a of the third conveying guide 27 are curved below the upper end of the fifth driven roller Ro5, the remaining portion Wa is easily guided to the second conveying path Cp2. Thereafter, the remaining portion Wa is clamped by the sixth drive roller Rk6 and the sixth driven roller Ro6, conveyed forward, and collected in the collection box 8. The third conveying guide 27 and the fourth conveying guide 26 constitute the second conveying path Cp2 of the remaining portion Wa from the first lower die 30 of the die unit 3 toward the collection box 8.
The conveying unit 2 further includes the first conveying sensor S1. The first conveying sensor S1 is, for example, a contact sensor, and is disposed behind the first drive roller Rk1 and the first driven roller Ro1. In response to the first conveying sensor S1 detecting the trailing end We1 of the printing medium W fed from the printing unit 1 to the conveying unit 2, the second drive circuit 116 (FIG. 3) starts driving of the conveying motor 23 according to a detection signal of the first conveying sensor S1. Accordingly, the conveyance of the printing medium W by the conveying unit 2 is started.
The conveying unit 2 further includes the second conveying sensor S2. The second conveying sensor S2 is, for example, a contact sensor, and is disposed between the first guide piece 21a and the second conveying guide 25. The second drive circuit 116 stops the driving of the conveying motor 23 in response to elapsed time from when the second conveying sensor S2 detects the trailing end We1 of the printing medium W reaching a movement time to a predetermined position of the printing medium W based on a rotation amount of the conveying motor 23. Accordingly, the printing medium W is conveyed with high accuracy to above the first lower die 30 in the die unit 3.
The conveying unit 2 further includes the third conveying sensor S3. The third conveying sensor S3 is, for example, a contact sensor, and is disposed in front of the fifth drive roller Rk5 and the fifth driven roller Ro5 and behind the sixth drive roller Rk6 and the sixth driven roller Ro6. It is possible to determine whether the remaining portion Wa is conveyed to the collection box 8 based on the detection result by the third conveying sensor S3. When the remaining portion Wa cannot be detected by the third conveying sensor S3 within a predetermined time after the second drive circuit 116 starts to reversely rotate the conveying motor 23, the control device 110 determines that a jam of the remaining portion Wa occurs. When the remaining portion Wa is still detected after a predetermined time after the remaining portion Wa is detected by the third conveying sensor S3, the control device 110 may determine that a jam of the remaining portion Wa occurs. When it is determined that a jam of the remaining portion Wa occurs, the control device 110 causes the second drive circuit 116 to stop the rotation of the conveying motor 23.
As described above, the conveying unit 2 conveys the printing medium W to above the button product such as the front member SE with the printing medium W clamped between the fifth drive roller Rk5 on the right side and the fifth driven roller Ro5 on the right side and between the fifth drive roller Rk5 on the left side and the fifth driven roller Ro5 on the left side. Here, the fifth drive roller Rk5 on the right side and the fifth drive roller Rk5 on the left side are disposed at an interval in the left-right direction and are in contact with the upper surface of the printing medium W. The fifth driven roller Ro5 on the right side and the fifth driven roller Ro5 on the left side are disposed at an interval in the left-right direction and are in contact with the lower surface of the printing medium W.
Therefore, the conveying unit 2 includes, for example, the fifth drive roller Rk5 on the right side and the fifth drive roller Rk5 on the left side as a first roller and a second roller disposed at an interval in a direction orthogonal to the first conveying direction Dc1 in which the printing medium W is conveyed above the button product. In addition, the conveying unit 2 includes, for example, the fifth driven roller Ro5 on the right side and the fifth driven roller Ro5 on the left side as a third roller that comes into contact with, among the surfaces of the printing medium W, a surface different from a surface in contact with the first roller, and a fourth roller that comes into contact with, among the surfaces of the printing medium W, a surface different from a surface in contact with the second roller and same as the surface in contact with the third roller. In this case, the first roller and the second roller are drive rollers, and the third roller and the fourth roller are driven rollers.
The fifth drive roller Rk5 on the right side and the fifth drive roller Rk5 on the left side are provided on the fifth drive shaft Sk5, and the fifth drive shaft Sk5 is coupled to the conveying motor 23 by the drive belts Be1 to Be5 via the drive gear Ga1 and the drive gears Gb1 to Gb5. A rotation direction of the fifth drive roller Rk5 on the right side and the fifth drive roller Rk5 on the left side changes according to a rotation direction of the conveying motor 23. Therefore, as the first roller and the second roller, for example, the fifth drive roller Rk5 on the right side and the fifth drive roller Rk5 on the left side may rotate normally and reversely. The printing medium W can be conveyed to the die unit 3 through the first conveying path Cp1 by the normal rotation of the fifth drive roller Rk5, the cover portion Wb and the remaining portion Wa of the printing medium W may be separated by the reverse rotation of the fifth drive roller Rk5, and the remaining portion Wa may be collected to the collection box 8 through the second conveying path Cp2.
The fifth drive shaft Sk5 is inserted through a center of the fifth drive roller Rk5 on the right side and a center of the fifth drive roller Rk5 on the left side. Therefore, the conveying unit 2 includes, for example, a drive unit including the fifth drive roller Rk5 and the fifth drive shaft Sk5 as a first drive unit including the first roller, the second roller, and a shaft inserted through the first roller and the second roller.
The fifth driven roller Ro5 on the right side and the fifth driven roller Ro5 on the left side are provided on the fifth drive shaft Sk5. Therefore, as the third roller and the fourth roller, for example, the fifth driven roller Ro5 on the right side and the fifth driven roller Ro5 on the left side are provided on the same shaft.
An interval J2 between the fifth driven roller Ro5 on the right side and the fifth driven roller Ro5 on the left side is wider than an interval J1 between the fifth drive roller Rk5 on the right side and the fifth drive roller Rk5 on the left side, as illustrated in the example of FIG. 7A. That is, an interval between the third roller and the fourth roller is wider than an interval between the first roller and the second roller. In this case, a left portion that is a part of the fifth driven roller Ro5 on the right side faces a right portion that is a part of the fifth drive roller Rk5 on the right side, and a right portion that is a part of the fifth driven roller Ro5 on the left side faces a left portion that is a part of the fifth drive roller Rk5 on the right side. The printing medium W is clamped and conveyed between a part of the fifth drive roller Rk5 and a part of the fifth driven roller Ro5 facing each other.
A first space between the fifth driven roller Ro5 on the right side and the fifth driven roller Ro5 on the left side is located below a second space between the fifth drive roller Rk5 on the right side and the fifth drive roller Rk5 on the left side, and is wider than a second space. Therefore, for example, the center of the printing medium W in the left-right direction may be bent below a left end and a right end thereof due to, for example, resistance during separation of the remaining portion Wa in the die unit 3 or a frictional force during conveyance in the conveying unit 2. In such a case, since a bent portion is accommodated in the first space, the printing medium W can also pass between the fifth driven roller Ro5 on the right side and the fifth driven roller Ro5 on the left side. Therefore, the conveying unit 2 has, for example, the first space between the fifth driven roller Ro5 on the right side and the fifth driven roller Ro5 on the left side as the allowing part 12 that allows bending of the printing medium W between the third roller and the fourth roller. Further, due to the bending of the printing medium W, the rigidity of the printing medium W increases, and the printing medium W is less likely to buckle in the front-rear direction, so that the printing medium W is smoothly conveyed forward. Therefore, it is possible to automatically produce a button product including the printing medium W.
As illustrated in the examples of FIGS. 5 and 6, the conveying unit 2 clamps and conveys the printing medium W between the sixth drive roller Rk6 on the right side and the sixth driven roller Ro6 on the right side and between the sixth drive roller Rk6 on the left side and the sixth driven roller Ro6 on the left side, downstream of the fifth drive roller Rk5 and the fifth driven roller Ro5 in the second conveying direction Dc2. Here, the sixth drive roller Rk6 on the right side and the sixth drive roller Rk6 on the left side are disposed at an interval in the left-right direction and are in contact with the upper surface of the printing medium W. The sixth driven roller Ro6 on the right side and the sixth driven roller Ro6 on the left side are disposed at an interval in the left-right direction and are in contact with the lower surface of the printing medium W.
Therefore, the conveying unit 2 includes, for example, the sixth drive roller Rk6 on the right side and the sixth drive roller Rk6 on the left side as a fifth roller and a sixth roller disposed downstream of the first roller and the second roller in the second conveying direction Dc2 of the printing medium W when the first roller and the second roller are reversely rotated. In addition, the conveying unit 2 includes, for example, the sixth driven roller Ro6 on the right side and the sixth driven roller Ro6 on the left side as a seventh roller that comes into contact with, among the surfaces of the printing medium W, a surface different from a surface with which the fifth roller comes into contact and an eighth roller that comes into contact with, among the surfaces of the printing medium W, a surface different from a surface with which the sixth roller comes into contact and same as the surface with which the seventh roller comes into contact. In this case, the fifth roller and the sixth roller are drive rollers, and the seventh roller and the eighth roller are driven rollers. In this way, the printing medium W is clamped by the fifth to eighth rollers in addition to the first to fourth rollers, so that it is possible to more smoothly convey the printing medium W and to automatically produce a button product.
The sixth drive shaft Sk6 is inserted through a center of the sixth drive roller Rk6 on the right side and a center of the sixth drive roller Rk6 on the left side. Therefore, the conveying unit 2 includes, for example, a drive unit including the sixth drive roller Rk6 and the sixth drive shaft Sk6 as a second drive unit including the fifth roller, the sixth roller, and a shaft inserted through the fifth roller and the sixth roller. The fifth drive shaft Sk5 and the sixth drive shaft Sk6 are coupled to the conveying motor 23 by the drive belts Be1 to Be6 via the drive gear Ga1 and the drive gears Gb1 to Gb6. Therefore, the conveying unit 2 includes, for example, the conveying motor 23 as a drive source for driving the first drive unit and the second drive unit. Accordingly, a first drive source and a second drive source cooperate, so that it is possible to smoothly convey the printing medium W and to automatically produce the button product.
An interval J4 between the sixth driven roller Ro6 on the right side and the sixth driven roller Ro6 on the left side is equal to an interval J3 between the sixth drive roller Rk6 on the right side and the sixth drive roller Rk6 on the left side, as illustrated in the example of FIG. 7B. That is, an interval between the fifth roller and the sixth roller is equal to an interval between the seventh roller and the eighth roller. In this case, for example, the entire sixth driven roller Ro6 on the right side and the entire sixth drive roller Rk6 on the right side face each other, and the entire sixth driven roller Ro6 on the left side and the entire sixth drive roller Rk6 on the right side face each other. Accordingly, since the printing medium W is clamped and conveyed between the sixth drive roller Rk6 and the sixth driven roller Ro6 facing each other, it is possible to reduce bending or the like of the printing medium W and to automatically manufacture a button product.

Pressing Unit

The pressing unit 6 includes a lower plate Mp1 disposed on the first lower die 30 and an upper plate Mp2 disposed on the lower plate Mp1, as illustrated in the example of FIG. 9. The lower plate Mp1 includes a lower plate body 121 having a substantially rectangular plate shape. The lower plate body 121 is provided with a circular notch 123 at a position overlapping a recess 30c of the first lower die 30 (that is, holding portion of front member SE). Since the lower plate body 121 is provided to surround the periphery of the notch 123, the lower plate body 121 can be provided with strength. A diameter of the notch 123 is equal to or slightly larger than a diameter of the recess 30c of the first lower die 30.
The upper plate Mp2 includes an upper plate body 124 having a substantially U-shaped plate shape. The upper plate body 124 is provided with a notch 128 at a position overlapping the notch 123 of the lower plate body 121 when viewed from above. The notch 128 has, for example, a shape in which a semicircular front portion protruding forward and a rectangular rear portion extending rearward from a linear portion of the front portion and opening at a rear end of the upper plate body 124 are integrally coupled. Such a shape can reduce a material cost of the upper plate body 124. The notch 128 is larger than the notch 123, and an edge of the notch 128 is disposed outside an edge of the notch 123.
The entire recess 30c of the first lower die 30 is exposed from the notch 128 via the notch 123. The printing medium W or the white film F passes between the lower plate Mp1 and the upper plate Mp2, and is conveyed to above the front member SE accommodated in the recess 30c. Here, the cover portion Wb of the printing medium W or the cover portion Fb of the white film F is disposed on the front member SE, as illustrated in the example of FIG. 10. Behind the cover portions Wb and Fb, the remaining portion Wa of the printing medium W or the remaining portion Fa of the white film F is disposed on the lower plate body 121 in a state of being exposed from the notch 128 of the upper plate Mp2. The other remaining portions Wa and Fa are clamped between the lower plate body 121 and the upper plate body 124.
The pressing unit 6 includes the pressing motor 60 (FIG. 3), a swing arm 63, a remaining portion depressing head 65, and a pressing head 66. A rotary shaft of the pressing motor 60 is coupled to a base end of the swing arm 63 via a gear. The remaining portion depressing head 65 and the pressing head 66 are attached to a distal end of the swing arm 63. When the pressing motor 60 is rotationally driven, the remaining portion depressing head 65 and the pressing head 66 press the printing medium W or the white film F clamped between the lower plate Mp1 and the upper plate Mp2.
Here, the pressing head 66 has a substantially cross shape extending in the front-rear direction and the left-right direction, and dimensions thereof in the front-rear direction and the left-right direction are slightly smaller than dimensions of the cover portions Wb and Fb, the notch 123, and the recess 30c. Front, left, and right ends of the pressing head 66 protrude downward from a center thereof in the front-rear direction and the left-right direction. Therefore, the pressing head 66 presses, via the notches 128 and 123, the cover portions Wb and Fb against the front member SE accommodated in the recess 30c. Accordingly, the coupling portion Wc is partially or entirely cut.
The remaining portion depressing head 65 includes a support shaft 65a, a head body 65b, and a spring 65c. The support shaft 65a extends in the front-rear direction, and has a front end connected to the spring 65c and a rear end connected to the head body 65b. The support shaft 65a is pivotably supported by the swing arm 63 between the spring 65c and the head body 65b. The head body 65b extends in the left-right direction, has left and right ends protruding downward, and is biased downward by an elastic force of the spring 65c. Therefore, the head body 65b presses the remaining portions Wa and Fa exposed from the notch 128 with the linear weak portion Wd clamped therebetween. Then, the remaining portions Wa and Fa are conveyed forward by the conveying unit 2.
Accordingly, the remaining portion Wa is conveyed forward by the conveying unit 2 from a position of the pressing head 66 where a vertex of a triangular cut portion 67 pointed rearward faces the front end of the linear weak portion Wd, so that the linear weak portion Wd is cut by the cut portion 67. Here, since the head body 65b presses the remaining portions Wa and Fa by the elastic force of the spring 65c, a conveyance force of the conveying unit 2 exceeds the elastic force, and the remaining portions Wa and Fa are conveyed forward. At this time, since the left and right remaining portions Wa separated by the linear weak portion Wd pass through the left and right of the pressing head 66 and move forward while the cover portions Wb and Fb are pressed by the pressing head 66, the remaining portions Wa and Fa are conveyed to the collection box 8 without being caught by the pressing head 66. In this way, the remaining portions Wa and Fa are collected in the collection box 8 while the cover portions Wb and Fb remain on the front member SE.

Die Unit

The die unit 3 includes the first lower die 30, the second lower die 31 different from the first lower die 30, a rotation support table 32, the lower die moving motor 140 (FIG. 3), the upper die lifting motor 34 (FIG. 3), and an upper die 33, as illustrated in the example of FIG. 2. The rotation support table 32 is a rotating portion that rotates the first lower die 30 and the second lower die 31 about a second shaft extending in the up-down direction, and has, for example, a substantially circular shape in a plan view. The first lower die 30 and the second lower die 31 are disposed at symmetrical positions with respect to a center of the rotation support table 32 in the rotation support table 32. The rotation support table 32 rotates around the shaft in the up-down direction Dz by rotational driving of the lower die moving motor 140. Accordingly, one lower die of the first lower die 30 and the second lower die 31 is located at a second die position P2 facing the upper die 33 in the up-down direction Dz, and the other lower die is located at the first die position P1 located on the opposite side of the second die position P2 across the center of the rotation support table 32 in the front-rear direction Dx. The first die position P1 is clamped between the front member slope 43 of the front member feed unit 4 and the back member slope 53 of the back member feed unit 5. When the first lower die 30 is at the first die position P1, the front member SE is fed from the front member feed unit 4 to the first lower die 30. On the other hand, when the second lower die 31 is at the first die position P1, the back member BE is fed from the back member feed unit 5 to the second lower die 31.
The first lower die 30 includes a columnar first pedestal 30a, a cylindrical first slide die 30b that surrounds a periphery of the first pedestal 30a and slides up and down with respect to the first pedestal 30a, and a first spring 30s that biases the first slide die 30b upward, as illustrated in the example of FIG. 12A. The first slide die 30b has an annular upper surface 30b5 and a cylindrical guide wall 30b2 protruding upward from an outer peripheral edge of the upper surface 30b5. A diameter of an inner peripheral surface of the guide wall 30b2 is larger than a diameter of an inner peripheral surface of the first slide die 30b, and a center shaft of the inner peripheral surface of the guide wall 30b2 and a center shaft of the inner peripheral surface of the first slide die 30b are arranged on the same straight line.
The second lower die 31 includes a columnar second pedestal 31a, a cylindrical second slide die 31b that surrounds a periphery of the second pedestal 31a and slides up and down with respect to the second pedestal 31a, and a second spring 31s that biases the second slide die 31b upward, as illustrated in the example of FIG. 13A. The upper die 33 includes a columnar inner die 33a and a cylindrical outer die 33b surrounding a periphery of the inner die 33a, as illustrated in the examples of FIGS. 12A and 13A. The inner die 33a and the outer die 33b are lifted and lowered by the upper die lifting motor 34.
The button product 200 is produced with the die unit 3, as illustrated in the examples of FIGS. 12A to 13B. In FIGS. 12A to 13B, the white film F between the printing medium W and the front surface portion SEb is not illustrated. When the first lower die 30 is at the first die position P1, the front surface portion SEb of the front member SE is disposed on the upper surface 30a2 of the first pedestal 30a of the first lower die 30, as illustrated in FIG. 12A,. The peripheral edge portion SEa of the front member SE is inserted between an outer peripheral surface of the first pedestal 30a and the inner peripheral surface of the first slide die 30b. The cover portions Wb and Fb are placed on the upper surface 30b5 of the first slide die 30b in the guide wall 30b2.
The first lower die 30 is moved to the second die position P2 and the second lower die 31 is moved to the first die position P1 by the rotation of the rotation support table 32, as illustrated in FIG. 12B. At the second die position P2, when the upper die 33 is lowered, the lower surface 33b1 of the outer die 33b abuts against the guide wall 30b2 of the first slide die 30b and presses down the first slide die 30b to a predetermined position with respect to the first pedestal 30a against the biasing force of the first spring 30s. Accordingly, a lower surface 33a1 of the inner die 33a crimps the cover portion Wb to the front member SE, the front member SE and the cover portions Wb and Fb are fitted into the outer die 33b, and the first front portion Wf1 and the clamped portion Wg of the cover portion Wb are bent downward. Thereafter, the upper die 33 is raised to separate the front member SE from the first lower die 30, as illustrated in the example of FIG. 13A.
At the first die position P1, the back member BE is disposed on the upper surface 31a1 of the second pedestal 31a of the second lower die 31. A periphery of the back member BE is surrounded by a tapered surface 31b2 which is an inner peripheral surface of the second slide die 31b whose diameter decreases downward. The second lower die 31 is moved to the second die position P2 by the rotation of the rotation support table 32, as illustrated in FIG. 13B.
Here, when the upper die 33 is lowered, the lower surface 33b1 of the outer die 33b comes into contact with the upper surface 31b1 of the second slide die 31b, and presses down the second slide die 31b to a predetermined position against the biasing force of the second spring 31s. At this time, the clamped portion Wg of the cover portion Wb comes into contact with the peripheral edge portion BEa of the back member BE and is folded between the back surface of the peripheral edge portion SEa of the front member SE and a front surface of the peripheral edge portion BEa of the back member BE, as illustrated in the example of FIG. 11B. The peripheral edge portion SEa of the front member SE is pressed and deformed by the tapered surface 31b2. In this manner, the front member SE and the back member BE are caulked to produce the button product 200.

Take-Out Unit

After the second lower die 31 holding the button product 200 is moved to the first die position P1 by the rotation of the rotation support table 32, the take-out unit 7 takes out the button product 200 from the second lower die 31 and guides the button product 200 to the button product container 9 disposed in front of the take-out unit 7, as illustrated in the example of FIG. 2. The take-out unit 7 is disposed in front of the front member feed unit 4.
The take-out unit 7 includes the take-out motor 70, a swing arm 71, a magnet member 72, and a seat 73. The swing arm 71 is an elongate member, the magnet member 72 such as a permanent magnet is provided at a distal end of the swing arm 71, and a rotary shaft of the take-out motor 70 is connected to a base end of the swing arm 71 via a gear. The swing arm 71 pivots in a direction approaching the second lower die 31 by the driving of the take-out motor 70, and attaches the magnet member 72 onto the button product 200 held by the second lower die 31. On the other hand, the swing arm 71 pivots in a direction away from the second lower die 31 by the driving of the take-out motor 70, and moves the button product 200 attached to the magnet member 72 to the seat 73. The seat 73 extends while being inclined obliquely downward toward the button product container 9. The button product 200 is detached from the magnet member 72 at the seat 73, slides toward the button product container 9, and is stored in the button product container 9.

Flow of Overall Processing

As illustrated in the example of FIG. 14, first, the control device 110 determines whether there is an instruction to produce a button product from a user (step S1). When there is no instruction to produce a button product (No in step S1), the control device 110 waits as it is. On the other hand, when there is an instruction to produce a button product (Yes in step S1), the control device 110 causes the front member feed unit 4 to feed the front member SE to the first lower die 30 (step S2).
Next, the control device 110 causes the conveying unit 2 to convey the white film F onto the front member SE (step S3). Next, the control device 110 causes the pressing unit 6 to cut the coupling portion Fc of the white film F (step S4). Then, the control device 110 causes the conveying unit 2 to separate the remaining portion Fa of the white film F from the cover portion Fb and to convey the separated remaining portion Fa to the collection box 8 (step S5).
Subsequently, the control device 110 causes the conveying unit 2 to convey the printing medium W printed by the printing unit 1 onto the cover portion Fb of the white film F (step S6). Next, the control device 110 causes the pressing unit 6 to cut the coupling portion Wc of the printing medium W (step S7). Then, the control device 110 causes the conveying unit 2 to separate the remaining portion Wa of the printing medium W from the cover portion Wb and to convey the separated remaining portion Wa to the collection box 8 (step S8).
Next, the control device 110 moves the first lower die 30 from the first die position P1 to the second die position P2 below the upper die 33 in the die unit 3, and then causes the upper die 33 to hold the front member SE and the cover portions Wb and Fb, which are held by the first lower die 30 (step S9). Further, the control device 110 causes the back member feed unit 5 to feed the back member BE to the second lower die 31 (step S10). Then, the control device 110 moves the second lower die 31 to the second die position P2 below the upper die 33 in a state where the front member SE and the cover portions Wb and Fb are held, and then lowers the upper die 33 to perform caulking processing (step S11). Accordingly, the button product 200 is produced. Thereafter, the control device 110 moves, to the first die position P1, the second lower die 31 in a state where the button product 200 is held, causes the take-out unit 7 to take out the button product 200 (step S12), and places the button product 200 into the button product container 9.
After taking out of the button product 200 by the take-out unit 7 is finished, the control device 110 moves the first lower die 30 at the second die position P2 to the first die position P1. Thereafter, the control device 110 determines whether a predetermined number of button products 200 is produced (step S13). When the predetermined number of button products 200 is not produced (No in step S13), the control device 110 returns to the processing of step S2 and repeats the subsequent processing. On the other hand, when the predetermined number of button products 200 is produced (Yes in step S13), the control device 110 ends the button product production processing.

Modification

The present invention is not limited to the above-described embodiment, and modifications can be adopted without departing from the gist of the present invention. For example, the present invention is modified as follows.
The shape of the first notch 123 in the lower plate Mp1 is not limited to the above-described shape, and may be, for example, a shape in which a semicircular rear portion protruding rearward and a rectangular front portion extending forward from the rear portion and opening at the front end of the lower plate body 121 are integrally coupled. In this way, the lower plate body 121 has a U shape due to the first notch 123 cut out rearward from the front end of the lower plate body 121. Since the shape of the first notch 123 is larger than a circular shape, the material cost of the lower plate Mp1 can be reduced. The number of the first notch 123 is not limited to one, and a plurality of first notches 123 may be provided.
The shape of the second notch 128 in the upper plate Mp2 is not limited to the above-described shape, and may be, for example, a circular shape. In this case, the upper plate body 124 surrounds the periphery of the second notch 128, and thus can have higher strength than the second notch 128 having a shape of which the rear end is opened. The number of the second notch 128 is not limited to one, and a plurality of second notches 128 may be provided.
In the above-described configuration, the second drive circuit 116 starts driving of the conveying motor 23 in response to the first conveying sensor S1 detecting the printing medium W, but the driving start timing is not limited thereto. For example, the second drive circuit 116 may start the driving of the conveying motor 23 before, during, or after printing an image on the printing medium W by the printing unit 1.
In the above-described configuration, the front member feed unit 4 is disposed above the printing unit 1 and to the right of the die unit 3, but is not limited thereto. The front member feed unit 4 may be disposed above the printing unit 1 and to the left of the die unit 3.
In the above-described configuration, the back member feed unit 5 is disposed above the printing unit 1 and to the left of the die unit 3, but is not limited thereto. The back member feed unit 5 may be disposed above the printing unit 1 and to the right of the die unit 3.

Reference Signs List

1: printing unit
2: conveying unit
3: die unit
12: allowing part
21: first conveying guide (conveying guide)
100: button product manufacturing device
Rk5: fifth drive roller (first roller, second roller, third roller, fourth roller)
Rk6: sixth drive roller (fifth roller, sixth roller, seventh roller, eighth roller)
Ro5: fifth driven roller (first roller, second roller, third roller, fourth roller)
Ro6: sixth driven roller (fifth roller, sixth roller, seventh roller, eighth roller)

Claims

A button product manufacturing device configured to manufacture a button product, comprising:
a printing unit configured to print an image on a printing medium; and

a conveying unit configured to convey the printing medium to above the button product, wherein

the conveying unit includes

a first roller and a second roller disposed at an interval in a direction orthogonal to a first conveying direction in which the printing medium is conveyed above the button product,

a third roller configured to come into contact with, among surfaces of the printing medium, a surface different from a surface in contact with the first roller,

a fourth roller configured to come into contact with, among the surfaces of the printing medium, a surface different from a surface in contact with the second roller and same as the surface in contact with the third roller, and

an allowing part configured to allow bending of the printing medium between the third roller and the fourth roller.
The button product manufacturing device according to claim 1, wherein
the third roller and the fourth roller are provided on a same shaft, and

an interval between the third roller and the fourth roller is wider than the interval between the first roller and the second roller.
The button product manufacturing device according to claim 1, wherein
the first roller and the second roller are capable of normal rotation and reverse rotation.
The button product manufacturing device according to claim 3, wherein
the conveying unit includes

a fifth roller and a sixth roller disposed downstream of the first roller and the second roller in a second conveying direction of the printing medium when the first roller and the second roller are reversely rotated,

a seventh roller configured to come into contact with, among the surfaces of the printing medium, a surface different from a surface with which the fifth roller comes into contact, and

an eighth roller configured to come into contact with, among the surfaces of the printing medium, a surface different from a surface with which the sixth roller comes into contact and same as the surface with which the seventh roller comes into contact.
The button product manufacturing device according to claim 4, wherein
the first roller and the second roller are drive rollers, and

the third roller and the fourth roller are driven rollers.
The button product manufacturing device according to claim 5, wherein
the fifth roller and the sixth roller are drive rollers, and

the seventh roller and the eighth roller are driven rollers.
The button product manufacturing device according to claim 6, wherein
the conveying unit includes

a first drive unit including the first roller, the second roller, and a shaft inserted through the first roller and the second roller,

a second drive unit including the fifth roller, the sixth roller, and a shaft inserted through the fifth roller and the sixth roller, and

a drive source configured to drive the first drive unit and the second drive unit.
The button product manufacturing device according to claim 4, wherein
an interval between the fifth roller and the sixth roller is equal to an interval between the seventh roller and the eighth roller.
The button product manufacturing device according to claim 1, wherein
the conveying unit includes

two conveying guides disposed at an interval in a direction orthogonal to the first conveying direction and configured to guide the printing medium conveyed in the first conveying direction.
The button product manufacturing device according to claim 1, wherein
the button product includes a front member having a front surface and a back surface, and a back member,

the conveying unit conveys the printing medium to above the front surface of the front member, and

the button product manufacturing device further comprises:
a die unit configured to deform the front member, the back member, or both of the front member and the back member to clamp a part of the printing medium between the back surface of the front member and the back member in a state where the printing medium covers the front surface of the front member.